CA2440525C - A structure and method for cutting slabs of natural cheeses into shape(s) via cutting blades of a pattern such that the shape(s) are tessellated or nested - Google Patents

Abstract

A process and system for cutting of slabs of a target food product. The slabs produced by this cutting step are within a predetermined size range, i.e., predetermined range as to height, length, and width. After a slab of target food product is cut so that it is of a size that is within the predetermined boundary of the predetermined size range it is introduced to a cutting tool at a predetermined time and at a predetermined speed. The cutting tool is of a predetermined size and includes at least one cutting area that is at least sufficient to cut a predetermined pattern of tessellated.or nested figures out of the slab of food product.

Description

Atty. Docket No.: 8160.17788-FOR CA

Patent A STRUCTURE AND METHOD FOR CUTTING SLABS OF NATURAL
CHEESES INTO SHAPE(S)VIA CUTTING BLADES OF A PATTERN' SUCH THAT THE SHAPE(S) ARE TESSELLATED OR NESTED
Background of the Invention This invention relates generally to the field of cutting patterns out of materials, and specifically to the cutting of nested, mosaic, or tessellated patterns from a slab or block of food product, e.g., cheese.
It is commercially desirable to provide food products in a variety of shapes that are appealing to consumers, e.g., cubes, stars, hearts, moons, various animals, various plants, various representations of real people or fictional characters, various shapes, various figures, etc. Typically, the production of such shapes and designs produces a commercially undesirable level of waste product, sometimes referred to as trim or "fines." It is the object of the present invention to provide for the production of such shapes through the use of specially designed tooling to provide a system, by which such food products of various shapes may be produced with little or no waste product, i.e., fines.
Summary of the Invention The process and system of the present invention may include pre-cutting a target food product

- 2 -into slabs. The slabs produced by this initial cutting step are within a predetermined size range, i.e., predetermined range as to height, length and width. After a slab of target food product is cut so that it is of a size that is within the predetermined boundary of the predetermined size range it is introduced to a cutting tool at a predetermined time and at a predetermined speed.
A cutting tool according to the present invention is of a predetermined size and includes at least one cutting blade. The cutting blade preferably includes a cutting edge having a contour defining a shape that is at least sufficient to cut a predetermined pattern of tessellated or nested figures out of the slab of food product.
A preferred cutting tool may be in the form of a flat die having a laterally extending lattice cutting blade capable of cutting a predetermined pattern, and may include a knockout block for removing the cut pieces from the die.
Alternatively, the cutting tool may be in the form of a rotary cutting tool having a radially extending lattice cutting blade capable of cutting a predetermined cutting pattern.
The invention, in a broad aspect, seeks to provide an apparatus for cutting a slab of food product into predetermined shapes. The apparatus comprises a support surface upon which a slab of food product can be placed, and a cutting die located above the support surface, the cutting die being moveable between a first, raised position and a second, cutting position. The cutting die has a plurality of intersecting cutting edges mounted therein which are oriented essentially orthogonally with respect to the support surface, the intersecting cutting edges defining a plurality of shapes located therebetween which shapes fit together in a pattern with substantially no spaces therebetween. A first drive device is arranged to move the cutting die from the first, raised, position to the second, cutting, position, and a feed device is arranged to feed a slab of food product on the support surface to a cutting area.

- 2a -Description of the Drawings Figure 1 is a perspective view of the apparatus according to the present invention.
Figure 2 is an exploded view of the apparatus shown in Figure 1.
Figure 2A is an enlarged, exploded view similar to that of Figure 2, but particularly showing the die plate and knockout block.
Figure 2B is an enlarged, fragmentary, exploded view with partial cross section of the portion of the die plate and knockout block shown generally in Figure 2A as 2B.

Atty. Docket No.: 8160.17788-FOR CA

- 3 -Figure 3 is a fragmentary section view of the apparatus seen in Figures 1 - 2B, taken along line 3 - 3 of Figure 1 and showing the die plate in the retracted position.
Figure 3A is a fragmentary section view similar to that of Figure 3, but showing the die plate in cutting position.
Figure 4 is a side plan view of the apparatus shown in Figures 1 - 3, but showing the apparatus in conjunction with an optional cheese block cutting assembly.
Figure 5 is a side plan view of the apparatus shown in Figures 1 - 4, and further showing a pre-sliced slab of food product in ready position relative the cutting area of the apparatus and prior to being cut into desired shapes.
Figure 6 is a side plan view similar to Figure 5, but showing the die plate lowered into cutting position relative to a slabbed food product.
Figure 6A is an enlarged fragmentary perspective view of area 6A of Figure 6.
Figure 7 is a side plan view similar to those of Figures 5 and 6, but showing the die plate lifting from the cut food product and retracting into the knockout block, thereby forcing the cut food product from the die plate.
Figure 8 is a side plan view similar to those of Figures 5 - 7, but showing the die plate in an optional, secondary, partially extended position.
Figure 9 is a side plan view similar to those of Figures 5 - 8, but showing the die plate in a resting position and retracted into the knockout block.
Figure 10 is a side plan view of an alternative method and structure of the present invention including discharge of the cut pieces of food Atty. Docket No.: 8160-17788-FOR CA

- 4 -product into the interior of a rotary cutting wheel and the use of pressurized air to remove the cut pieces of food product.
Figure 11 is a perspective view of another alternative cutting tool design having removable or demountable cutting dies as well as open or non-cutting areas.
Figure 12 is a side view of an alternative procedure and structure of the present invention.
Figure 13 is a side plan view of another alternative structure and method of the present invention.
Figure 14 is a perspective view of yet another alternative cutting tool arrangement including a tumbler and a feeder tube through which a predetermined material, such as a coating material, may be added to the cut pieces of food product.
Figures 15 through 25 disclose a variety of alternative cutting patterns into which a cutting edge may be formed and that may be employed to cut a food product with minimal or zero waste, with Figures 15A
15E illustrating views of a food product cut according to the cutting pattern of Figure 15, by way of example.
Detailed Description Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention, which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
The invention may be practiced as illustrated in the Figures. With particular reference to Figures 1 - 9 the structure and method of a Atty. Docket No.: 8160.17788-FOR CA
preferred embodiment of the present invention may be seen. As seen particularly in Figures 4 - 9, slabs 10 of a food product 12, such as cheese, are pre-positioned and ready for introduction to a cutting die

5 20, having a predetermined cutting pattern. The predetermined pattern configured of the die 20 is capable of cutting or stamping an introduced slab 10 of predetermined thickness into tessellated or nested figures of food product. See, e.g., Figures 15 - 26, which show some suggested types of cutting patterns that could, without limitation, be used.
As shown in Figures 1 - 2B, inclusive, an apparatus 14 according to the present invention may be seen. The apparatus 14 as shown is a press type cutter and preferably utilizes a vertical motion to cut slabs 10 of food product 12 (see Figure 4). The apparatus 14 preferably includes a support workstation 16 for supporting feeder means, seen herein as a belt-type conveyer 18 and other apparatus components as will hereinafter be described. The apparatus 14 further preferably includes a planar cutting die 20 having a plurality of laterally extending cutting knives 22 (see Figures 2A and 2B). The cutting knives 22 are preferably arranged in a predetermined latticed cutting pattern 24 corresponding to the shape of food desired.
Since a desired goal of the present invention is to minimize waste, such as trim or "fines" during a cutting procedure, a latticed cutting pattern 24 according to the present invention preferably includes a nested or tessellated configuration.
Seen particularly in Figures 2 through 2B, the apparatus 14 may further include a knockout block 26. The knockout block 26 is arranged to knock out the individual cut food products 17 (depicted in Figure 7) from the cutting die 20 after the slab 10 of food Atty. Docket No.: 8160.17788-FOR CA

- 6 -product 12 has been cut. To accomplish this task, and as seen particularly in Figure 2B, the knockout block 26 preferably includes a plurality of downwardly protruding knockout shapes 27 each having a knockout surface 28. The knockout surfaces 28 each define a predetermined perimeter 29. The perimeter 29 of each knockout surface 28 preferably adjoins and defines a re-entrant channel 30. The channels 30 form an interlocking pattern, which preferably corresponds to the predetermined cutting pattern 24 of the cutting knives 22. As seen particularly in Figure 3, this arrangement allows the cutting knives 22 to retract into the respective channels 30 of the stationary knockout block 26 when withdrawn between cutting actions. Further, and as seen in Figure 7, the knockout surfaces 28 are adapted to urge the cut food product from the cutting die 20 after cutting. It is to be understood that while the various Figures depict knockout surfaces 28 that correspond to the shape of the desired, finished food shape, other knockout surface configurations may be envisioned. Minimally, the knockout surfaces 28 are of at least a shape and size able to fit inside a respective knife shape profile, thereby knocking out the cut food 17 from within the knife perimeter, which perimeter will hereinafter be described and discussed. Further, the knockout surfaces 28 may be optionally provided with a raised or countersunk surface (not shown), to thereby allow for embossing, stamping, or imprinting the cut food 17. An example of a cut food 17 having an embossed portion 120 may be seen in Figures 15 - 15 E, by way of example.
As may be seen particularly in Figures 2A
and 2B, the individual knockout shapes 29 are preferably of a predetermined height H. The Atty. Docket No.: 8160.17788-FOR CA

_ f _ predetermined height H may be of any acceptable height, but is preferably of a height at least corresponding to the height H of the cutting knives 22. In particular, as seen in Figure 3, the individual heights H of each knockout shape 27 may vary in the staggered pattern shown. A staggered height pattern provides a more even force distribution across the cutting die 20 when the cut food product 17 is forced from the cutting die 20 after cutting (see Figure 7), and thereby having a greater efficiency of design.
Referring now to Figures 1 - 3, the various components of a preferred apparatus 14 according to the present invention may be seen. As mentioned earlier, the apparatus 14 preferably includes a support workstation 16. A prime mover, seen as an air operated cylinder and piston 32 is supported by the workstation.
16. While the various Figures depict an air operated cylinder and piston 32 as the prime mover, it is within the province if the present invention to use other prime movers, such as solenoids, linear servos, cams-or other known means. A reciprocating, movable operating cross bar 34 is threadingly connected with an operating rod 36 extending from the prime mover (as detailed in Figure 3A). The reciprocating, movable operating cross bar 34 is attached to at least one vertically operating traveling member 38, with two, oppositely disposed traveling members 38 being shown in the Figures. The vertically operating traveling member 38 further includes a secondary cross bar 40 having upwardly extending threaded studs 42. The threaded studs 42 are adapted to be received by through bores 41 located in the cutting die 20. The threaded studs 42 are further adapted to be received and threadingly seated in threaded apertures 44 formed in the lower ends 46 of a respective extension 48. The extensions 48 each Atty. Docket No.: 8160.17788-FOR CA

include an upper end 50 having a threaded portion 52 to be threadingly received by manually operable wing nuts 54. Although other fastening means may be envisioned, wing nuts 54, as shown, are preferred for ease of breakdown and setup of new die and knockout combinations. The upper end 50 is further adapted to be received by a corresponding through bore 56 in an upper cross bar 58 and sufficiently extending to be threadingly received by manually operable wing nuts 54.
While the Figures illustrate a pair of generally parallel cross bars 58 the invention may be practiced with other numbers of cross bars 58.
The workstation 16 further includes upright support posts 60. The support posts preferably each include an upper end portion 62 adapted to be slidingly received by through bore 64 of cutting die 20, a first upper portion 66 adapted to be received by through bore 68 in knockout block 26, and a second, threaded upper portion 67 to be threadingly received by wing nuts 54.
This arrangement effectively secures the stationary knockout block 26 to the workstation, while allowing for vertical movement of the cutting die 20.
As may be seen in the Figures, the upper pair of parallel cross bars 58 further preferably includes transversely disposed supports 70, each of which include a plurality of downwardly extending rod members 72. The rod members 72 are slidably engaged by corresponding cooperating apertures 74 (seen particularly in Figure 2B) in the stationary knockout block 26 and extend downwardly to rest upon the upper surface 76 of the cutting die 20. As may be seen particularly in Figure 6A, the rod members 72 preferably rest upon the upper surface 76 at pre-selected intersections 78 of the lattice cutting pattern 24. The rod members 72 provide equal Atty. Docket No.: 8160.17788-FOR CA

distribution of force throughout the top surface 76 of the cutting die 20 during the cutting process.
Referring now to Figures 4 - 9 the process and method of the present invention may be seen. As may be seen particularly in Figure 4, slabs 10 of a food product 12, such as cheese, are introduced to a cutting die 20 having a predetermined cutting pattern 24 as discussed previously. The predetermined pattern 24 is capable of cutting an introduced slab 10 into tessellated or nested figures of food product. See, e.g., Figures 14 - 26, which show some suggested types of cutting patterns that could, without limitation, be used. As seen in Figure 4, slab 10 may be sliced from a block 12 of cheese, or other acceptable food product, to a predetermined thickness by a slicing tool 80, as shown as part of the method, or may be precut prior to being introduced to the apparatus 14. The slab of food product 10 is moved by conveyor 18, as shown in the Figures, or by other means, to a position directly below a cutting die 20 (shown in Figure 5). The piston of the prime mover 32 (not seen in this view) moves the operating cross bar 34 and vertical traveling member 38 and, as seen by the arrows in Figure 6, thereby lowers the cutting die 20 toward the slab 10. The knives 22 of the cutting die 20 are thereby pressed into the slab 10. As seen in Figure 7, as the cutting die 20 is retracted into the countersunk channel 30 of knockout block 26, the now cut food product 17 is urged from the cutting die 20 by the knockout surfaces 28 (described earlier with reference to Figure 3).
As may be seen in Figures 8 and 9, the method of the present invention may preferably further include the optional step of partially lowering the cutting die 20 after a first cut has been made, and retracting the cutting die 20 for a second time into Atty. Docket No.: 8160.17788-FOR CA

the countersunk channel 30 of the knockout block 26.
This optional step ensures removal of all cut food 17 from the cutting die 20 and knockout block 26 prior to cutting the next incoming slab 10.
With attention to Figure 10, an alternative embodiment cutting apparatus 90 may be seen. As shown, slabs 10 of a food product 12, such as cheese, are introduced to a rotary cutting die 90, having a predetermined cutting pattern 24 (See Figures 15 - 25, which show some suggested, non-inclusive types of cutting patterns that could be used), and a compression wheel 92. As is further seen, the slab 10 is fed into a pinch point 94. The compression wheel 92 forces the slab 10 into the cutting pattern 24 of the cutting wheel 90. Substantially, the entire slab 10 is cut into individual pieces 17 as determined by the cutting pattern 24 that is used; very little or no waste material, i.e., material that cannot now be packaged, is produced. The resulting cut pieces 17 may then either be allowed to fall into the interior 95 of the cutting wheel 90 and tumble out an end 96 or, alternatively, may be carried between the cutting blades 97 of the cutting pattern 24 and discharged tangentially at a later point in the rotation via any number of means such as gravity, centrifugal force, an automated plunger, application of compressed air, etc.
Similarly to the previously described embodiment, and to ensure that the cutting pattern 24 is in appropriate position, the cheese slabs 10 are advanced via a conveyor belt 18 that operates at a predetermined speed. As noted previously the cheese slabs 10 all fall within a predetermined size range. A
sensor 98 may be used to ascertain the position of the cheese slab 10. An encoder 99 is preferably communicatively coupled to servomotors 100 that are Atty. Docket No.: 8160.17788-FOR CA

operatively coupled to both the cutting wheel 90 and the compression wheel 92. The encoder 99 tells the servomotors 100 the speed of the belt 18 and thus the speed of the slab 10. The servomotors 100 then match the speed of the belt 18. The servomotors 100 are capable of adjusting the speed of the cutting wheel 90 and the compression wheel 92 to match the speed of the cheese slab 10. The cutting pattern 24 of the cutting wheel 90 is at a known starting position. The servomotors 100 preferably cause both the cutting wheel 90 and the compression wheel 92 to rotate at a speed that matches the speed of the slab 10 and at a time that cutting pattern 24 is in position to cut the slab 10. Alignment with both the compression wheel 92 and the cutting wheel 90 is preferably maintained by use of side belts (not shown). In this manner slab 10 after slab 10 may be cut and the resulting pieces 17 packaged.
A specific example of an alternative embodiment of the present invention may be seen in Figure 11. The alternative embodiment shown may include a cutting wheel 90 comprised of first and second cutting sections 102 and first and second non-cutting sections 104. The first cutting section 102 will cut a particular pattern out of a first slab 10 of predetermined food product, such as cheese. The first non-cutting section 104 will sequentially follow the first cutting section 102 to allow for discharge of the now cut pieces 17 of the first slab 10 of cheese as well as separation from the subsequent type of cheese slab 10 entering the second cutting section 102. The non-cutting sections 104 allow the cut pieces 17 to fall through for packaging.
Another alternative embodiment may employ the use of a cutting wheel 90 having first and second Atty. Docket No.: 8160.17788-FOR CA

cutting sections 102 in conjunction with a compression belt (not shown) instead of a compression wheel 92 as illustrated.
Alternatively, and as seen in Figure 12, the cutting wheel 90 may be replaced by a reciprocating cutting plate 106 having a cutting pattern 24 (not shown). The cutting plate 106 preferably matches the speed of the slab 10 advanced from belt 18 and slides the slab 10 under a compression wheel 92 whereby slab 10 would be forced onto and through cutting pattern 24 producing cut pieces 17 with minimal or no waste.
As seen in Figure 13, a vented belt 110 may be substituted for belt 18 and a vacuum chamber 112 used to apply a negative pressure to hold the slab 10 down and against belt 110 during and after the application of a reciprocating cutting head 90a.
Thereby holding the cut pieces 17 in place on the belt 110 until after they have been advanced past the reciprocating cutting head 90a.
Another arrangement may be seen in Figure 14. Here, a rotary cutting tool 90 may include a cutting pattern portion 24 and a tumbler 114. The cut pieces (not shown in this view) are allowed to fall into the interior 95 of the tool 90 wherein a feeder 116 may introduce a coating such as an anti-caking agent, for example (not shown) to the cut pieces 17.
The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.

Claims (20)

WHAT IS CLAIMED IS:

1. An apparatus for cutting a slab of food product into predetermined shapes, said apparatus comprising:
a support surface upon which a slab of food product having a predetermined thickness and an overall surface area may be placed;
a cutting die supported above said support surface, said cutting die being moveable between a first position spaced away from said support surface and a second position that is configured to contact one of the slab of food product placed on the support surface or said support surface, said cutting die having a plurality of intersecting knife blades mounted therein, each of the knife blades having substantially the same predetermined height and oriented essentially orthogonally with respect to said support surface, said knife blades defining a plurality of different shapes corresponding to a desired food shape, which shapes fit together in an interlocking nested pattern with substantially no spaces therebetween, the interlocking nested pattern configured to extend over the same surface area as the slab of food product, said knife blades of said cutting die being arranged and configured to define more than one of said desired food shapes in each of two orthogonal directions, with the plurality of shapes occupying the entire interlocking nested pattern in each of the two orthogonal directions, said knife blades being located above the slab of food product located on said support surface under said cutting die in a cutting area when said cutting die is located in said first position, and said knife blades cutting completely through the slab of food product located on said support surface in said cutting area when said cutting die is located in said second position, wherein the slab of food product is configured in individual, interlocking nested pieces;
a cutter drive device arranged to move the cutting die between said first and second positions; and a feed device arranged to feed a slab of food products on said support surface to said cutting area.

2. The apparatus of claim 1 further including a knockout block, said knockout block including a plurality of knockout shapes arranged to be received by said plurality of shapes defined by said knife blades.

3. The apparatus of claim 2 wherein said knockout block further includes at least one countersunk channel, said countersunk channel arranged to slidably receive at least one of said plurality of knife blade

4. The apparatus of claim 2 wherein said knockout shapes each have predetermined heights and wherein said plurality of laterally extending knife blades all have a predetermined height.

5. The apparatus of claim 4 wherein said predetermined heights of said knockout shapes are randomly selected but are all higher than the predetermined height of said plurality of said knife blades.

6. The apparatus of claim 1 wherein said plurality of shapes defined by said knife blades comprise a tessellated pattern.

7. The apparatus of claim 2 wherein said plurality of knockout shapes each include a knockout surface, at least one knockout surface including at least one raised area.

8. The apparatus of claim 2 wherein said plurality of knockout shapes each include a knockout surface, at least one knockout surface including at least one countersunk area.

9. An apparatus for cutting a slab of food product into predetermined shapes, said apparatus comprising:
a support surface upon which a slab of food product can be placed;

a cutting die located above said support surface, said cutting die being moveable between a first, raised position and a second, cutting position, said cutting die having a plurality of intersecting cutting edges mounted therein which are oriented essentially orthogonally with respect to said support surface, said intersecting cutting edges defining a plurality of shapes located therebetween which shapes fit together in a pattern with substantially no spaces therebetween;
a first drive device arranged to move said cutting die from a said first, raised, position to said second, cutting, position;
a feed device arranged to feed a slab of food product on said support surface to a cutting area.

10. The apparatus of claim 9 further including a knockout block, said knockout block including a plurality of knockout shapes arranged to be received by said plurality of shapes defined by said knife blades.

11. The apparatus of claim 10 wherein said knockout block further includes at least one countersunk channel, said countersunk channel arranged to slidably receive at least one of said plurality of knife blades.

12. The apparatus of claim 10 wherein said knockout shapes each have predetermined heights and wherein said plurality of laterally extending knife blades all have a predetermined height.

13. The apparatus of claim 12 wherein said predetermined heights of said knockout shapes are randomly selected but are all higher than the predetermined height of said plurality of said knife blades.

14. The apparatus of claim 9 wherein said plurality of shapes defined by said knife blades comprise a tessellated pattern.

15. The apparatus of claim 10 wherein said plurality of knockout shapes each include a knockout surface, at least one knockout surface including at least one raised area.

16. The apparatus of claim 10 wherein said plurality of knockout shapes each include a knockout surface, at least one knockout surface including at least one countersunk area.

17. An apparatus for cutting a slab of food product into a plurality of segments each having a predetermined shape, said apparatus comprising:
a support surface upon which a slab of food product can be placed;
a cutting die supported above said support surface, said cutting die being moveable between a first position spaced away from said support surface and a second position configured at a vertical position lower than said first position that is one of at least close adjacent to or contacting said support surface, said cutting die having a plurality of intersecting cutting edges mounted therein, each of the cutting edges having the same predetermined height and are oriented essentially orthogonally with respect to said support surface, wherein said cutting edges define a tessellated pattern of different first and second desired food shapes, said cutting edges being located above a food product located on said support surface under said cutting die in a cutting area when said cutting die is located in said first position, and said cutting edges extending completely through and cutting a food product located on said support surface in said cutting area when said cutting die is located in said second position; and a cutter drive device arranged to move said cutting die between said first and second positions;

wherein said cutting edges define a plurality of shapes corresponding to a desired food shape, which shapes fit together in an interlocking nested pattern with substantially no spaces therebetween and wherein the slab of food product is configured in individual, interlocking nested pieces.

18. The apparatus as defined in claim 17, wherein said cutting edges define a tessellated pattern of first and second shapes.

19. The apparatus as defined in claim 17, additionally comprising:
a knockout block comprising a plurality of shapes which extend downwardly from said knockout block, said knockout block being mounted above said cutting die such that said plurality of shapes which extend downwardly from said knockout block are relatively aligned with said plurality of shapes of said cutting edges in said cutting die and wherein said shapes of said knockout block are arranged such that they may selectively be received within said shapes of said cutting edges in said cutting die.

20. The apparatus as defined in claim 19, wherein said cutting edges in said cutting die have a first predetermined height and wherein said shapes of said knockout block each have a predetermined height which is sufficient to push segments of food product out of said shapes of said cutting edges in said cutting die.