IP Library › Granted Patent US 12667109

Granted Patent B2

US 12667109 · App. 18/386,736 · Granted Jun 30, 2026

Multi-layered food product and method for forming

Inventor: Peter Jacobson (Cleveland, OH)

Assignee: Arlington Valley Farms LLC

A21D13/31 A21C11/08 A21C11/163 A21D8/06 A21D13/14 A21D13/22 A21D13/24 A21D13/32 A21D13/37 A21D13/40

View Patent ↗

Loading inventors, assignments & file history…

Monitor This Case

Get email alerts when status or documents change.

Order Certified Copies

Most orders are placed with the USPTO same day — all within 24 business hours.

Order via The Patent Place →

Pre-filled with this patent's details

Quick Facts

Patent No.: US 12667109
App. No.: 18/386,736
Granted: Jun 30, 2026
Kind: B2

External Links

USPTO Patent Center↗ Full Patent PDF↗

Abstract

A multi-layered food product comprises a filling encapsulated by a partially or fully baked dough layer, and wherein the dough layer is optionally partially or fully encapsulated by a partially or fully baked batter layer that was applied to the dough layer after the dough layer had been partially or fully baked, and the multi-layered food product can optionally include one or more toppings atop the outer dough or batter layer.

Claims (92)

1 . A method for forming a plurality of filled food products on an automated assembly line system; said method comprising the steps of:

a. providing a food insert; said food insert includes a filling and a dough layer; said dough layer encapsulates at least 80% of said filling; a composition of said filling and dough layer is different;

b. providing an automated assembly line; said automated assembly line including I) a plurality of plate assemblies, II) a drive arrangement to cause said plurality of plate assemblies to continuously move through various regions of said automated assembly line, III) an automated food insert feeder arrangement, IV) an automated mating arrangement, V) a preheat heating system, and VI) an oven system; each of said plate assemblies includes a first plate and a second plate; said first plate includes a depression that is configured to at least partially receive said food insert; said second plate is configured to be inserted over said first plate to form a closed cavity that at least partially encapsulates said food insert when said food insert is positioned in said closed cavity;

c. continuously moving each of said plate assemblies into said preheat heating system to heat said plate assemblies to a predetermined temperature;

d. causing said automated food insert feeder arrangement to place said food insert into said depression in said first plate of each of said plate assemblies after said plate assembly has been heated to said predetermined temperature;

e. moving said plurality of said plate assemblies by said drive arrangement into said oven system;

f. baking said food insert in each of said plate assemblies for a period of time as said plate assemblies are moved by said drive arrangement through said oven system to form a baked food insert;

g. causing said automating mating arrangement to mate said second plate with said first plate of each of said plate assemblies while said plate assemblies are moved through said automated assembly line assembly so that said food insert in each of said plate assemblies is at least partially encapsulated in said closed cavity during at least a portion of time said food insert is moved through said oven system;

h. moving said plurality of plate assemblies by said drive arrangement so as to cause said plurality of plate assemblies to be removed from said oven system after said period of time;

i causing said first and second plates to move away from one another to open said cavity after at least partially baking of said food insert while in said closed cavity; and

j. causing said baked food insert in each of said cavities of said plate assemblies to be automatically removed from said plate assembly after said first and second plates have been separated.

2 . The method as defined in claim 1 , further including the step of inverting each of said plate assemblies during the movement of said plate assemblies through said oven system while said second plate is mated with said first plate.

3 . The method as defined in claim 2 , wherein said automating mating arrangement causes said mated first and second plates to move away from one another to open said cavity after said first and second plates have exited said oven.

4 . The method as defined in claim 3 , further including the step of a1) proofing said food insert prior to said food insert being inserted into said depression of said first plate, and/or b1) baking said food insert at least 10% of full baking of said dough layer prior to said food insert being inserted into said depression of said first plate.

5 . The method as defined in claim 4 , further including the step of inserting one or more toppings on said food insert; said topping having a different composition from said filling and said dough layer.

6 . The method as defined in claim 5 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

7 . The method as defined in claim 6 , wherein said the step of inverting said plate assemblies during the movement of said plate assemblies through said oven system occurs after said leavened batter has been poured into said depression in said first plate.

8 . The method as defined in claim 4 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

9 . The method as defined in claim 8 , wherein said the step of inverting said plate assemblies during the movement of said plate assemblies through said oven system occurs after said leavened batter has been poured into said depression in said first plate.

10 . The method as defined in claim 3 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

11 . The method as defined in claim 10 , wherein said the step of inverting said plate assemblies during the movement of said plate assemblies through said oven system occurs after said leavened batter has been poured into said depression in said first plate.

12 . The method as defined in claim 2 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

13 . The method as defined in claim 12 , wherein said the step of inverting said plate assemblies during the movement of said plate assemblies through said oven system occurs after said leavened batter has been poured into said depression in said first plate.

14 . The method as defined in claim 1 , wherein said automating mating arrangement causes said mated first and second plates to move away from one another to open said cavity after said first and second plates have exited said oven.

15 . The method as defined in claim 14 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

16 . The method as defined in claim 1 , further including the step of a1) proofing said food insert prior to said food insert being inserted into said depression of said first plate, and/or b1) baking said food insert at least 10% of full baking of said dough layer prior to said food insert being inserted into said depression of said first plate.

17 . The method as defined in claim 16 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

18 . The method as defined in claim 1 , further including the step of inserting one or more toppings on said food insert; said topping having a different composition from said filling and said dough layer.

19 . The method as defined in claim 18 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

20 . The method as defined in claim 1 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

21 . A method for forming a plurality of filled food products on an automated assembly line system; said method comprising the steps of:

b. providing an automated assembly line; said automated assembly line including I) a plurality of plate assemblies, II) a drive arrangement to cause said plurality of plate assemblies to continuously move through various regions of said automated assembly line, III) an automated food insert feeder arrangement, IV) an automated mating arrangement, V) a preheat heating system, VI) a proofing system, and VII an oven system; each of said plate assemblies includes a first plate and a second plate; said first plate includes a depression that is configured to at least partially receive said food insert; said second plate is configured to be inserted over said first plate to form a closed cavity that at least partially encapsulates said food insert when said food insert is positioned in said closed cavity;

c. continuously moving each of said plate assemblies into said preheat heating system to heat said plate assemblies to a predetermined temperature;

d. moving said food insert through said proofing system to proof said dough layer of said food insert;

e. causing said automated food insert feeder arrangement to remove said food insert from said proofing system and to place said food insert into said depression in said first plate of each of said plate assemblies after said plate assembly has been heated to said predetermined temperature;

f. moving said plurality of said plate assemblies by said drive arrangement into said oven system;

g. baking said food insert in each of said plate assemblies for a period of time as said plate assemblies are moved by said drive arrangement through said oven system to form a baked food insert;

h. causing said automating mating arrangement to mate said second plate with said first plate of each of said plate assemblies while said plate assemblies are moved through said automated assembly line assembly so that said food insert in each of said plate assemblies is at least partially encapsulated in said closed cavity during at least a portion of time said food insert is moved through said oven system;

i. moving said plurality of plate assemblies by said drive arrangement so as to cause said plurality of plate assemblies to be removed from said oven system after said period of time;

j. causing said first and second plates to move away from one another to open said cavity after at least partially baking of said food insert while in said closed cavity; and

k. causing said baked food insert in each of said cavities of said plate assemblies to be automatically removed from said plate assembly after said first and second plates have been separated.

22 . The method as defined in claim 21 , further including the step of inverting each of said plate assemblies during the movement of said plate assemblies through said oven system while said second plate is mated with said first plate.

23 . The method as defined in claim 22 , wherein said automating mating arrangement causes said mated first and second plates to move away from one another to open said cavity as said plate assemblies are moved through said automated assembly line assembly.

24 . The method as defined in claim 23 , further including the step of inserting one or more toppings on said food insert; said topping having a different composition from said filling and said dough layer.

25 . The method as defined in claim 24 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

26 . The method as defined in claim 25 , wherein said the step of inverting said plate assemblies during the movement of said plate assemblies through said oven system occurs after said leavened batter has been poured into said depression in said first plate.

27 . The method as defined in claim 23 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

28 . The method as defined in claim 27 , wherein said the step of inverting said plate assemblies during the movement of said plate assemblies through said oven system occurs after said leavened batter has been poured into said depression in said first plate.

29 . The method as defined in claim 22 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

30 . The method as defined in claim 29 , wherein said the step of inverting said plate assemblies during the movement of said plate assemblies through said oven system occurs after said leavened batter has been poured into said depression in said first plate.

31 . The method as defined in claim 21 , wherein said automating mating arrangement causes said mated first and second plates to move away from one another to open said cavity after said first and second plates have exited said oven.

32 . The method as defined in claim 31 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

33 . The method as defined in claim 21 , further including the step of inserting one or more toppings on said food insert; said topping having a different composition from said filling and said dough layer.

34 . The method as defined in claim 33 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

35 . The method as defined in claim 21 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

36 . A method for forming a plurality of filled food products on an automated assembly line system; said method comprising the steps of:

each of said plate assemblies includes a first plate and a second plate; said first plate includes a depression that is configured to at least partially receive said food insert; said second plate is configured to be inserted over said first plate to form a closed cavity that at least partially encapsulates said food insert when said food insert is positioned in said closed cavity;

c. causing said automated food insert feeder arrangement to place said food insert into said depression in said first plate of each of said plate assemblies;

d. moving said plurality of said plate assemblies by said drive arrangement into said oven system;

e. baking said food insert in each of said plate assemblies for a period of time as said plate assemblies are moved by said drive arrangement through said oven system to form a baked food insert;

f. causing said automating mating arrangement to mate said second plate with said first plate of each of said plate assemblies while said plate assemblies are moved through said automated assembly line assembly so that said food insert in each of said plate assemblies is at least partially encapsulated in said closed cavity during at least a portion of time said food insert is moved through said oven system;

g. moving said plurality of plate assemblies by said drive arrangement so as to cause said plurality of plate assemblies to be removed from said oven system after said period of time;

h. causing said first and second plates to move away from one another to open said cavity after at least partially baking of said food insert while in said closed cavity; and

i. causing said baked food insert in each of said cavities of said plate assemblies to be automatically removed from said plate assembly after said first and second plates have been separated.

37 . The method as defined in claim 36 , further including the step of inverting each of said plate assemblies during the movement of said plate assemblies through said oven system while said second plate is mated with said first plate.

38 . The method as defined in claim 37 , wherein said automating mating arrangement causes said mated first and second plates to move away from one another to open said cavity after said first and second plates have exited said oven.

39 . The method as defined in claim 38 , further including the step of inserting one or more toppings on said food insert; said topping having a different composition from said filling and said dough layer.

40 . The method as defined in claim 39 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

41 . The method as defined in claim 40 , further including the step of:

I) providing a preheat heating system that is configured to preheat said first plate and/or said second plate prior to said first and/or second plate moving into said oven system, and/or II) providing a proof system that is configured to at least partially proof said food insert prior said food insert being fully baked.

42 . The method as defined in claim 38 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

43 . The method as defined in claim 42 , further including the step of:

44 . The method as defined in claim 37 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

45 . The method as defined in claim 44 , further including the step of:

46 . The method as defined in claim 36 , wherein said automating mating arrangement causes said mated first and second plates to move away from one another to open said cavity after said first and second plates have exited said oven.

47 . The method as defined in claim 46 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

48 . The method as defined in claim 47 , further including the step of:

49 . The method as defined in claim 36 , further including the step of inserting one or more toppings on said food insert; said topping having a different composition from said filling and said dough layer.

50 . The method as defined in claim 49 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

51 . The method as defined in claim 50 , further including the step of:

52 . The method as defined in claim 36 , further including the step of pouring a leavened batter into said depression in said first plate of each of said plate assemblies that include said food insert; said dough layer and said filling having a different composition from said leavened batter.

53 . The method as defined in claim 52 , further including the step of:

54 . The method as defined in claim 36 , further including the step of: