AU3439901A

AU3439901A - Chocolate product having break-away portion

Info

Publication number: AU3439901A
Application number: AU34399/01A
Authority: AU
Inventors: William Harding; John Martin; Steven D. Stephens
Original assignee: Mars Inc
Current assignee: Mars Inc
Priority date: 1999-11-18
Filing date: 2000-11-17
Publication date: 2001-05-30
Also published as: DE10085211T1; WO2001035758A3; CA2390861A1; GB2371733B; GB2371733A; WO2001035758A2; GB0211821D0

Description

WO 01/35758 PCTIUSOO/42218 TITLE CHOCOLATE PRODUCT HAVING BREAK-AWAY PORTION BACKGROUND OF THE INVENTION Field of the Invention 5 The present invention relates to a chocolate product having a break-away portion that forms an opening when the break-away portion is subjected to a breaking force. Related Background Art 10 There are a variety of chocolate confections that provide a dimension of enjoyment beyond the pleasure derived from eating the chocolate. An example is the chocolate product that presents the viewer with a semblance of a topical character. Such products 15 include those made in the shape of Santa Claus, a rabbit, a star, an egg, a turkey, a Jack O'Lantern, or a cartoon character.

WO 01/35758 PCT/USOO/42218 -2 Such topical characters are generally large, ranging in size from several inches to over three feet in height. In order to keep the cost of the larger-size shaped chocolate products down, the shaped products are often 5 hollow. Hollow products contain less chocolate than solid products for a given external size, and thus, chocolate cost, as well as the costs associated with shipping a heavier product, can be saved. Hollow chocolate products are typically consumed by 10 breaking off a convenient portion for eating. Generally, the choice of where to break off the portion is a matter of individual preference. The prior art hollow products generally do not have designed weak portions to aid in breaking the chocolate. Instead, 15 such products are likely to have reinforcement at areas of structural weakness in order to prevent breakage prior to sale of the products. A dimension of pleasure can also be derived from breaking a chocolate product into pieces. For example, 20 a chocolate orange is formed from a multitude of solid chocolate segments in the shape of orange slices. The chocolate segments are arranged in the shape of a whole orange and connected to each other by chocolate connections. The consumer is thus presented with a 25 chocolate orange that breaks into a multitude of solid chocolate "orange slice" segments when the whole "orange" is struck forcefully. Another dimension of pleasure can be derived from discovering or revealing a concealed component inside a 30 hollow chocolate product. For example, a hollow chocolate in the shape of an M&M's@ candy piece, available from Mars, Incorporated, McLean, VA, has WO 01/35758 PCTIUSOO/42218 -3 M&M's@ candy pieces inside. The M&M's@ candy pieces become assessable to the consumer when the hollow chocolate product is broken open. Hollow chocolate products are generally made by 5 attaching two or more chocolate shell portions to form the overall hollow chocolate shell. U.S. Patent Nos. 5,635,230 and 5,705,217 describe methods and apparatus for producing chocolate articles. The patents are incorporated by reference herein. 10 SUMMARY OF THE INVENTION This invention is directed to a chocolate product having a break-away portion of a sheet-like member. The break-away portion frangibly detaches in order to provide access through the opening formed from the 15 detachment. The invention is also directed to a method of forming a break-away portion including forming a frangible channel that bounds the break-away portion. In a preferred embodiment of this invention the chocolate product is hollow and removal of the break 20 away portion of the sheet-like member allows access to the interior of the hollow chocolate product. In one aspect of the present invention, a chocolate confection includes a chocolate sheet having a break away portion formed therein, and a frangible portion 25 bounding the break-away portion. A frangible force exerted on the break-away portion frangibly detaches the break-away portion from the chocolate sheet to form an opening in the chocolate sheet.

WO 01/35758 PCT/USOO/42218 -4 In another aspect of the present invention, a method to form a chocolate confection having a solid surface that includes a break-away portion which upon detachment forms an opening in the solid surface includes the step 5 of forming a frangible portion on the solid surface. The frangible portion encloses the break-away portion and is effective to cause the frangible detachment of the break-away portion at the frangible portion when a frangible force is exerted upon the break-away portion. 10 In yet another aspect of the present invention, a method to form a chocolate confection having a sheet portion having a sheet thickness that includes a break away portion which upon detachment forms an opening in the sheet portion includes the step of forming an area 15 having a frangible thickness in the sheet portion. The frangible thickness being less than about 75% of the sheet thickness is effective to form an opening in the sheet portion when a frangible force is applied to the area of frangible thickness. 20 These and other aspects, and many of the attendant advantages of this invention will be readily appreciated and understood by reference to the following detailed description when considered in connection with the accompanying drawings. 25 BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1A is a cross-sectional view of an embodiment of this invention prior to exertion of a frangible force. Fig. 1B is a cross-sectional view of an embodiment of this invention after exertion of a frangible force.

WO 01/35758 PCT/USOO/42218 -5 Fig. 2A is a cross-sectional view of an embodiment of this invention prior to exertion of a frangible force. Fig. 2B is a cross-sectional view of an embodiment of this invention after exertion of a frangible force. 5 Fig. 3A is a cross-sectional view of an embodiment of this invention prior to exertion of a frangible force. Fig. 3B is a cross-sectional view of an embodiment of this invention after exertion of a frangible force. Fig. 4A is a cross-sectional view of an embodiment of 10 this invention prior to exertion of a frangible force. Fig. 4B is a cross-sectional view of an embodiment of this invention after exertion of a frangible force. DETAILED DESCRIPTION OF THE INVENTION This invention is directed to chocolate confections 15 having at least one portion that has a sheet-like structure. The sheet-like structure has an outer surface on which is formed at least one break-away portion. The break-away portion provides access to an opposite side of the sheet-like structure through an 20 opening formed by a force applied by pressing, pulling or twisting on the break-away portion. In one embodiment, referring to Fig. 1A, a chocolate sheet 11 has an outer surface and an opposite inner surface. A sheet portion 14 includes an inner-surface 25 portion 13 in communication with at least part of a cavity portion 15, and an outer-surface portion 12 WO 01/35758 PCTIUSOO/42218 -6 correspondingly opposite inner-surface portion 13. A break-away portion 16 includes an outer-break-away surface 17 and a frangible portion 18. Frangible portion 18 bounds break-away portion 16. Referring to 5 Figs. 1A and 1B, a frangible force exerted on outer break-away surface 17 causes break-away portion 16 to frangibly detach from sheet portion 14, effective to form an opening 19 in sheet portion 14. In another embodiment, referring to Fig. 2A, a 10 chocolate sheet 201 has an outer surface and an opposite inner surface. A sheet portion 204 includes an inner-surface portion 203 in communication with at least part of a cavity portion 205, and an outer surface portion 202 correspondingly opposite inner 15 surface portion 203. A break-away portion 206 includes an outer-break-away surface 207, a frangible portion 208 substantially bounding break-away portion 206, and a pivot portion 210. Referring to Figs. 2A and 2B, a frangible force exerted on outer-break-away surface 207 20 causes break-away portion 206 to frangibly detach from sheet portion 204, effective to form an opening 209 in sheet portion 204 by pivoting at pivot portion 210. In another embodiment, referring to Fig. 3A, a chocolate sheet 301 has an outer surface and an 25 opposite inner 'surface. 'A sheet portion 304 includes an inner-surface portion 303 in communication with at least part of a cavity portion 305, and an outer surface portion 302 correspondingly opposite inner surface portion 303. A break-away portion 306 includes 30 an outer-break-away surface 307, a frangible portion 308 substantially bounding break-away portion 306, and a pull member 311. Referring to Figs. 3A and 3B, a frangible force exerted on pull member 311 causes WO 01/35758 PCT/USOO/42218 -7 break-away portion 306 to frangibly detach from sheet portion 304, effective to form an opening 309 in sheet portion 304. In another embodiment, referring to Fig. 4A, a 5 chocolate sheet 401 has an outer surface and an opposite inner surface. A sheet portion 404 includes an inner-surface portion 403 in communication with at least part of a cavity portion 405, and an outer surface portion 402 correspondingly opposite inner 10 surface portion 403. A break-away portion 406 includes an outer-break-away surface 407, a frangible portion 408 substantially bounding break-away portion 406, a pivot portion 410, and a pull member 411. Referring to Figs. 4A and 4B, a frangible force exerted on pull 15 member 411 causes break-away portion 406 to frangibly detach from sheet portion 404, effective to form an opening 409 in sheet portion 404 by pivoting at pivot portion 410. The sheet portion that includes the break-away portion 20 can be situated at any convenient location of the chocolate product. For example, the chocolate product can be any convenient hollow shape defined by a shell of chocolate. The sheet portion can then be a portion of the shell. Thus, when the break-away portion forms 25 an opening, access is provided into the interior of the hollow shell of chocolate. The interior can contain any convenient component such as, for example, confectionery bits, food particles, or toy items. Such hollow shapes include, for example, an egg, a 30 pumpkin, a sphere, a rhombic solid, a cube, a conic solid, or a football. Such hollow shapes also include, for example, shapes having resemblances to stars, WO 01/35758 PCT/USOO/42218 -8 moons, people, buildings, houses, rabbits, bears, birds, dinosaurs, or other real or imaginary characters or animals. As another example, the chocolate product can be a 5 house, building, wardrobe, chest, car, airplane, ship or a model of any other convenient structure having hinged elements such as, for example, doors or windows. The action of the break-away portion can then resemble the action of such hinged elements to provide an 10 element of play to the chocolate product. The frangible portion generally is a portion of the chocolate sheet that is weaker than its neighboring areas, the proximate sheet portion. The frangible portion is sufficiently weaker so that a frangible 15 force exerted on the frangible portion will cause the frangible portion to break. Further, a frangible force exerted on the break-away portion will transfer to the frangible portion effective to cause the frangible portion to break. Accordingly, reinforcement members 20 can be formed on the sheet portion effective to prevent the opening, formed by the application of frangible pressure, from extending beyond the frangible portion. As shown in the figures, the frangible portion is conveniently a portion having a thickness dimension 25 less than that of its neighboring chocolate sheet area. The diminished thickness can be conveniently be caused by a channel on either side or both sides of the chocolate sheet. When the frangible portion is formed by a region of 30 diminished thickness, it is advantageous that the frangible portion be from about 25% to about 75% of the WO 01/35758 PCT/USOO/42218 -9 thickness of the chocolate sheet region adjoining and proximate to the frangible portion. Preferably, the frangible portion may be from about 35% to about 70%, and more preferably, the frangible portion may be from 5 about 60% to about 65% of the thickness of the chocolate sheet region adjoining and proximate to the frangible portion. The frangible portion can be conveniently formed by a difference in composition of frangible portion from 10 that of the neighboring areas of the chocolate sheet. The frangible portion can also be conveniently formed by a multiplicity of dimples or perforations that define the frangible portion. The frangible portion can also be conveniently formed by a configuration of 15 approximately parallel ridges that define frangible portions between the ridges. The frangible portion should be sufficiently strong not to break during manufacture, transport, or storage of the chocolate item. The frangible portion should 20 conveniently break when an appropriate force is exerted. Accordingly, items designed for children can have frangible portions different from those designed for adults. Further, frangible portions can be designed to break when subjected to different force 25 levels even within the same item. Such cases include, for example, items designed to have sequentially detached portions, items designed to have multiple sections break away together, and items designed to have sections that break away unexpectedly to surprise 30 the user. The frangible force can be exerted from any convenient direction appropriate to the design of the chocolate WO 01/35758 PCT/USOO/42218 - 10 article. Thus, the force can be a push, a pull, a twist, or a combination. Generally, the frangible force is exerted to the break-away portion to act on the frangible portion. In certain applications, the 5 chocolate article may be designed so that the force is exerted elsewhere and the force is transferred mechanically by members such as, for example, levers, pivots, and cams, to act on the frangible portion. The chocolate sheet portion that includes the break 10 away portion can be any convenient shape. Although the figures show a generally flat sheet portion, the sheet portion can be any convenient shape such as, for example, a part of a spherical contour, a part of an ovoid contour, or a part of a figure contoured to 15 resemble an animal. The sheet portion can include creases, convex or concave areas, as well as any convenient decorative or structural feature such as, for example, a nose, an ear, a bellybutton, a fleur-de lis, an emblem, a star, or a handle. 20 The frangible portion can be formed by any convenient method such as, for example, molding (spin, book, or shell) or cold forming. Cold forming is a preferred method where the hollow shell portions are formed by a receiving cavity and corresponding pressing member, and 25 the shell portions are then assembled together to form the complete chocolate article. The shell portion(s) that includes the frangible region(s) and the break away portion(s) may be formed by molding members that have raised ridge features that, in relief, form the 30 corresponding frangible regions. Such raised features can conveniently be on the convex or concave molding members, or on both.

WO 01/35758 PCT/USOO/42218 - 11 Cold-forming equipment typically includes a receiving cavity and a corresponding pressing member which is received in the cavity. In the cold-forming process, an amount of chocolate, having a temperature preferably 5 between 20-40 degree C, is deposited into the receiving cavity and the pressing member, having a temperature of approximately 0 0C, is brought to close proximity to the cavity. The pressing member is separated from the cavity by a distance that corresponds to the design 10 thickness of the resulting chocolate sheet/shell. The chocolate solidifies rapidly when the pressing member is placed in contact thereto, thus resulting in a shell having a thickness equal approximately to the distance between the pressing member and the cavity. 15 The raised ridge features can be conveniently incorporated into the receiving cavity and/or the pressing member. Such raised ridge features form portions of the chocolate sheet having a reduced thickness - thereby forming frangible regions. The 20 height and thickness of the raised ridges can be readily varied to absorb the frangible force necessary to dislocate the break-away portions from the sheet. Generally, the frangible thickness will be at least 75% of the sheet thickness, preferably between 75% and 25% 25 of the sheet thickness, move preferably about 66% to about 33% of the sheet thickness. For example, a chocolate sheet having a thickness of about 3mm, will have a frangible portion or region, defined for example by a channel or groove, having a frangible thickness of 30 about 2mm to about lmm thick. The receiving cavity and/or the pressing member may be conveniently heated or cooled. Further, the receiving cavity and/or the pressing member can be formed from WO 01/35758 PCT/USOO/42218 - 12 any convenient material such as, for example, metal, ceramic, or polymeric material. Another less desirable method to form the frangible regions is by applying a scoring knife to the formed 5 chocolate sheets. The scoring knife removes chocolate, thereby forming regions of reduced thickness corresponding to the desired frangible regions. The formed chocolate sheet/shell portions can be then assembled by any convenient method to form a chocolate 10 product. Thus, one aspect of this invention is a method to form a chocolate confection having a solid surface that includes a break-away portion. When the break-away portion detaches, an opening is formed in the solid 15 surface. The method includes forming a frangible channel on the solid surface surrounding the break-away portion and effective to cause the frangible detachment of the break-away portion at the frangible channel when a frangible force is exerted upon the break-away 20 portion. As described above, the frangible force can be exerted from either side of the solid surface on which is the frangible channel. In one embodiment, the Method forms an area having a frangible thickness in the sheet portion, the frangible 25 thickness being less than about 75% of the sheet thickness, and effective to form an opening in the sheet portion when a frangible force is applied to the area of frangible thickness. The frangible thickness in the sheet is preferably a defined by a channel or 30 groove in the chocolate sheet bounding the break-away portion. The groove or channel defining the boundary WO 01/35758 PCT/USOO/42218 - 13 of the break-away portion is preferable continuous, but also may be discontinuous as long as the boundary is defined. Less. desirably, it is possible to move the whole break-away portion having a frangible thickness 5 as defined above. The Examples which follow are intended as an illustration of certain preferred embodiments of the invention, and no limitation of the invention is implied. 10 Example 1 A hollow chocolate shell resembling Santa Claus carrying a bag of presents having M&M's@ candy pieces inside was prepared. The chocolate shell was generally about 3 mm thick on average. The bag of presents was 15 made a break-away portion by forming a channel 2 mm deep around the appropriate section on the inside of the shell. The chocolate sheet was about 1 mm thick at this area. A force, easily managed by a child, was effective to break off the break-away portion (the bag 20 of presents) to allow access to the M&M's@ candy pieces inside the figure. The figure was formed by assembling two cold-formed half shells together. The half shells were formed with a raised portion in the -forming device that created and 25 defined the frangible portion (the channel). Example 2 A Jack-O-Lantern, approximately 35 mm in diameter and 35 mm in height, was made containing about 7.5 grams of mini-M&M's@ candy pieces inside. Channels were formed on the interior surface of the shell to define break away portions from the eyes, nose, and mouth of the WO 01/35758 PCT/USOO/42218 - 14 figure. The channels (frangible portions) were about 0.5 mm to 1.0 mm thick while the remainder of the chocolate shell was about 2.5 mm thick. The channels were formed by a 2 mm raised ridge on the mold that 5 formed that section of the Jack-O-Lantern. The Jack-0 Lantern was also formed by cold-forming, where the cold-formed sections were bonded together by book molding. Other variations and modifications of this invention 10 will be apparent to those skilled in this art after careful study of this application. This invention is not to be limited except as set forth in the following claims.

Claims

1. A chocolate confection comprising: a chocolate sheet having a break-away portion formed therein; and a frangible portion bounding said break-away portion, wherein a frangible force exerted on said break-away portion frangibly detaches said break-away portion from said chocolate sheet to form an opening in said chocolate sheet.

2. The chocolate confection according to claim 1, wherein said chocolate sheet includes an inner surface at least partially enclosing a cavity, and wherein said confection further includes at least one component accessible through said opening formed in said chocolate sheet.

3. The chocolate confection according to claim 2, wherein said component is selected from the group consisting of candy pieces, nuts, cookie bits, toys or mixtures thereof.

4. The chocolate confection according to claim 1, further comprising a pivot portion partially bounding said break-away portion, wherein a frangible force exerted on said break-away portion frangibly detaches said break-away portion from said chocolate sheet to form an opening in said chocolate sheet by pivoting at said pivot portion.

5. The chocolate confection according to claim 4, wherein said chocolate sheet includes an inner surface at least partially enclosing a cavity, and said chocolate confection further includes at least one WO 01/35758 PCT/USOO/42218 - 16 component accessible through said opening formed in said chocolate sheet.

6. The chocolate confection according to claim 5, wherein said component is selected from the group consisting of candy pieces, nuts, cookie bits, toys and mixtures thereof.

7. The chocolate confection according to claim 4, further comprising a member formed on said break-away portion, wherein a frangible force exerted on said member causes said break-away portion to frangibly detach from said chocolate sheet to form an opening in said chocolate sheet by pivoting at said pivot portion.

8. The chocolate confection according to claim 7, wherein said chocolate sheet includes an inner surface at least partially enclosing a cavity, and wherein said confection further includes at least one component accessible through said opening formed in said chocolate sheet.

9. The chocolate confection according to claim 8, wherein said component is selected from the group consisting of candy pieces, nuts, cookie bits, toys and mixtures thereof.

10. The chocolate confection according to claim 1, further comprising a member formed on said break away portion, wherein a frangible force exerted to said member causes said break-away portion to frangibly detach from said chocolate sheet to form an opening in said chocolate sheet. WO 01/35758 PCT/USOO/42218 - 17

11. The chocolate confection according to claim 10, wherein said chocolate sheet includes an inner surface at least partially enclosing a cavity, and wherein said chocolate confection further includes at least one component accessible through said opening formed in said chocolate sheet.

12. The chocolate confection according to claim 10, wherein said component is selected from the group consisting of candy pieces, nuts, cookie bits, toys and mixtures thereof.

13. A method to form a chocolate confection having a solid chocolate surface that includes a break away portion which upon detachment forms an opening in the solid chocolate surface, said method including the step of: forming a frangible portion on the solid chocolate surface, the frangible portion surrounding the break away portion and effective to cause the frangible detachment of the break-away portion at the frangible portion when a frangible force is exerted upon the break-away portion.

14. The method according to claim 13, wherein the frangible portion is defined by at least one of a channel, a groove, a symbol, or an emblem in said solid chocolate surface.

15. A method to form a chocolate confection having a chocolate sheet portion having a sheet thickness that includes a break-away portion which upon detachment forms an opening in the sheet portion, said method including the step of: WO 01/35758 PCTIUSOO/42218 - 18 forming an area having a frangible thickness in the sheet portion defining a boundary of said break away portion, the frangible thickness being less than about 75% of the sheet thickness, and effective to form an opening in the sheet portion when a frangible force is applied to the area of frangible thickness.

16. The method of claim 15, further including the step of forming reinforcement members on the sheet portion effective to prevent the opening, formed by the application of the frangible force, from extending to the sheet portion having the sheet thickness.