ZA200509829B - Flexible bakeware - Google Patents

Description

FLEXIBLE BAKEWARE

1. Field of the Invention

This invention relates g=enerally to flexible bakewvare and in particular to an improved flexible bakeware container that is made from a novel compoound and inc=ludes a carrier for assisting 2 user in carrying the bakeware container. 2. Description of Related Art

Flexible bakeware is typically made from a silicone rubber formulation. The sili cone composition prevents strong odors from being transferred to thee food, yet provides a tough, temperature resistant material that, dume to its flexibility, =allows food to be removed more easily tha n with traditional bakewawe. One downside to using a silicone composition for bake=ware is that the flexibili ty of the materizal makes it difficult to handle. The bakewaare cannot be easily carrieed with one hand. Instead, it must be fully supported unde r its bottom surface, ancd most users simply place a meatal cooking sheet or other rigid pan underneath time bakeware to tzransfer the bamkeware to and from the over. This solution is impractical because the poresence of a solid sheet of metal undermeath the flexible bakewaare can provide i nconsistent (a nd uneven) baking of the food product containeci by the bakew=are. More spmecifically, the sides and top of the bakeware experieance convective heeating from thee hot air within the oven. ~The bottom of the bakewvare experiences conductive heating since it is in direct contact with the solid metal coking sheet. Thi=s difference in heating methods can cause uneven cooking of the food product. The ineconvenience of using a coeoking sheet to transport flexible bakewaree is also a drawback.

A need therefore exists for an apparatus that could be used in conjunction wiiith a flexible baking contai ner that would permit e=asy transport of the baking container. A need further exissts for an apparatus that could be incorporaated into the flexible baking container so that together the devices and bakeware are a self- ~ontained unit. Still anothew need exists for an ap-paratus that can be readily re=moved from the baking container periodically for clearing.

Flexible bakeware alsec experiences release problems with ce riain foods.

C ompared to conventional no n-flexible bakeware, it is often easier to re move foods from flexible bakeware becausse the basin containing thee food product caan be turned in side out. However, with cewrtain foods such as muffimns, cakes, or breexds, residue

A-

from fhe foods may remain stuck fo the flexible bakeaware, thereby causing an uneven and unattractive outer surface on the food procluct following re moval from the bamkeware.

One solution to the p roblem of food release is to pre-lubricat=e a baking contaié ner with cooking spray, cooking oil, or flour. While= this can prevert food from stickimg to baking containers, the solution is undesfirable because it involves additiconal steps in cooking the food (i.e. the step of pere-lubricating) a.nd requires additieonal cooking supplies (i.e. the spray, oil, or flour). Another drawback is that the use oF oils or flour can alter the taste and texture of the baked food produsct.

A need therefore existss for flexible bakeware that has improved food release qualit ies as compared to currently used flexible bakewamre. A need furthaer exists for a commpound that can be «easily and inexpensively manufactured into flexible bakewwnare. The compound sshould be non-toxic and simould not impart an odor or taste to food products preparexd in the bakeware.

BRIEF SUMMARY OF THE INVENTION

The problems presen-ted by existing flexible b=keware are soslved by the present invention. A flexible bakeware compound is provided that includes a methyl vinyl silicone polymer from akoout 40 to 70 weight percemt, a filler from aabout 5 to 50 weight percent, a curing agent from about 0.1 #o § weight p ercent, and polytestrafiuoroethylene from about 0.1 to 15 weigh® percent. In a preferred embodiment, the polytetraflucroethylene is present in arn amount of aborut 6 percent.

The filer is preferably ground quartz, and the curingg agent is prefe=rably chloro plata nic acid. ' .

Also provided by the present invention is a fl exible bakeware compound havirig a methyl! vinyl silicone polymer of about 61 wei ght percent, a fiiller of about 28.5 weight percent, a curing agent of about 057 weight p ercent, and polyt etrafluoroethylene of about 6 weight percent. Preferably, the fill er is ground quariz, and the curing agent is chloro platanic acid. The flexible bakeware compoound may also include high viny! silicone gum fron about 1.1 weig-hf parcent, a pigmeent from about 1.1 wesight percent, zinc stearamte from about 0.14 weight perceent, silicone hydride fro-m about 1.7 weight perce=nt, and ethynl ecyciohexanol from about 0.01 weight percesnt.

A method for baking aa food product is also provicled by the prese=nt invention.

The method includes the step of providing a flexible bakzing container formed from an addition-ecured silicone polymer h aving polytetrafluo roethylene from atmout 0.1 to 15 weight psercent. A food product is deposited in the baking container, and the containewr is placed in an oven at & baking temperatire for a predetermilined time until the food product is baked. The food product is then removed fromm the baking container.

THe invention further provides an elastomerics baking container Faving a basin and showulder surrounding the bassin. A receiving ch=annel is disposed ir the shoulder of the baking container and rece-ives a carrier. Thee placement of the= carrier within the rece iving channel provides amdditional rigidity to the shoulder, whi ch makes the baking c-ontainer easier to carry.

A method of baking a foo«d product is provicded by the present invention and includes the steps of providing a flexible baking container having am basin and a shoulder. A receiving channel is- disposed in the slnoulder, and a carr ier is received by the receiving channel. A food product is depossited in the baking container, and 16 the flexible baking container is carried to an oven by gripping the caarrier, or some portion of the carrier along with the shoulder of theme baking container—. The baking container is placed in an oven ak a baking temperamture for a predetermined amount of time until the food product is baked. -

T he carrier of the present invention can be perovided in many di~fferent shapes and sizees. The shape of the carrier will generally mmatch the shape of the receiving channel For example, the carrier can be made from a rod with a circular cross section. The receiving channel i nthis case would have a circular cro ss section. in some irmstances, a portion of the carrier may extend out of the shoulder of the bakewamre as a handle. The pre=sence of handles i-s not required but mmay make the bakewamre easier to carry.

A-nother carrier that may be used is one for a plurality of muffin cups (i.e. bakewamre, or baking containers) . This carrier is p referably a flat, riglid plate with a plurality of apertures. A flexible muffin cup is placed within each ape rture so that a receiving channel on a shouldest of the muffin clip receives a portion of the flat carrier. The receiving channel may even have -a depression for receiving a lip formed on an edge of the carrier’ s aperture. When —the depression enggages the lip of the carrier, the muffin cup is more securely attache=d to the carrier aned less likely to become inadvertently disengaged from the carrier.

Other objects, features, and advantages of the present inve=ntion will become apparent with refereence to the drawings and detailed description that follow.

BRIEF DESCRIPTION OF “THE DRAWINGS

FIG. 1 depicts a perspective view of a flexible bakeware camrrier for a plurality of flexible muffin cmups according to a preferred e=mbodiment of the present invention;

FIG. 2 illustrates a top view of the flexible bakeware carrier Of FIG. 1;

FIG. 3 depicts a cross-sectional front view of the flexible b akeware carrier of

FIG. 2 taken at II-III;

FIG. 4 illustrates an enlarged front view of" the of flexible bal<eware carrier of

FIG. 3 taken at De*tail IV,

FIG. 5 depicts a cross-sectional front views of a flexible muffin cup according to a preferred embodiment of the present invention, the muffin cup> designed for use with the flexible baakeware carrier of FIG. 1;

FIG. 6 illusstrates an enlarged front view of the flexible muffin cup of FIG. 5 taken at Detail VI;

FIG. 7 depi- cts an enlarged front view of za flexible muffin caup according to an alternative embod :iment of the present inventiorm, the view being t-aken at an area of the flexible muffin cup similar to that shown in Fi G. 6;

FIG. 8 illustrates a perspective view of a flexible bake=ware carrier for a plurality of flexible muffin cups according to an alternative embodirment of the present invention;

FIG. 9 depicts a top view of a rectangul ar, flexible bakew~are according to a preferred embodiment of the present invention;

FIG. 10 illeustrates a cross-sectional front view of the rectangular, flexible bakeware of FIG. 9 taken at X-X;

FIG. 11 depicts an enlarged front view of the rectangular, fEexible bakeware of

FIG. 10 tak en at Detail XI;

FIG. 12 ill ustrates a cross-sectional top view of the resctangular, flexible bakewarc of FIG. 10 taken at XI-Xil:

FIG. 13 de=picts a top view of a flexib le bakeware carrier according to a preferred embodirment of the preferred invention, the carrier dessigned for use with the flexible bakew~are of FIG. 9;

FIG. 14 illLustrates a top view of a flexitwle bakeware carrier according to an alternative embod iment of the present inventionz

FIG. 15 depicts a top> view of a rectangular , flexible bakeware according to an alternative embodiment of the present invention, t he bakeware desigred for use with the carrier of FIG. 14;

FIG. 16 illustrates = cross-sectional fron—t view of the rectaangular, flexible bakeaware of FIG. 15 taken at XVI-XVI;

FIG. 17 depicts ane nlarged front view of thme rectangular, flexitole bakeware of

FIG. 16 taken at Detail XVI I;

FIG. 18 illustrates = top view of a round, flexible bakeware according to a prefesrred embodiment of ttme present invention;

FIG. 19 depicts a cross-sectional front viewv of the round, flexi ble bakeware of”

FIG_ 18 taken at XIX-XIX;

FIG. 20 illustrates &an enlarged front view of the round, flexikole bakeware of™ © FIG- 19 taken at Detail XX;

FIG. 21 depicts a cwross-sectional top vieww of the round, flexible bakeware of

FIG_- 19 taken at XXI-XXI;

FIG. 22 illustrates aa top view of a flexibl € bakeware carrier— according to a pref-ered embodiment of the present invention, tte carrier designed for use with the- rourd, flexible bakeware off FIG. 18;

FIG. 23 depicts a top view of a flexible bakeware carrier according to an alternative embodiment of the present invention;

FIG. 24 illustrates a perspective view of a round, flexible bake=ware according" to =an alternative embodiment of the present invention, the fle=xible bakeware= des@gned for use with the flexible bakeware carrie=r of FIG. 23;

FIG. 25 depicts a cross-sectional front view of the round, flexi: ble bakeware of~

FIG . 24; and

FIG. 26 illustrates aan enlarged front view of the round, flexiBole bakeware of~

FIG . 25 taken at Detail XV.

FIG. 27 depicts a flow chart of a method off baking a food product according toe the mrasent invention.

DETAILED DESCRIPTION OF THE PEIREFERRED EMBO DIMENT

In the following det=ailed description of the= preferred embodirments, reference- is made to the accompanying drawings which feorm a part hereof, and in which is shown by way of illustration specific preferred e mbodiments in whiech the invention may be practiced. These embodiments are desscribed in sufficient detail to enable those skilled in the art to practice the imwvention, and It iss understood t hat other embodimentss may be utilized and that logical mechanical, structural, and chemical changes may= be made without departing from the spirit or sc .ope of the inve=ntion. To avoid detail mot necessary to enable those skilled in the art fo practice the invention, 5 . the descripticon may omit certain information known to thosee skilled in the art. The following detailed description is, thereforer, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appeended claims.

In describing the present invention, the term “elastorrer’ refers geneerally to a polymeric material that has rubberlike properties. More specifically, most e=lastomers have elongation rates greater than 100% and a significant a mount of resilience. The resilience of a material refers to the maaterial’s ability to recover from an elastic deformation. Examples of elastomers could include, but amre not limited “to, natural rubbers, polyyisoprene, styrene butadiene rubber, chloroprerne rubber, polylkoutadiene, nitrile rubber, butyl rubber, ethylene propylene rubber, e—thylene propyleene diene 16 monomer, chlorosulfonated polyethylene, polysulfide rutober, polyuretane, and silicones.

The te=rm “flexible” refers to an object or material that= is able to beni or flexed.

The use of tPhe term flexible in connection with a material or— bakeware of tEne present invention ge nerally refers to a material or bakeware made fr- om an elastom er or other material tha—t allows the container portiorw, or basin, of the bakeware to De at least partially turn ed inside out without plastic d eformation of the material.

Referring to FIGS. 1-4, a carrier 11 according to one embodim ent of the present inve=ntion is illustrated. The carrier apparatus 11 iss used in conjumnction with flexible mufffin cups. Carrier 11 is a substantially rigid, flamt plate made f~rom either - 25 metal or temperature-resistant plastic. Carrier 11 includes ax plurality of ap=ertures 13, each adapte=d to receive a flexible muffin cup. Carrier 11 is= preferably rectangular in shape with = chamfer 21 at each corner of the carrier. Carrier 11 is prefer—ably made from brushe -d stainless steel, and all perirmeter edges 23 of ” the carrier 11 have been rolled to forrm a perimeter lip 25 (see FIG. 4). Similarly. the edges 29 of apertures 13 have also bezen rolled to form perimeter ligos 31. By rolling t he exposed ed ges 23, 25 of the carrie=r 11, the sharpness of the edt ges is eliminated. Carrier 11 alsso includes a hanger hoole 33 at one end of the carrie x 11 for allowing te carrier to be hung on a ‘ kitchen wall _

Referring to FI GS. 5 and 6, a flexible b=aking container, or muffin cup 41, accorcling to a prefermed embodiment of the pre=sent invention imncludes a bsasin 43 formecd by a substantially cylindrical, tapering waall 44 integrally connected too a floor 45. Omne end of wall 214 terminates in a shoulder 45, the shouide r having a receiving chanel 47. Receiviing channel 47 preferably includes a deppression 49 that is adapteed to receive tke perimeter lip 31 of carriger 11. In order— to obtain coptimum flexibi lity and release, the wall thickness of each wmuffin cup should be betwee=n 0.020 and O .100 inches. Preeferably, the wall thickness is 0.050-0.075 irches.

In operation, e=ach aperture 13 on carriemr 11 receives a muffin cup ~41 such that am portion of the czarrier 11 fits within receiving channel 47. When insta lled, the perimeter lip 31 of thes carrier 11 is firmly seated in the depressiomn 49 of the reeceiving chanel 47. The eng agement of the lip 31 by dezpression 49 momre firmly sec ures the muffir cups 41 on thes carrier and prevents acciciental or inadvertent disengagement of the= muffin cups 41 and the carrier 11.

The carrier 11 provides rigidity to the muffin cups 41 in aan area arouind each shoulider 45 and alloews a user to carry the flexible muffin cupss 15 with ore hand.

The flexibility of the ranuffin cups 41 allows a use=r to easily remove the cups from the carrier 11. The removal of the muffin cups coldld aid a user in removing food from the muffin cup, althomugh it is not necessary to remove the cup to effectuate= release of a food product. The ease with which thes muffin cups can be remowwed also prom otes the use of rnuffin cups having different: shapes and depths. For exsample, a muffin cup having a koasin 17 that is heart shape d may be used t-o bake heartt-shaped muffims on Valentine 's Day. Other possible shaapes include wit-hout limitatieon stars, clove=r leaves, squares, triangles, and diamonds _

Referring to F=IGS. 7 and 8, a muffin cup 51 and a carrier 61 according to alterrative embodimeents of the present inventi on are illustrate d. Muffin c=up 51 is similar to muffin cup 41 and includes a basin 53 formed by a sukostantially cywiindrical, taper—ing wall 54 conenected to a floor (not shown) at one end and terminamting in a shou Ider 55 at anoth er end. Shoulder 55 includies a receiving cBhanne!l 57, bout unlike muffi n cup 41, does rot include a depression 49

Muffin cup 5-1 is designed for use witth a carrier such as carrie=r 11, or prefesrably carrier 61 Referring to FIG. 8, carrieer 61 is a rectangular, flat plete made from metal or tempoerature-resistant plastic. ~~ Carrier 61 incsludes a plirality of apertures 63 for rece=iving muffin cups 51. The porimary differencse between carrier 61 and carrier 11 (FIGS. 1-4) is that carrier 61 does not include rcalled lips at perimeter edges 635 or edges 67 of the apertures. The lack of a lip at edges 67 allows tke carrier 11 to better mate with muffin cup 61, which includees no depression in receivinag channel 57.

Referring to FIGS. 9-12, a rectangular, flexible bamking container 111 according to a preferred embodiment of the present invention includes a basin 1712 formed by a pair of major walls 113 and a pair of minor walls 11 4, the walls 113, 114 being irtegrally joined to each other and at one end to a floor 1 M5. A shoulder 117 is formed at an end of the walls 1-13, 114 opposite floor 11:5, the shoulder 1 17 extending completely around the perimeter of the baking contzainer 111. Shoulder 117 inc=ludes an outer surface 121, an inner surface 122, an upper surface 123, a nd a lower surface 125. A receiving channel 131 having a circular cross section is dispose=d in the shoulder 117 with an entry slot 135 positione=d between the lover surface= 125 of the shoulder 117 and the receiving channel 1 31. In the preferred embod iment, the entry slot 135 is disposed adjacent the lo~wer surface 125 (Cas shown in FIG. 11), but it is conceivable that the entry slot 1335 could be dispos-ed adjacemnt the outer surface 121, the inner surface 122, or the upper surface 123. : "Referring more specifically to FIG. 12, the receiving channel 131 and ematry slot 1:35 are not continuous around the entire perimeter of the flexible baking contairter 111. Instead, the receiving channel 131 includes a central portion 141 that runs ¢ ontinuously in the shoulder 117 adjacent each majoer wall 113. As €he "receiving channel 131 approaches corner portions 151 of the skoulder 117, a turnming . portion 143 of the receiving channel 131 follows the shouldeer around the correr portion 151. An exit portion 145 of the receiving channel the=n turns in a directmon oppositte minor walls 114 and exits the outer surface 121 of the shoulder 1-17.

Becausse of the discontinuous nature of the receiving charanel 131, the baking contairer 111 actually contains a pair of receiving channels 131 as illustrated in F NG. 12. “The preferred location of the central portion 141 of the receiving channel 1 31 is in the shoulder 117 adjacent each major wall 113. This configuration provides #he most s upport for the carrier that is received by the receiving channel 131 (explairmed in moree detail below). However, a person of ordinary skill in the art will recogn ize that the= central portion 141 of each receiving channel 131 could instead be located in the shoulder adjacent each minor wall 114.

Referrirg to FIG. 13, a carrier 161 according to a preferresd embodiment of the present invention is used in conjunction with flexible baking comntainer 111. Camrrier 161 is formed by a substantially rigid rod havi ng a substantially circular cross section and made off metal or temperature-resistant plastic. Prefesrably, the material composition of the rod is 304 stainless steel_ Carrier 161 inclu des a pair of ce=ntral stays 165 thatz are substantially parallel to one another and are j- oined at each erd to an arcuate stay 167. An end of each arcuate stay 167 is joired to one end of a handle 169. Wogether, the pair of central stays 165, the four arcuate stays 167, and the pair of haandles 169 form a closed loop. The shape and length of the ce=ntral stays and the= arcuate stays closely approxi mate those of cermtral portion 141 and turning portior 143 of the receiving channel 131. Preferably, the central stays 165, arcuate stays 167, and handles 169 are wellded together from stainless steel mrods, but the carrier 161 could be formed usiing any other sulitable manufact uring . techniques krmow to those of ordinary skill in the art. ’ 16 In ope-ration, carrier 161 is received by flexible bakirhg container 11 1 by inserting the centrals stays 165 and arcuate stays 167 through the entry slot 135 of the baking co ntainer 111 and into the receivi ng channel 131. The flexible propestties of the baking— container 111 allow the shoulder 117 to bend su ch that the entry slot 135 is temporarily enlarged to accommodate the carrier 161 as it passes throug hthe entry slot 135 and into the receiving channes! 131. After the central stays 165 are positioned wi-thin the central portions 141 of the receiving channels 131 and the arcuate stayss 167 are positioned within the tuming portions 143 of the recesiving channels 131 , the shoulder 117 elastically returns to its origimal shape. With the shoulder in =m “non-deformed” shape, the emiry slot 135 is aggain smaller tham the receiving chamnel 131, which secures carrier 161 within the receaiving channel 131.

With the carrier 161 installed in the weceiving channel 131, a portion of the handle 169 iss disposed within the exit portion 145 of the recei=ving channel, but the majority of thes handle 169 is located outside the walls of the flex<ible baking contzainer 444, Handle 18Q enahles a user of the flaxitsle baking containemr 111 to easily lift and carry the bak ing container 111 by holding either or both handiess on the that portion of the handle 169 that protrudes from the baling container.

The carrier 161 provides rigidity to the flexible baking cortainer 111 inan area around each shoulder 117 and allows a user to more easily lift and carry the baking container 11-1. The flexibility of the bakincg container 111 alleows a user to easily remove the carrier “161 from the receiving chanel 131 of the bakineg container 111.

The removal of the carrier 161 could aid a usesr in removing food from the baking container 111, although it is not necessary to remove the carrier 1 61 to effectuate release of a food product.

Referring to FIGS. 14-17, a rectangu lar, flexible baking container 171 according to an altemrnative embodiment of the present invention includes a basin 172 formed by a pair of major walls 173 and a pair o—f minor walls 174, th e walls 173, 174 being integrally joinead to each other and at one end to a floor 175. A= shoulder 177 is formed at an end of the walls 173, 174 oppoosite floor 175, th e shoulder 177 extending complete ly around the perimeter of the baking container— 171. Shoulder 177 includes an outeer surface 181, an inner surface 182, an upper surface 183, and a lower surface 185a. A receiving channel 191 having a rectangular cross section is disposed in the shoulder 177 with an entry slo t 195 positioned between the lower surface 185 of the shoulder 177 and the recei~ving channel 191. In the preferred embodiment, the emntry slot 195 is disposed adjacent the lower ssurface 185 (as shown in FIG. 17), but it is conceivable that ttme entry slot 195 comuld be disposed - adjacent the outer smurface 181, the inner surface= 182, or the upper st_irface 183.

The receivingg channel 191 and entry slot 195 are prefer-ably continuous around the entire perimeter of the flexible baling container 171. However, it is conceivable that a cdiscontinuous receiving chan nel 191 and entry slot 195 could be used similar to those of baking container 111 (se e FIG. 12).

Referring more specifically to FIG. 14, a carrier 201 a ccording to an alternative embodiment of the present inventiorm is used in conjunction with flexible baking container 17 1. Carrier 201 is a rectang ular plate having a central aperture 203 and is made of” metal or temperature-resistzant plastic. The sh-ape and size of carrier 201 closely approximate those of the receiving channel 191 of baking container 171.

In operation, carrier 201 is received byw flexible baking coentainer 171 by inserting the carrier 201 through the entry slot 1 95 of the baking comntainer 171 and into the receiving ctmannel 191. The flexible pramperties of the bakinag container 171 . allow the shoulder 1°77 to bend such that the entry slot 195 is temporarily enlarged or deformed to accomrmodate the carrier 201 as it passes through thes entry slot 195 and into the receivirng channel 191. After the =carrier 201 is positiconed within the receiving channel 19 1, the shoulder 177 elasticalllly retums to its origiral shape. With the shoulder 177 in a “non-deformed’” shape, the entry slot 135 is again srmaller than the receivings channel 191, which sexcures carrier 201 withir the receivirg channel 191.

Carrie=t 201 provides rigidity to the flexible baking container 171 in an area around shoumlder 177 and allows a user to more easily lift and carry “the baking container 17-1. The flexibility of thes baking container 171 allows a use=r to easily remove the scarrier 201 from the receiving channel 191 of thae baking con. tainer 171.

The removal of the carrier 201 could aid a user in removirg food from the baking container, alithough it is not necessary to remove the carrier 201 to effectuate the release of a food product.

Refer ring to FIGS. 18-21, a round, flexible baking comntainer 211 a_ccording to a preferred =embodiment of the pres ent invention includes am basin 212 fcomed by a substantially= cylindrical, tapering wall 213 that is integrally joined at ome end to a floor 215. Aw shoulder 217 is formed at an end of the wall 21 3 opposite flor 215, the 16 shoulder 21 7 extending completely around the perimeter of the bakineg container 211. Shouleder 217 includes an outer surface 221, an inne=r surface 2222, an upper surface 223-, and a lower surface 225. A receiving chann el 231 havinag a circular cross section is disposed in the shoulder 217 with an emntry slot 235 positioned between thes lower surface 225 of the shoulder 217 and thes receiving ciannel 231. © In the prefeared embodiment, the entry slot 235 is disposed adjacen t the lower surface 225 (as shown in FIG. 20), bout it is conceivable that the entry slcot 235 could be disposed adjacent the outer surface 221, the inner surface 222, o.r the upper surface 223 .

Refemrring more specifically to FIG. 21, the receivingg channel 231 and entry slot 235 are not continuous around the entire perimetesr of the flexible baking container 211. Instead, the receiving channel 231 includes an arcuate portion 241 that is cont inuous in a portion of the shoulder 217 and suibtends an a:ngle that is preferably greater than or equal to 90 degrees. An exit portion 24 5 is of the recoiving channel 231 is located at baoth ends of the arcuate portion 241. Exit portion 245 turns im a direction away from wall 213 and exits the outer surface= 221 of the shoulder 21 7. Because of the disco ntinuous nature of the reaceiving chan nel 231, the baking cont ainer 211 actually contains a pair of receiving cihannels 231 liametrically opposed on: the shoulder 217 (see F 1G. 21).

Referring to FIG. 22, a carrier 261 according to a preferred embodime=nt of the © present invention is used in conjunction with flexible baking container 211. Carrier 261 is formed by a substantially rigid rod having a subestantially circular cros=s section and made of metal ow temperature-resistant plastic. Preferably, the material composition of the rod iss 304 stainless steel. Carrier 261 includes a pair of central stays 265 that are joined at each end to a handle 2683. Together, the pair cof central stays 265 and the pair of handles 269 form a closed loop. The shape and length of the central stays 265 closely approximate those Of arcuate portion 2441 of the receiving channel 231. Preferably, the central stamys 265 and handles 269 are welded together from stainless steel rods, but the carrier 261 could be formed using any other suitable manu facturing techniques know to ~those of ordinary skill inthe art. _ In operation, carrier 261 is received by flexible baking containe r 211 by inserting the centrals stays 265 and a portion of the handles 269 through the entry slot 235 of the baking container 211 and into the recesiving channel 231. Tie fiexibie properties of the baking container 211 allow the shoulder 217 to deform sucsh that the entry slot 235 is tempo warily enlarged to accommodate the carrier 261 as it passes through the entry slot 235 and into the receiving charnel 231. After the certral stays 265 are positioned withiin the arcuate portions 241 of the receiving channeles 231, the shoulder 217 elastically returns to its original shape=. With the shoulder &n a “non- deformed” shape, the e niry slot 235 is again smaller than the receiving channel 231, which secures carrier 261 within the receiving channel 231.

With the carrier 261 installed in the receiving channel 231, a port ion of the handle 269 is disposed within the exit portion 245 osf the receiving channe=s), but the majority of the handle 269 is located outside the wal 1 of the flexible baking container 211. Handle 269 enabl es a user of the flexible bakin g container 211 to eassily lift and carry the baking contairer 211 by holding either or booth handles on the portion of the handle 269 that protrud es from the baking container.

The carrier 261 provides rigidity to the flexible baking container 211 in an area around each shoulder 217 and allows a user to morse easily lift and carry the baking container 211. The flexibility of the baking contairier 211 allows a usemr to easily remove the carrier 261 from the receiving channel 2231 of the baking container 211.

The removal of the casrier 261 could aid a user in removing food from t=he baking container 211, although it is not necessary to remawve the carrier 261 to effectuate the release of a food product.

Referring to FIGS. 23-26, a round, flexible baking contauiner 271 accorcding to an alternative embodiment of the present irwention includes a Ioasin 272 formed by a substantially cylindrical, tapering wall 273 that is integrally jo7ined at one ermd to a floor 275. A sshoulder 277 is formed at an end of the wall 273 Opposite floor 2775, the ° shoulder 277 extending completely arourd the perimeter of the baking container 271. Shouldesr 277 includes an outer surface 281, an inner ssurface 282, ana upper surface 283, =and a lower surface 285. A receiving channel 291 having a rect=angular cross sections is disposed in the shoulder 277 with an entry slot 295 possitioned between the Mower surface 285 of the shoulder 277 and the reeceiving chann-el 291.

In the prefermred embodiment, the entry slot 295 is dispose=d adjacent the= lower surface 285 (=as shown in FIG. 26), but it iss conceivable that thme entry slot 2955 could be disposed adjacent the outer surface 281, the inner surfaace 282, or the= upper surface 283. : The receiving channel 291 and entry slot 295 are preferably confitinuous around the e=ntire perimeter of the flexible baking container 271. However, it is conceivable t hat a discontinuous receiving channel 291 and e=ntry slot 295 could be used similar t © that of baking container 21-1 (see FIG. 21).

Referring more specifically to FEG. 23, a carrier 301 according to an alternative ermbodiment of the present inwention is used in coanjunction with flexible baking container 271. Carrier 301 is a ring-shaped plate haveing a central a perture 303 and is made of metal or temperaturex-resistant plastic. T he shape and size of "- carrier 301 oclosely approximate those of the receiving cheannel 291 of baking container 271°.

In ope=ration, carrier 301 is received by flexible bak ing container 2271 by inserting the carrier 301 through the entry slot 295 of the bak ing container 2 71 and - into the receiving channel 291. The flexible properties of the baking contairer 271 allow the sho ulder 277 to bend such that the entry slot 295 is temporarily enla rged or deformed to accommodate the carrier 301 as it passes through the entry s lot 295 and into the receiving channel 201. After the carrier 301 is positioned wit hin the receiving cha nnel 291, the shoulder 277 elastically returns to it s original shape. With the shoulder =277 in a “non-deformed” shapoe, the entry slot 2955 is again small er than the receiving channel 291, which secures carrier 301 within the receiving czhannel 291. 1 3-

Carrier 301 provides rigidity to the flexible bakirg container 271 in an area a round shoulder 277 and =llows a user to more easily lift and carry thes baking . container 271. The flexibil ity of the baking container 271 allows a user to easily remove the carrier 301 from the receiving channel 291 of the baking container 271.

T he removal of the carrier 301 could aid a user in.rercoving food from th € baking container, although it is no® necessary to remove the «carrier 301 to effectuate the release of a food product.

The flexible bakewawe (i.e. the muffin cups 41, 51, the rectangular baking containers 111, 171, and tte round baking containers 211, 271) compositieon of the present invention is preferambly made from an addition-ccured silicone matemrial. The following table illustrates thee preferred amounts and po tential ranges for th e flexible

Ibakeware composition of thee present invention:

Preferred Range

Compound Amount (Weight %) (Weight %)

PolydimethylvinyBsiloxane/Silica 60.88 40-70

High Vinyl Silicorme Gum 0.5-10

Polytetrafluoroeti—ylene | eo | 0.1-15

Black Iron Oxide (pigment) 1.1 0.1-5

Zinc Stearate (internal mold 0.14 T 0.1-5 release)

Silicon Hydride 0.1-25

Chloro Platanic Acid {cross- 0.57 0.1-5 linking agent)

Ethyni Cyclohexzanol (inhibitor) 0.05-5

The flexilole bakeware compound prefe=rably contains OB.1 to 15 weight percent of polytetrafluorcoethylene (PTFE). Testing of" silicone bakewaare with these armounts of PTFE has reavealed superior release properties compare«d to silicone bat<eware without PTFE. Several different compounds=s were tested toy baking foods in the bakeware and then determining the amowmnt of food res idue remaining in the . bakeware followwing the removal of the baked egoods. Clearly, less food residue in the bakeware indic=ates better release properties. Silicone b=akeware without PTFE required the usse of a non-stick spray or flour to eliminate food residue fo=llowing baking. Althou gh silicone bakeware having PTFE ranging from 0.1 to 15 weight percent exhibite=d improved release properties without the use of a non-stick s pray or flour, the optimmum composition was determ ined to include six (6) weight percent

PTFE.

The preferred particle size of PTFE used with thee present invertion is approximately & um (i.e. microns), with a m aximum particle= size of 25 ym. While larger particle ssizes of PTFE can also impart improved re lease properties to the bakeware, the plasticity of the resulting cormpound is some=times increased to an "extent that extrusion and molding of the compound is diffiecult or impossib le. An example of PTFE commonly used in preparing the flexible Moakeware compound of the present inveantion is Polymist F-5A, which can be obtaine=d from Ausimorit USA.

Polymist F-5A contains particles of a relatively small size, typi: cally at or below 6 pm.

The comupounding of PTFE in the formulation of the present invention results in the migratiorm of PTFE to the surface of the flexible bakewware. The presence of the PTFE at ow near the surface at least partially results iin the superior welease properties of thes bakeware. Another advantamge provided by the PTFE is that it does not impart an oor or taste to food products baaked in the bake=ware.

The flexi ble bakeware compound is pmreferably combirned with a cross linking . agent to insure- that the bonds of the compeound properly fom. The cross linking agent may be &x catalyst, such as platinum, eor a curing ager—it such as peroxzide. A niatinum cataly. st (ie chloro platanic acid) is preferably ussed in conjunction with silicon hydride ~to insure that the proper bon ds form betwee=n the platinum and the silicone compound. If a curing agent, such a.s peroxide, were= used, silicone Ehydride would not be r-equired. However, peroxide is not preferre=d because it geznerally imparts an unpleasant odor and smell to Foods baked in the bakeware. Other catalysts, includding but not limited to cesium, palladium, rhodium, iron, cobalt, nickel,

rubidium, osmium, or iridium, could be used in place of plati num. However, thesse substances ares generally not favored becausse they are eithemr more expensive (eg. palladium) or hmave problems associated with contamination (eg. iron).

The preferred filler for the bakeware czompound is grourd quartz in an amosunt P of about 28.5 weight percent; however, filler in an amount of 5-50 weight perczent could be used.. Alternative fillers include silica, calcium, or anyw other mineral.

The baleeware compound preferably contains black irorn oxide in an amourmt of 1.1 weight per-cent, which gives the finished bakeware a blac k color. Dependings on the desired co-lor for the bakeware, many diiflerent pigments ecould be used, and the "amount of pigment used could also be vamried to alter the color. Preferably, the weight range ofthe pigment is between 0.1 &and 5 weight perceent.

High vir! silicone gum is preferably added to the cormmpound in an amourt of about 1.1 weicght percent; however, the cormpound could inc Iude high vinyl silic-one gum in any ammount between about 0.5 and 10 weight percentz. The vinyl comporent of high vinyl ssilicone gum is preferably 8-2@ percent pendan:t vinyl with a prefemrred amount of 14 poercent.

The nomevel composition of the pres-ent invention pre=ferably has a speecfiic gravity of abort 1.12 to 1.64.

Each iteem of flexible bakeware is preferably injection, compression, or tran-sfer 20 . molded. To fuurther enhance the release properties of the bamkeware, a molding tool having a finiskh between A1 and B2 is used to form the bakev-vare, with the prefemred - finish being A=. Molding finishes of this type are known stand# ards within the molding industry.

Referrirg to FIG. 27, a method for bamking a food produmct 309 according to the present invention includes, in step 311, providing a flexible b aking container forrmed from an additi on-cured silicone polymer hawing polytetrafluor- cethylene in amournt of about 0.1 to “M5 weight percent. In step 33 a carrier adapt=ed to be received Ioy a receiving charnel in the flexible baking container is provided. A user deposits a food product in the baking container af step 315, and the baking ceontainer is placed ir an oven at a balking temperature for a predestermined time urtil the food product is baked atstep 317. The baked food product is removed from the baking container at step 319.

Several variations of the method illusstrated in FIG. 27 are possible. First, the use of the camrier is not required if the baaking container iss made from the novel flexiblea bakeware compound of th e present invention. Alteernatively, the carrier may be usexd with a traditional flexible baking container instea=d of one incorgporating the flexibles bakeware compound. in «either situation, ail of thes features and advantages explaited previously in connectiom with the flexible bakewrare compouncd and carrier are apeplicable to the bakeware us ed with the method.

It should be apparent thaat although the flexible bakeware of the present invention has been described in terms of a round muffin cup, a rectan- gular baking container, and a round baking container, any size or s-hape of flexib le bakeware could be included within the scope of the present invermtion. Similarly, the carrier could be provided in many different shapes or sizes, and may incluzde single or multiple handles that extend outward from the bakeware>. Alternativel=y, the carrier may have no handles at all. The receiving channel shape=s and sizes tht are formed "in eamch piece of flexible bakewware could also vary ass long as the bakeware is securely attached to the carrier member and will not be=come disenga ged from the carrieer member while the bakewaare is being transported or carried.

It is also important to note that while the fle=xible bakewamre has been descmribed as having an entry slot communicable with the receivings channel! for allowwing the carrier to be place d in the receiving chanmnel, the entry slot could be omitted. Without an entry slot, t he carrier would preferakoly be integrall—y molded into the sshoulder of the bakeware. ~The carrier would not be= removable, tout the carrier woul-d still be carried by a receeiving channel that was- formed arournd the carrier durirag the molding process.

The primary advantage provided by the carrier is that it allows a user of flexibole bakeware to more easilly lift and transport the Boakeware whilee baking. By prov iding rigidity around the perimeter of the flexible bakeware, it is no longer necessary to support the flexible from underneath suchm as with a cocking sheet or tray. Another advantage is provided by the handle pmortions of the carrier. The hanclle portions extend outward from the perimeter off the flexible koakeware and prov-ide a larger grinning surfa ce for a user carrying the bakeware. Still another . 30 advaantage of the carrier system is that it is easily and inexpensively mmanufactured.

Flexcible bakeware can be easilyw manufactured with a rec=eiving channe=l in a shoulder that surrounds the perimeter off the bakeware. The camrrier can then be made fo fit with in the receiving channel #o provide the needed rigidity to a poortion of the © bakeaware.

The novesl composition for flexible baakeware presented herein is preferably used in conjunction with a carrier to provide the added benefits of being able to mor=e easily lift and caarry the bakeware. Howeve r, the advantages perovided by the noves! composition are= independent of those provi ded by the carrier. As a result of thes-e 5 . independent, yest valuable, results, the nove! composition may be used without thee carrier in a marmner similar to that of traditioral flexible bakewares. tis also importart to note that usse of the composition described herein for flex ible bakeware is neot limited to use wwith bakeware having a particular size or shape.

The primary advantage provided by he bakeware comp-osition of the present invention is that it enables improved releaase of food productss being baked in the bakeware. Thme composition was obtaine d and refined by extensive testing ard experimentatiomn. Testing revealed that traditional flexible ba=keware suffers food release problemms unless pre-lubricated with either cooking spray, cooking oil, or flour. The ad dition of PTFE to an additlon-cured silicone compound aliows time manufacture ofF flexible bakeware that releamses baked food witknout the need for pre- "lubrication.

The composition described herein is not limited to flexiblee bakeware, but could be used with aany product requiring the adwantages presented by the compound. In addition to the ‘release” or “non-stick’™ advantage described previously, tlhe compound pro-vides excellent thermal insulating properties. Thme compound also h as exceptional st=ability when exposed to colcl and heat. The m:aterials used with tlhe compound are all food grade materials, so the product can be placed in contact w ith food. Finally , since the compound is silicone based, the= compound provid es excellent resis-tance to ultraviolet (UV) ligrmt. Some of the postential applications ~for the compouncd, outside of the flexible baakeware application , include but are rot limited to spatmulas and other cooking utenssils, jello and confectionary molds, and &ce cube trays. Other uses include cookware handles that are- essentially insulative sleeves that stip over the hot handle of am item of cookware. The compound could be made into pot holders for removing hot items from an ove=n, or flat baking maats that can be placed on a cooking tray for baaking cookies or othmer food products. Still another use ceould be sealing materials for appliance doors or windows, or any otter sealing application where a flexible corwpound with good release properties is needed. 1s8-

© WO» 2004/111128 PCT/U=S2004/017697 it should be apparent from the foregoing that &an invention hawing significant adwantages has been provided. While the invention is shown in on ly a few of its forrs, it is not just limited bmut is susceptible to variowus changes and modifications without departing from the sp irit thereof. “‘Comprises/comprisingy" when used in this spec-ification is taker to specify the presence of stated featwures, integers, steps or ecomponents but does not pre clude the presence or addition of one or more othear features, integers, steps or components or groups themreof. -19-

AMENDED SHEET

Claims (25)

© WO 2004/111128 PCCT/US2004/017697 CLAIMS We claim:

1. A fleaxible bakeware compouned comprising: an addition-cured silicosne polymer; and polytetrafluoroethylene in amount of abou:t0.1 to 15 weight gpercent.

2. A flexxible bakeware compouned according to clairm 1, wherein the poly-tetrafluoroethylene is present in an amount of about 6 weight paercent.

3. A flexible bakeware compound according to clairm 1, further comprising a platinum catalyst in an amount of about 0.1 to 5 weight percent.

4. A flexible bakeware compoun«d comprising: a methyl vinyl silicone goolymer from abou 40 to 70 weight pmercent; a filler from about 5 to 250 weight percent; polytetrafluoroethylene- from about 0.1 to 15 weight percent; and a cross-linking agent from about 0.1 to 5 weight percent.

5. A flexible bakeware compound according to clairm 4, wherein the nmethyi vinyl silicone poly=mer is polydimethyivinyisi loxane.

6. A flexible bakeware compoun d according to claimm 4, wherein the fi ller is ground qua riz.

7. A flexible bakeware compoun d according to claimm 4, wherein the ¢ ross-linking agent is chloro platanic acid.

8. A flexible bakeware compoun d according to claimm 4, wherein the polyrtetrafluoroethylene is present in an amount of about 6 percent.

9. A flexible bakeware compoun d according to claimm 4 further compri=sing: silicone hydride from albout 0.1 to 25 weight percent; and wherein the cross-linkisng agent is chloro polatanic acid.

10. A flexible bakeware compoun d according to claimm 4 further compri=sing: high vinyl silicone gum from about 0.5 to —10 weight percent; a pigment from about O.1 to 5 weight percent; zinc stearate from abowmt 0.1 to 5 weight peercent; silicone hydride from a bout 0.1-25 weight percent; ethynl cyclohexanol from about 0.05 to 5 weight percent; wherein the methyl vinyl silicon polymer iss polydimethylvinyBisiloxane; wherein the filler is gro und quarts; and wherein the cross-linkimng agent is chloro polatanic acid. -20- AMEN DED SHEET

11. A flexib®le bakeware compound comprising: aa methyl vinyl silicone polymeer of about 61 weight= percent; a filler of about 28.5 weight percent; Polytetrafluoroethylene of alb»out 6 weight percent; and a cross-linking agent of about 0.57 weight percent.

12. Aflexib le bakeware compound acc ording to claim 11, wherein the methyl viny 1 silicone polyme ris polydimethylvinylsiloxan e.

13. A flexilex bakeware compound acco rding to claim 11, wherein the filler is grourmd quartz.

14. A flexib=le bakeware compound according to claim 11, wherein the cross-linkin g agent is chlor- 0 platanic acid.

15. A flexibsle bakeware compound according to claim 11 fur—ther comprising: silicone hydride of about 1.7” weight percent; and wherein the cross-linking ag ent is chloro platanic acid.

16. A flexibmle bakeware compound according to claim 11 fur—ther comprising: Ehigh vinyi silicone gum from about 1.1 weight peracent; a= pigment from about 1.1 weight percent; =zinc stearate from about 0.1 4 weight percent; ssilicone hydride from about 1.7 weight percent; ecthynl cyclohexanol from at»out 0.01 weight percent; =wherein the methyl! vinyl silicone polymer is polydllimethylvinyisiloxane; ~wherein the filler is ground quartz; and -wherein the cross-linking agent is chloro platanic acid.

17. A methmod for baking a food product comprising the step=s of: providisng a flexible baking container formed from an addition-cured silicone polymer having polytetrafluoroethyle ne in amount of abou t0.1 to 15 weight percent; depositing the food product in the baking container; placing the baking container in an oven at a baking tempgperature for a predete rmined time until the food product iss baked; and removi ng the baked food product from the baking conta iner. -21- AMENDED SHEET

© WO 2004/111128 PCT/US2004/017697

18. A method accordi ng to claim 17, wherei n the addition-cure=d silicone polyme r further includes: a methyl vi nyl silicone polymer from about 40 to 70 weight percent; a filler from about 5 to 50 weight percent; polytetraflLaoroethylene from abowit 0.1 to 15 weight percent; and a cross-linking agent from about 0.1 to 5 weight per—cent.

19. A method according to claim 17, wherein the addition-cure=d silicone polyme=r includes polytetrafluoroeths ylene in amount of abeout 6 weight percemt.

20. A method accord@ng to claim 17, wherean the addition-cure=d silicone polyme=r further includes: polydimettylvinylsiloxane from a bout 61 weight per-cent; a filler from about 28.5 weight pe=rcent; polytetraflLoroethylene from abo ut 6 weight percent; chloro plat-anic acid from about (3.57 weight percent; high vinyl silicone gum from abo at 1.1 weight perce=nt; a pigment from about 1.1 weight percent; zinc stearate from about 0.14 weight percent; silicone hywdride from about 1.7 vweight percent; andl ethynl cyclohexanol from about 0.01 weight percent. - 22. AMENDED SHEET

21. A flexible baking con®ainer comprising: a basin having at lea=st one wall attached at a fairst end to a floor; a shoulder surroundimng at least a portion of the- basin, the shoulder being attached to a second end of the wall opposite the floowr; a receiving channel discontinuously disposed v=vithin the shoulder; zand a carrier received by the receiving channel for goroviding additional mrigidity to the shoulder of thes baking container, thereb y enabling a user to more easily carry the baking cortainer.

22. A flexible baking container according to claim 21, wherein the wall &s integrally connected to the floosr and the shoulder.

23. A flexible baking container according to claim 21, wherein a cross section of the receiving channel is «circular.

24. A flexible baking container according to claim 221, wherein a cross section of the receiving channel is mrectangular.

25. A flexible baking con tainer according to claim 21 further comprising an entry slot communicable with tlhe receiving channel for alllowing placement o=fthe carrier within the receiving channe=l.

26. A flexible baking con tainer according to claim 21, wherein the carrier is integrally molded into the rece mving channel.

27. A flexible baking con tainer according to claim 21, wherein: the wall of the basin includes a pair of minor walls integrally connected to a pair of major walls sLich that each of the minor walls is spaced apar—tand each of the major walls is spaced apart; the receiving channe=| includes a central portior, a turning portion, &and an exit portion, the central po ation being in the shoulder- adjacent one of the major walls, the turning portior being in a corner portion of the shoulder, andl the exit portion being in the skoulder adjacent one of thee minor walls; the carrier includes am central stay, an arcuate sstay, and a handle; a nd the central stay is recceived by the central portion of the receiving channel, the arcuate stay is received by the turning portion off the receiving chanrmel, and at least a portion of the handle is re ceived by the exit portion of the receiving charnel.

-23.- AMENDED SHEET

© WO 2004/111128 PCE/US2004/017697

28. A flexible bakineg container according to claim 27, wherein the carrie ris formed from a metal rod havin g a circular cross section.

29. Aflexible bakineg container according to claim 21, wherein: the wall of the asin is a substantially cylindrical wall; the receiving channel includes an arcuate portion and an exit portior, the carrier inclu .des a central stay and a handle; and the central stay is received by the arcuate portion and at least a porstion of the handle is receiveed by the exit portion.

30. Aflexible bakin-g container according to claim 29, wherein the arcua_te portion subtends an ammgle greater than or equal to 90 degrees.

331. Aflexible bakin g container according to claim 29, wherein the carrie=r is formed from a metal rod havinag a circular cross section.

32. An elastomeric baking container comprising: a plurality of bam sins each having at least one wall attached at a first end to a floor; a shoulder surr-ounding at least a portion of each basin, the shoulde-r being attached to a seconcd end of the wall opposite the floor; a receiving cha _nnel disposed within each shoulder and including a depression; and a carrier formecd from a substantially flat plate having a plurality of agpertures, each aperture= having an edge with a lip, each aperture of the carrieer receiving one of the basimns such that the depression of the receiving channel engages the lip of the carri=er.

333. A flexible bakirag receptacle according to claim 32, wherein each koasin and shoulder form a muffin c ap.

34. A flexible bak _eware including any new and inventive integer or combination of integers, substantially as herein described.

35. Aflexible bakewware according to the invention, as hereinbefore gen erally described.

36. A flexible bake=ware as specifically described with reference to or =as illustrated in the accompanying drawings.

37. A method acceoording to the invention for baking a food product, subestantially as herein described or exemplified.

38. A method for baking a food product including any new and inventive integer or combination of integers, substantially as herein described. ~24- AMENDED SHEET

© WO 20004/111128 PCT/US2004/0217697

38. An e-lastomeric baking container including any ne-w and inventive integer or comb “ination of integers, substamtially as herein describe=d.

40. An elastomeric baking container according to the inventtion, as hereinbefore generally descr ibed.

41. An elastomeric baking container as specifically descmribed with references to or as illustrated in the accompanying drawings.

42. A flexible baking container including any new and invemntive integer or com bination of integers, substantially as herein described.

43. A flexible baking container according to the invention, as hereinbefore= generally described.

44. A flexible baking container as specifically described witzh reference to or ass illustrated in the= accompanying drawings.

45. A flexible baking receptacle including any new and inve=ntive integer or commbination of integers, substantially as herein described.

46. A fle xible baking receptacle according to the inventi on, as hereinbefore generally descmribed.

47. A flexible baking receptacle as specifically described wath reference to or ass illustrated in the accompanying drawings.

25. AMENDED SHEET