DESC:FORM 2
THE PATENTS ACT 1970
[39 OF 1970]
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
[See Section 10; rule 13]

"APPARATUS, SYSTEM, AND METHOD FOR COOKING FLATBREADS"

SECTORQUBE TECHNOLABS PRIVATE LIMITED
an Indian company,
of Startup Village, Kinfra Hi-Tech Park, HMT Colony P.O,
Kalamassery, Kochi, Kerala – 683503, India

The following specification particularly describes the invention and the manner in which it is to be performed

APPARATUS, SYSTEM, AND METHOD FOR COOKING FLATBREADS

FIELD OF THE INVENTION
[001] The present invention relates to an apparatus, system, and a method for cooking dough products. More particularly, the present invention relates to an apparatus for pressing a dough ball to prepare a flatbread and cooking the flatbread using conductive and radiative heating methods.

BACKGROUND
[002] The embodiments described herein relate generally to the field of making of flatbreads.

[003] Some known dough-flattening devices employ mechanism of flattening a dough ball between opposite surfaces of two plates, and baking the dough ball through heating of the two plates. Such dough-flattening devices are mainly hand driven and operate at high temperatures. Further, such dough-flattening devices cause cracking or breakage of dough ball, or result in over cooked flatbread due to human error. Furthermore, such devices are mainly hand driven, and cooking of the flatbread requires manual flipping of the flatbread. This causes much hassle to a user handling such device.

[004] Thus, a need exists for an apparatus, a system, and a method for automating the process of making flatbreads while maintaining a predefined operating temperature, and enabling cooking of a perfect flatbread by avoiding breakage of a dough ball during a pressing operation.

OBJECTS OF THE INVENTION
[005] It is an object of the present invention to provide an apparatus for pressing a dough ball to prepare a flatbread and cooking the flatbread by conductive and radiative heating methods.

[006] It is another object of present invention to maintain a predefined operating temperature inside an apparatus for cooking flatbread(s) by controlling power of heating element.

[007] It is another object of the present invention to provide conductive and radiative heating methods for proper cooking and increased speed of cooking of the flatbread.

SUMMARY OF THE INVENTION
[008] The present invention relates to an apparatus for cooking of a flatbread by conductive and radiative heating methods. The apparatus may comprise a bottom heater plate mounted over a base. A top surface of the bottom heater plate may be configured to receive a dough ball. A top heater plate may be positioned at a first predetermined height, above the bottom heater plate. The top heater plate may be present along a holding structure. A presser motor may be held by a load bearing structure. The load bearing structure may be supported from beneath by the holding structure. The presser motor may drive the top heater plate towards or away from the bottom heater plate using a lead screw. A downward motion of the top heater plate may press the dough ball to prepare a flatbread of a predefined thickness. Heating elements may be connected to the top heater plate and/or the bottom heater plate for heating the flatbread to a predefined temperature.

[009] In an embodiment, the apparatus may further comprise stoppers present on at least one set of diagonally opposite ends over the top surface of the bottom heater plate. The stoppers may avoid the top heater plate coming in contact with the bottom heater plate . For example, a height of the stoppers may define a minimum distance between the top heater plate and the bottom heater plate during the downward motion of the top heater plate. In an aspect, a pressing power of the presser motor may be controlled using a rotary encoder based on a user input.

[0010] In another embodiment, the apparatus may further comprise a heating coil mounting clamp for holding the heating elements against the top heater plate and/or the bottom heater plate. A thermocouple assembly may be connected to the heating element for turning off power supply to the heating element when the predefined temperature is attained.

[0011] In yet another embodiment, the apparatus may further comprise a halogen heater mounted on one side of the top heater plate for cooking the flatbread through radiative heating. In one scenario, after the top heater plate reaches a second predetermined height, the halogen heater may be activated. In an aspect, the apparatus may further comprise a fan placed adjacent to the bottom heater plate for uniform heating of the flatbread.

[0012] In yet another embodiment, the apparatus may further comprise a guide system including an upper segment, a bottom segment, and guide shafts. The upper segment of the guide system may move upon movement of the lead screw. The upper segment may move the top heater plate (08) through the guide shafts. A plate spacer may be positioned over the bottom segment. A height of the plate spacer may define a minimum distance between the upper segment and the bottom segment during a downward motion of the guide shafts.

BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings constitute a part of the description and are used to provide further understanding of the present invention. Such accompanying drawings illustrate the embodiments of the present invention which are used to describe the principles of the present invention together with the description.

[0014] Fig. 1 illustrates an apparatus for pressing and cooking a dough ball, in accordance with an embodiment of the present invention;

[0015] Fig. 2 illustrates a front view of the apparatus represented in the Fig. 1, in accordance with an embodiment of the present invention;

[0016] Fig. 3 illustrates a pressed position of the apparatus represented in the Fig. 1, in accordance with an embodiment of the present invention;

[0017] Fig. 4 illustrates a perspective view of an apparatus for pressing and cooking a dough ball, in accordance with another embodiment of the present invention;

[0018] Figs. 5a and 5b illustrate an isometric view of a bottom heater plate and an exploded view of top heater plate respectively, in accordance with an embodiment of the present invention;

[0019] Fig. 6 illustrates an isometric view of a bottom heater plate, in accordance with another embodiment of the present invention; and

[0020] Figs. 7a-7d illustrate various stages involved in cooking of a flatbread, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
[0021] The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the present invention and is not intended to represent the only embodiments in which the present invention may be practiced. Each embodiment described in this disclosure is provided merely as an example or illustration of the present invention, and should not necessarily be construed as preferred or advantageous over other embodiments.

[0022] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0023] Fig. 1 illustrates an apparatus (101) of pressing dough ball (19) to prepare a flatbread and cooking the flatbread, according to an embodiment of the present invention. The apparatus (101) for cooking the flatbread by conductive and radiative heating methods is proposed. The apparatus (101) is provided with a presser motor (01) to flatten the dough ball (19) by controlling vertical movement of a top heater plate (08). The presser motor (01) may be held in its position by a load bearing structure (02), a motor mount (02), and a guide system. A halogen heater holder (04) may be configured for holding a halogen heater (05). The halogen heater (05) may cook the flatbread using radiations. A fan (06) may be utilized for uniform heating of the flatbread. A top surface of a bottom heater plate (07) may be configured to receive the dough ball (19). The bottom heater plate (07) may be mounted over a base (10). The top heater plate (08) may travel downwards to press the dough ball (19) to prepare the flatbread (20). At least two stoppers (09) may be present on at least one set of diagonally opposite ends over the top surface of the bottom heater plate (07). More preferably four stoppers each placed at each corner of the top surface of the bottom heater plate (07) may restrict the downward motion of the top heater plate (08) towards the bottom heater plate (07). The stoppers (09) may avoid the top heater plate (08) coming in contact with the bottom heater plate (07) and therefore prevent breaking of flatbread (20) by maintaining a minimum distance between the top heater plate (08) and the bottom heater plate (07). The minimum distance may be defined by a height of the stoppers (09). In an aspect, each of the stoppers (09) may have same height for an even thickness of the flatbread (20) throughout a surface area of the flatbread (20).

[0024] The present invention is made fully automated and is enabled to maintain a predefined temperature during cooking and producing a perfectly cooked flatbread.. In an aspect, the predefined temperature may vary based on a type of dough selected.
[0025] The cooking of flatbread in the present invention involves both means of heating by conduction and radiation to effectively increase the speed of cooking process and making the cooking more efficient.
[0026] In order to achieve the purpose of the present invention, the apparatus (101) may be provided with means for adjusting pressing power of the presser motor (01). Such adjusting may be achieved by rotatory encoders configured to receive a user’s input.
[0027] Fig. 2 shows a front view of the apparatus (101) according to an embodiment of the present invention. Particularly, a lead screw (11) may be provided in the apparatus (101) through which force may be transmitted to the top heater plate (08). Further, Fig. 3 shows an arrangement of the apparatus (101) in a pressing operation when the lead screw (11) may be pressed to transfer force to the top heater plate (08). A holding structure (12) may hold the top heater plate (8), and allow the load bearing structure (02) to be placed atop.
[0028] Fig. 4 illustrates a perspective view of the apparatus (401), in accordance with another embodiment of the present invention. The presser motor (01) may provide power for vertical motion of the top heater plate (08). The presser motor (01) may be configured to rotate the lead screw (11) on a vertical axis of the lead screw (11). A second screw (not shown) connected to the guide system may be mounted over the lead screw (11). The guide system may include an upper segment (30), guide shafts (32), and a bottom segment (34). Rotation of the lead screw (11) would result into upward and downward movement of the upper segment (30). In an aspect, clockwise rotation of the lead screw (11) may result into a downward movement of the upper segment (30), and anti-clockwise rotation of the lead screw (11) may result into an upward movement of the upper segment (30). The upper segment (30) may be connected to the top heater plate (08) through the guide shafts (32), and the vertical motion of the upper segment (30) may therefore lead to a vertical motion of the top heater plate (08). The bottom segment (34), positioned over the holding segment (12), may be stationary.
[0029] In an embodiment, the apparatus (401) may comprise a plate spacer (18) positioned over the bottom segment (34). The plate spacer (18) may restrict the vertical motion of the upper segment (30). A minimum distance between the upper segment (30) and the bottom segment (34) may be defined by a height of the plate spacer (18). In an exemplary implementation, the first predetermined height, between the top heater plate (08) and the bottom heater plate (07) is 80mm. The upper segment (30) could travel a distance of 79mm downwards before being restricted by the plate spacer (18) having a height of 1mm. When the top plate (08) moves downwards, the plate spacer (18) may prevent the motion of the upper segment (30) beyond a particular range, thereby leaving some distance between the top heater plate (08) and the bottom heater plate (07). Therefore, a least possible distance between the top heater plate (08) and the bottom heater plate (07) is defined by the height of the plate spacer (18). Such least possible distance between the top heater plate (08) and the bottom heater plate (07) would define the thickness of the flatbread prepared upon pressing of the dough ball (19). Therefore, the thickness of the flatbread may be 1mm, in current implementation.
[0030] In another embodiment, rotary encoders (20) may be provided over the guide system. The rotary encoders (20) may receive user input so that a required thickness of the flatbread is achieved. For example, a user may input that the guide system should travel a distance of 78mm downward. Such movement of the guide system may be controlled by the presser motor (01). Therefore, in current case, while a distance of 78mm is defined by the user, a flatbread of 2mm may be obtained. A reset switch (22) may reset the input provided by a user, so that the guide system could travel the downward distance of 79mm. Further, an opening (24) may be provided so that the fan (06) may be accommodated within the opening (24). The fan may allow circulation of heat over the flatbread, therefore resulting in uniform cooking of the flatbread.
[0031] Fig. 5a represents an isometric view of the bottom heater plate (07). In an aspect, either one or both of the bottom heater plate (07) and the top heater plate (08) may have a heating element (14) affixed thereto. An arrangement of a custom shaped tubular heating coils (14), preferably tubular coils (14), is shown on the bottom heating plate (07). Fig. 5a also illustrates an arrangement of thermocouple assembly (15) connected to the heating element (14), arranged in the apparatus (101) for temperature measurement. A heating coil mounting clamp (16) may be utilized for holding the heating elements (14) to the bottom heater plate (07).
[0032] Fig. 5b represents an exploded view of the top heater plate (08). Preferably, a halogen heater (05) may be mounted on one side of the top heater plate (08). More preferably, two halogen heaters may be mounted on opposite sides of the top heating plate (08). A halogen holder (04) may hold the halogen heater (05) on the side of the top heater plate (08).
[0033] Fig. 6 represents an isometric view of a bottom heater plate (600), in accordance with another embodiment. In an aspect, either one or both of the bottom heater plate (600) and a top heater plate may have a heating element (602) affixed thereto. An arrangement of a custom shaped tubular heating coils (602), preferably rectangular coils, is shown on the bottom heating plate (600). Fig. 6 also illustrates an arrangement of a thermocouple assembly (604) connected to the heating element (602) for temperature measurement, arranged in an apparatus for cooking a flatbread. A heating coil mounting clamp (606) may be utilized for holding the heating elements (602) to the bottom heater plate (600). The heating element (14) may be in a rectangular shape, circular shape, U shape, concentric shape, or a combination thereof.
[0034] The present invention has a functioning of pressing the dough ball to prepare a flatbread and cooking the flatbread. The functioning is described below with respect to Figs. 7a-7d.
[0035] When the dough ball (19) is received, as illustrated in Fig. 7a, on the top surface of the bottom heater plate (07), the presser motor (01) may get activated. Rotational torque generated from the presser motor (01) may be transferred to the top heater plate (08) using a lead screw (11) connected directly to the presser motor (01). The top heater plate (08) may move downwards and press the dough ball (19), as illustrated in Fig. 7b, until the stoppers (09) restrict the downward motion beyond a limit defined by heights of the stoppers (09). In an aspect, a level of pressing, by the presser motor (01), may be defined based on user's input through rotatory encoders (20). The top heater plate (08) and the bottom heater plate (07) may be powered to heat up to the predefined temperature. The thermocouple assemblies (15) connected to the heating elements (14) may be used to monitor the temperatures of both the top heater plate (08) and the bottom heater plate (07). After reaching the predefined temperature, the top heater plate (08) and the bottom heater plate (07) may be powered off, and the thermocouple assembly (15) may maintain the temperature of the top heater plate (08) and the bottom heater plate (07) by controlling the power of respective heating element (14). A fan (06) may be utilized to enable uniform heating of the flatbread.
[0036] In an aspect, the top heater plate (08) and the bottom heater plate (07) may be powered before pressing of the dough ball (19). Such powering of the top heater plate (08) and the bottom heater plate (07) may be enable heating of the dough ball (19) during the pressing operation, as well as swift cooking of the flatbread.
[0037] As illustrated in Fig. 7c, a flattened dough ball (19) is obtained after the pressing operation and heating operation. Thereafter, the top heater plate (08) may return to a second predetermined height above bottom heater plate (07). Upon reaching such height, the halogen heater (05) placed on the side of the top heater plate (08) may be switched on. Preferably, two halogen heaters (05) may be placed on opposing sides of the top heater plate (08). Radiative heat energy from the halogen heaters (05) may be adjusted either electronically or by changing the predefined height of the top heater plate (08). The halogen heaters (05) may help cook the flatbread evenly and quickly. As illustrated in Fig. 7d, a cooked flatbread (30) is obtained upon radiative heating of the flattened dough ball (19).
[0038] In the above detailed description, reference is made to the accompanying drawings that form a part thereof, and illustrate the best mode presently contemplated for carrying out the invention. However, such description should not be considered as any limitation of scope of the present unit. The structure thus conceived in the present description is susceptible of numerous modifications and variations, all the details may furthermore be replaced with elements having technical equivalence.
,CLAIMS:We claim:
1. An apparatus (101) for cooking a flatbread, the apparatus (101) comprising:
a bottom heater plate (07) mounted over a base (10), wherein a top surface of the bottom heater plate (07) is configured to receive a dough ball;
a top heater plate (08) positioned at a first predetermined height, above the bottom heater plate (07), and present along a holding structure (12);
a presser motor (01) held by a load bearing structure (02), wherein the load bearing structure (02) is supported from beneath by the holding structure (12), wherein the presser motor (01) drives the top heater plate (08) towards or away from the bottom heater plate (07), using a lead screw (11), and wherein a downward motion of the top heater plate (08) presses the dough ball to prepare a flatbread of a predefined thickness; and
heating elements (14) connected to at least one of the top heater plate (08) and the bottom heater plate (07) for heating the flatbread to a predefined temperature.

2. The apparatus (101) as claimed in claim 1, further comprising stoppers (09) present on at least one set of diagonally opposite ends of the bottom heater plate (07) to avoid the top heater plate (08) coming in contact with the bottom heater plate (07).

3. The apparatus (101) as claimed in claim 2, wherein a height of the stoppers (09) define a minimum distance between the top heater plate (08) and the bottom heater plate (07), during the downward motion of the top heater plate (08).

4. The apparatus (101) as claimed in claim 1, wherein a pressing power of the presser motor (01) is controlled using at least one rotary encoder (20) based on a user input.

5. The apparatus (101) as claimed in claim in 1, further comprising a heating coil mounting clamp (16) for holding the heating elements (14) against at least one of the top heater plate (08) and the bottom heater plate (07).

6. The apparatus (101) as claimed in claim 1, further comprising a thermocouple assembly (15) connected to the heating element (14) for turning off power supply to the heating element (14) when the predefined temperature is attained.

7. The apparatus (101) as claimed in claim 1, further comprising at least one halogen heater (05) mounted on at least one side of the top heater plate (08) for cooking the flatbread through radiative heating, after the top heater plate (08) has reached a second predetermined height.

8. The apparatus (101) as claimed in claim 1, further comprising a fan (06) placed adjacent to the bottom heater plate (07) for uniform heating of the flatbread.

9. The apparatus (101) as claimed in claim 1, further comprising a guide system including an upper segment (30), guide shafts (32), and a bottom segment (34), wherein the upper segment (30) of the guide system moves upon movement of the lead screw (11), and the upper segment (30) moves the top heater plate (08) through the guide shafts (32).

10. The apparatus (101) as claimed in claim 9, further comprising a plate spacer (18) positioned over the bottom segment (34), wherein a height of the plate spacer (18) defines a minimum distance between the upper segment (30) and the bottom segment (34), and wherein the minimum distance between the upper segment (30) and the bottom segment (34) is equal to a minimum distance between the top heater plate (08) and the bottom heater plate (07).

Dated this 09/04/2019
[JAYANTA PAL]
IN/PA No. 172
OF REMFRY AND SAGAR
ATTORNEY FOR THE APPLICANT(S)