FIELD OF THE INVENTION

The present invention relates to the field of food products, and more particularly, to structures and production processes of edible wafer tubes for holding food substances, such as ice cream.

BACKGROUND OF THE INVENTION

There are two general techniques for manufacturing ice cream cones. A casting or molding process involves pouring batter into a cone-shaped mold, baking the batter, and then removing the cones from the mold. Specifically, a batter is set into a concave mold (female mold), which is pressed against a convex die (male mold), forming a high pressure (e.g., 100 bar). The batter bakes in between the molds (subject to a baking temperature) and then the molds are opened to extract the finished cone, and the process repeated for a next batch. The batter is substantially liquid, such as being composed of approximately 50% water (and/or other liquid), along with other ingredients (e.g., flour, oil, baking powder). The casting ovens may include multiple casting pans that are subject to exposed heating at high temperatures. An individual casting pan may include multiple molds, such that multiple cones are produced concurrently for a given molding session.

In a rolling production process, the batter is baked while flat and then quickly rolled before hardening. This entails pouring a thicker batter onto a waffle iron, baking the batter into a waffle, rolling the hot waffle into a cone, and pressing overlapping segments of the waffle walls together so that they cool and retain a conical form. The batter, which is generally more viscous than in a casting process, is infused onto a first pan and pressed against a second pan to form a flat (pancake-like) wafer. The baking is generally quicker than for a molding process (e.g., 60 seconds rather than a couple of minutes). The batter usually contains a flexibility producing agent, such that the resultant baked wafer retains flexibility for a brief duration until it hardens. While in the flexible state, the flat wafer is passed through a rolling apparatus having a pair of rollers with a rotor and a stator, such that the wafer sticks to the rotating rotor and forms a cone. The rotating rotor typically has a thin diameter, such as approximately 8-9 millimeters (mm). Each session of pan infusion followed by baking and rolling produces a single rolled cone.

Both these techniques are dependent on specialized equipment and cannot easily accommodate production variations. In the absence of significant equipment investment, manufactured cones are generally limited to a constant length and diameter. For example, molded cones are limited to a fixed mold size and cannot be produced with variable dimensions. A rolling production process requires significant modifications to enable altering cone dimensions, such as for receiving additional batter material and for varying rolling alignments to form an extended cone length having an enclosed tip. Furthermore, the cone walls in molded cones are single-layered and are therefore prone to breakage. Rolled cones may be partially double-layered at the overlapping portions but may nevertheless lack rigidity and be susceptible to fracturing. Additionally, existing cones lack the capacity to receive various edible linings during the manufacturing process.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, there is thus provided a flattened wafer tube, including a multi-layered wafer tube having a tube wall, and formed of a flattened baked dough strip having a first strip segment and a contiguous second strip segment, the second strip segment wrapped onto a portion of the first strip segment, the wafer tube including a flattened tube segment, at a first end of the wafer tube; an opening, for receiving a food substance, the opening at a second end of the wafer tube opposite the first end; and an intermediate tubular section, for containing the food substance, between the opening and the flattened segment. The flattened tube segment may include a first portion and a second portion of the tube wall pressed in abutment and sealed together. The opening may have an inner diameter between 20-80 millimeter (mm). The opening may have an inner diameter between 50-70 mm. The wafer tube may have a length between 50-200 mm. The flattened tube segment may have a length between 5-25 mm. The flattened tube segment may have a length between 5-15 mm. The flattened wafer tube may include an edible inner lining, coating an inner surface of the wafer tube. The flattened wafer tube may include an edible external coating, coating an exterior surface of the wafer tube. The external coating may be a helical coating. The flattened wafer tube may include a first intermediate tubular section extending from the flattened tube segment into a first opening, for receiving a first food substance, and a second intermediate tubular section extending from the flattened tube segment into a second opening, for receiving a second food substance. The flattened tube segment may include a crimping of the tube wall, the wafer tube bent about the crimped tube wall, such that a first bent portion of the wafer tube forms the first intermediate tubular section, and a second bent portion of the wafer tube forms the second intermediate tubular section. The second intermediate tubular section may be disposed substantially parallel to the first intermediate tubular section. The second intermediate tubular section may have a length different than a length of the first intermediate tubular section. The flattened tube segment may have a perforation. At least one of the first intermediate tubular section and the second intermediate tubular section may include an edible inner lining, coating an inner surface thereof. In accordance with another aspect of the present invention, there is thus provided an apparatus for producing a flattened wafer tube. The apparatus includes a first roller and a second roller, configured for flattening a baked dough strip passing between the first roller when rotating and the second roller when rotating, and to wrap a contiguous second strip segment of the baked dough strip onto a portion of a first strip segment of the baked dough strip, during advancement between the first roller and the second roller, to form a multi-layered wafer tube having a tube wall. The apparatus further includes a cutter, configured for cutting the wafer tube into a selected length, and a presser, configured for pressing a first portion and a second portion of the tube wall into abutment, pressed portions of the tube wall being sealed by cooling of the wafer tube, to form a flattened tube segment, such that the wafer tube includes: the flattened tube segment, at a first end of the wafer tube; an opening, for receiving a food substance, at a second end of the wafer tube opposite the first end; and an intermediate tubular section, for containing the food substance, between the opening and the flattened tube segment. The first roller may have a first diameter and the second roller has a second diameter, the second diameter defining an inner diameter of the wafer tube. The first roller may be a threaded roller, and the second roller may be an exchangeable roller. The first roller may include at least one helical groove. The second roller may include at least one port, communicatively coupled with an edible lining material source, the port configured to inject edible lining material, during advancement of the baked dough strip between the first roller and the second roller, to form an edible inner lining, coating an inner surface of the wafer tube. The cutter may be configured to cut a continuously conveyed wafer tube at a predetermined cutting frequency. The apparatus may further include a coater, configured to deliver edible coating material to coat an exterior surface of the wafer tube. Pressing a first portion and a second portion of the tube wall into abutment may include crimping the tube wall at an intermediate region of the wafer tube, wherein the wafer tube is bent about the crimped tube wall, such that a first bent portion of the wafer tube forms a first intermediate tubular section extending from the flattened tube segment into a first opening, for receiving a first food substance, and a second bent portion of the wafer tube forms a second intermediate tubular section extending from the flattened tube segment into a second opening, for receiving a second food substance. The second intermediate tubular section may have a length different than a length of the first intermediate tubular section. The apparatus may further include a perforator, configured to provide a perforation on the flattened tube segment.

In accordance with a further aspect of the present invention, there is thus provided a method for producing a flattened wafer tube. The method includes the step of flattening a baked dough strip by passing through a rotating first roller and a rotating second roller, and wrapping a contiguous second strip segment of the baked dough strip onto a portion of a first strip segment of the baked dough strip, during advancement between the first roller and the second roller, to form a multi-layered wafer tube having a tube wall. The method further includes the steps of cutting the wafer tube into a selected length; pressing a first portion and a second portion of the tube wall into abutment; and sealing pressed portions of the tube wall by cooling of the wafer tube, to form a flattened tube segment, such that the wafer tube includes: the flattened tube segment, at a first end of the wafer tube; an opening, for receiving a food substance, at a second end of the wafer tube opposite the first end; and an intermediate tubular section, for containing the food substance, between the opening and the flattened tube segment. The second roller may be an exchangeable roller, and the method may include selecting an inner diameter of the wafer tube by providing the second roller having a corresponding selected diameter. The method may include injecting edible lining material from at least one port of the second roller, during advancement of the baked dough strip between the first roller and the second roller, to form an edible inner lining, coating an inner surface of the wafer tube. Cutting the wafer tube into a selected length may include cutting a continuously conveyed wafer tube at a predetermined cutting frequency. The method may include delivering edible coating material, to coat an exterior surface of the wafer tube. Pressing a first portion and a second portion of the tube wall into abutment may include crimping the tube wall at an intermediate region of the wafer tube, the method further comprising bending the wafer tube about the crimped tube wall, such that a first bent portion of the wafer tube forms a first intermediate tubular section extending from the flattened tube segment into a first opening, for receiving a first food substance, and a second bent portion of the wafer tube forms a second intermediate tubular section extending from the flattened tube segment into a second opening, for receiving a second food substance. The second intermediate tubular section may have a length different than a length of the first intermediate tubular section. The method may include perforating the flattened tube segment.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the drawings in which:

Figure 1 is a schematic side-view illustration of an apparatus for production of flattened wafer tubes, operative in accordance with an embodiment of the present invention;

Figure 2 is a perspective-view illustration of a rolling stage in the production of a flattened wafer tube using the apparatus of Figure 1 , operative in accordance with an embodiment of the present invention;

Figure 3 is a perspective-view illustration of a pre-cutting and prepressing stage in the production of a flattened wafer tube using the apparatus of Figure 1 , operative in accordance with an embodiment of the present invention;

Figure 4 is a side-view illustration of a flattened wafer tube, according to an embodiment of the present invention;

Figure 5 is a front-view illustration of the flattened wafer tube depicting its flattened end, according to an embodiment of the present invention;

Figure 6 is a top-view illustration of the flattened wafer tube depicting its open end for food receipt, according to an embodiment of the present invention;

Figure 7 is a perspective-view illustration of a flattened wafer tube having an elongated flattened end and loaded with a food product, according to an embodiment of the present invention;

Figure 8 is a front-view illustration of a flattened wafer tube having a flavored inner lining, according to an embodiment of the present invention; Figure 9 is a front-view illustration of a flattened wafer tube having a flavored inner lining and an external helically striped coating, according to an embodiment of the present invention;

Figure 10 is a side-view illustration of a flattened wafer tube in a double tube configuration having two openings and tubular sections, according to another embodiment of the present invention;

Figure 11 is a perspective-view illustration of a flattened wafer tube in a double tube configuration, according to another embodiment of the present invention;

Figure 12 is a front-view illustration of a flattened wafer tube in a double tube configuration, according to another embodiment of the present invention;

Figure 13 is a perspective-view illustration of a user holding a flattened wafer tube, according to an embodiment of the present invention; and

Figure 14 is a perspective-view illustration of a user holding a flattened wafer tube in a double tube configuration, according to another embodiment of the present invention.

It will be appreciated that for the sake of clarity, elements shown in the figures may not be drawn to scale and reference numerals may be repeated in different figures to indicate corresponding or analogous elements.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The following description is provided so as to enable any person skilled in the art to make use of the invention and sets forth examples contemplated by the inventor of carrying out this invention. Various modifications, however, will remain apparent to those skilled in the art, since the generic principles of the present invention have been defined specifically. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and claims and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.

It will be understood that, although the terms first, second, etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. Rather, these terms are only used to distinguish one element, component, region, layer and/or section, from another element, component, region, layer and/or section.

It will be understood that when an element is referred to as being “on”, “attached” to, “operatively coupled” to, “operatively linked” to, “operatively engaged” with, “connected” to, “coupled” with, “contacting”, “added to, another element, it can be directly on, attached to, connected to, operatively coupled to, operatively engaged with, coupled with, added to, and/or contacting the other element or intervening elements can also be present. In contrast, when an element is referred to as being “directly contacting” another element or “directly added” to another element, there are no intervening elements and/or steps present.

Whenever the term “about” or “approximately” is used, it is meant to refer to a measurable value such as an amount, a temporal duration, and the like, and is meant to encompass variations (e.g., ±20%, ±10%, ±5%, ±1 %, ±0.1 %) from the specified value, as such variations are appropriate to perform the disclosed methods.

Certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

Throughout this application, various embodiments of this invention may be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range, regardless of the breadth of the range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1 , 2, 3, 4, 5, and 6. Whenever a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range. For example, the phrases “ranging/ranges between” a first indicated number and a second indicated number and “ranging/ranges from” a first indicated number “to” a second indicated number are used herein interchangeably and are meant to include the first and second indicated numbers and all fractional and integral numerals there between.

Whenever terms “plurality” and “a plurality” are used it is meant to include, for example, “multiple” or “two or more”. The terms “plurality” or “a plurality” may be used throughout the specification to describe two or more components, devices, elements, units, parameters, or the like. The term set when used herein may include one or more items. Unless explicitly stated, the method embodiments described herein are not constrained to a particular order or sequence. Additionally, some of the described method embodiments or elements thereof can occur or be performed simultaneously, at the same point in time, or concurrently.

The terms “dough” and “batter” are used interchangeably herein to describe a mixture of flour and liquid with other ingredients, such as leavening agents, yeast, sugar, salt, eggs, and/or flavorings, and used for baking or cooking processes.

The term “wafer” is used herein to broadly refer to a baked food product, of any texture, shape, or thickness, and produced by baking dough or batter.

The terms “user” and “operator” are used interchangeably herein to refer to any individual person or group of persons using or operating a method, apparatus or machine in accordance with embodiments of the present invention.

The present invention overcomes the disadvantages of the prior art by providing novel wafer tubes capable of holding food substances, such as ice cream, and apparatuses and methods for producing such wafer tubes. The wafer tube includes a flattened tube segment at one end, an opening for receiving a food substance at an opposite end, and an intermediate tubular section for containing the food substance, between the opening and the flattened tube segment. The wafer tube is produced by flattening a baked dough strip by passing through a rotating first roller and a rotating second roller, and wrapping a contiguous second strip segment of the baked dough strip onto a portion of a first strip segment of the baked dough strip, during advancement between the first roller and the second roller, to form a multi-layered wafer tube having a tube wall. The formed tube is cut into a selected length, and portions of the tube wall are pressed into abutment and sealed together by cooling to form the flattened tube segment. The flattened wafer tube may be provided with a flavored inner lining, coating an inner surface, and/or a flavored external coating, coating an exterior surface. The wafer tube may be formed with multiple openings for respectively containing multiple food substances, such as different scoops of ice cream in each opening. In particular, the wafer tube may be in a double tube configuration, produced by crimping the tube wall at an intermediate region of the wafer tube to form the flattened tube segment, and bending the wafer tube about the crimped tube wall, such that a pair of intermediate tubular sections extend from either side of the crimped tube wall with respective openings for receiving respective food substances. The wafer tube may be characterized with high rigidity and structural integrity by its multilayering and may be substantially averse to fracturing or breakage. The wafer tube is conducive to manufacture in a variety of dimensions, such as a variable length and a variable inner diameter, without significant investment in specialized equipment. Accordingly, the disclosed embodiments may facilitate large scale commercialization and overcome challenges associated with current apparatuses and methods for ice cream cone production.

Embodiments of the present invention relate to wafer tubes, and specifically to an edible flattened wafer tube having the capacity to hold various foods. Without diminishing in scope, this application will discuss the flattened wafer tube in the context of holding ice cream.

Turning now to the Figures, Fig.1 is a schematic side-view illustration of an apparatus, referenced 100, for production of flattened wafer tubes, operative in accordance with an embodiment of the present invention. Apparatus 100 is configured for rolling dough or batter for producing a flattened wafer tube. Apparatus 100 includes a driven threaded first roller 102 and an exchangeable second roller 103. First roller 102 may include at least one helical groove (not shown) extending circumferentially around the exterior of roller 102 along its length, and operative to advance dough horizontally while the baked dough is wrapped during rotation of rollers 102, 103. First roller 102 is directed to rotate axially about a first rotational direction 102R (e.g., clockwise). Second roller 103 is substantially smaller in diameter than first roller 102 and defines a maximum inner diameter of a rolled wafer tube. For example, second roller 103 may have a diameter between 20-80 millimeters (mm), such as approximately 50mm, which may be substantially larger than the diameter of corresponding rollers of existing wafer rolling machines (e.g., 8-9 mm). An exemplary diameter of first roller 102 is 2 meters (m). Second roller 103 is directed to rotate axially about a second rotational direction 103R (e.g., counterclockwise). Second roller 103 may include at least one ridge or groove (not shown), such as a plurality of grooves arranged circumferentially around the exterior of roller 103, each groove extending longitudinally across the length of roller 103. Second roller 103 is fitted with at least one port 104 disposed on a segment of roller 103, such as on a reduced diameter segment 105. For example, roller 103 may include a plurality of ports 104 arranged circumferentially along roller segment 105. Port 104 is in communication with a filler pump (not shown) operative to deliver a liquid filler to an inner surface of a flattened wafer tube to form an inner lining, as will be discussed hereinbelow. Reduced diameter segment 105 provides space for the filler during injection while wrapping a baked dough strip into a tube.

Reference is made to Figure 2, which is a perspective-view illustration of a rolling stage in the production of a flattened wafer tube using the apparatus of Figure 1 , operative in accordance with an embodiment of the present invention. As shown, a single continuous baked dough strip 106 is fed in between rotating rollers 102 and 103 of a flattened wafer tube production apparatus 100. Segments of dough strip 106 are flattened while passing between rotating rollers 102 and 103. First roller 102 may be subject to a baking temperature (e.g., approximately 180°C) such that dough strip 106 is baked while contacting the surface of roller 102, such as throughout the duration of a full rotation thereof. The heating of roller 102 and/or dough strip 106 may be effected using an open flame, such as a gas burner, or via electrical heating. The baked dough strip 106 advances around second roller 103 such that each strip segment 107 is wrapped concentrically around part of a previous dough strip segment 107 during advancement along roller 103 to form a multi-layered wafer tube 108. Each strip segment 107 may be wrapped over a previous strip segment, such as partially overlapping the previous strip segment diagonally. The overlap displacement may be defined by a relative angle between the strip segments 107 and roller 103 and by the rotation speed of roller 103. The rotation speed of each roller 102, 103 may be adjustable. An inner tube diameter of a flattened wafer tube diameter produced by apparatus 100 may be defined by the diameter of roller 103. An advancement rate of baked dough strip 106 may be defined by the degree of helicity and the rotation speed of threaded first roller 102.

After the rolling stage is completed, wafer tube 108 is cut, such as using a suitable cutting tool or cutting mechanism, into a selected size while in a heated state, and a portion of the tube walls are pressed together, either partially or entirely. Reference is made to Figure 3, which is a perspective-view illustration of a pre-cutting and pre-pressing stage in the production of a flattened wafer tube using the apparatus of Figure 1 , operative in accordance with an embodiment of the present invention. The continuously formed multi-layered wafer tube 108 is directed along a conveyor 111 toward a cutting area (not shown in Figure), such as by passing through an aperture 116 of a divider 115. On the other side of divider 115 is a cutting tool or cutter (not shown), such as a knife, configured to cut through the conveyed wafer tube 108 at predetermined intervals, or a predetermined cutting frequency, defining a length of a cut wafer tube. The cut wafer tube is then brought to a pressing device (not shown), which presses the tube walls together at a section of the tube, such as at an end or a middle section of the tube. In particular, a portion of the tube walls at an end of the wafer tube are pressed into abutment with one another. The cutting and pressing are performed while the wafer tube is still in a heated and flexible state, such as during a period of about 15 seconds after baking. The pressed tube walls are sealed or fastened together through cooling, to form a flattened segment at the wafer tube end. The flattened segment may resemble a sealed end of a toothpaste tube. The portions of wafer tube where the tube walls are not pressed together retain a tubular structure, with an opening for receipt of food at an opposite end of the wafer tube from the flattened segment.

Reference is made to Figures 4, 5, 6, which depict a side-view, a front-view, and a top-view illustration, respectively, of a flattened wafer tube, according to an embodiment of the present invention. The flattened wafer tube, generally referenced 120, includes a flattened tube segment 122 at a first end (e.g., a bottom end) of wafer tube 120, an opening 126 at a second end (e.g., a top end) of wafer tube 120 opposite from the first end, and an intermediate tubular section 124 in between flattened tube segment 122 and opening 126. Opening 126, which can be seen clearly in the top-view (Fig.6), is configured to receive a food product, such as ice cream. At least part of the received food product may permeate into intermediate tubular section 124 to be contained therein. Flattened segment 122, which can be seen clearly in the front-view (Fig.5), is configured to seal an end (e.g., a bottom end) of wafer tube 120, to prevent the contained food from leaking or falling out of wafer tube 120 and to facilitate consuming of the wafer tube 120 with contained food. Flattened wafer tube 120 is formed by concentric strip segments 123 of a baked dough strip, where tube walls at the first end are pressed together into abutment when heated, and then sealed during a cooling process to form flattened segment 122. The pressing may be automated or implemented manually, such as using a suitable pressing device or mechanism (i.e., presser). The tube wall sections not pressed together retain a tubular structure and form intermediate tubular section 124 of flattened wafer tube 120. The concentric strip segments may reinforce the tube wall thereby reducing undesired fracturing or breakage common in existing ice cream cones.

As noted above, an inner diameter of opening 126 is defined by a diameter of exchangeable second roller 103 of flattened wafer tube production apparatus 100, which may be modified by exchanging roller 103 with another roller having a desired diameter. Flattened wafer tube 120 may have an opening 126 with an inner diameter between 20-80 millimeters (mm), for example, or an inner diameter between 50-70 mm. While opening 126 is depicted as substantially circular, the opening may comprise other cross-sectional shapes, such as substantially elliptical or oval, or an edged shape such as substantially square or rectangular. Intermediate tubular section 124 may comprise multiple inner diameters and multiple cross-sectional shapes, such as having a wider diameter and a substantially circular cross-section adjacent to opening 126, and gradually tapering to a narrower diameter and substantially oval cross-sectional shape as intermediate section 124 extends toward flattened segment 122.

The total length of the disclosed flattened wafer tube (i.e., measured along a longitudinal axis of wafer tube 120 extending between open end 126 and an edge of flattened segment 122) may be, for example, between 50-200mm, such as between 70-170 mm. The length of the flattened wafer tube may be variable and is defined by cutting the wafer tube at a desired length during production, thereby eliminating the need to change rolling equipment or production machine components as would be necessary for varying cone length in current ice cream cone production. For example, the length of the flattened wafer tube may be varied by modifying a cutting frequency of a cutter configured to cut through a continuously conveyed wafer tube at predetermined intervals. Flattened segment 122 may have varying lengths, as a proportion of the entire length of flattened wafer tube 120. For example, the length of flattened segment 122 (i.e., measured along a longitudinal axis of wafer tube 120) may between 5-25 mm, such as between 5-15 mm. According to an embodiment, the flattened segment may have an extended length and define a concavity, so as to facilitate the depositing or removal of a food, such as the ladling or scooping of a liquid or viscous food substance. Reference is made to Figure 7, which is a perspective-view illustration of a flattened wafer tube, having an elongated flattened end and loaded with a food product, according to an embodiment of the present invention. The flattened wafer tube, generally referenced 130, includes a flattened tube segment 132 at a first (e.g., bottom) end of wafer tube 130 with an elongated length (such as compared to flattened tube segment 122 depicted in Fig.5). A food product, embodied by an ice cream scoop 135, is loaded into an open (e.g., top) end of wafer tube 130, for consuming by a user.

The disclosed flattened wafer tube may be produced with a flavored lining. The flavored lining may coat at least a portion of an inner surface of the intermediate tubular portion of the flattened wafer tube. Reference is made to Figure 8, which is a front-view illustration of a flattened wafer tube, generally referenced 140, having a flavored inner lining, according to an embodiment of the present invention. Flattened wafer tube 140 includes a flattened segment 142 at a first (e.g., bottom) end, an opening 146 at a second (e.g., top) end opposite from the first end, and an intermediate tubular section 144 in between flattened segment 142 and opening 146. A flavored coating or lining 148 coats an inner surface of flattened wafer tube 140. Lining 148 may have variable dimensions and be composed of various materials or ingredients. For example, lining 148 may extend along an entire length of flattened wafer tube 140. Alternatively, lining 148 may coat an inner surface of only intermediate tubular section 144, and not of flattened segment 142. Lining 148 may extend at least partially over an outer surface of flattened wafer tube 140, such as coating an exterior edge surface adjacent to opening 146. Lining 148 may be provided during the production process using apparatus 100, such as by hot injection of lining material through port 104 of roller 103 during the wrapping of hot baked dough strip 106 (as can be seen in Fig.2). A flavored lining of the flattened wafer tube may be composed of one or more materials or ingredients capable of being hot injected, or alternatively cold injection, during production of the flattened wafer tube, and suitable for user consumption. Exemplary flavored lining compositions include but are not limited to: chocolate; caramel; vanilla; butterscotch; fruit flavorings; and other injectable edible materials. The flavored lining may contain additional ingredients, such as ground up nuts or seeds (e.g., coconut shavings); dried fruits bits; candy sprinkles; and the like, which may be applied to the lining during the production process while the lining is still hot after injection. The flattened wafer tube may also include multiple flavored linings, such as a first lining (e.g., having a first flavor) coating a first portion of an inner surface, and a second lining (e.g., having a second flavor) coating a second portion of an inner surface.

A flavored lining or coating may also be provided on an outer surface of a disclosed flattened wafer tube, such as instead of or in addition to an inner coating. Reference is made to Figure 9, which is a front-view illustration of a flattened wafer tube having a flavored inner lining and an external helically striped coating, according to an embodiment of the present invention. Flattened wafer tube 150 resembles wafer tube 140 (Figure 8) having a flattened segment 152 at one end, an opening 156 at an opposite end, an intermediate tubular section 154 therebetween, and a flavored lining 158 coating an inner surface. In addition, an external coating 159 is disposed in a spiral or helical pattern around an outer surface of flattened wafer tube 150. External coating 159 may extend along an entire length of flattened wafer tube 150, or a partial length thereof, such as extending along only intermediate tubular section 145 and not flattened segment 152. Coating 159 may be disposed in any arrangement, where a helical pattern is depicted for exemplary purposes. For example, an external coating may be arranged in one or more vertical, horizontal and/or diagonal stripes, or to form a particular illustration, design, or shape, or in a random configuration. External coating 159 may be provided during the production process, such as by forming coating by mixing suitable ingredients, such as at least one coloring or flavoring agent, into an edge segment spanning a length of hot baked dough strip 106 (Fig.2), using a suitable coating mechanism (i.e., coater). Coating 159 may have variable dimensions (e.g., thickness) and be composed of various edible materials, such as the exemplary compositions provided above for flavored inner lining 148. Coating 159 may also contain additional ingredients, such as ground up nuts or seeds; dried fruits bits; candy sprinkles; and the like, which may be applied to the coating during the production process. Coating 159 may be implemented in the absence of an inner flavored lining 158.

According to another embodiment, a flattened wafer tube may be formed in a double tube configuration, such that a flattened segment is disposed between two tubular sections and corresponding openings. In particular, a flattened tube segment may be formed in a middle or intermediate region of a wafer tube 108 cut from a hot baked dough strip 106 (Fig.2), by crimping or pressing together a portion of the tube wall to form a flattened segment at a middle region of wafer tube 108, and folding or bending wafer tube 108 around the flattened segment, while wafer tube 108 is still hot or warm enough to be flexible. The flattened segment is sealed during the cooling of the wafer tube, as before. Each bent portion of the wafer tube on either side of the flattened segment defines an intermediate tubular section with an opening at each end, for receiving a respective food product.

Reference is made to Figures 10, 11 , 12, which depict a side-view, a perspective-view, and a front-view illustration, respectively, of a flattened wafer tube in a double tube configuration, according to an embodiment of the present invention. The flattened double wafer tube, generally referenced 160, includes a flattened tube segment 162 at one end, formed by crimping the cut heated wafer tube during the production process. Flattened double wafer tube 160 includes a first intermediate tubular section 164A, extending into a first opening 164A on one side of flattened tube segment 162, and a second intermediate tubular section 164B, extending into a second opening 164B on another side of flattened tube segment 162. Intermediate tubular sections 164A and 164B are thus adjoined by common flattened tube segment 162 at one end thereof, and extend into respective openings 166A, 166B at an opposite end thereof (as can be seen in Fig.11 ). Each opening 166A, 166B is configured to receive a respective food product, such as ice cream. In particular, double flattened wafer tube 160 advantageously enables loading of two different food products, in respective openings 166A, 166B, such as a first scoop of ice cream (e.g., having a first flavor) in opening 166A and a second scoop of ice cream (e.g., having a second flavor) in opening 166B. At least part of the received food products may permeate into the respective intermediate tubular sections 164A, 164B to be contained therein, where flattened segment 162, seals an end (e.g., a bottom end) of double wafer tube 160, to prevent the contained food from leaking or falling out of wafer tube 160 and to facilitate consuming of wafer tube 160 with contained food. First intermediate tubular section 164A and second intermediate tubular section 164B may be disposed substantially in parallel (as shown), and may have substantially similar lengths. Alternatively, tubular section 164A and 164B may be configured with different lengths. Double wafer tube 160 is provided with an optional flavored inner lining 168, which may alternatively be absent. Double wafer tube 160 may optionally be provided with a flavored external coating (not shown). Flattened segment 162 may optionally be perforated, to facilitate separation of the two intermediate tubular sections into discrete elements, each of which may be maintained with an individual flattened segment at a bottom end thereof (to prevent the contained food from leaking or falling out of wafer tube 160 and facilitate its consumption). The perforation may be automated or implemented manually, such as using a suitable perforating tool or mechanism (i.e. , perforator).

It will be appreciated that the disclosed flattened wafer tubes may be easily held to facilitate consumption of the wafer tube and contained food substance, while the flattened segment prevents leakage or falling out of the contained food. The wafer tube walls are made from overlapping concentric segments of baked dough strips to form a multi-layering that may substantially reinforce the tube walls to reduce the likelihood of fracturing or breakage. Reference is made to Figures 13 and 14, which depict perspective-view illustrations of a user holding a flattened wafer tube (Fig.13), and a flattened wafer double tube (Fig.14), according to embodiments of the present invention.

It is further appreciated that the disclosed flattened wafer tubes may be manufactured with variable dimensions, including varying lengths and diameters, such as by cutting a rolled baked dough strip to a desired length during the production process (e.g., by modifying a cutting frequency of a cutter), and/or by selecting an exchangeable roller having a desired diameter. The flattened wafer tube may contain flavored inner linings and/or flavored external coatings which may further enhance the consumption experience. The flavored inner lining may be added to the flattened wafer tube during the production process by the apparatus (e.g., by injection of a filler material onto rotating multi-layered wafer tube 108 through port 104 of roller 103), without requiring a separate step for lining the wafer tube after its production. Furthermore, the flattened wafer tube may have a flattened segment with a surface geometry conducive to ladling liquids or scooping viscous food substances. The wafer tube may be formed in a double tube configuration, allowing for containing multiple food substances in respective openings.

According to an aspect of the present invention, a method for producing a flattened wafer tube may be provided. The method may include the step of flattening a baked dough strip passing through a rotating first roller and a rotating second roller, and wrapping a contiguous second strip segment of the baked dough strip onto a portion of a first strip segment of the baked dough strip, during advancement between the first roller and the second roller, to form a multi-layered wafer tube having a tube wall. The method may further include the steps of cutting the wafer tube into a selected length; pressing a first portion and a second portion of the tube wall into abutment; and sealing pressed portions of the tube wall by cooling of the wafer tube, to form a flattened tube segment, such that the wafer tube includes: the flattened tube segment, at a first end of the wafer tube; at least one opening, for receiving a food substance, at a second end of the wafer tube opposite the first end; and an intermediate tubular section, for containing the food substance, between the opening and the flattened tube segment.

While certain embodiments of the disclosed subject matter have been described, so as to enable one of skill in the art to practice the present invention, the preceding description is intended to be exemplary only. It should not be used to limit the scope of the disclosed subject matter, which should be determined by reference to the following claims.