PASTRY SHELL AND RELATED METHODS

Abstract

Confectionery products with filled portions. The invention provides a confectionery product comprising a main confectionery body formed around at least one removable portion defined by one or more areas of weakness in the main confectionery body, wherein the removable portion or each removable portion comprises at least one closed and at least partially filled cavity.

Description

1 / 34 PASTRY SHELL AND RELATED METHODS Field of invention

[0001] The present invention relates to confectionery products comprising filled portions, particularly to confectionery products comprising removable filled portions and to confectionery shells comprising filled portions, and to methods of manufacturing the same. Background of the invention

[0002] It is common in the confectionery industry to supply bars and shells of solid chocolate.

[0003] Some chocolate bars may be made to have thick chunks with removable filled centers, for example, blocks / chunks filled with caramel, comprising a closed and at least partially filled cavity inside, which can be separated around the periphery of the bar and consumed individually. However, these bars do not allow a consumer to break or pierce through these thick chunks with filled centers that are not part of the bar's periphery, and each chunk that is broken must be removed around the edge of the bar.

[0004] There is therefore a need to provide a confectionery product that includes a chocolate bar or shell, comprising a main confectionery body and one or more removable portions surrounded by the main body, each removable portion comprising at least one closed and at least partially filled cavity.

[0005] It would be additionally advantageous to provide such a confectionery product in which the removable portion or each removable portion could be pushed through, or out of, Petition 870250074897, dated 08 / 25 / 2025, page 15 / 152 2 / 34 of the main pastry body, thus leaving a corresponding gap or hole in the main pastry body.

[0006] Chocolate shells, such as chocolate Easter eggs, tend to be limited to a single solid chocolate composition of a specific shape and, as such, are very limited in the variety of consumer experiences they offer, such as visual variety, flavor profile, mouthfeel, and the number of different portions or sections that vary in some identifiable way (typical Easter eggs comprise only a single portion), as well as varying structures or types of confectionery material. These shells can also only be consumed in a limited number of ways, for example, by biting the edge or breaking or crushing it into many pieces and eating the pieces individually.

[0007] There is therefore a need to provide a confectionery shell that offers the consumer a more varied experience than traditional confectionery shells, such as Easter eggs.

[0008] It would therefore be advantageous to provide a confectionary shell comprising at least one closed and at least partially filled pocket formed within the shell wall.

[0009] It would be additionally advantageous to provide such a confectionary shell in which the removable portion or each removable portion is removable from the shell or the shell wall.

[0010] It would be additionally advantageous to provide such a confectionary shell in which the removable portion or each of the removable portions could be pushed through or out of the shell or shell wall, thereby leaving a corresponding gap or hole in the shell or shell wall. Petition 870250074897, dated 08 / 25 / 2025, p. 16 / 152 3 / 34

[0011] It is therefore an objective of the embodiments of the invention to overcome or mitigate at least one problem of the prior art, whether described here or not. Summary of the invention

[0012] According to a first aspect of the invention, a confectionery product is provided comprising a main confectionery body formed around at least one removable portion defined by one or more areas of fragility in the main confectionery body, wherein the removable portion or each removable portion comprises at least one closed and at least partially filled cavity.

[0013] A “removable” portion means a portion that can be removed from the main confectionery body by virtue of one or more areas of fragility located around its perimeter. The removable portion or each removable portion can be removed, for example, by applying force to its surface (for example, with a finger) in order to push or pull the portion out of the body, or by impacting it (in order to break at least one portion of the area(s) of fragility) and shaking it out of the body.

[0014] A “closed cavity” includes a completely sealed cavity, but also includes a cavity that may not be completely sealed, but is closed enough to retain one or more fillings situated within it, regardless of the orientation of the product.

[0015] In some forms, the removable portion or each removable portion may be surrounded by one or more areas of fragility. Petition 870250074897, dated 08 / 25 / 2025, p. 17 / 152 4 / 34

[0016] The product may be configured so that removing a removable portion of the main confectionery body creates a gap or hole through the main confectionery body.

[0017] The main confectionery body and / or each removable portion may independently comprise chocolate, such as white chocolate, milk chocolate, dark chocolate, plain chocolate and / or compound chocolate. In some embodiments, at least one removable portion may comprise the same confectionery material as the main confectionery body and / or at least one removable portion may comprise a confectionery material different from the main confectionery body.

[0018] The main confectionery body and one or more removable portions may comprise the same or different types of chocolate, or chocolate composition. One or more removable portions may comprise substantially similar or identical percentage weights of milk and / or cocoa solids as the main confectionery body composition, for example. When the confectionery product comprises more than one removable portion, each removable portion may comprise the same or different types of chocolate, or chocolate composition. One or more removable portions may comprise substantially similar or identical chocolate composition, but the main confectionery body may comprise a different chocolate composition.

[0019] In some embodiments, the main confectionery body and one or more removable portions comprise, for example, milk chocolate, white chocolate, dark chocolate, plain chocolate or compound chocolate. Petition 870250074897, dated 08 / 25 / 2025, page 18 / 152 5 / 34

[0020] In preferred embodiments, the main confectionery body and all removable portions comprise the same confectionery composition, preferably chocolate or a chocolate composition.

[0021] The main confectionery body and one or more removable portions may be integrally formed and are preferably integrally formed as a single piece or confectionery product.

[0022] The main confection body may comprise any suitable shape which may be geometric or irregular. The main confection body may comprise a triangular prism, a cuboid, a pentagonal prism, a hexagonal prism, a heptagonal prism, an octagonal prism, a nonagonal prism or a decagonal prism, a sphere, an ellipsoid or an ovoid shape, for example.

[0023] In preferred embodiments, the main confectionery body may comprise a closed confectionery shell such as a hollow confectionery product, for example, a hollow egg, or an open confectionery shell such as a half eggshell, for example.

[0024] The main confectionery body may comprise a cuboid shape and may define a substantially rectangular bar. The main confectionery body may comprise a rectangular cuboid comprising a length greater than the width, and a width greater than the depth. The main confectionery body may be in the form of a plate, bar, or sheet, for example. The main confectionery body may comprise an angular cross-section that remains substantially similar along the length of the body. The length and width of the main confectionery body Petition 870250074897, dated 08 / 25 / 2025, page 19 / 152 6 / 34 can independently be less than or equal to 10 mm, or at least 10 mm, 20 mm, 30 mm, 40 mm, 50 mm, 75 mm, 100 mm, 200 mm or 300 mm, for example.

[0025] The maximum depth or thickness, or average depth or thickness, of the main pastry body may be less than or equal to 5 mm. The minimum depth or thickness, or average depth or thickness, of the main pastry body may be at least 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm or 50 mm, for example.

[0026] At least one removable portion may comprise a plurality of closed cavities located therein, such as at least 2, 3, 4, or 5 cavities, or it may comprise a single cavity. The cavity or each cavity of the removable portion or of each removable portion may occupy alone or collectively at least 10% of the volume and / or area (i.e., the area defined within one or more areas of fragility that define the removable portion or each removable portion) defined by the removable portion or each removable portion, or at least 20%, 30%, 40%, 50%, 60%, 70%, or at least 75%. In preferred embodiments, at least one removable portion comprises a single closed cavity therein, which preferably occupies at least 50% of the area and / or volume defined by the removable portion or each removable portion.

[0027] Substantially all the area and / or volume of one or more removable portions may comprise a cavity or cavities, or only a portion thereof, such as not more than 90%, 80%, 70%, 60% or not more than 50% of the area and / or volume. In some embodiments, at least 50%, 60%, 70%, 80%, 90% or at least 95% of the area and / or volume of one or more removable portions may comprise a cavity or cavities. Petition 870250074897, dated 08 / 25 / 2025, p. 20 / 152 7 / 34

[0028] The cavity or each cavity may independently encompass or fill at least 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or at least 95% of the area and / or volume of one or more removable portions, and / or not more than 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or no more than 95% of the area and / or volume.

[0029] In some embodiments, at least one removable portion may comprise one or more larger cavities, such as a single larger cavity or at least 2, 3, 4 or 5 larger cavities, for example, and one or more smaller cavities, wherein the smaller cavity or each smaller cavity is disposed within a larger cavity and comprises an area and / or volume smaller than that of the larger cavity in which it is disposed. At least one larger cavity may comprise a single smaller cavity disposed within it, or at least 2, 3, 4 or 5 smaller cavities disposed within it, for example.

[0030] The incorporation of one or more larger and smaller cavities allows for the incorporation of a plurality of distinct and different fillings in these removable portions, which allows for greater variety in the final product(s).

[0031] The cavity or each cavity may be independently or at least partially filled with one or more food items, which may be independently selected from chocolate confections, fondant, marshmallow, caramel, aerated fat-based fillings such as mousse, fruits, nuts, baked goods such as cake or biscuit, chewing gum, boiled candy, jelly or gummy candy, for example.

[0032] In some embodiments, at least one cavity of at least one removable portion may comprise a non-food product. Petition 870250074897, dated 08 / 25 / 2025, page 21 / 152 8 / 34 food, such as an innovative item or a child's toy, for example.

[0033] At least 50%, 60%, 70%, 80%, 90%, 95%, or substantially 100% of the volume of a cavity may be occupied by a filling.

[0034] In particularly preferred embodiments, at least one removable portion comprises a single cavity that occupies at least 70% of the volume and / or area defined by each removable portion and that is at least 70% filled, and preferably at least 80%, 90%, 95% or 100% filled.

[0035] The removable portion or each removable portion may be formed integrally with the main confectionery body. At least one portion of at least one removable portion may be an integral continuation of the main confectionery body, through one or more integral areas of fragility.

[0036] One or more fragile areas may comprise one or more fragile lines. For example, one or more fragile areas may comprise one or more areas or lines encircling at least partially (or completely encircling) one or more removable portions, wherein said area(s) or line(s) have reduced thickness relative to the apparent thickness of the main confectionery body and / or areas of the main confectionery body adjacent to the removable portion.

[0037] One or more fragility zones may be configured to retain the removable portion(s) in the main confectionery body during product transport and storage. One or more fragility zones may be configured to allow each removable portion to be separated from the main confectionery body and Petition 870250074897, dated 08 / 25 / 2025, page 22 / 152 9 / 34 removed when pressure is applied, for example, manually, during use. A removable portion can be removed by a consumer holding the main confectionery body with one side, and applying force directly to the removable portion with the other side, so that the removable portion separates from the main confectionery body, during use, for example.

[0038] One or more areas of fragility may allow the removable portion or each removable portion to be removed from the main confectionery body without removing any other part of the main confectionery body and / or without significantly fracturing, breaking, damaging or destroying the remainder of the main confectionery body, and / or without affecting the overall structure or shape of the main confectionery body or the confectionery product. It should be understood that minor breakage in the area around a removable portion when it is removed is permitted, provided that the vast majority of the material removed from the product or the main confectionery body comprises the removable portion.

[0039] The removable portion or each removable portion may be connected to the main confectionery body by means of a single line or area of ​​fragility encircling the removable portion, or by one or more separate lines or areas of fragility extending along each side of the removable portion. The line(s) or area(s) of fragility may extend along the entire boundary between one or more removable portions and the main confectionery body, and thus may be one or more continuous lines or areas of fragility. Alternatively, one or more removable portions may be connected to the main confectionery body by one or more intermittent areas. Petition 870250074897, dated 08 / 25 / 2025, p. 23 / 152 10 / 34 or discontinuous or fragile lines, such as one or more perforation lines, for example. One or more removable portions may be adjusted from the perimeter of the main confectionery body (in embodiments where the main confectionery body comprises a perimeter, for example, a sheet, plate, bar or open chocolate shell) and, in some embodiments, may be situated substantially centrally within the perimeter of the main confectionery body. When the confectionery product comprises a single removable portion, the geometric center of the removable portion may be situated substantially close to, or at, the geometric center of the main confectionery body, in some embodiments.

[0040] One or more removable portions may be situated off-center within the main confectionery body, such as toward a perimeter edge of the main confectionery body. One or more removable portions may be situated closer to a single edge or surface area than the other edges or surface areas of the main confectionery body.

[0041] When the confectionery product comprises a plurality of removable portions, a removable portion may be situated towards each of the edges of the main confectionery body. The removable portions may be distributed uniformly within the main confectionery body, or irregularly within the main confectionery body, or randomly within the main confectionery body.

[0042] When the confectionery product comprises a single removable portion, the removable portion may be located Petition 870250074897, dated 08 / 25 / 2025, p. 24 / 152 11 / 34 near an edge, or near a corner area, of the main pastry body.

[0043] One or more removable portions may be substantially closer to any one or more edges than any other edge.

[0044] In some embodiments, the main confectionary body may be substantially continuous, so as not to comprise a perimeter edge or periphery, as in embodiments where the main confectionary body or product is a closed confectionary shell (such as a chocolate shell), such as a hollow confectionary shell, for example, a hollow egg. In such embodiments, the removable portion or each removable portion may be situated in any suitable position on / in the main confectionary body. In embodiments where a closed confectionary shell comprises a joining line or junction resulting from the joining and / or sealing of two open shells, the removable portion or each removable portion may be adjusted from the joining line or junction and may be situated substantially in the geometric center of the corresponding open shell, or elsewhere in / on the open shell(s).

[0045] In embodiments where the confectionery product and / or the main confectionery body comprises a closed chocolate shell, such as a hollow chocolate egg, or an open chocolate shell, the removable portion or each removable portion may be removable from the main confectionery body without affecting the overall shell shape, such as the shape of the egg or the overall egg half. In preferred embodiments, the chocolate shell retains its overall shape when one or more removable portions are removed and, Petition 870250074897, dated 08 / 25 / 2025, p. 25 / 152 12 / 34 therefore, it becomes a chocolate shell, like a chocolate egg or half an egg, with one or more gaps or holes formed through its wall(s).

[0046] One or more removable portions may comprise any desired shape. One or more removable portions may comprise any regular or irregular shape. At least one removable portion may comprise a heart-shaped portion or a splat-shaped portion, for example. All removable portions may comprise the same shape, or one or more removable portions may comprise a different shape.

[0047] At least one removable portion may comprise substantially the same thickness as at least one portion of the main confectionery body. At least one removable portion may comprise a thickness substantially similar or identical to the adjacent areas of the main confectionery body that are contiguous with or surround the removable portion(s).

[0048] Each removable portion may comprise substantially the same thickness. The main confectionery body may comprise one or more substantially flat or uniform regions surrounding one or more removable portions, and the removable portions may have the same or different thickness from the surrounding flat or uniform regions.

[0049] At least one removable portion may comprise a thickness less than that of the main confectionery body, and / or adjacent or contiguous areas of the main confectionery body. Petition 870250074897, dated 08 / 25 / 2025, p. 26 / 152 13 / 34

[0050] At least one removable portion may comprise a thickness greater than that of the main pastry body and / or adjacent or contiguous areas of the main pastry body, and may project from one or more surfaces of the main pastry body, such as the top / front and / or bottom / rear surface. Such embodiments are useful as they allow more filling to be located inside the closed cavity(ies) of such removable portions.

[0051] In preferred embodiments where the product comprises a closed or open confectionary or chocolate shell, such as an egg or half an egg, at least part of the removable portion or of each removable portion may project from the outer and / or inner surface of the shell. It may be advantageous for at least part of the removable portion or of each removable portion to project only from the inner surface of the shell, as this allows more filling to be placed inside the cavity(ies) of the removable portion or of each removable portion without affecting the overall external appearance / shape (such as egg shape) of the shell. However, it may also be advantageous for each removable portion to project additionally or alternatively from the outer surface of the shell, as this may be more visually interesting, attractive or seductive to a consumer, who may be able to see that there is filling located inside the removable portion or of each removable portion.

[0052] At least one removable portion may comprise one or more edges or rims (corresponding to the shape of one or more wells), which may, in some embodiments, move around the perimeter of each removable portion, and one or Petition 870250074897, dated 08 / 25 / 2025, page 27 / 152 14 / 34 plus layers of support or cover extending along each well and / or sealing the well or each well, rim or edge to form the cavity or each cavity. Each well, cavity, rim or edge may comprise its own substrate or cover layer, or two or more may share a common substrate or cover layer. The well or each well, cavity, rim, edge and / or substrate or cover layer may comprise confectionery material, preferably chocolate.

[0053] Any number of one or more removable portions may comprise any number of additional removable subportions. One or more removable portions may comprise one or more removable subportions that comprise one or more areas of fragility, as previously described in this document, and therefore, one or more removable portions may comprise one or more removable subportions.

[0054] The main confectionary body may comprise a plurality of thick pieces or consumable units, separated by one or more areas or lines of fragility. The one or more areas or lines of fragility separating the thick pieces from the main confectionary body are different from the one or more areas or lines of fragility surrounding the removable portion(s), and may be lines or areas of reduced thickness that separate pieces or consumable units in a solid chocolate bar, for example. The one or more areas or lines of fragility surrounding the removable portion(s) may be configured so that pressure on one or more removable portions will remove the removable portion or portions from the main confectionary body (for example, by breaking areas or lines of Petition 870250074897, dated 08 / 25 / 2025, page 28 / 152 15 / 34 fragility surrounding the removable portion) without affecting the perimeter of the main confectionery body (in embodiments where the main confectionery body comprises a perimeter) and / or without requiring the removal of any other part of the product from the main confectionery body and / or without fracturing, breaking, damaging or significantly destroying the remainder of the main confectionery body, and / or without affecting the overall structure or shape of the main confectionery body or confectionery product, while any other areas or lines of fragility separating thick pieces or consumable units will remain intact and uninterrupted.

[0055] The confectionery product, the main confectionery body and / or the removable portion or each removable portion may comprise molded chocolate.

[0056] At least one removable portion may comprise surface details on one or more surfaces thereof, for example, embossing / embossing, or applied details such as confectionery bows or icing or other confectionery products (such as chocolate), for example. At least one removable portion may comprise a surface detail mark, which may, in some embodiments, inform a consumer about the type of filling located therein.

[0057] According to a second aspect of the present invention, a method is provided for forming a removable portion in a confectionery body comprising the steps of; a) to form a confectionery body comprising one or more removable portions defined by one or more areas of fragility around the perimeter of the removable portion or Petition 870250074897, dated 08 / 25 / 2025, page 29 / 152 16 / 34 of each removable portion, wherein the removable portion or each removable portion comprises one or more cavities; and (b) to at least partially fill the cavity or each cavity in the removable portion or in each removable portion and then seal the at least partially filled cavity or each at least partially filled cavity to form one or more closed and at least partially filled cavities in the removable portion or in each removable portion.

[0058] The removable portion may be a substantially removable portion as described in relation to the first aspect of the invention.

[0059] The confectionery body may comprise a main confectionery body substantially as described in relation to the first aspect of the invention.

[0060] Step a) may include molding, preferably integral molding, of the confection body and of each removable portion.

[0061] Step b) may comprise locating one or more packings within said perimeter and including the packing or each of the packings to form one or more closed and at least partially filled cavities. The packing or each of the packings may be located within the perimeter in any suitable form or state, such as solid, semi-solid or liquid, for example.

[0062] Step a) may involve forming one or more wells within the perimeter that correspond to the shape of the cavity or cavities and step b) may involve filling at least partially the well or each well.

[0063] The method described in the second aspect of the invention is particularly useful when using less viscous fillings. Petition 870250074897, dated 08 / 25 / 2025, page 30 / 152 17 / 34 (such as semi-solid or liquid packings), since one or more wells act to retain such packings, so that they can be more easily incorporated into the cavity(ies). Step b) may further comprise substantially sealing the well or each well during or after at least partially filling it / them, so that the substantially sealed well or each well forms a closed and at least partially packed cavity. Sealing and packing simultaneously may be carried out by co-deposition of packing and sealing material, for example, but in preferred embodiments, packing is initiated and preferably completed before sealing.

[0064] In some embodiments, the method comprises forming a single cavity within the perimeter. In such embodiments, the method may comprise forming a single cavity that covers / encompasses the entire area of ​​the removable portion.

[0065] In some embodiments, the method may involve the formation of a plurality of cavities within the perimeter, such as a matrix of spaced cavities.

[0066] In some embodiments, the method comprises the formation of one or more main cavities within the perimeter, and the formation of one or more smaller cavities within at least one larger cavity. In these embodiments, the method may comprise the formation of one or more larger pits, and the formation of one or more smaller pits within at least one larger pit. The smaller and larger pit(s) and / or cavity(ies) may be filled, left unfilled, and sealed in any appropriate order.

[0067] The method may comprise enclosing the entire area defined by the perimeter, or only a portion thereof, as no more Petition 870250074897, dated 08 / 25 / 2025, p. 31 / 152 18 / 34 that 90%, 80%, 70%, 60% or not more than 50% of the area defined by the perimeter. The method may involve enclosing at least 50%, 60%, 70%, 80%, 90% or at least 95% of the area defined by the perimeter.

[0068] The method may comprise forming one or more cavities, wherein the cavity or each cavity may independently cover at least 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or at least 95% of the area defined by the perimeter, and / or wherein the cavity or each cavity may independently cover not more than 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or not more than 95% of the area defined by the perimeter.

[0069] The cavity, pit and / or defined area or each cavity, pit and / or defined area by the perimeter of each removable portion (or a portion or portions thereof) may be sealed or closed in any suitable manner, for example, by applying a covering of molten confectionery material followed by cooling, or by applying a sealing member, such as a confectionery sealing member, for example, a thick pebble or piece of chocolate, as a substrate or covering layer, which may be performed by heating the contact point(s) between them and then cooling the joint.

[0070] In some embodiments, the method comprises cold stamping. In such embodiments, step a) may comprise the formation of a confectionary body and simultaneously the formation of one or more areas of fragility, for example, by using one or more grooves and / or protrusions in the stamp(s) and / or molded cavities to form said area(s). Any Petition 870250074897, dated 08 / 25 / 2025, page 32 / 152 19 / 34 cavity(ies) and / or well(s), as described above, may also be cold stamped at the same time as the confection body and the fragile area(s), for example, by using such grooves and / or protrusions.

[0071] According to a third aspect of the invention, a method of manufacturing a confectionery product of the first aspect of the invention is provided, comprising the steps of: a) to form a main confectionery body; and b) forming one or more removable portions in the main confectionery body, wherein the removable portion or each removable portion is formed by the method of the second aspect of the invention.

[0072] The method may include cold stamping. In such embodiments, step a) and at least part of step b) may be performed substantially simultaneously.

[0073] In embodiments where the method comprises the formation of a plurality of removable portions, the perimeters (comprising one or more areas of fragility) of each removable portion, and any cavities and / or pits associated with the respective removable portions, may be formed substantially simultaneously with each other and with step (a), preferably by cold stamping.

[0074] According to a fourth aspect of the invention, a closed or open confectionery shell is provided comprising a confectionery wall, wherein the shell comprises at least one closed and at least partially filled pocket formed within the confectionery wall.

[0075] A “closed shell” is defined in the present invention as a substantially continuous shell that does not have a terminal edge, for example, a sphere or an egg. A shell of Petition 870250074897, dated 08 / 25 / 2025, p. 33 / 152 20 / 34 A closed confection can therefore be substantially hollow, for example, an Easter egg. An “open shell” is defined here as a shell that has a terminal edge. As an example, a hemispherical or half-egg shell can be considered an open shell, with the circular or ovoid edge being the “terminal” edge. Two identical open shells can therefore be joined at their terminal edges to form a closed shell, for example.

[0076] The pastry wall can be a non-planar wall.

[0077] The closed confectionery shell or the open confectionery shell may comprise a main confectionery body substantially as described in relation to the first aspect of the invention, and may therefore exhibit any suitable combination of features as discussed therein.

[0078] A “closed pocket” includes a completely sealed pocket, but also includes a pocket that may not be completely sealed, but is sufficiently closed to retain one or more fillings located therein, regardless of the orientation of the product.

[0079] At least one pocket may comprise a projection in the pastry wall, which may project from the inner surface of the pastry wall and / or the outer surface of the pastry wall. The inner and outer surfaces may comprise concave and convex surfaces, respectively. Such embodiments are useful as they allow more filling to be located inside the closed pocket(s). It may be advantageous for the projection or each projection to project only from the inner surface of the pastry wall, since Petition 870250074897, dated 08 / 25 / 2025, page 34 / 152 21 / 34 This allows more filling to be located inside the pocket(s) without affecting the overall external appearance / shape (such as egg or half-egg shape) of the shell. However, it may also be advantageous for the protrusion or each protrusion to project additionally or alternatively from the outer surface of the pastry wall, as this may be more interesting, attractive or enticing to a consumer, who may be able to determine that there is something located inside the protrusion or each protrusion.

[0080] Substantially the entire pastry wall may comprise a pocket or pockets, or only a portion thereof, such as not more than 90%, 80%, 70%, 60% or not more than 50% of the pastry wall. In some embodiments, at least 50%, 60%, 70%, 80%, 90% or at least 95% of the pastry wall may comprise a pocket or pockets.

[0081] The pocket or each pocket may independently cover at least 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or at least 95% of the pastry wall, and / or no more than 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or no more than 95% of the pastry wall.

[0082] The pocket or each pocket may independently be at least partially filled with one or more foodstuffs selected from confectionery products (such as chocolate or chocolate compound), fondant, marshmallow, caramel, aerated fat-based filling such as mousse, fruit, nuts, baked goods such as cake or biscuit, chewing gum, boiled candy, jelly or gummy candy, for example.

[0083] In some categories, at least one pocket may contain a non-food item, such as a novelty item or a child's toy, for example. Petition 870250074897, dated 08 / 25 / 2025, page 35 / 152 22 / 34

[0084] At least 50%, 60%, 70%, 80%, 90%, 95%, or substantially 100% of the volume of a pocket may be occupied by stuffing.

[0085] In some embodiments, at least one pocket may comprise one or more sub-pockets arranged within it, wherein (each) comprises an area and / or volume smaller than that of the pocket in which it / they are arranged. At least one pocket may comprise a single sub-pocket arranged within it, or at least 2, 3, 4 or 5 sub-pockets arranged within it, for example.

[0086] The incorporation of sub-pockets allows for the incorporation of a plurality of distinct and different fillings in these pockets, which allows for greater variety in the final product(s).

[0087] At least one pocket may be set from the edge of the pastry wall in embodiments in which the pastry wall comprises an edge, that is, when the pastry wall forms an open shell, and may be situated substantially centrally within the open-shell pastry wall. When the open-shell pastry shell comprises a single pocket, the geometric center of the pocket may be situated substantially near, or at, the geometric center of the pastry wall.

[0088] One or more pockets may be located off-center within the pastry wall, such as toward a perimeter edge of the pastry wall. One or more pockets may be located closer to a single edge or surface area than the other edges or surface areas of the pastry wall.

[0089] When the pastry wall comprises a plurality of pockets, a pocket may be situated towards Petition 870250074897, dated 08 / 25 / 2025, p. 36 / 152 23 / 34 on each edge of the pastry wall. The pockets can be evenly distributed around the pastry wall, or irregularly around the pastry wall, or randomly around the pastry wall.

[0090] When the pastry wall comprises a single pocket, the pocket may be situated near an edge, or near a corner region of the pastry wall.

[0091] One or more pockets may be substantially closer to any one or more edges of the pastry wall than to any other edge.

[0092] In embodiments where the confection wall does not comprise a border (i.e., where the confection wall forms a closed confection shell), the pocket or each pocket may be situated in any suitable position on the confection wall. In embodiments where a confection shell (and therefore the confection wall) comprises a joining line or junction resulting from the joining and / or sealing of two open shells, the pocket or each pocket may be adjusted from the joining line or junction and may be situated substantially in the geometric center of the corresponding open shell, or elsewhere on / over the open shell(s).

[0093] The confectionery wall may comprise a matrix of pockets.

[0094] The pastry wall may comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more than 10 pockets.

[0095] At least one pocket, and preferably all pockets, may be formed entirely from the confectionery material from the confectionery wall. Petition 870250074897, dated 08 / 25 / 2025, page 37 / 152 24 / 34

[0096] One or more pockets may comprise any desired shape. One or more pockets may comprise any regular or irregular geometric shape comprising straight or curved edges. At least one pocket may comprise a heart-shaped cavity or a splat-shaped pocket, for example. All pockets may comprise the same shape, or one or more pockets may comprise a different shape. The shape of a pocket may be visible from the outside, for example, when it comprises a protrusion on the confectionery wall.

[0097] In embodiments where at least one pocket comprises a protrusion on the confectionery wall, at least one protrusion may comprise surface details on one or more surfaces thereof, for example, embossing / relief, embossing, or details applied as fondant or confectionery glaze or other confectionery product (such as chocolate), for example. At least one protrusion may comprise a surface detail mark, which may, in some embodiments, inform a consumer about the type of filling located therein.

[0098] One or more pockets may form part of one or more removable portions, as described in the first aspect of the invention.In such embodiments, the closed pastry shell or the open pastry shell may comprise any suitable combination of features relating to removable portions, as described in relation to the first aspect of the invention, but whereby the “main pastry body”, as described herein, is limited to a closed pastry shell, an open pastry shell or a pastry wall (and being. Petition 870250074897, dated 08 / 25 / 2025, p. 38 / 152 25 / 34 which cavity or cavities therein should be interpreted as pocket or pockets in this aspect of the invention).

[0099] In preferred embodiments, the closed confectionery shell or the open confectionery shell comprises a confectionery egg or half of an egg, preferably a chocolate egg or half of an egg.

[0100] The shell is preferably made from chocolate or compound chocolate, preferably molded chocolate.

[0101] According to a fifth aspect of the invention, a method is presented for forming at least one closed and at least partially filled pocket inside or on the confectionery wall of a closed or open confectionery shell, comprising the steps of: a) provide a pastry wall; and b) to form at least one closed and at least partially filled pocket inside or on the wall of the pastry shop.

[0102] The pocket(s) may be substantially as described in relation to the fourth aspect of the invention.

[0103] The confectionery wall, the closed confectionery shell and / or the open confectionery shell may be substantially as described in relation to the fourth aspect of the invention.

[0104] Step a) may comprise providing a confectionery wall with at least one pit, notch or other cavity formed in the wall. In such embodiments, the pit, notch or cavity may be formed by a protruding edge that defines the pit, notch or cavity, which may project from the inner surface or outer surface of the wall, preferably from the inner surface. In other embodiments, the Petition 870250074897, dated 08 / 25 / 2025, page 39 / 152 26 / 34 A well, notch, or cavity can be formed by a projection that extends from the confectionery wall.

[0105] Such designs may be advantageous for less viscous fillings (such as semi-solid or liquid fillings), since the well(s), notch(es) or cavity(ies) may act to retain such fillings, so that they may be more easily incorporated into the pocket(s).

[0106] Step a) may involve shaping the pastry wall and may involve cold stamping of the wall.

[0107] Step b) may comprise placing one or more fillings on the pastry wall or inside any pit, notch or cavity in the pastry wall, and enclosing the filling or each of the fillings to form one or more closed and at least partially filled pockets. The filling or each of the fillings may be placed on or in the pastry wall in any suitable form or state, such as solid, semi-solid or liquid, for example.

[0108] Step b) may comprise providing or forming one or more wells in or on the pastry wall and at least partially filling the well or each well. Such embodiments may be advantageous for less viscous fillings (such as semi-solid or liquid fillings), since the well(s) may act to retain such fillings so that they can be more easily incorporated into the pocket(s). Step b) may further comprise substantially sealing the well or each well after at least partially filling it / them, so that the substantially sealed well or each well forms the closed and at least partially filled pocket. Petition 870250074897, dated 08 / 25 / 2025, page 40 / 152 27 / 34

[0109] In some embodiments, the method comprises forming one or more sub-pockets within at least one pocket. In such embodiments, the method may comprise forming one or more pits on, or in, the confectionery wall, and forming one or more sub-pits within at least one pit. The pit(s) and sub-pit(s) and / or pocket(s) and sub-pocket(s) may be filled, left unfilled, and sealed in any appropriate order.

[0110] The method may comprise the formation of one or more pockets covering the entirety of one or both surfaces of the pastry wall, or only a portion thereof, such as not more than 90%, 80%, 70%, 60% or not more than 50% of one or both surfaces of the pastry wall. The method may comprise the formation of one or more pockets covering at least 50%, 60%, 70%, 80%, 90% or at least 95% of one or both surfaces of the pastry wall.

[0111] The method may comprise forming at least one pocket that covers at least 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or at least 95% of the pastry wall, and / or not more than 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% or not more than 95% of the pastry wall.

[0112] The sealing can be done in any suitable way, for example, with an applied sealing member, such as a confectionery sealing member, for example, covering it with molten confectionery followed by cooling, or by applying a sealing member such as a confectionery sealing member, such as a piece or thick chunk of chocolate, which can be sealed to the confectionery wall by heating the contact point(s) between them and cooling the joint. In embodiments Petition 870250074897, dated 08 / 25 / 2025, p. 41 / 152 28 / 34 preferred, the sealing comprises applying a layer of substrate or coating of molten chocolate confectionery or compound chocolate, followed by cooling.

[0113] In some embodiments, the method comprises cold stamping. In such embodiments, step a) may comprise cold stamping of a pastry wall and simultaneous formation of one or more pits in or on the pastry wall, for example, by using one or more notches and / or protrusions in the stamp(s) and / or mold to form said pit(s). The pit or pit(s) may then be filled and covered during step b) to form the closed and at least partially filled pocket(s) inside the wall.

[0114] In some embodiments, the method may comprise the formation of at least one pocket as part of a removable portion. Such removable portions may be substantially as described in the first aspect of the invention (but wherein the “main confectionery body”, as described herein, is limited to a closed confectionery shell, an open confectionery shell or a confectionery wall), and thus the method may comprise any suitable combination of features thereto, as described in the second aspect of the invention, wherein the “main confectionery body”, as described herein, is limited to a closed confectionery shell, an open confectionery shell or a confectionery wall. “Cavity” and “cavities”, as described herein, shall be interpreted as meaning “pocket” or “pockets” in this aspect. Petition 870250074897, dated 08 / 25 / 2025, page 42 / 152 29 / 34

[0115] The closed confectionery shell or the open confectionery shell is preferably a confectionary egg or half an egg, which may be hollow or filled.

[0116] The method may comprise forming at least one well on the convex and / or concave face of the pastry wall, preferably during step a).

[0117] According to a sixth aspect of the invention, a method is presented for manufacturing a closed confectionery shell of the fourth aspect of the invention, which comprises sealing an open confectionery shell of the fourth aspect of the invention.

[0118] The method of the sixth aspect of the invention may comprise sealing the open confectionery shell with another open confectionery shell, which may be an open confectionery shell of the fourth aspect of the invention, and / or which may be obtainable or obtained by the method of the fifth aspect of the invention, for example.

[0119] The confectionary shell is preferably a confectionary egg and the method comprises sealing together two halves of confectionary eggs, one or both of which are halves of confectionary eggs of the fourth aspect of the invention, obtainable or obtained by the method of the fifth aspect of the invention. Detailed description of the invention

[0120] In order for the invention to be more clearly understood, one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0121] Figure 1a illustrates a front view of an embodiment of a confectionery product from the first aspect. Petition 870250074897, dated 08 / 25 / 2025, p. 43 / 152 30 / 34 of the invention and of an open confectionery shell of the fourth aspect of the invention;

[0122] Figure 1b is a cross-section through the product / shell of Figure 1a, along line A in Figure 1a;

[0123] Figure 2a illustrates an internal view of the product / shell of Figure 1 during its manufacture, showing a hollow pit formed in it;

[0124] Figure 2b illustrates an internal view of the product / shell of Figure 1 during its manufacture, showing the well filled with fondant;

[0125] Figure 2c illustrates an internal view of the product / shell of Figure 1 after it has been manufactured, showing the filled well filled with chocolate; and

[0126] Figure 3 illustrates an embodiment of a closed confectionary shell of the fourth aspect of the invention, which was manufactured by an embodiment of the method of the sixth aspect of the invention.

[0127] With reference to Figures 1a, 1b, 2a, 2b and c, an embodiment of a confectionary product of the first aspect of the invention and of an open confectionary shell of the fourth aspect of the invention is shown, in the form of a chocolate egg half 100. The egg half 100 comprises a main confectionary body / confectionery wall in the form of a milk chocolate egg-shaped shell body 102 having a terminal edge 104. The chocolate body 102 comprises a removable portion in the form of a thick piece of milk chocolate with a removable filled center 106 comprising a cavity / pocket formed therein containing two different fondants 108, 110. The cavity / pocket is formed by a well Petition 870250074897, dated 08 / 25 / 2025, p. 44 / 152 31 / 34 114 defined by a continuous raised chocolate border 116 formed integrally with the chocolate body 102 and extending into the shell body 102, and a chocolate substrate layer 118 arranged on top of, and sealed to, the border 116. The perimeter of the thick piece with a filled center 106 is defined by a continuous fragility line 112 in the chocolate body 102. The fragility line 112 is formed from milk chocolate, is integral with the chocolate body 102 and the removable portion 106, and comprises an area of ​​reduced thickness relative to these two components.

[0128] Figures 2a and 2c illustrate the sequential manufacturing of half of the chocolate egg 100 in Figure 1 (and Figure 2c) by an embodiment of the methods of the second, third and fifth aspects of the invention. As can be seen in Figure 2a, first a chocolate body 102 is manufactured comprising a centrally disposed well 114. The well 114 is defined by a continuous raised chocolate rim 116 which is integrally formed with the chocolate body 102 and is substantially aligned with the brittle line 112 (visible in Figures 1 a and 1b). The chocolate body 102 can be formed in any suitable manner, such as by molding, but is preferably cold stamped. By using a molded stamp and / or cavity with at least one protrusion and / or recess, the chocolate body 102, the rim 116 of the well 114 and the brittle line 112 can be formed simultaneously in a single stamping action.

[0129] As can be seen in Figures 2b and 2c, well 114 is then filled with, for example, a white fondant 108 and an orange fondant 110 (which can replicate the filling of a Petition 870250074897, dated 08 / 25 / 2025, p. 45 / 152 32 / 34 Cadbury Crème Egg (RTM)) and filled / sealed with a layer of chocolate substrate 118 that forms the back wall of the thick piece with removable filled center 106, and thus creates the closed cavity / pocket therein, inside which reside the fondants 108, 110. The layer of chocolate substrate 118 can be added as a solid piece that is sealed to the rim 116 of the well 114, or it can be deposited on top of the well 114 and rim 116 in a molten state and then allowed to cool.

[0130] The large piece with a removable filled center 106 can be removed from the chocolate body 102 by a consumer applying pressure to its surface and pushing it (facilitated by the relatively easier breaking of the continuous fragility line 112 compared to the rest of the chocolate body 102), thus leaving a hole or gap through the body 102. The fragility line 112 also ensures that the piece 106 can be removed without significantly damaging or destroying the rest of the egg half 100 and / or without affecting the overall shape of the egg half 100. Once removed, the consumer can consume the thick piece 106 as a distinct, filled-center item, and can also continue to consume the rest of the chocolate body 102 as they see fit.

[0131] In other embodiments, half of the egg 102 may comprise one or more sub-cavities / sub-pockets located within the main cavity / pocket, which may be formed from one or more smaller filled and sealed sub-wells / wells located within the main well / larger well 114. Such smaller sub-wells / wells may be filled with a filling different from the main well / well. Petition 870250074897, dated 08 / 25 / 2025, page 46 / 152 33 / 34 larger 114 and can be formed simultaneously with the main well / larger well 114 and with the chocolate body 102, for example, by cold stamping.

[0132] Figure 3 illustrates another embodiment of a confectionary product of the first aspect of the invention and a closed confectionary shell of the fourth aspect of the invention, in the form of a hollow chocolate egg 200. The chocolate egg 200 comprises two of the halves of the chocolate eggs of Figures 1, 100, 100' which have been sealed together, with each half of the egg 100, 100' thus comprising a thick piece with a removable filled center 106, 106' surrounded by a fragility line 112, 112'. The egg 200 comprises a joining line 202 corresponding to the place where the two halves of the eggs 100, 100' have been sealed together.

[0133] The sealing of the two egg halves 100, 100' by an embodiment of the sixth aspect of the invention can be performed by heating the respective edges (see 104 in figures 1b and 2a ac) of the egg halves 100, 100', placing them in contact and then allowing the union to cool so that the half-shells 100, 100' are sealed together to form the egg 200. A consumer can therefore remove the two thick, removable filled-center pieces 106, 106' from the egg 200, in the same manner as described for the half-egg 100 of Figures 1a abe 2a ac, and consume them as distinct, filled-center items, and can also continue consuming the remainder of the egg 200 as they see fit.

[0134] The one or more modalities described above are only examples. Many variations are possible without considering them. Petition 870250074897, dated 08 / 25 / 2025, p. 47 / 152 34 / 34 remove claims from the scope of protection provided in the attachments. by Petition 870250074897, dated 08 / 25 / 2025, p. 48 / 152

Claims

1 / 3 CLAIMS 1. Hollow, closed or open confectionery shell, characterized by comprising a confectionery wall, wherein the shell comprises at least one closed and at least partially filled pocket formed wholly within the confectionery wall, wherein the one or more pockets form part of one or more removable portions and wherein the portion or each removable portion is defined by one or more areas of weakness in the confectionery wall.

2. Closed or open confectionery shell, according to claim 1, characterized in that the confectionery wall comprises chocolate.

3. Closed or open pastry shell, according to claim 1 or 2, characterized in that at least one pocket comprises a projection in the pastry wall.

4. A method for forming at least one closed and at least partially filled pocket inside or on the wall of a closed or open hollow confectionery shell, characterized by comprising the steps of: a) providing a confectionery wall; and b) fully forming at least one closed and at least partially filled pocket inside or on the confectionery wall, wherein the one or more pockets form part of one or more removable portions and wherein the portion or each removable portion is defined by one or more areas of weakness in the confectionery wall.

5. Method according to claim 4, characterized in that step a) comprises shaping the confectionery wall, preferably by cold stamping. Petition 870250074897, dated 08 / 25 / 2025, page 83 / 152 2 / 3 6. Method according to claim 4 or 5, characterized in that step a) comprises providing a confectionery wall with at least one pit, notch or other cavity formed in the wall.

7. Method according to claim 6, characterized in that step b) comprises at least partially filling the well or each well, notch or cavity and substantially sealing the well or each well, notch or cavity during or after at least partially filling the well or each well, notch or cavity, such that the substantially sealed well or each well, notch or cavity forms a closed and at least partially filled pocket.

8. Method, according to claim 6 or 7, characterized in that the well or each well, notch or cavity is formed by a protruding ring that defines the perimeter of each well, notch or cavity.

9. A method according to any one of claims 6 to 8, characterized in that the well, or each well, notch or cavity, is formed by a projection extending from the confectionery wall.

10. A method according to any one of claims 6 to 9, characterized in that the seal comprises applying a coating of molten confectionery material followed by cooling the molten confectionery material, or applying a confectionery sealing member to the confectionery wall, heating the contact points between them, and then cooling the joint.

11. Method of manufacturing a closed confectionery shell, as defined in any one of claims 1 to 3, characterized by comprising sealing an open confectionery shell, as defined in any one of claims 1 to 3. Petition 870250074897, dated 08 / 25 / 2025, p. 84 / 152 3 / 3

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