Adjustable Conveyor Toaster for Variable Food Thickness
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Solution Overview
Problem
Conveyor toasters are ill-suited for consumer use due to their size, high manufacturing cost, power requirements, and difficulty in accommodating food products of varying thicknesses, as well as issues with marking soft foods and jamming, and are challenging to clean due to fixed conveyor attachments.
Innovation Solution
An adjustable conveyor toaster system with independently adjustable mechanical components, including a conveyor assembly with a bracket, gears, and a tension spring, allowing for variable conveyor belt tension and position adjustment relative to the platen, enabling the toaster to accommodate a wide range of food products by controlling the conveyor speed, tension, and platen temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed conveyor spacing is used in prior art conveyor toasters, then the structure is simple and manufacturing is easy, but the toaster cannot accommodate food products of varying thicknesses, causing thin foods to fall through and thick foods to jam
Solution Approach 1:
The patent applies the dynamics principle by making the conveyor belt position adjustable rather than fixed. The mounting bracket allows the conveyor assembly to be positioned at multiple heights relative to the platen, enabling the system to adapt to different food thicknesses. This transforms a static structure into a dynamic one that can be reconfigured based on operational needs.
Solution Approach 2:
The patent implements parameter changes by allowing the spacing between the conveyor belt and platen to be varied. By changing the positional parameter of the conveyor assembly through the mounting bracket mechanism, the system can accommodate different food product dimensions without requiring complete redesign of the toaster structure.
2Productivity
If heavy-gauge wire conveyors are used to urge food against the platen, then the conveyor can effectively move food through the toaster, but it leaves marks in soft food products like breads and bagels
Solution Approach 1:
The patent applies this principle by using a flexible conveyor belt instead of rigid heavy-gauge wire conveyors. The belt material can be selected to be gentle on soft food surfaces while still providing sufficient friction to move food products effectively through the toasting chamber without leaving marks or damage.
Solution Approach 2:
The patent changes the physical parameter of the conveyor from rigid wire to flexible belt material. This material parameter change allows the conveyor to maintain effectiveness in moving food while eliminating the harmful marking effect on soft food products.
3Stability of the object's composition
If the conveyor is fixably attached to the toaster body, then the structure is stable and simple, but the toaster becomes difficult to clean
Solution Approach 1:
The patent applies segmentation by dividing the conveyor assembly into a separable unit that can be detached from the toaster body through the mounting bracket. This allows the conveyor belt to be removed independently for cleaning while the main toaster structure remains stable and intact.
Solution Approach 2:
The patent transforms the fixed attachment into a dynamic, adjustable mounting system. The mounting bracket enables the conveyor assembly to be positioned securely during operation but removed or accessed for cleaning when needed, providing both structural stability and cleaning ease.
4Productivity
If a conventional conveyor toaster design is used, then continuous processing capability is achieved, but the size, manufacturing cost, and power requirements make it unsuitable for consumer use
Solution Approach 1:
The patent applies universality by designing a toaster that combines continuous processing capabilities with the compact form factor and lower cost structure of consumer appliances. The adjustable conveyor system provides commercial-style continuous operation while the overall design maintains consumer-friendly size and price points.
Solution Approach 2:
The patent uses dynamic adjustment mechanisms to provide continuous processing capability in a compact design. The adjustable conveyor and platen positioning allow for optimized throughput while maintaining a smaller overall footprint compared to traditional commercial conveyor toasters.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for flexible toasting of various food products, preventing marking, jamming, and facilitating easy cleaning by providing a customizable conveyor-platen gap and tension, enhancing the toaster's adaptability and operational efficiency.
Implementation Method 1
A tension spring is connected between the bracket and the second gear. The tension spring applies a tensioning force on the second gear in a direction away from the first gear to place a variable tension on the conveyor belt.
Implementation Method 2
A drive motor is operably connected to the first gear. The drive motor operates the drive gear to move the conveyor belt about the first and second gears.
Implementation Method 3
A platen is configured to be heated and is positioned relative to the conveyor belt.
Data Source
AI summary
A conveyor toaster includes a conveyor assembly with a bracket and a conveyor belt. The conveyor belt rotates about first and second gears. A drive motor operates to move the conveyor belt about the first and second gears. A platen is configured to be heated and is positioned relative to the conveyor belt. A mounting bracket is connected to the bracket of the conveyor assembly. Movement of the mounting bracket changes the position of the conveyor assembly relative to the platen.