Adjustable Conveyor Toaster for Variable Food Thickness Accommodation
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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 leaving marks on soft items and being difficult to clean.
Innovation Solution
An adjustable conveyor toaster with independently adjustable mechanical systems, including a conveyor assembly with a bracket, gears, and a tension spring, allowing for variable tension and spacing between the conveyor belt and the heated platen, enabling the toaster to accommodate a wide range of food products by controlling conveyor speed, tension, and platen temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed spacing conveyor toaster is used, then the structure is simple, but it cannot accommodate food products of varying thicknesses
Solution Approach 1:
The patent implements adjustable conveyor spacing through a mechanical system with movable conveyor assemblies that can be positioned at different distances from the platen. This dynamic adjustment capability allows the toaster to accommodate food products of varying thicknesses, transforming a static fixed-spacing design into a dynamic adaptable system.
Solution Approach 2:
The patent changes the physical parameter of conveyor spacing by providing multiple adjustable positions for the conveyor assemblies relative to the platen. This parameter adjustment enables the same device to handle different food thicknesses without requiring multiple specialized toasters.
2Reliability
If heavy-gauge wire conveyors are used to urge food against the platen, then the food is held firmly, but marks are left on soft food products
Solution Approach 1:
The patent replaces heavy-gauge wire conveyors with flexible conveyor belts that can conform to the food product surface without leaving marks. These thin film-like belts provide sufficient friction to hold food firmly while being gentle enough not to damage soft surfaces.
Solution Approach 2:
The patent changes the material parameter of the conveyor from rigid wire to flexible belt material, fundamentally altering how the conveyor interacts with the food surface. This material substitution maintains holding capability while eliminating the harmful marking effect.
3Stability of the object's composition
If the conveyor is fixably attached to the toaster body, then the structure is stable, but the device is difficult to clean
Solution Approach 1:
The patent divides the conveyor assembly into separable components that can be detached from the toaster body. This segmentation allows the conveyor belts and associated mechanisms to be removed for cleaning, transforming a permanently attached difficult-to-clean design into a modular easy-to-clean system.
Solution Approach 2:
The patent implements removable and reattachable conveyor assemblies that can be dynamically positioned between operational and cleaning states. This dynamic attachment/detachment capability provides stability during operation while enabling easy access for cleaning.
4Productivity
If a conveyor toaster is designed for high-volume throughput, then productivity increases, but the device becomes unsuitable for consumer use due to size and cost
Solution Approach 1:
The patent divides the conveyor system into compact modular assemblies that can be efficiently arranged within a smaller footprint. This segmentation allows high-volume processing capability to be achieved in a more compact configuration suitable for consumer environments.
Solution Approach 2:
The patent designs the conveyor toaster with adjustable features that allow a single device to handle multiple food types and thicknesses, replacing the need for multiple specialized toasters. This multi-functionality achieves high productivity through versatility rather than through sheer size.
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 adjustable system allows for consistent toasting of various food products, preventing damage and ensuring proper engagement with the platen, while being easier to clean and maintain, thus enhancing flexibility and efficiency in toasting operations.
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 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 positon of the conveyor assembly relative to the platen.