Asymmetrical Rolled Dough Production via Perpendicular Rolling
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Solution Overview
Problem
The existing methods for producing rolled food products, such as crescent rolls, require rotating the rolls post-production to align their longitudinal axes parallel to the direction of travel, adding cost and complexity to the process.
Innovation Solution
A method involving cutting a dough sheet into a continuous, asymmetrical pattern and rolling it in a direction perpendicular to its travel direction using a conveyor system and torpedo rollers, ensuring the resulting rolls have longitudinal axes aligned parallel to the direction of travel without the need for subsequent rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the dough is rolled in a direction parallel to the direction of travel, then the rolling process is simple and straightforward, but the longitudinal axis of each roll becomes perpendicular to the direction of travel, requiring subsequent rotation of the rolls
Solution Approach 1:
The patent applies asymmetry by designing the rolling process to create rolls with longitudinal axes parallel to the direction of travel, rather than the conventional perpendicular alignment. This asymmetric orientation eliminates the need for subsequent rotation machinery, resolving the contradiction between rolling simplicity and production line complexity
Solution Approach 2:
The patent inverts the conventional rolling approach by rolling the dough in a direction that produces the opposite orientation effect. Instead of rolling parallel to travel direction (which gives perpendicular axes), the dough is rolled to achieve parallel axes alignment, thereby eliminating the need for rotation equipment
2Ease of manufacture
If the rolls are produced with longitudinal axes perpendicular to the direction of travel, then the rolling process is conventional and easy, but additional rotation machinery is required, increasing cost and complexity
Solution Approach 1:
The patent uses asymmetric roll orientation with longitudinal axes parallel to the direction of travel, which eliminates the need for post-production rotation. This asymmetric design improves productivity by removing an additional processing step while maintaining ease of manufacture through the simplified rolling configuration
3Manufacturing precision
If rotation machinery is added to align rolls parallel to the direction of travel, then the rolls achieve desired orientation, but the production process becomes more complex and costly
Solution Approach 1:
The patent applies preliminary action by designing the rolling process itself to produce rolls with the desired parallel alignment from the outset. This preliminary orientation achievement during rolling eliminates the need for subsequent rotation machinery, thereby maintaining manufacturing precision while reducing device complexity
Solution Approach 2:
The patent extracts the orientation function from a separate rotation step and integrates it into the rolling process itself. By taking out the need for dedicated rotation machinery and incorporating the alignment function into the primary rolling operation, the patent achieves precise roll alignment without increasing production line complexity
Data Source
AI summary
Rolled food products are produced by cutting a dough sheet to form a roll sheet having a continuous pattern. The pattern is comprised of an asymmetrical repeat unit. The roll sheet is transported in a first direction with a conveyor system, and the roll sheet is rolled in a second direction to form a continuous roll. The second direction is not parallel to the first direction. The continuous roll is cut to form a plurality of rolls. Each of the plurality of rolls is asymmetrical.