Permanent Casting Mould for 3D Confectionery Shaping
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Solution Overview
Problem
Existing methods for producing three-dimensional confectionery items using sugar mass result in poor dimensional stability and quality due to the use of thin, lightweight casting moulds that are prone to defects, especially when folding mechanisms are used, leading to incomplete three-dimensional shaping and potential tearing of the confectionery item.
Innovation Solution
A method involving a reusable permanent mould with two casting mould parts that are moved from an open position to a closed intermediate position and then into a horizontal transport position, ensuring precise alignment and complete three-dimensional shaping without defects, using a controlled movement and closing mechanism to ensure tight adhesion of the sugar mass portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thin and light casting mould parts made from foil are used, then the mould can be easily manufactured and assembled, but the dimensional stability deteriorates leading to poor quality three-dimensional shaping
Solution Approach 1:
The patent changes the material parameters of the casting mould parts from thin foil to thick-walled permanent mould material. This parameter change transforms the mould from a disposable, easily manufactured component to a durable, dimensionally stable tool that can be reused multiple times while maintaining precise three-dimensional shaping capability.
Solution Approach 2:
The patent employs composite construction by combining the permanent mould parts with a closing means mechanism. The mould parts themselves are designed with sufficient wall thickness to provide dimensional stability, while the closing means (separate from the mould parts) provides the necessary assembly and closing functionality without compromising the mould's structural integrity.
2Ease of operation
If a pivot axis fold groove is used to close the casting mould, then the mould can be assembled, but the quality of the three-dimensional shape deteriorates due to incomplete shaping and potential tearing
Solution Approach 1:
The patent segments the closing function from the mould parts themselves. Instead of integrating the closing mechanism into the mould structure (which would compromise shaping quality), the closing means is implemented as a separate, removable component that attaches to the mould parts only during the closing operation, allowing complete three-dimensional shaping without interference.
Solution Approach 2:
The closing means acts as an intermediary element between the two mould parts during assembly. This separate closing mechanism facilitates the joining of mould parts without requiring fold grooves or pivot axes that would interfere with the three-dimensional shaping process, thereby maintaining high manufacturing precision.
3Device complexity
If the casting mould parts are moved directly into the final position, then the process is simpler, but the alignment precision deteriorates leading to defects in the confectionery item
Solution Approach 1:
The patent implements preliminary alignment action by introducing an intermediate position before the final closed position. The closing means first guides the mould parts into proper alignment at the intermediate position, ensuring precise positioning before the final closing operation. This two-stage process maintains high alignment precision without significantly increasing overall device complexity.
Data Source
AI summary
The invention relates to a method for producing a three-dimensional confectionery item from at least one sugar mass (19, 28) using a casting mould (1) which can be assembled from at least two casting mould parts (2, 3, 15, 16), wherein each casting mould part has at least one partial cavity (5, 17, 18), with the proviso that the two casting mould parts (2, 3, 15, 16) can be brought into an assembled state in which the two partial cavities (5, 17, 18) produce a common mould cavity (8, 20) which gives the confectionery item its three-dimensional shape, wherein the two casting mould parts (2, 3, 15, 16) are arranged in an open casting position (PG) in which the partial cavities (5, 17, 18) are arranged so as to be open towards the top, and the two casting mould parts (2, 3, 15, 16) are then put together and brought into a closed transport position (PT).