Chocolate Cap Formation with Flat Surface and Hermetic Seal

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Solution Overview

Problem

Conventional methods for producing confectionery products with a cup-like configuration face challenges in achieving a uniformly thick and hermetically sealed cap, particularly in industrial automation, as they often result in irregular cap thickness, leakage, and excessive waste due to manual operation and limitations in molding techniques.

Innovation Solution

A process where caps are formed in a molten state with a flat and uniform surface, coupled to pre-solidified shells, and sealed by rotating the shells upside down to align with the caps, allowing for precise control over cap thickness and decoration, and achieving a hermetic seal through heat transfer and meniscus formation, adaptable for automated industrial production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional pouring methods are used to form caps, then the process is simple, but the cap thickness becomes irregular and uncontrolled

Engineering Contradiction:

Improvesimplicity of cap formation processVSAvoiduniformity of cap thickness

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The mold cavity is pre-formed with the desired cap geometry and thickness profile before the chocolate mass is poured in. This preliminary shaping of the mold cavity ensures that the cap achieves uniform thickness without requiring complex post-forming operations, resolving the contradiction between simple manufacturing and precise thickness control.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If manual operation is used for cap formation and sealing, then flexibility is maintained, but productivity is low and waste is excessive

Engineering Contradiction:

Improveflexibility in operationVSAvoidproduction volume

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The process is divided into distinct sequential operations: cap formation in dedicated molds, shell preparation, and sealing operations. This segmentation allows each step to be optimized independently and automated separately, enabling high-volume production while maintaining the flexibility to adapt to different product specifications through modular process adjustment.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If caps are formed separately and then sealed to shells, then the sealing process becomes complex, but cap formation precision is improved

Engineering Contradiction:

Improveprecision of cap formationVSAvoidcomplexity of sealing process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The cap formation and sealing operations are merged into a single integrated process step. The cap is formed in the mold and immediately sealed to the shell in one continuous operation, eliminating the need for separate sealing steps and reducing overall process complexity while maintaining precise cap formation through the integrated mold design.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If excess chocolate is poured off during cap formation, then the cap can be formed, but material waste increases

Engineering Contradiction:

Improvecap formation capabilityVSAvoidchocolate material waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The mold cavity is pre-formed with the exact desired cap geometry and volume before chocolate is poured in. This preliminary preparation of the mold cavity shape allows the chocolate to be poured in controlled amounts that match the cavity capacity, minimizing excess material and reducing waste while maintaining ease of cap formation.

Inventive Principle:

Principle #10Preliminary action

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

This method ensures a consistently uniform cap thickness, prevents leakage and external penetration, minimizes waste, and optimizes production by enabling precise control over cap formation and sealing, suitable for high-volume industrial automation.

Implementation Method 1

a cap (6) formed in a molten state in a mold (9) provided with cavities (V)

Methodology Applied

Scientific EffectPouring:

Implementation Method 2

the body (4) being subjected to softening in a position corresponding to the mouth rim (5) to enable sealing of the cap (6)

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

achieving a hermetic seal through heat transfer and meniscus formation

Methodology Applied

Scientific EffectMeniscus formation: Surface Tension

Data Source

PatentEP1919296B1A process for making foodstuff products, and a foodstuff product thus made

Publication Date: 2009.04.01 SOREMARTEC SA(BE)

Figure 1~2
Figure 3

AI summary

Foodstuff products (1) such as chocolates and the like are made through the steps of : making a shell (4) with a general cup-like configuration having a mouth rim (5); making a cap (6) for closing the shell (4) by pouring foodstuff in a mould (9); connecting the cap (6) to the shell (4) whilst the foodstuff poured into the mould (9) is in the molten state with a free inner surface that is substantially flat and and outer surface of a desired shape, by bringing about the connection of said cap (6) with the mouth rim (5) of said shell (4); and achieving consolidation of the cap (6) connected to the shell (4).