Chocolate Shell Edge Compression for Uniform Contact
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Solution Overview
Problem
The production of 3D hollow chocolate products faces challenges in achieving good contact surfaces between two shell shapes, as existing methods often result in uneven or sticky connections due to excess food mass and the risk of water stains from fogging stamps.
Innovation Solution
A second stamp is inserted into the shell shape to compress the edge region, allowing for a defined edge formation without reheating the mold, ensuring a perfect connection by maintaining the food in a liquid state during assembly, and the use of a cooled stamp to prevent fogging and water stains.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooled stamp is used to form a warm edible mass, then the stamp surface temperature is below the dew point causing fogging and ice formation, but the stamp becomes difficult to remove and water stains form on the food
Solution Approach 1:
The patent applies parameter changes by heating the stamp surface to a temperature above the dew point of the surrounding atmosphere. This temperature parameter modification prevents condensation of moisture on the stamp surface, eliminating fogging and subsequent ice formation. The heated stamp surface also prevents water stains on the food product and facilitates easy removal of the stamp after forming.
2Quantity of substance
If excess food mass is added to the mold to ensure complete shell formation, then the shell can be fully formed, but the excess mass creates uneven edges and sticking problems when joining shell halves
Solution Approach 1:
The patent applies preliminary action by forming an excess rim of food mass around the shell edge during the initial forming process. This excess rim is then compressed and flattened in a preliminary step before the shell halves are joined. This pre-compression ensures that when the shells are assembled, the edges are flat and uniform, preventing sticking problems and ensuring precise alignment without requiring additional trimming or adjustment.
3Manufacturing precision
If the shell edges are heated to improve contact surface quality for joining, then the contact area improves, but additional heating steps increase production time and complexity
Solution Approach 1:
The patent applies preliminary action by compressing and flattening the shell edges to the desired contact surface quality during the initial forming process, before the shells are cooled and assembled. This pre-flattening creates optimal contact surfaces that require no additional heating or processing steps for alignment. The shells can be directly joined together with precise alignment, significantly reducing production cycle time and eliminating complex heating steps.
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 good contact area between shell edges, preventing sticking and water stains, while maintaining the food in a liquid state for easier assembly without additional heating, and allows for the production of various geometric configurations.
Implementation Method 1
at least partial Solidification of the consumption mass in the form of this consumption mass is given a shell shape
Implementation Method 2
the stamp having a surface temperature which is below the dew point of the atmosphere surrounding the food to be consumed
Data Source
Figure 1~3
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Figure 7~9
AI summary
The invention relates to a method for producing a consumable product (18), particularly a chocolate product, from at least two shell shapes (13, 13.1, 13.2) at least partially interconnected at their shell edges (12, 12.1, 12.2), a liquid consumable compound (3) being introduced into a mould (2) and at least one die (4) then being dipped into said consumable compound (3) wherein, by virtue of at least partial solidification of the consumable compound (3) in the mould, this consumable compound obtains a shell shape (13, 13.1, 13.2). A second die (5) should then be inserted into the shell shape (13), pushing an edge region of said shell shape upwards.