Contact Toaster Belt Assembly for Variable Bun Thickness Accommodation
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Solution Overview
Problem
Conventional contact toasters struggle to accommodate buns of varying thicknesses, leading to inconsistent toast quality, potential bun deformation, and cumbersome maintenance processes.
Innovation Solution
A conveyorized contact toaster with a belt assembly featuring independently compressible gripping bodies that adjust to bun thickness and a separate gripping body heat platen for uniform heating, allowing for efficient toasting of buns with different thicknesses without the need for frequent gap adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single gap setting is used across all bun thicknesses, then the toaster structure is simple and easy to operate, but thicker buns are overly compressed while thinner buns receive insufficient compression, resulting in variable toast quality
Solution Approach 1:
The patent employs a dynamically adjustable gap mechanism that allows the gap between the conveyer and platen to be customized for each bun thickness. This dynamic adjustment capability enables optimal compression force for each bun type, ensuring consistent toast quality across varying bun thicknesses while maintaining operational simplicity through a user-friendly adjustment interface.
2Manufacturing precision
If the gap is continually reset to accommodate different bun thicknesses, then optimal gap sizing is achieved for each bun, but the operation becomes time-consuming and impractical for high-volume restaurants
Solution Approach 1:
The patent implements preliminary classification and pre-setting of gap dimensions based on bun thickness categories. Before the high-volume toasting operation begins, the system pre-configures multiple gap settings corresponding to different bun thicknesses. During operation, operators can quickly select the appropriate pre-configured gap setting without time-consuming adjustments, thereby maintaining both optimal compression and high throughput.
3Manufacturing precision
If multiple separate toasters are used for different bun types, then each toaster provides optimal gap sizing, but the equipment cost and space requirements increase significantly
Solution Approach 1:
The patent designs a universal toaster system that can handle multiple bun thicknesses within a single device. The toaster incorporates an adjustable gap mechanism and a conveyer system that can be configured for different bun types, eliminating the need for multiple specialized toasters. This multi-functional design reduces equipment cost and space requirements while maintaining optimal toasting performance across various bun thicknesses.
4Adaptability or versatility
If compressible gripping elements are used to accommodate varying bun thicknesses, then the toaster can handle different bun sizes, but the gripping elements may puncture or deform the buns
Solution Approach 1:
The patent utilizes a flexible belt conveyer system that can bend and conform to different bun thicknesses without applying excessive localized pressure. The flexible nature of the belt allows it to accommodate varying bun sizes while distributing pressure evenly across the bun surface, preventing puncture and deformation. This flexible conveyer mechanism maintains adaptability to different bun thicknesses while avoiding the harmful effects of rigid compressible gripping elements.
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 solution ensures consistent toasting quality across various bun thicknesses, minimizes bun deformation, and facilitates easy maintenance by allowing quick disassembly and cleaning of the belt assembly.
Implementation Method 1
a plurality of gripping bodies (20) extending from the belt body (16)... Each gripping body (20) may be fixedly attached to the belt body (16) and is resiliently flexible relative to the belt body (16)
Implementation Method 2
a toasting platen (18) having a planar toasting surface... configured to interface with a food item to urge the food item against and along the planar toasting surface
Data Source
AI summary
A conveyorized contact toaster includes a toasting platen having a planar toasting surface and a belt assembly configured to interface with a food item to urge the food item against and along the planar toasting surface. The belt assembly includes a belt body having a first end portion, a second end portion, an inner surface, and an opposing outer surface. A first belt connector is coupled to the first end portion of the belt body, and a second belt connector is coupled to the second end portion of the belt body. The belt body is configurable in a loop configuration with the first end portion being positioned adjacent the second end portion, and the first belt connector detachably coupled to the second belt connector to maintain the belt body in the loop configuration.