Contact Toaster with Movable Compression Plates for Varied Food Shapes

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Solution Overview

Problem

Conveyor toasters have high power requirements, require long preheating times, deform or mark soft food products, and struggle with toasting varied sizes and thicknesses due to fixed platen spacing, and are difficult to clean.

Innovation Solution

A contact toaster with a vertically arranged central platen and movable compression plates that conform to different food product shapes, allowing for efficient heating and automated cleaning, reducing energy consumption and preventing deformation of food products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conveyor toasters are used for continuous processing, then productivity is improved, but power consumption increases and preheating time increases

Engineering Contradiction:

Improvecontinuous processing capabilityVSAvoidpower consumption

Core Design Contradiction:

ProductivityVSUse of energy by stationary object

Solution Approach 1:

The toaster is divided into multiple independent heating zones along the conveyor path, allowing only the necessary sections to be activated at any given time. This segmentation enables continuous processing while reducing overall power consumption by avoiding heating of the entire conveyor simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating elements are activated periodically as food items pass through different zones, rather than maintaining continuous heating throughout the entire conveyor. This periodic activation maintains productivity while significantly reducing power consumption and preheating requirements.

Inventive Principle:

Principle #19Periodic action

2Device complexity

If fixed platen spacing is used in conveyor toasters, then device complexity is reduced, but adaptability to different food sizes deteriorates

Engineering Contradiction:

Improveplaten spacing mechanismVSAvoidaccommodation of varied food sizes

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The platens are made adjustable with variable spacing capabilities, allowing the distance between heating surfaces to be dynamically changed according to the size and type of food item being processed. This maintains simple overall device structure while providing adaptability for different food dimensions.

Inventive Principle:

Principle #15Dynamics

3Productivity

If conveyor toasters process soft food products, then productivity is improved, but food product deformation occurs

Engineering Contradiction:

Improveprocessing speedVSAvoidfood product deformation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The heating and compression forces are localized to specific contact points where the food touches the platens, rather than applying uniform pressure across the entire food surface. This localized approach toasts the food effectively while minimizing deformation of soft products.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The platens feature curved or contoured surfaces that match the natural shape of food items, distributing pressure more evenly and preventing flat spots or deformation marks on soft food products while maintaining effective toasting contact.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Productivity

If conveyor toasters are designed for continuous operation, then productivity is improved, but cleaning difficulty increases

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidcleaning accessibility

Core Design Contradiction:

ProductivityVSEase of repair

Solution Approach 1:

The heating elements and critical toasting components are designed to be removable or accessible from the exterior of the conveyor housing, allowing easy cleaning of surfaces that contact food without requiring disassembly of the entire continuous operation mechanism.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enables quick and efficient toasting of various food shapes and sizes without deformation, with reduced energy use and an automated self-cleaning process, improving operational efficiency and product quality.

Implementation Method 1

A heating element is configured to heat the first and second toasting surfaces

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11844464B2Contact toaster

Publication Date: 2023.12.19 MARMON FOODSERVICE TECH INC

AI summary

A contact toaster includes a vertically arranged central platen with a first toasting surface that is contoured and a second toasting surface. A heating element is configured to heat the first and second toasting surfaces. A first compression plate is spaced apart from the first toasting surface to define a first slot between the first compression plate and the first toasting surface. A second compression plate spaced apart from the second toasting surface to define a second slot between the second compression plate and the second toasting surface. The first compression plate and the second compression plate are selectively movable from respective first positions away from the central platen to respective second positions proximate to the central platen.