Dough Rolling with Separator Sheet Cylinder
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Solution Overview
Problem
Existing methods for rolling dough pieces with a separator sheet are inefficient and prone to unrolling, as they require stopping the conveyor and do not effectively manage the different handling characteristics of paper and dough, leading to oblique rolls and increased production complexity.
Innovation Solution
A method using at least three conveyors to rotate the dough piece 90 degrees with respect to the transport direction, forming a rolling chamber that curls the separator sheet into a cylinder, with the leading edge of the sheet exceeding the dough piece and using adhesive to secure it, allowing for continuous rolling and handling of multiple dough pieces without additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conveyor with dough pieces is stopped from time to time to roll dough pieces and baking paper, then the rolling process can be performed, but the production speed becomes slow and efficiency decreases
Solution Approach 1:
The patent implements continuous rolling by having the separator sheet and dough pieces conveyed continuously through a rolling chamber formed by three conveyors. The conveyors work simultaneously to curl the separator sheet and roll the dough pieces without stopping the main production line, thereby maintaining continuous useful action and eliminating idle time between rolling operations.
2Ease of manufacture
If two conveyors are used to roll dough as in prior art, then rolling can be achieved, but the separator sheet moves straight on instead of rolling up
Solution Approach 1:
The patent introduces a three-dimensional rolling chamber formed by three conveyors arranged in a triangular configuration, where each conveyor is inclined at a specific angle. This spatial arrangement transforms the two-dimensional conveyor movement into a three-dimensional rolling action, forcing the separator sheet to curl upward and form proper rolls instead of moving straight ahead.
Solution Approach 2:
The patent introduces an intermediary rolling chamber as a mediating structure between the separator sheet supply and the final product. This chamber, formed by the interaction of three conveyors, acts as a mediator that transforms the linear movement of the separator sheet into a rolling motion, enabling the dough pieces to be properly rolled without directly manipulating them.
3Ease of operation
If the leading edge of the separator sheet is folded over the dough piece prior to rolling, then rolling can be initiated, but oblique rolls are formed due to non-straight edges
Solution Approach 1:
The patent applies preliminary action by pre-cutting the separator sheet into strips with straight edges before the rolling process. This preliminary preparation ensures that when the separator sheet enters the rolling chamber, it already has the proper geometry to form straight rolls, eliminating the need for folding operations that could introduce obliqueness.
4Strength
If additional cylindrical support parts are used to support the roll during production, then structural support is provided, but the device complexity increases and additional handling steps are required
Solution Approach 1:
The patent applies self-service by designing the separator sheet itself to provide the necessary structural support during rolling and transport. The three-conveyor system manipulates the separator sheet in such a way that it forms a self-supporting structure, eliminating the need for additional cylindrical support parts and simplifying the overall device configuration.
5Ease of manufacture
If the separator sheet is cut into pieces with non-straight edges, then the sheet can be formed, but the resulting rolls become oblique and difficult to handle
Solution Approach 1:
The patent applies local quality by ensuring that only the leading edge of the separator sheet has the specific property of being straight and exceeding the dough piece length. This localized precision at the critical cutting edge ensures proper roll formation and handling, while other parts of the separator sheet can maintain flexibility for the rolling process.
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 approach enables the formation of straight rolls with enhanced flexural strength, preventing unrolling and ensuring dough freshness, while allowing for uninterrupted processing and handling of various dough shapes, reducing production time and complexity.
Implementation Method 1
providing a strip or a number of dots of adhesive along the second side, and fixing the rolled up dough piece and separator sheet by means of the strip or dots of adhesive
Data Source
AI summary
The present invention leads to a method for preparing a dough piece (4) rolled up with separator sheet (5), comprising supplying in a transport direction (7), a dough piece (4) positioned on a separator sheet (5), the dough piece (4) and the separator sheet (5) having a length (6) and a width (7), wherein a leading edge (12) of the separator sheet (5) exceeds the dough piece (4) at at least a first side, rolling up the at least one side of the dough paper (5) that exceeds the dough piece (4), thus forming a cylinder of separator sheet (5), extending in a width direction of the dough piece (4) and rolling up the rest of the separator sheet (5) with the dough piece (4) around the cylinder. The invention further relates to a device (1) for performing the method and a roll (16) formed by the method and/or device (1).