Edible Image Transfer via Deformable Carrier Mold
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Solution Overview
Problem
Applying decorative images to non-planar surfaces of comestible products is laborious and prone to distortion due to the limitations of conventional techniques, which are not suitable for mass production.
Innovation Solution
A method involving the application of a disproportionate color image to a substantially planar carrier, which is then deformed to form a non-planar relief mold, allowing the edible material to be deposited and the image to be proportionately aligned with the three-dimensional surface, using techniques such as screen printing and vacuum forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hand painting is used to apply decorative images to non-planar surfaces, then image accuracy is maintained, but production time and cost increase significantly
Solution Approach 1:
The patent uses a transfer film that contains a disposable layer with the decorative image and a reusable carrier layer. The transfer film is pressed against the non-planar surface, allowing the image to be copied onto the complex geometry without hand painting. This enables mass production while maintaining image accuracy through the precise transfer mechanism.
Solution Approach 2:
The patent replaces the manual mechanical process of hand painting with an automated transfer film pressing system. The transfer film is applied using a pressing mechanism that conforms to the non-planar surface, eliminating the need for manual brush application and significantly increasing production speed.
2Productivity
If conventional transfer techniques are used on non-planar surfaces, then mass production is enabled, but image distortion occurs due to raised areas
Solution Approach 1:
The transfer film is designed with a disposable layer that can be locally deformed to match the specific contours of the non-planar surface. The film's flexibility allows different regions to conform to local surface variations, ensuring the image remains proportional and undistorted even on complex geometries like raised areas.
Solution Approach 2:
The transfer film transitions from a rigid planar state during application to a dynamic conforming state that adapts to the non-planar surface. This dynamic deformation allows the film to follow the surface contours, maintaining image proportionality while enabling mass production of 3D decorated products.
3Manufacturing precision
If edible substrates are made thin and fragile for image transfer, then texture and appearance are preserved, but durability during printing and transferring processes is reduced
Solution Approach 1:
The transfer system is segmented into three functional layers: a disposable layer containing the decorative image, a carrier layer providing mechanical strength and durability, and the edible substrate receiving the transfer. This segmentation allows each layer to optimize its specific function - the carrier layer provides durability during handling and printing while the disposable layer maintains image quality.
Solution Approach 2:
The carrier layer acts as an intermediary between the fragile disposable image layer and the edible substrate. It provides the necessary mechanical strength to withstand printing and transferring processes, while the disposable layer transfers the image to the substrate without compromising the substrate's texture or appearance.
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 enables efficient and accurate application of decorative images to non-planar surfaces, facilitating mass production by ensuring alignment and maintaining the integrity of the image, even on complex shapes.
Implementation Method 1
A comestible material, such as chocolate or a gelatinous composition, may be deposited into the relief mold to substantially overlie the color image
Data Source
AI summary
A method for applying a color image to a non-planar comestible may include applying a color image onto a substantially planar carrier and deforming the carrier to form a non-planar relief mold of a three-dimensional image, including deforming the color image whereby the deformed color image is proportionate relative to, i.e., is in register with, the three-dimensional image. A comestible material, e.g., chocolate or a gelatinous edible composition, may be deposited into the relief mold to substantially overlie the color image. The comestible material may be removed from the relief mold, with the color image applied thereto. In one implementation, the color image may be applied to the substantially planar carrier by screen printing one or more colors forming the color image onto the carrier using an edible ink composition.