Frozen Confection Extrusion with Non-Planar Base
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Solution Overview
Problem
Existing methods for producing three-dimensional frozen confectionery products are either costly and complex, such as moulding processes that require low-temperature moulds or air blowing to prevent sticking, or limited to two-dimensional shapes using the extrude and cut process.
Innovation Solution
A process and apparatus that modify the extrude and cut process by using a mould block and base with a non-straight line cross-section to create three-dimensional shapes, allowing the frozen confection to be extruded into a cavity and then moved relative to the base for removal, with the base and mould block having translational symmetry to maintain shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If moulding process is used to produce three-dimensional frozen confectionery products, then three-dimensional shapes can be achieved, but the process becomes costly and complex due to requirements for low-temperature moulds or air blowing to prevent sticking
Solution Approach 1:
The mould is segmented into two separate parts: a mould block with a cavity and a base. This segmentation allows the frozen confection to be extruded into the cavity and then released by moving the mould block relative to the base, eliminating the need for complex release mechanisms or low-temperature moulds required by traditional moulding processes.
Solution Approach 2:
The base is designed with a non-straight line cross-section (curved or angled surface) rather than a flat plane. This dimensional change in the base geometry directly imparts three-dimensional shaping to the frozen confection during extrusion, achieving complex shapes without requiring complex moulding operations or post-processing.
2Ease of manufacture
If traditional extrude and cut process is used, then simple two-dimensional shapes can be produced, but three-dimensional shaping is not possible
Solution Approach 1:
The base is designed with a non-straight line cross-section (curved or angled surface) rather than a flat plane. This dimensional change in the base geometry directly imparts three-dimensional shaping to the frozen confection during extrusion, achieving complex shapes without requiring complex moulding operations or post-processing.
Solution Approach 2:
The shaped surface is formed during the extrusion process itself through the geometry of the base, rather than requiring subsequent shaping operations. The frozen confection takes on the three-dimensional shape as it is extruded into and against the non-planar base surface, making the shaping function self-contained in the extrusion step.
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 the production of three-dimensional frozen confectionery products efficiently without the need for additional cost or complexity, allowing for varied shapes like half cylinders but not hemispheres, using partially frozen ice cream at specific temperatures.
Implementation Method 1
extruding a frozen confection from a filling means into a cavity defined by a mould block and a base
Implementation Method 2
The frozen confection which is filled into the cavity is of a consistency such that it can be extruded from the nozzle and filled into the cavity, but which is solid enough that it retains its shape on removal from the cavity. The frozen confection is preferably partially frozen ice cream, typically at a temperature of about -5 to -15°C
Data Source
Figure 1a~3
Figure 4a~4e
Figure 5a~5b
AI summary
A process for shaping a frozen confectionery product is provided, the process comprising: extruding a frozen confection from a filling means into a cavity defined by a mould block and a base; moving the mould block relative to the base; and removing the frozen confection from the cavity, characterized in that the cross-section of the base, when viewed along the direction of relative motion of the cavity and the cutting means, is not a straight line. An apparatus for performing the process is also provided.