Flexible Sheet Cone Molding via Dynamic Forming
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Solution Overview
Problem
Existing production assemblies for edible cones lack a flexible sheet that can reversibly assume a conical shape to mold batter effectively, relying on rigid molds which are not adaptable or efficient.
Innovation Solution
A conveyor system with a resilient, flexible sheet that is molded into a conical shape by forming units within a heating unit, allowing for the production of edible cones with precise control over batter distribution and baking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rigid two-part molds are used for cone production, then the structure is stable and easy to manufacture, but the adaptability and efficiency are limited
Solution Approach 1:
The patent employs a flexible sheet that can be reversibly formed into a conical shape by forming units. This flexible sheet replaces the traditional rigid two-part mold, enabling the system to adapt to different cone configurations while maintaining ease of manufacture through a single-piece design.
Solution Approach 2:
The flexible sheet is dynamically formed into a conical shape during the baking process using forming units, and then returns to its original flat configuration after use. This dynamic transformation allows the same component to serve multiple functions: as a flat conveyor surface and as a conical mold, thereby improving adaptability without complicating manufacturing.
2Device complexity
If rigid two-part molds are used for cone production, then the structure is simple, but the productivity and consistency are insufficient
Solution Approach 1:
The flexible sheet enables continuous cone production as it can be repeatedly formed and released without complex mold opening and closing mechanisms. This increases productivity while keeping the device relatively simple by eliminating the need for two-part rigid molds and their associated actuation systems.
Solution Approach 2:
The flexible sheet is pre-positioned on the conveyor in a flat configuration, and the forming units apply formative action only when needed during the baking process. This preliminary positioning simplifies the overall device structure while enabling high-speed continuous production through efficient timing of the forming action.
3Productivity
If a flexible sheet is used to mold batter, then the adaptability and production efficiency are improved, but the device complexity increases
Solution Approach 1:
The forming units dynamically shape the flexible sheet into a conical configuration during the baking process, and the sheet automatically returns to its flat state after release. This dynamic operation enables continuous high-volume production without requiring complex mechanical systems, as the flexibility of the sheet itself facilitates easy formation and release.
Solution Approach 2:
The flexible sheet serves dual functions: as a conveyor surface in its flat state and as a conical mold when formed. This self-service capability eliminates the need for separate rigid molds, reducing overall device complexity while maintaining high productivity through continuous operation.
4Ease of manufacture
If rigid molds are used, then the manufacturing process is simple, but the manufacturing precision and consistency of cone shape are poor
Solution Approach 1:
The flexible sheet can be precisely formed into a consistent conical shape by the forming units during baking, ensuring uniform cone dimensions and geometry. After baking, the sheet easily releases the cone and returns to its flat configuration, ready for the next cycle. This process maintains manufacturing simplicity while achieving high precision and consistency in cone production.
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 efficient, adaptable, and high-volume production of conical edible products like ice cream cones with consistent shape and texture, improving upon the limitations of rigid molds by using a flexible sheet and controlled heating and forming units.
Implementation Method 1
A heating unit substantially encompasses a section of the conveyor between the first end and a second end of the conveyor
Implementation Method 2
A sheet, which is resiliently flexible, has a centerline that is engaged to the platform
Data Source
AI summary
An edible cone production assembly for streamlined production of edible cones includes a conveyor, which comprises a pair of belts. A platform is engaged to and extends between the belts. A sheet, which is resiliently flexible, is engaged to the platform. A hopper, which is engaged to the conveyor, contains a batter, and portions the batter onto the sheet. A heating unit substantially encompasses a section of the conveyor between the first end and a second end of the conveyor. A guide is engaged to the conveyor within the heating unit and is positioned to selectively engage a plurality of forming units engaged to the platform as it traverses the heating unit to mold the batter into a cone as the heating unit bakes the batter. The cone drops from the platform as the platform rounds an end of the conveyor. The platform is one of a plurality of platforms.