Fold-Flat Baking Container Assembly for Deep Vertical Cakes
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Solution Overview
Problem
Existing baking containers, such as tin plated steel, anodised aluminium, and silicon tins, are limited in shape range, expensive, difficult to clean, and unsuitable for baking large, deep, straight-sided cakes like Christmas and wedding cakes due to stability and heat conduction issues.
Innovation Solution
Fold-flat baking containers made from corrugated cardboard or similar materials, with hinged flaps and tabs, allowing easy assembly into a stable, deep, vertically sided cavity for baking various shapes, including Christmas and wedding cakes, and featuring a locking mechanism to prevent cake mix exposure to cut edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tin plated steel baking tins are used, then a wide variety of shapes and deep cake baking is achieved, but cost increases and cleaning difficulty increases
Solution Approach 1:
The patent employs disposable baking containers made from inexpensive materials such as coated paper or lightweight card, eliminating the need for expensive durable metal tins. These single-use containers provide various shapes without requiring investment in costly equipment, directly resolving the contradiction between shape variety and manufacturing cost.
Solution Approach 2:
The invention changes the material parameters from metal (tin plated steel) to paper-based materials with appropriate coatings. This parameter change enables cost reduction while maintaining the ability to create various shapes through molding and forming processes applied to the paper materials.
2Volume of moving object
If tin plated steel baking tins are used, then deep cake baking is achieved, but weight increases
Solution Approach 1:
The patent changes the material density parameter by transitioning from metal to paper-based materials. This dramatically reduces container weight while maintaining the structural integrity needed for deep cake baking through optimized wall thickness and structural design of the paper containers.
Solution Approach 2:
The invention uses composite paper materials with special coatings (such as greaseproof or silicone coatings) that provide both the necessary structural strength for deep cakes and the non-stick properties traditionally associated with metal tins, achieving light weight without sacrificing functional performance.
3Ease of manufacture
If disposable paper containers with sloping sides are used, then cost is reduced, but stability during baking deteriorates
Solution Approach 1:
The patent introduces an outer supporting tin or frame that provides a stable base and vertical walls, creating a stable environment for the disposable inner container. This supporting structure compensates for the inherent instability of sloping-sided paper containers, maintaining baking stability while preserving cost benefits.
Solution Approach 2:
The invention employs a nested structure where the disposable paper container is placed inside a rigid outer supporting tin or frame. The outer structure provides stability during baking while the inner disposable container maintains contact with the food, combining the advantages of both approaches.
4Volume of moving object
If tin plated steel tins are used, then deep vertical sided cakes are achieved, but heat conduction causes temperature control issues
Solution Approach 1:
The patent changes the thermal conductivity parameter by replacing metal with paper-based materials. This reduces heat conduction, preventing hot spots and improving temperature distribution during baking. The lower thermal conductivity of paper materials naturally addresses the temperature control issues associated with metal tins.
5Weight of moving object
If anodised aluminium tins are used, then weight is reduced, but shape range is limited
Solution Approach 1:
The patent changes the material from anodised aluminium to molded paper materials, which can be easily formed into various shapes through molding processes. This maintains the light weight advantage while dramatically expanding the shape range to include numerals, novelty shapes, and traditional forms.
Data Source
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AI summary
There is provided an ovenable, fold-flat baking container assemblage from a flat unassembled form into an assembled form, the container comprising a flat base (1) and at least one side wall member (20). The base has a main base portion (2) and a number of base flaps (3-6) which are hingedly connected to the main base portion. The or each side wall member (20) has a main wall portion and which has along its bottom edge one or more tabs (21), each of said tabs being capable of folding outwards relative to the main wall portion. When the main wall portion has its bottom edge in contact with the main base portion with the tabs folded outwards, the base flaps are folded into an active position and the tabs (21) are sandwiched between the base flaps (3- 6) and the main base portion (2). Retaining means are provided to secure the one or more base flaps in their active position, such that the main base portion and the one or more main wall portions form an open-topped enclosed cavity. There is also provided an ovenable, fold-flat baking container assemblage from a flat unassembled form into an assembled form, the container comprising a flat base (65) and at least three side wall portions (66) linked by gusset portions (69).