Modular Baking Tray Frame With Replaceable Inlay for Thermal Warping
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Solution Overview
Problem
Industrial baking trays face issues such as warping due to different thermal expansion coefficients of materials, frequent inlay replacement, and difficulty in on-site maintenance, leading to inefficiencies and increased energy consumption.
Innovation Solution
A baking tray design featuring a frame with transverse and longitudinal struts supporting a lightweight inlay, allowing for easy replacement and reduced thermal mass, along with detachable connections that enable on-site maintenance and reduced material stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a frame made of stainless steel and an inlay made of aluminum are used together, then the baking tray can be constructed with different materials to optimize performance, but the different coefficients of thermal expansion cause warping of the inlay and loosening of rivets
Solution Approach 1:
The baking tray is divided into separate components (frame and inlay) that can be independently replaced. The inlay is made detachable so it can be removed and replaced without affecting the frame, allowing each component to be optimized for its specific function while avoiding the thermal expansion compatibility issue through modular design.
Solution Approach 2:
The invention changes the material parameter by making the entire inlay removable and replaceable. This allows the inlay to be made of aluminum for optimal thermal conductivity during baking, while the frame can be made of stainless steel for durability, without the warping issue because the inlay is not permanently fixed and can be replaced when wear occurs.
2Strength
If the inlay is permanently attached to the frame with rivets, then the structure is stable during use, but the inlay must be replaced by drilling new holes in the frame, limiting the frame's usable life
Solution Approach 1:
The inlay is designed as a separate, detachable component from the frame. This segmentation allows the inlay to be easily removed and replaced without drilling new holes in the frame. The frame maintains its structural integrity throughout its entire service life, while multiple inlays can be cycled through during the frame's duration.
Solution Approach 2:
The connection between inlay and frame is made dynamic rather than static. The inlay can be attached and detached as needed, transforming from a permanent fixed connection to a reversible connection. This allows the frame to remain in service indefinitely while inlays are replaced based on wear.
3Strength
If a heavy stainless steel frame and aluminum inlay are used, then the baking tray has sufficient strength and durability, but the weight is high (approximately 16.4 kg), increasing energy consumption during handling and operation
Solution Approach 1:
The baking tray is segmented into a permanent frame and replaceable inlay. The frame provides the necessary structural strength and durability, while the inlay can be optimized for minimal weight. This segmentation allows the heavy-duty frame to be reused indefinitely while lighter inlays are cycled through, reducing the average weight and energy consumption during operation.
Solution Approach 2:
The inlay is designed as a consumable component that can be replaced when worn. This allows the use of lighter materials for the inlay that would not be economically viable if permanently fixed, reducing the overall weight and energy consumption during the operational phase while maintaining frame durability.
4Ease of operation
If the inlay is made with a non-stick coating, then the release properties are improved, but the coating degrades over time and requires replacement
Solution Approach 1:
The inlay with its non-stick coating is segmented as a separate replaceable component. When the coating degrades after 1-1.5 years of use, only the inlay needs to be replaced, not the entire baking tray or frame. This maintains the release properties for each inlay's service life while extending the overall system lifespan through frame reuse.
Solution Approach 2:
The inlay is designed to be discarded after its coating degrades and recovered as a worn component. The frame is retained and reused for multiple inlay cycles. This allows the non-stick coating to be refreshed periodically without losing the investment in the durable frame structure.
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
The design enhances operational efficiency, extends tray lifespan, reduces energy consumption, and facilitates quick inlay replacement without specialized tools, improving overall baking process speed and quality.
Implementation Method 1
The inlay is made of a material such as aluminum
Implementation Method 2
the stainless steel frame and the inlay, being made of different materials, have different coefficients of thermal expansion, which can lead to unwanted warping of the inlay
Data Source
Figure 1a~1b
Figure 1c~1g
Figure 2a~2e
AI summary
The invention relates to a baking tray for industrially operated baking systems, comprising a frame and an inlay. The baking tray is characterized in that the frame has a structure of several transverse and longitudinal struts for supporting the inlay.