Pocket Bun Pan with Ejector Plate for Leak-Resistant Sandwich Buns
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Solution Overview
Problem
Conventional sandwiches face issues with filling leakage when consumed on the go, as the bread fails to effectively contain the filling, leading to a need for an improved bun design that can maintain fillings like hotdogs, sausages, and hamburgers without becoming soggy.
Innovation Solution
A pan is designed to produce pocket buns with a base plate, housing, ejector plate, and divider, allowing for the formation of buns with cavities that can be ejected easily, featuring a pneumatic system or ejection pins for deep-draw goods, and customizable shapes for unique branding, ensuring the buns are baked with a browned interior to resist moisture absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional bread is used for sandwiches, then the sandwich can be easily assembled, but the filling leaks out when eaten on the go
Solution Approach 1:
The bun is segmented into a body portion and a separate pocket portion that forms a cavity. This segmentation allows the bun to contain filling securely within the pocket while maintaining ease of assembly for the sandwich components.
Solution Approach 2:
The bun is designed with a pocket portion that forms a flexible cavity structure. This flexible shell-like pocket can conform to the filling while containing it securely, preventing leakage during transport and consumption.
2Reliability
If the bun is designed with a pocket cavity to contain filling, then filling leakage is prevented, but the bun structure becomes more complex
Solution Approach 1:
The bun is divided into a body portion and a pocket portion that can be formed separately in the mold. This segmentation creates the complex cavity structure through a relatively simple modular mold design, reducing overall manufacturing complexity.
Solution Approach 2:
The mold is designed with a removable pocket portion that can be used to form different types of pockets and cavities. This universal mold design can accommodate various filling types and pocket configurations, reducing the need for multiple specialized molds.
3Reliability
If the bun has a browned interior surface to resist moisture, then filling sogginess is prevented, but the baking process becomes more complex
Solution Approach 1:
The mold is designed to create a browned surface specifically on the interior of the pocket portion where the filling contacts the bread. This localized browning provides moisture resistance exactly where needed, without requiring the entire bun to undergo complex baking treatments.
Solution Approach 2:
The pocket portion is formed with a pre-browned surface during the initial baking process. This preliminary browning action creates a moisture-resistant barrier before the filling is added, preventing sogginess without requiring additional post-baking treatments.
4Productivity
If the pan is designed for easy ejection of buns, then production efficiency is improved, but the pan structure becomes more complex
Solution Approach 1:
The mold is segmented into a base plate, housing, and a removable pocket portion. This segmentation allows the pocket portion to be easily removed from the baked bun, enabling simple ejection without requiring complex ejection mechanisms like pneumatic systems or multiple ejection pins.
Solution Approach 2:
The pocket portion is designed to be removable from the mold after baking. This dynamic design allows the mold components to move and separate, facilitating easy bun ejection while maintaining a relatively simple overall pan structure compared to systems with integrated ejection mechanisms.
Data Source
AI summary
A pan is provided that has a male mold portion, a housing that surrounds the male mold portion, and a top portion with a wing plate that has a complimentary outer surface to the end surface of the male mold portion. The complimentary outer surface forms a more consistent thickness of a baked item. The housing has a bottom surface with an aperture in the bottom to receive the male mold portion. The bottom surface acts to eject the baked item from the pan as the male mold portion is removed from the pan. The top portion can be formed with a continuous surface or have a wing plate that is spaced from a planar portion.