Popcorn Funnel Assembly With Kernel-Separating Curved Holes
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Solution Overview
Problem
Microwave popcorn bags often result in scorched popcorn due to over-popping, and existing funnels allow un-popped kernels to enter the consumer's mouth, posing a need for a solution that prevents kernel scorching and separates popped and un-popped kernels effectively.
Innovation Solution
A popcorn bag funnel assembly with an inwardly curved surface featuring pear-shaped holes to allow un-popped kernels to pass while blocking popped popcorn, combined with a sleeve to capture un-popped kernels and a secure fit around the bag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the microwave process is allowed to run until all kernels are popped, then complete popping is achieved, but substantial portion of popped kernels become scorched
Solution Approach 1:
The funnel assembly is prepared in advance with specific geometric features (inwardly curved surface, pear-shaped holes) that enable selective kernel passage before the microwave process completes. This preliminary structural preparation allows the system to automatically separate popped and un-popped kernels without requiring post-processing or manual intervention.
2Object-affected harmful factors
If the microwave process is stopped before all kernels are popped to prevent scorching, then popped popcorn is not scorched, but a small number of un-popped kernels remain
Solution Approach 1:
The funnel assembly segments the kernel population into two distinct pathways: popped kernels pass through the pear-shaped holes in the inwardly curved surface, while un-popped kernels are blocked and collected in the reservoir. This segmentation enables the system to handle both popped and un-popped kernels simultaneously without requiring separate processing steps.
Solution Approach 2:
The funnel assembly acts as an intermediary device between the microwave bag and the consumer's mouth. It intercepts both popped and un-popped kernels, separates them through its geometric structure, and delivers only popped kernels to the mouth while capturing un-popped ones in the reservoir, thus mediating the potential harm of un-popped kernels.
3Ease of operation
If a funnel is used to direct popped popcorn from the bag into the mouth, then popcorn delivery is improved, but un-popped kernels can escape through the funnel into the mouth
Solution Approach 1:
The funnel assembly incorporates local quality variations in its structure: the inlet end has a specific shape to receive the bag opening, the middle section has an inwardly curved surface with pear-shaped holes for selective passage, and the outlet end has a discharge opening for mouth delivery. Each section's local geometry is optimized for its specific function of separating and directing kernels.
4Device complexity
If the funnel allows un-popped kernels to pass through, then the funnel structure is simple, but consumer safety is compromised
Solution Approach 1:
The funnel assembly utilizes curved surfaces, specifically an inwardly curved surface with pear-shaped holes, to achieve kernel separation. The curvature of this surface creates a geometric filter that allows popped kernels to pass while blocking un-popped kernels, achieving a relatively simple structure that effectively addresses the safety issue without requiring complex mechanical components.
Data Source
AI summary
A popcorn funnel assembly for directing popcorn from a popcorn bag includes an inlet end having an inlet opening that is arranged to fit a popcorn bag and an outlet end having an outlet opening suitable for conveying popped popcorn into the mouth of a person who is eating popcorn. The funnel assembly includes a funnel portion and a sleeve portion. The funnel portion includes a transversely oriented inwardly curved lower wall that is adjacent to the outlet end of the funnel portion and that presents a transversely arranged pattern of holes that are pear shaped with wider lower portions and that are of a suitable size for rejecting popped popcorn and for receiving un-popped kernels and directing them out of the funnel portion and into a receiving space for retaining kernels, the receiving space being enclosed by the inwardly curved wall of the funnel portion and the sleeve portion.