Shortcake Packaging Mold Inversion for Cream Volume Retention

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Solution Overview

Problem

Conventional shortcake manufacturing processes make it difficult to deliver and sell shortcakes outside of the cake factory due to their fragile nature, as they are prone to damage during transportation and require extensive manual handling and packaging steps.

Innovation Solution

A method using a package container as a mold to reverse the shortcake production process, stacking cream layers on a sponge cake or pancake, and utilizing an insole film to facilitate easy removal and packaging, allowing for mass production of shortcakes with increased cream and sauce volume without compromising shape retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the shortcake is made by conventional cutting process, then the shortcake can be produced, but it is prone to damage during transportation and difficult to deliver to remote stores

Engineering Contradiction:

Improvedamage resistance during transportationVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent inverts the conventional manufacturing sequence by first forming the cream layer and topping in the package container, then placing the sponge cake on top to be compressed into shape. This reverse approach allows the cake to be formed within the packaging container itself, eliminating the need for separate cutting and packaging operations, and providing damage resistance during transportation.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The package container serves multiple functions: it acts as the mold for forming the cream layer and topping, provides structural support for the finished shortcake, and serves as the final packaging for transportation and storage. This multi-functionality eliminates the need for separate molding and packaging processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Quantity of substance

If the shortcake is made with large amount of cream and sauce, then the volume and appeal increase, but the shape retention during delivery deteriorates

Engineering Contradiction:

Improvecream and sauce volumeVSAvoidshape retention during delivery

Core Design Contradiction:

Quantity of substanceVSShape

Solution Approach 1:

The cream layer and topping are formed in advance within the package container before the sponge cake is placed. The sponge cake then serves as a compression element that consolidates the cream layer into a stable shape during the baking process, allowing large volumes of cream to be retained while maintaining shape integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sponge cake undergoes parameter changes during baking, transitioning from a soft, uncompressed state to a firm, compressed state that provides structural support. This parameter change allows the sponge cake to bear the weight of large volumes of cream and sauce while maintaining the overall shape of the shortcake.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the conventional packaging process is used, then the shortcake can be packaged, but extensive manual handling and multiple steps are required

Engineering Contradiction:

Improvemass production capabilityVSAvoidpackaging process steps

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The molding process and packaging process are merged into a single operation. The shortcake is formed directly within the package container, eliminating the need for separate molding, cutting, and packaging steps. This integration enables mass production while simplifying the overall process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sponge cake is extracted from its traditional role as the base layer and repurposed as a compression element placed on top of the cream layer. This extraction and repositioning of the sponge cake's function enables the cream layer to be formed first and consolidated into shape, simplifying the overall process.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12178220B2Method and system of making a shortcake in a package container

Publication Date: 2024.12.31 TAGUCHI & CO LTD

AI summary

A system for manufacturing a multi-layer shortcake can be realized by reversing the manufacturing process of the shortcake to normal. The assembly line conveyor system includes a package container having a top opening as a cake mold and a take-out film set as an insole in the package container. The packaged shortcake includes a topping layer of a cake, a first cream layer, a shape retaining sponge block, a second cream layer, and a cake base platform on the insole film and closed with a bottom lid. Preferably, the packaged shortcake contains a cake block between the first cream layer and the second cream layer for supporting the shape of the shortcake.