Single-mode Microwave Popper with Segmented Heating Zones

Solution Overview

Problem

Conventional methods for making popcorn are inefficient, leading to uneven heating, low yield, and the production of burnt kernels, which can be toxic, while also requiring advance preparation and resulting in non-fresh popcorn.

Innovation Solution

A microwave device with a heating chamber and air blower that uses focused microwave energy to uniformly heat kernels, creating high-intensity microwave regions for rapid and complete popping, with an air circulation system to separate popped flakes from un-popped kernels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional microwave devices are used to heat popcorn kernels, then the kernels can be heated, but the processing time is too long resulting in burning of a significant number of popcorn kernels and flakes

Engineering Contradiction:

Improveheating temperatureVSAvoidprocessing time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The heating chamber is divided into multiple zones with different microwave power levels. The first heating zone uses lower power for initial heating, while the second heating zone uses higher power for rapid popping. This segmentation allows different parts of the heating process to occur at optimal temperatures without excessive burning.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The microwave power is dynamically adjusted during the heating process. The system transitions from lower power in the first heating zone to higher power in the second heating zone, allowing the heating rate to adapt to the changing state of the kernels from solid to popped flake.

Inventive Principle:

Principle #15Dynamics

2Productivity

If conventional heating methods are used, then popcorn can be made, but the heating is non-uniform resulting in uneven or incomplete popping

Engineering Contradiction:

Improvepopping efficiencyVSAvoidheating uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The heating chamber is segmented into multiple zones with different microwave power levels. The first heating zone uses lower power for initial heating, while the second heating zone uses higher power for rapid popping. This segmentation allows different parts of the heating process to occur at optimal temperatures without excessive burning.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The microwave power is dynamically adjusted during the heating process. The system transitions from lower power in the first heating zone to higher power in the second heating zone, allowing the heating rate to adapt to the changing state of the kernels from solid to popped flake.

Inventive Principle:

Principle #15Dynamics

3Quantity of substance

If large quantities of popcorn are prepared in advance, then availability is improved, but the product does not remain fresh

Engineering Contradiction:

Improvequantity of popcornVSAvoidfreshness

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The heating chamber is divided into multiple zones with different microwave power levels. The first heating zone uses lower power for initial heating, while the second heating zone uses higher power for rapid popping. This segmentation allows different parts of the heating process to occur at optimal temperatures without excessive burning.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The microwave power is dynamically adjusted during the heating process. The system transitions from lower power in the first heating zone to higher power in the second heating zone, allowing the heating rate to adapt to the changing state of the kernels from solid to popped flake.

Inventive Principle:

Principle #15Dynamics

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 solution achieves rapid, complete popping with high yield and lower density popcorn flakes, reducing the risk of burnt kernels and improving the freshness and quality of popcorn.

Implementation Method 1

a microwave emitter configured to produce microwave energy within the heating chamber

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Implementation Method 2

an air blower configured to create airflow within the heating chamber sufficient to move the popcorn kernels within the heating chamber

Methodology Applied

Scientific EffectForced convection: Forced Convection

Implementation Method 3

Heating the kernels turns the moisture inside the hull into a superheated pressurized steam, which causes the starch to gelatinize and pressure to build up in the kernel until the hull ruptures

Methodology Applied

Scientific EffectPressure buildup and phase change: Phase Change

Data Source

PatentUS8993946B2Single-mode microwave popping device

Publication Date: 2015.03.31 JACOBSEN INNOVATIONS INC

AI summary

The present invention relates to an apparatus for popping kernels, comprising a heating chamber configured to contain kernels, a microwave emitter configured to produce microwave energy within the heating chamber and heat the kernels, a single-mode resonant microwave applicator configured to generate a stable focused high intensity microwave region within the heating chamber, and an air blower configured to create airflow within the heating chamber sufficient to move the kernels within the heating chamber.