Tapered Auger Popcorn Machine for Coated Kernels

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Solution Overview

Problem

Existing popcorn machines face challenges in efficiently producing coated or flavored popcorn, as flavorings or coatings often accumulate in components, leading to operational issues and reduced heat transfer, especially in auger-driven systems.

Innovation Solution

A popcorn machine design featuring an auger within a tube with a housing and heating element, where the auger's central portion tapers to form an annular process chamber of increasing volume, allowing for simultaneous popping and coating of popcorn, with a corkscrew flight for efficient ingredient movement and differential heating zones for optimal cooking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If flavorings or coatings are added to auger-driven popcorn machines, then coated or flavored popcorn can be produced, but ingredient accumulation occurs in the auger and components which prevents proper operation and reduces heat transfer

Engineering Contradiction:

Improveability to produce coated or flavored popcornVSAvoidmachine operation reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The process chamber is divided into multiple zones along the auger length, with each zone having different volume characteristics. The tapered auger design creates segments that control ingredient movement and prevent accumulation in specific areas, allowing coating ingredients to be applied and distributed without clogging the auger mechanism.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different sections of the process chamber have different volumes and functions. The increasing volume toward the discharge end creates space for ingredient accumulation without blocking the auger, while the heating zones are strategically positioned to provide differential heating. This local variation in chamber properties prevents harmful accumulation while maintaining coating capabilities.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If flavorings or coatings are added to mesh drum popcorn machines, then coated popcorn can be produced, but sticky flavorings accumulate in the drum and components requiring time-consuming and costly cleaning

Engineering Contradiction:

Improveability to produce coated popcornVSAvoidcleaning time and cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The harmful accumulation problem is extracted and isolated to a specific zone in the process chamber where the increasing volume provides space for ingredient storage without interfering with auger rotation. This separates the coating application function from the ingredient transport function, allowing easy removal of accumulated materials without disassembling the entire machine.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If flavorings or coatings are added to mesh drum popcorn machines, then coated popcorn can be produced, but heat transfer between heating elements and ingredients is significantly reduced

Engineering Contradiction:

Improveability to produce coated popcornVSAvoidheat transfer efficiency

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The process chamber incorporates differential heating zones with varying volumes along the auger length. This creates local variations in ingredient distribution and heating intensity, ensuring that coating ingredients are properly heated and distributed without forming insulating layers that would block heat transfer to the popcorn kernels in critical zones.

Inventive Principle:

Principle #3Local quality

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

Enables efficient production of coated or flavored popcorn by preventing ingredient accumulation and maintaining heat transfer, ensuring proper machine operation and improved popcorn quality.

Implementation Method 1

The housing carries a heating element to heat the tube

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

the auger includes a flight that extends around the central portion in a corkscrew pattern. When the auger rotates about the longitudinal axis in operation, the flight moves ingredients (e.g., popcorn) through the heated tube from the first end toward the second end

Methodology Applied

Scientific EffectMechanical transport: Screw

Data Source

PatentUS11044929B2Popcorn machines having process chambers of increasing volume, and associated systems and methods

Publication Date: 2021.06.29 C CRETORS & CO

AI summary

Popcorn machines having process chambers of increasing volume, and associated systems and methods of operation are disclosed herein. In one embodiment, a popcorn machine includes a tube, a heating element positioned to heat the tube, and an auger positioned at least partially within the tube. The auger can include a central portion extending along a longitudinal axis from a first end to a second end. The central portion decreases in diameter from the first end to the second end, and the central portion and the tube at least partially define an annular popping chamber that increases in volume from the first end toward the second end. A flight extends around the central portion in a helical pattern between the central portion and an inner wall of the tube. In operation, the auger rotates about the longitudinal axis to move ingredients through the heated tube via the flight.