Unitized Vacuum Fryer With Hermetic Tunnel Sealing
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Solution Overview
Problem
Existing vacuum frying technologies face challenges with high production costs, large space requirements, and cumbersome maintenance in both batch and continuous production configurations, particularly due to the need for external pressure vessels and complex sealing mechanisms.
Innovation Solution
A unitized vacuum fryer with a monocoque construction and hermetically sealed two-part shell, equipped with hoists for easy maintenance and hermetic locks for product handling, operates as its own pressure vessel without external enclosures, utilizing elastomeric seals to maintain a vacuum environment and minimize space and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a removable fryer apparatus is placed within an external pressure vessel for continuous vacuum frying, then continuous production is achieved, but manufacturing costs and floor space requirements increase significantly
Solution Approach 1:
The patent merges the pressure vessel function and fryer support structure into a single integrated unit. The fryer basket serves dual purposes: containing the cooking oil and acting as the structural support within the pressure vessel, eliminating the need for separate external support frameworks and reducing manufacturing complexity
Solution Approach 2:
The fryer basket is designed as a multi-functional component that simultaneously serves as the cooking vessel, oil container, and structural support element within the pressure vessel. This universal design reduces the number of separate components needed, lowering manufacturing costs while maintaining continuous production capability
2Productivity
If a removable fryer apparatus is placed within an external pressure vessel for continuous vacuum frying, then continuous production is achieved, but floor space requirements increase due to external support structures
Solution Approach 1:
The patent combines the fryer support structure with the pressure vessel walls, eliminating the need for external support frameworks. The fryer basket is positioned directly within the pressure vessel chamber, utilizing the vessel's structural integrity for support, thereby minimizing the overall footprint and floor space requirements
3Ease of repair
If a large sealable hatch is provided in the pressure vessel for fryer insertion and removal, then continuous production maintenance is enabled, but manufacturing costs and space requirements increase
Solution Approach 1:
The patent divides the access mechanism into multiple smaller components: a relatively small hatch opening in the pressure vessel wall,配合 with a latch mechanism and seal system. This segmented approach provides adequate maintenance access while minimizing the size of the hatch opening, reducing manufacturing costs and structural requirements compared to a single large hatch
4Reliability
If traditional batch cooker design is used for vacuum frying, then product quality is satisfactory, but production output is low and equipment costs are high
Solution Approach 1:
The patent transitions from a static batch cooking chamber to a dynamic continuous flow system. The fryer basket is designed to be removable and replaceable, allowing continuous operation where cooked batches are removed and fresh batches are inserted without interrupting the vacuum environment. This dynamic design maintains product quality while significantly increasing production output
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 enables efficient, continuous vacuum frying with reduced acrylamide formation and oil uptake, while being economical to manufacture and maintain, with a compact footprint and reliable sealing that withstands repeated vacuum cycles, enhancing product quality and reducing operational complexity.
Implementation Method 1
Vacuum system apparatus coupled to the tunnel selectively removes the vapor atmosphere within the tunnel down to a substantially full vacuum, minus 14.7 psi or 28 mm Hg
Implementation Method 2
An elastomeric seal material is provided between the confronting surfaces of the flanges to withstand repeated compression and release cycles as vacuum pressure is applied and released in the tunnel
Implementation Method 3
Where the cooking environment is in a range of about a minus 14.0 psi absolute or 28.5 mm Hg vacuum, foods can be cooked at lower temperatures. In the case where cooking oil or fats are the cooking medium effective temperatures may be on the order of 120° C. to about 140° C.
Data Source
AI summary
The unitized vacuum fryer is capable of low atmosphere vacuum cooking and has an elongate cooking tunnel having an upper portion separable from a base portion for cleaning and maintenance. When hermetically sealed together the two portions function to retain a high vacuum for an enclosed fry cooking system. Hermetic sealing locks at each end of the tunnel afford product entry and exit. The vacuum fryer does not require a separate enclosing pressure vessel.