Multi-piece Upright Casting Mold for Complex Baked Shapes
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Solution Overview
Problem
Existing baking technologies struggle to produce comestible baked products in complex shapes, as most systems are limited to simple shapes and fail to retain intricate details due to issues with baking medium distribution and egression during the baking process.
Innovation Solution
A system comprising a multi-piece mold with detachable components and a self-supporting bakeware material that forms a contiguous shell, allowing for the creation of complex shapes by ensuring even filling and preventing medium egression, using seals such as waffle iron patterns, snaps, or silicone zippers to maintain the shape and structure during baking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional simple molds are used, then the baking process is simple and easy to operate, but the baked product cannot achieve complex shapes with intricate details
Solution Approach 1:
The mold is divided into multiple detachable components including a first piece with a first cavity, a second piece with a second cavity, and a third piece with a third cavity. These segments can be assembled in different configurations to create complex three-dimensional shapes while maintaining ease of manufacture and operation for each individual component.
Solution Approach 2:
The mold pieces are designed to nest within each other when detached, with smaller cavity portions fitting inside larger ones. This nesting arrangement allows the complex multi-cavity mold to be stored compactly and transported conveniently without requiring excessive space, thus managing device complexity effectively.
2Shape
If the mold uses multiple detachable pieces, then the mold can form complex shapes, but the baking medium may escape through seams between pieces
Solution Approach 1:
The seal components are integrated directly into the mold pieces themselves rather than being separate attachments. The first piece includes a first seal, the second piece includes a second seal, and the third piece includes a third seal, all designed to work together as a unified sealing system that prevents baking medium egression while maintaining the detachable multi-piece structure.
Solution Approach 2:
The seals are designed as flexible components that can deform to accommodate slight variations in assembly and maintain contact between mold pieces. This flexibility ensures reliable sealing across all seams regardless of minor manufacturing tolerances or thermal expansion during the baking process.
3Ease of operation
If the mold pieces are detachably coupled, then the mold is easier to assemble and disassemble, but the coupling mechanism adds complexity to the mold structure
Solution Approach 1:
The coupling mechanism is extracted as a distinct, standardized feature that can be independently designed and manufactured. By separating the coupling function from the cavity-forming function, each mold piece can be optimized for its primary purpose while the coupling mechanism provides a simple, repeatable interface that reduces overall system complexity.
Solution Approach 2:
The coupling mechanism is designed to be universal across all mold pieces, allowing the same interface to connect the first piece to the second piece, the second piece to the third piece, and potentially multiple molds to be coupled together. This multi-functionality reduces the number of different coupling types needed and simplifies the overall structure.
4Shape
If the baking medium is poured into the mold, then the baked product takes the mold's shape, but the medium may not distribute evenly in complex multi-cavity molds
Solution Approach 1:
The mold pieces are designed with predetermined cavity configurations and interconnected channels that guide the baking medium flow before the actual baking process begins. This preliminary design ensures that when the medium is poured, it naturally distributes evenly across all cavities through the pre-planned flow paths, achieving uniform filling without requiring active control during pouring.
Data Source
AI summary
A system and method for producing a comestible baked product in complex shapes using upright cast molding wherein a portion of the interior cavity forms a baking cup which can optionally receive a liner. Embodiments generally include a first part and second part that are configured to be joined together along a seam. When configured, an outer surface is created and an inner surface cavity which creates a contiguous internal hollow space in the form of a three-dimensional shape is formed. A portion of this internal hollow space forms a cup. The cup can be circular shaped or a different shape entirely such as a square. The mold may provide a means for supporting the mold in its designated position. Other embodiments may include a single piece that is attachable to the rim of a cup of a multi-cup baking pan or to a single stand-alone cup.