Vacuum Dosing Disk for Air-Free Inclusion Incorporation
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Solution Overview
Problem
Existing methods struggle to incorporate crisp texture inclusions into multiregion confections like ice cream without introducing air pockets, which detract from the desired organoleptic experience.
Innovation Solution
An apparatus featuring a dosing module with a rotating disk and suction cavities to precisely control the inclusion of inclusions into an extrudable material, minimizing air incorporation by holding inclusions to apertures with negative pressure and releasing them at the right moment to combine with the extrudable material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple inclusions are incorporated into multiregion confections as a layer or filling, then the variety of tastes and textures is improved, but air pockets are introduced that detract from the organoleptic experience
Solution Approach 1:
The patent employs a vacuum-based dosing mechanism where a dosing wheel with cavities creates negative pressure to draw inclusions into the confection matrix. The vacuum source removes air from the cavities before inclusions are deposited, ensuring that inclusions are placed without introducing air pockets. This pneumatic approach directly addresses the contradiction by using vacuum technology to eliminate the harmful air pockets while maintaining the ability to incorporate multiple inclusion types for variety.
Solution Approach 2:
The system performs preliminary vacuum treatment on the dosing cavities before inclusion deposition. The cavities are evacuated of air prior to receiving inclusions, and this vacuum state is maintained during the transfer process. This preliminary action ensures that when inclusions are deposited into the confection material, no air pockets are introduced, thus maintaining organoleptic quality while still allowing multiple inclusion varieties.
2Manufacturing precision
If inclusions are precisely controlled and incorporated into extrudable material, then manufacturing precision is improved, but device complexity increases due to dosing module requirements
Solution Approach 1:
The dosing wheel cavities are designed to automatically draw inclusions through vacuum pressure without requiring additional actuation mechanisms. The vacuum source continuously maintains negative pressure on the cavities, causing inclusions to be passively drawn in and held until deposition. This self-service mechanism reduces device complexity by eliminating the need for complex actuators, sensors, or control systems while maintaining high manufacturing precision for inclusion placement.
3Reliability
If inclusions are held with negative pressure and released at the right moment, then inclusion integrity is preserved, but energy consumption increases due to continuous vacuum application
Solution Approach 1:
The vacuum application is implemented as a periodic rather than continuous process. The vacuum source is activated during the inclusion drawing and holding phases, then deactivated or reduced during the deposition phase when inclusions are transferred to the confection material. This periodic vacuum application maintains inclusion integrity through proper holding pressure while significantly reducing overall energy consumption compared to continuous vacuum operation.
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 apparatus effectively reduces air pockets, maintaining the integrity of both the extrudable material and inclusions, enhancing the indulgent experience of multiregion confections by ensuring a consistent and controlled incorporation of inclusions.
Implementation Method 1
A suction cavity and non-suction structure are disposed close to the second side of the disk such that negative pressure is applied to the aperture as the aperture travels during rotation of the disk, from the pick-up location to a release location
Implementation Method 2
a material feeder configured to force extrudable material through the first orifice
Data Source
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AI summary
Embodiments disclosed herein related to an apparatus for the manufacture of a multiregion confection. The apparatus includes a housing defining a holding cavity configured to hold inclusions, a suction cavity, and a port. The apparatus also includes a disk rotatably mounted with respect to the holding cavity. The disk defines a plurality of apertures for holding the inclusions. As the disk rotates the plurality of apertures move with respect to the housing such that each of the plurality of apertures arrives at a first location where the aperture is exposed on one side of the disk to the holding cavity and on the reverse side of the disk to a suction cavity. Inclusions released from the plurality of apertures at a second location travel into the port. The inclusions travel from the port to a nozzle which is configured to direct the inclusions to combine with the extrudable material.