Wafer Block Forming System with Segmented Cream Coating
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Solution Overview
Problem
Conventional systems for forming wafer blocks are limited in their ability to use multiple types of cream layers, leading to cream mixing and product rejection, as they can only apply a single type of cream continuously, lacking flexibility in layer sequence and number.
Innovation Solution
A system comprising multiple conveyor surfaces and coating stations allows for the selective application of two different cream layers on wafer sheets, enabling flexible arrangement and stacking of wafer blocks with alternating layers of two distinct creams, with adjustable transport speeds to maintain a continuous surface for efficient coating and stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple smear heads are provided along a single linear conveying surface to apply different creams, then multiple cream types can be applied, but the creams get mixed on the wafer sheet causing product rejection
Solution Approach 1:
The system divides the wafer sheet conveying into multiple separate linear conveying surfaces (first conveying surface, second conveying surface, third conveying surface), each handling a specific cream type or uncoated sheets. This segmentation prevents cream mixing by isolating the application zones while maintaining continuous production through coordinated stacking.
Solution Approach 2:
The patent transitions from a single-dimensional linear conveying approach to a multi-dimensional arrangement with multiple parallel conveying surfaces. Wafer sheets are distributed across different conveying planes, allowing multiple creams to be applied simultaneously without interference, then stacked in the desired sequence at the stacking station.
2Productivity
If a continuous band of wafer sheets is coated with a single cream for efficient coating, then coating efficiency is improved, but flexibility in cream layer sequence and number is lost
Solution Approach 1:
The system employs dynamic control of multiple independent conveying surfaces, each capable of operating continuously for its assigned cream type. The stacking station dynamically selects and stacks sheets from different conveying surfaces in any desired sequence and quantity, enabling flexible wafer block structures while maintaining continuous efficient coating on each surface.
Solution Approach 2:
Each conveying surface serves multiple functions: it can convey uncoated wafer sheets, convey sheets coated with a specific cream type, and feed to the stacking station. The stacking station itself is universal, capable of stacking sheets from any conveying surface in any sequence, creating wafer blocks with variable cream layer configurations.
3Adaptability or versatility
If multiple conveying surfaces with switch arrangements are used to achieve flexible stacking, then adaptability is improved, but device complexity increases
Solution Approach 1:
The system segments the wafer sheet handling into three distinct conveying surfaces, each dedicated to a specific function (first cream application, second cream application, uncoated sheets). This segmentation simplifies control compared to a single complex conveying system with multiple switches, as each surface operates more independently with simpler switch arrangements.
Data Source
Figure 1~2
AI summary
The invention relates to a system and method for forming wafer blocks (1), said wafer blocks (1) comprising at least three wafer sheets (2) and at least two cream layers (3) consisting of two different creams, the wafer sheets (2) and the cream layers (3) being arranged alternately and lying in parallel on top of each other.