Preforming and Deep-Drawing Wafer Cake for Hollow Body Stability
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Solution Overview
Problem
Existing methods for producing edible hollow-bodied baked products, such as wafers, struggle to create targeted multi-layered structures that enhance stability, appearance, crispiness, and eating experience, while also being cost-effective and flexible in shaping and fold structure control.
Innovation Solution
A method and device that involve preforming and deep-drawing edible wafers in a hot, malleable state to create cup-shaped products with symmetrical, rotationally distributed multi-layered fold areas, using a preforming device with protruding elements and a deep-drawing process that includes a stamp and holding force, allowing for controlled shaping and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If deep-drawing is used to form hollow baked products, then production efficiency is improved, but wrinkle formation occurs in the opening area due to geometric relationships
Solution Approach 1:
The patent applies preliminary action by pre-forming the wafer cake into a cup-shaped intermediate structure before the final deep-drawing process. This pre-forming step creates initial folds and curvature that guide the subsequent forming process, preventing random wrinkle formation while maintaining production efficiency. The cup-shaped intermediate form serves as a controlled starting point for the final hollow body formation.
2Stability of the object's composition
If thicker areas are created in wafer products to improve stability, then physical properties are enhanced, but the areas become soft or too hard after hardening
Solution Approach 1:
The patent applies local quality by creating fold areas with specific multi-layer structures in predetermined locations of the wafer product. These localized fold structures provide enhanced stability in specific regions without affecting the overall hardness or softness of the entire product. The folding creates thicker areas with controlled physical properties through the layering effect, maintaining consistency after hardening.
3Stability of the object's composition
If multi-layered structures are created to enhance stability and appearance, then physical properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses preliminary action by pre-forming the wafer into a cup-shaped intermediate structure that already contains the desired fold patterns. This pre-organization of layers before final forming simplifies the manufacturing process compared to creating multi-layer structures through complex post-processing or assembly operations. The multi-layer effect is achieved through the folding action during pre-forming, reducing device complexity.
Solution Approach 2:
The patent applies dimensionality change by transforming the flat two-dimensional wafer into a three-dimensional cup-shaped intermediate form with folds. This dimensional transformation creates multi-layer structures through spatial rearrangement rather than through complex assembly processes. The folding action in three-dimensional space achieves multi-layering that would be much more complex to create through traditional manufacturing methods.
4Adaptability or versatility
If the wafer is freely rolled into hollow shape, then flexibility in shaping is improved, but calibration precision is reduced
Solution Approach 1:
The patent applies preliminary action by first forming the wafer into a cup-shaped intermediate structure with predetermined fold patterns before final calibration. This pre-forming step establishes the basic geometry and fold locations, which then guides the subsequent calibration process. The calibration can focus on adjusting specific parameters like longitudinal extension while maintaining the overall shape and fold structure, improving precision without sacrificing flexibility.
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 method produces hollow-body-shaped baked products with improved stability, appearance, and eating experience by creating targeted multi-layered structures that are cost-effective and flexible in production, ensuring consistent physical properties and crispiness.
Implementation Method 1
plasticizing it at the baking temperature or just below with the melted sugar content
Implementation Method 2
allowing the sugar to solidify by simple and rapid cooling
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
The invention relates to a hollow-shaped, baked product as well as a method and a device for producing the product, which is at least partially formed from an edible, baked wafer, which is malleable in the hot state and has a solidified, cup-shaped form during and/or after the forming process, wherein the wafers are fed to a deep-drawing opening in the hot, malleable state, pre-formed in the fold areas by a pre-forming device, and deep-drawn into a deep-drawing opening by a punch, wherein, influenced by the pre-forming, the fold areas of each individual wafer are layered on top of each other during the deep-drawing process.