Wave-Shaped Displacer Pump Roller for Dough Deposition
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Solution Overview
Problem
Existing extrusion and deposition technologies in the food industry face issues with controlling dough texture due to friction-induced compression and require complex configurations for pressure build-up, which are not suitable for doughs with low friction engagement or high fat content, and are difficult to clean and maintain.
Innovation Solution
A simplified apparatus with a vertical channel allowing 'first in - first out' mass flow into wave-shaped displacers on a pump roller, eliminating static overpressure and using a single feed roller to support mass transport, enabling efficient and gentle handling of various dough types with inclusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If friction engagement with disc-shaped rotors is used to transport dough, then dough can be moved through the extruder, but the texture of the dough becomes unpredictable and altered due to increasing compression
Solution Approach 1:
The patent replaces the friction-based mechanical engagement system with a positive displacement pump system using wave-shaped displacers. The displacers create sealed cavities that mechanically push the dough through the extruder without relying on friction, thereby eliminating unpredictable compression and texture alteration while maintaining reliable transport.
Solution Approach 2:
The patent changes the fundamental mechanism of dough transport from friction-dependent to volume-displacement-based. By using wave-shaped displacers that create sealed cavities of constant volume, the system maintains consistent dough compression and texture regardless of dough composition variations, enabling precise control over final product quality.
2Adaptability or versatility
If disc-shaped rotors with friction engagement are used, then dough transport is achieved, but the system cannot handle dough types with low or diminishing friction engagement such as cookie doughs with high fat content
Solution Approach 1:
The patent replaces the friction-based mechanical engagement system with a positive displacement pump system using wave-shaped displacers. The displacers create sealed cavities that mechanically push the dough through the extruder without relying on friction, thereby eliminating unpredictable compression and texture alteration while maintaining reliable transport.
Solution Approach 2:
The patent divides the continuous dough stream into discrete segments using the wave-shaped displacers. Each rotor creates individual sealed cavities that transport portions of dough independently, ensuring that each segment is handled consistently regardless of the dough's friction characteristics, thereby enabling reliable processing of diverse dough types.
3Manufacturing precision
If a closed configuration with secondary mass chamber and multiple feed rollers is used to build constant pressure, then accurate extrusion is achieved, but the device complexity increases and cleaning becomes difficult
Solution Approach 1:
The patent merges the functions of multiple feed rollers and the secondary mass chamber into a single integrated pump roller assembly. The wave-shaped displacers on the pump roller perform both the pressure-building and dough-transport functions that previously required separate components, thereby simplifying the overall device structure while maintaining extrusion accuracy.
Solution Approach 2:
The pump roller with wave-shaped displacers serves multiple functions simultaneously: it builds constant pressure, transports dough, and maintains accurate dosing. This multi-functional component replaces several specialized components (feed rollers, secondary chamber, pressure regulation mechanisms), reducing device complexity while preserving extrusion precision.
4Stress or pressure
If the pump roller diameter is small compared to trough width (1/4 of width), then pressure build-up is achieved, but the pump capacity is diminished and requires high revolutions per minute which reduces cavity exposure time
Solution Approach 1:
The patent uses wave-shaped (curved) displacers on the pump roller to create expanding and contracting cavities during rotation. This curved geometry allows the pump to generate high pressure through the wave action while maintaining adequate cavity volume and exposure time, thereby achieving both pressure build-up and high pump capacity without requiring excessive rotational speed.
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
This solution provides accurate and reliable extrusion for a broad range of dough densities and viscosities, is easy to clean and maintain, and effectively handles doughs with high inclusion content without altering their inner structure.
Implementation Method 1
The disc-shaped rotors are formed as planar discs, that transports the dough by means of friction engagement in the intermediary channels between the disc-shaped rotors during rotation
Implementation Method 2
The inside chamber extends as a vertical channel from the top of the trough and down to an upper part of the pump roller periphery
Implementation Method 3
The two rollers rotate in opposite directions in towards each other. The mass in the trough is transported in between the two feed rollers and down into the secondary mass chamber
Data Source
Figure 1
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AI summary
Apparatus (1) for depositing edible mass, comprising an elongated trough (2) with an inside chamber (3) and a pump roller (4) housed in a channel (5) at the bottom (6) of the trough (2). A row of deposit openings (7) are arranged along the bottom (6). The pump roller (4) comprises a single, central shaft (8) having a succession of disc-shaped rotors (9) defining the outer periphery (10) of the pump roller (4). The rotors (9) are formed as wave-shaped displacers (11) arranged in a succession of arc-shaped channels (12). A closure plate (13) is arranged longitudinally in a groove (14) in the channel (5) and radially to the shaft (8). The plate (13) comprises a succession of notches (15) into which the rotors (9) engage, so that the plate (13) is given a reciprocal movement by the rotation of the pump roller (4). The inside chamber (3) extends as a vertical channel (16) from the top of the trough (2) and down to an upper part (17) of the pump roller periphery. So the mass is free to flow downwards and then effectively fills radially in between the wave-shaped displacers 11 and into the arc-shaped chambers 12 of the pump roller 4.The wave-shaped displacers 11 of the pump roller 4 effectively take the full action of a pump, which continuously transports the mass on to the openings 7 at the bottom of the trough 2.Mass with high contents of inclusions may then enter into the roller pump right away and very smoothly, still bringing with it the inclusions into the pump cavities.