COOKING APPLIANCE USING THIN-FILM HEATING ELEMENT
In a cooking appliance and method for baking a food product, the appliance has a generally solid plate member, a first heating element disposed above the solid plate member in spaced relationship therewith and a thin-film heating element coupled to the solid plate member.
This application claims the benefit of U.S. Provisional Application No. 61/980,468 filed Apr. 16, 2014, which is incorporated herein in its entirety.
BACKGROUNDThe present invention relates generally to cooking appliances used for baking foods such as crusted foods, and more particularly to cooking appliances that include one or more thin-film heating elements.
Cooking appliances such as portable or tabletop cooking appliances that are used for baking crusted-type foods, e.g., breads, pizzas, calzones, and the like, are well known. Typically, such cooking appliances include a heat source and a flat stone or ceramic plate—often referred to as a pizza stone—on which the food to be baked is placed and subjected to heating by the heat source. The pizza stone has a high thermal mass to evenly and efficiently distribute heat over the pizza stone, and thus to the food being baked.
One drawback associated with using a pizza stone is that the pizza stone typically requires a long preheat time. Thus, while the heat generated by the heat source of the cooking appliance may be at a desired temperature for baking the food to be baked, the pizza stone may not be. As a result, the top of the food may be baked to a desired finish, while the bottom or crust of the food is undercooked.
Other types of cooking appliances, such as broilers, tabletop grills, and outdoor grills, may also require a relatively long preheat time. There is a need, therefore, for a cooking appliance that allows for faster heating or preheating for cooking food products.
SUMMARYIn one embodiment, a cooking appliance generally comprises a generally solid plate member, a first heating element disposed above the solid plate member in spaced relationship therewith, and a thin-film heating element coupled to the solid plate member.
In another embodiment, A method for baking a food product generally comprises supplying current to a first heating element of a cooking appliance to generate heat from the heating element. Current is supplied to a thin-film heating element separate from the first heating element, the thin-film heating element coupled to a solid plate member to initiate heating of the solid plate member, the first heating element being positioned above the solid plate member in spaced relationship therewith. A food product to be baked is placed on the solid plate member.
In another embodiment, a cooking appliance generally comprises a bottom unit, and a top unit hingedly coupled to the bottom unit, wherein at least one of the bottom unit and the top unit includes a thin-film heating element.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTIONWith reference now to the drawings and in particular to
The plate member 103 of the baking plate 101 is suitably constructed of a high insulative material, such as, without limitation, ceramic, clay, stone, glass, concrete, brick, porcelain, or other suitable high insulative material. The illustrated plate member 103 is generally circular, such as in the form that is commonly referred to as a pizza stone. However, it is understood that the plate member 103 may be other than circular without departing from the scope of this disclosure.
The heating element 105, according to one embodiment, is an electrically conductive wire and in one particular embodiment is a nichrome wire that is arranged in a continuous pattern within the plate member 103. For example,
It is understood that in other embodiments the wire 107 may be arranged within the plate member 103 in any suitable pattern that covers a substantial area of the plate member. The wire 107 according to one embodiment may have a length (e.g., as measured from one terminal 109 to the other terminal 111) in the range of about 100 inches to about 140 inches. However, the length of the wire 107 may be less than or greater than this range, and may vary depending on the overall size or surface area of the plate member 103. It is also contemplated that more than one wire 107 may be used to define the heating element 105 without departing from the scope of this disclosure.
It is understood that the oven-type cooking appliance 200 may be configured other than as illustrated in
As illustrated in
The baking plate 201, with particular reference to
In operation, before food is placed in the cooking appliance 200, the appliance is turned on to supply current to the upper heating system 240 as well as to the heating element 205 of the baking plate 201. In this manner, the plate member 203 of the baking plate 201 is brought up to a desired temperature more rapidly along with the air temperature (e.g., due to the upper heating system 240) in the interior space of the appliance. The food to be baked is then placed on the upper surface of the baking plate. In one embodiment, the heating element 205 of the baking plate 201 may be controlled to reduce or terminate heating of the plate member 203 after a predetermined time period, or after a threshold temperature of the interior space and/or the plate member is reached. In other embodiments, the heating element 205 may be maintained at constant heating for the entire cooking period of the food to be baked.
The core insert 312 is suitably configured for attachment to the top housing 308 within the interior space 326. The core insert 312 includes a frame 338, a reflector 340, and at least one top heating element 342. The frame 338 has a top wall 344, a first end wall 346, a second end wall 348, a first side wall 350, and a second side wall 352 that define a cavity 354 in which the reflector 340 and the top heating element(s) 342 are disposed. The walls 346, 348, 350, and 352 have a receiving mechanism for receiving and retaining the reflector 340 and the top heating element(s) 342 therein. Notably, in other embodiments, the top unit 302 may not include the frame 338 but, rather, the top housing 308 may perform the function of supporting the reflector 340 and/or the top heating element(s) 342 in the manner set forth herein. The illustrated top heating elements 342 are suitably quartz-type heating elements formed as a substantially linearly extending tube. However, it is understood that the top heating elements 342 may be any known heating elements other than quartz-type heating elements and remain within the scope of this disclosure.
Referring back to
As in the previous embodiments, the baking plate 301 includes a plate member 303 and a heating element 305 (
With reference back to
In some embodiments, a thin-film heating element is utilized. As used herein, a thin-film heating element refers to an electrically conductive material (e.g., a conductive film) deposited on a substrate for heating the substrate. The heating element is said to be a “thin-film” heating element in the sense that the substrate and the electrically conductive material have a collective thickness that is only marginally greater than the substrate itself (i.e., the material forms a thin film on the substrate).
The thin-film heating element may include, for example, a metal oxide (e.g., tin oxide) resistive film bounded on opposing edges by electrical bus bars or wires. The bus bars or wires may connect to a controller and power source to run current through the resistive film to generate heat. Specifically, by applying a voltage between the bus bars or wires, current flows through the resistive film, heating the resistive film and the substrate on which the resistive film is deposited. Using a thin-film heating element improves power efficiency, heating uniformity, and speed of heating. Further, the thinness and conductive heat directionality of a thin-film heating element also permit a cooking appliance, such as a toaster, to have a thinner profile.
A thin-film heating element may also be implemented, for example, in the cooking appliance 200 (shown in
Alternatively, or additionally, a thin-film heating element may be used to replace the heating elements 242 in the upper heating system 240. Notably, the resistive film may be substantially transparent. Accordingly, in one embodiment, at least a top portion of the housing 206 is made of a transparent material (e.g., ceramic glass) such that a user can look through the top portion and the resistive film to observe a food product during cooking.
Thin-film heating elements may also be implemented in the cooking appliance 300 (shown in
In the embodiment shown, the thin-film heating elements 2006 and 2010 are substantially planar. Alternatively, the heating elements 2006 and 2010 may have any suitable shape. For example, ribs (i.e., substantially parallel bars) may be formed on the heating elements 2006 and 2010 to facilitate forming sear marks on cooked food products. Notably, in this embodiment, the second thin-film heating element 2010 and substrate 2012 form a non-scratch surface. Accordingly, once a food product is cooked using the cooking appliance 2000, the food product may be cut while resting on the bottom unit 2004.
The cooking appliance 2000 also includes a drip tray 2030 that may be removably coupled to bottom unit 2004. When a food product is cooked in the cooking appliance 2000, the drip tray 2030 collects grease or oil emitted from the food product during cooking. Notably, the cooking appliance 2000 has a relatively slim profile. Further, because of the thin-film heating elements 2006 and 2010, the cooking appliance 2000 may heat up faster than at least some known cooking appliances. Further, the thin-film heating elements 2006 and 2010 cook food products using a combination of infrared and conduction cooking. The cooking appliance 2000 may be powered using direct current (DC) power or alternating current (AC) power.
The cooking appliance 2100 includes a lower heating element 2110 and an upper heating element 2112. In this embodiment, the lower heating element 2110 is a Nichrome heating element having a ribbed or grill-shaped configuration, and the upper heating element 2112 is a thin-film heating element. Alternatively, the upper and lower heating elements 2110 and 2112 may be any type of heating element that enables the cooking appliance 2100 to function as described herein.
The thin-film heating element 2112 includes a resistive film 2124 extending between first and second bus bars (not shown in
Notably, the thin-film heating element 2112, the upper substrate 2120, and the lower substrate 2122 are substantially transparent. Accordingly, as seen in
Because of the thin-film heating element 2112, the cooking appliance 2100 may heat up faster than at least some known cooking appliances, and may also provide improved thermal recovery and temperature stabilization. Further, the thin-film heating element 2112 cooks food products using a combination of infrared and conduction cooking. Moreover, because the food product cooked within the cooking appliance 2100 is not squeezed between the lower heating element 2110 and the upper heating element 2112, the food product may retain more moisture during cooking as opposed to if the food product was cooked in at least some known cooking appliances. The cooking appliance 2100 may be powered using direct current (DC) power or alternating current (AC) power.
As shown in
Thin-film heating elements may also be implemented in the cooking appliance 300 (shown in
In some embodiments, a user may control cooking appliances 200, 300, 1900, 2000, 2100, and 2500 using a computing device (e.g., a tablet, a desktop computer, a laptop computer, a mobile phone, etc.), where the computing device communicates remotely with the cooking appliance over a wired and/or wireless network, such as the Internet, or any other communications medium (e.g., Bluetooth®). For example, the user may use a software application on a computing device that enables the user to set a cooking time, where the input is communicated from the computing device to the cooking appliance. Further, the cooking appliance may communicate information to the computing device (e.g., remaining cook time) to notify the user.
When introducing elements of the present invention or the preferred embodiment(s) thereof, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
Claims
1. A cooking appliance comprising:
- a generally solid plate member;
- a first heating element disposed above the solid plate member in spaced relationship therewith; and
- a thin-film heating element coupled to the solid plate member.
2. The cooking appliance of claim 1 wherein the solid plate member is constructed of at least one of: ceramic, clay, stone, glass, concrete, brick, porcelain, or the like.
3. The cooking appliance of claim 1 wherein the first heating element comprises an additional thin-film heating element.
4. The cooking appliance of claim 3 wherein the additional heating element is coupled to a substantially transparent substrate.
5. The cooking appliance of claim 1 wherein the thin-film heating element comprises a resistive film extending between a pair of electrical bus bars.
6. The cooking appliance of claim 5 wherein the resistive film is coupled to a top surface of the solid plate member.
7. The cooking appliance of claim 5 wherein the resistive film is coupled to a bottom surface of the solid plate member.
8. The cooking appliance of claim 1 wherein the cooking appliance further comprises a bottom housing, the solid plate member being supported by the bottom housing and providing a heatable cooking surface, and a top housing, the first heating element being supported by the top housing.
9. The cooking appliance of claim 8 wherein the top housing is configurable between a raised position and a lowered cooking position, the first heating element being spaced from the solid plate member in the lowered cooking position of the top housing.
10. A method for baking a food product, the method comprising:
- supplying current to a first heating element of a cooking appliance to generate heat from the heating element;
- supplying current to a thin-film heating element separate from the first heating element, the thin-film heating element coupled to a solid plate member to initiate heating of the solid plate member, the first heating element being positioned above the solid plate member in spaced relationship therewith; and
- placing a food product to be baked on the solid plate member.
11. The method of claim 10 further comprising adjusting a height of the first heating element above the solid plate member at least in part as a function of the size of the food to be baked by the cooking appliance.
12. The method of claim 10 further comprising encasing the solid plate member and thin-film heating element within a housing of the cooking appliance.
13. The method of claim 10 further comprising one of reducing or terminating operation of the thin-film heating element independent of operation of the first heating element.
14. The method of claim 10 wherein supplying current to a first heating element comprises supplying current to an additional thin-film heating element.
15. A cooking appliance comprising:
- a bottom unit; and
- a top unit hingedly coupled to the bottom unit, wherein at least one of the bottom unit and the top unit comprises a thin-film heating element.
16. The cooking appliance of claim 15, wherein the bottom unit comprises a first thin-film heating element, and wherein the top unit comprises a second thin-film heating element.
17. The cooking appliance of claim 16, wherein each of the first and second thin-film heating elements comprises a resistive film extending between a pair of electrical bus bars.
18. The cooking appliance of claim 16 wherein at least one of the first and second thin-film heating elements is coupled to an electrically insulating substrate.
19. The cooking appliance of claim 18 wherein at least one of the first and second thin-film heating elements is sputter coated onto the electrically insulating substrate.
20. The cooking appliance of claim 15, wherein the top unit comprises a substantially transparent thin-film heating element coupled to a substantially transparent substrate, the substantially transparent thin-film heating element and the substantially transparent substrate forming a window that enables a user to view a food product placed in the cooking appliance.
21. The cooking appliance of claim 15, wherein the bottom unit comprises a perforated grill plate comprising the thin-film heating element.
22. The cooking appliance of claim 15, wherein the cooking appliance is a broiler.
23. The cooking appliance of claim 15, wherein the cooking appliance is an outdoor grill.
Type: Application
Filed: Apr 15, 2015
Publication Date: Oct 22, 2015
Inventors: Jacob Daniel Smith (Madison, WI), David W. Everett, JR. (Verona, WI), Victor Tenorio Chamixaes Cavalcanti (Madison, WI), Charles Nelson (Minneapolis, MN), Matthew Arthur Christian Guckenberger (Oconomowoc, WI)
Application Number: 14/687,254