The present disclosure relates to a combination electric toaster oven and air fryer. More particularly, the present disclosure relates to a combination electric toaster oven and air fryer that includes a heating element disposed adjacent to a removable rotating basket.
A variety of stand-alone toaster ovens have been developed to cook and toast different food products (e.g., pizza, toast, sandwiches, chicken nuggets, instant foods, and the like) without the use of a conventional kitchen oven. Separately, a variety of stand-alone air fryers have been developed to cook/fry different food products (e.g., French fries, chicken nuggets, chickens, vegetables, etc.) without the use of a conventional kitchen oven or deep fryer.
Toaster ovens and air fryers offer a variety of conveniences including being energy-efficient alternatives to turning on a full-size oven. Toaster ovens and air fryers also provide extra cooking space during the holidays and other events. Air fryers substantially shorten cooking times by constantly replacing the air facilitating convection heating in the cooking chamber or basket, thereby increasing the rate of energy transfer from the heating element to the food product. Toaster ovens provide additional utility, such as baking and broiling. Generally, toaster ovens also include a removable rack to easily transport food product to a serving dish, while air fryers include removable baskets or basins that similarly facilitate transportation of food product to a serving dish or platter.
Typical toaster ovens include electric resistive heating rods for applying heat to the bottom and top of food product. These heating rods are typically dispersed throughout an interior cooking chamber of the toaster oven to provide approximately uniform heating to all regions of the cooking chamber. The food product typically rests upon a removable rack or tray, which in turn rest upon rails mounted on the interior of the cooking chamber. Such racks and trays are often constructed of aluminum, stainless steel or enameled steel for reasons of durability and sanitation.
Typical air fryers include a heating source positioned to heat food product in a removable basket or basin housed within a cooking chamber of the air fryer. This heating is facilitated and enhanced by circulating heated air through the cooking chamber to continuously replace air that has cooled on contact with the food product. Like the racks and trays used in toasting ovens, the basins and baskets are often constructed of aluminum, stainless steel or enameled steel for reasons of durability and sanitation.
Existing toaster ovens and air fryers share several components and purposes, but each provides additional utility making it desirable for a home kitchen to have both a toasting oven and an air fryer. However, it is disadvantageous for a home kitchen to contain superfluous cooking implements taking up precious storage and countertop space.
Thus, it would be advantageous to have a toasting oven that included air fryer functionality to limit the space used by the cooking appliance and increase the utility of that cooking appliance.
A combination toasting oven and air fryer is described. The combination toasting oven and air fryer includes a housing, a door coupled to the housing, a fan within the housing, a basket drive element, a basket including a drive shaft, a first heating element located below the basket, a second heating element within the housing, and a control panel. The basket has a first state and a second state. In the first state, the basket is coupled to the basket drive element. In the second state, the basket is separate from the basket drive element. The first heating element including an infrared heater and a quartz heater.
In another embodiment, a combination toasting oven and air fryer is described, which includes a housing, a door coupled to the housing, a fan within the housing, a basket drive element, a basket including a drive shaft, a first heating element located below the basket, a second heating element within the housing, and a control panel. The basket has a first state and a second state. In the first state, the basket is coupled to the basket drive element. In the second state, the basket is separate from the basket drive element. The first heating element including an infrared heater and a quartz heater. The control panel includes an air fryer cooking selection and a toaster cooking selection.
The present invention will be more fully understood by reference to the following drawings which are presented for illustrative, not limiting, purposes.
Persons of ordinary skill in the art will realize that the following description is illustrative and not in any way limiting. Other embodiments of the claimed subject matter will readily suggest themselves to such skilled persons having the benefit of this disclosure. It shall be appreciated by those of ordinary skill in the art that the apparatus, systems and methods described herein may vary as to configuration and as to details. The following detailed description of the illustrative embodiments includes reference to the accompanying drawings, which form a part of this application. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the claims.
The designations “right” and “left” as used herein when describing the illustrative embodiments disclosed in the drawings are included for clarity only. In various embodiments, the components of the illustrative toaster oven and air fryer 100 may be mirror images of the illustrative embodiments described herein, i.e. all right-side components may also be left-side components and all left-side components may be right-side components in other embodiments.
The combination toaster oven and air fryer disclosed herein overcomes the deficiencies of existing toaster ovens and air fryers by integrating the functionality of a toaster oven and an air fryer into a single stand-alone countertop unit. Existing air fryers include a cooking container, such as a basket or bowl, but lack the capability of accepting an alternative cooking surface, such as a tray or rack. Further, existing air fryers lack the capability to toast or bake food products, and therefore are unable to cook food products, such as bread, pizza, and cookies. In contrast, existing toaster ovens may include a basket or rack, but more often utilize a tray. Existing toaster ovens frequently utilize trays because crumbs, grease, and other food morsels fall through the spaces or holes in racks and baskets onto the heating elements below. Further, the heating elements of existing toaster ovens are arrayed evenly along the bottom and top of the cooking chamber to provide even radiant heat throughout. Thus, the industry standard for toaster ovens is to predominantly utilize a tray to shield the arrayed heating elements from various food morsels and only occasionally employ a rack or basket to limit the mess, fire hazard, and toaster oven wear-and-tear.
The illustrative combination toaster oven and air fryer disclosed herein solves the problems presented by existing toaster ovens and air fryers by providing the functionality of both a toaster oven and an air fryer in a single countertop unit, thereby saving precious countertop, cooking, and storage space. The combination toaster oven and air fryer includes an alternative heating element to the standard array of resistive rods commonly employed in toaster ovens that enables rotisserie style cooking in a basket without concerns of crumbs falling onto an active heating element. This heating element is located such that crumbs falling from the rotating basket do not contact this active heating element. The further inclusion of a fan in the presently disclosed combination toaster oven and air fryer facilitates cooking in a convection or air fryer mode, allowing a user to select among toasting, baking, and air frying cooking options within a single combination toaster oven and air fryer unit.
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The combination toaster oven and air fryer 100 may therefore include a housing 102, a door 104, and a control panel 106. The control panel 106 has a variety of selectors including a temperature selector 108a, a function selector 108b, and a timer 108c.
In various embodiments, the temperature selector 108a may allow a user to select among a plurality of cooking temperatures. In one embodiment, the plurality of temperatures may range from 100 degrees Fahrenheit up to and including 500 degrees Fahrenheit. In another embodiment, the plurality of temperatures may range from 200 degrees Fahrenheit up to and including 450 degrees Fahrenheit. The temperature selector 108a may further include a thermostat (not shown) that regulates the cooking temperature. The function selector 108b may allow a user to select from several cooking modes or functions including Broil, Rotisserie, Toast, Bake, and Air Fryer.
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In a further embodiment, the guide rails 111a and 111b may comprise flanges that are attached to the side walls 112a and 112b extending away from the side walls and into the cooking chamber. The flanges or guide rails 111a and 111b provide a guide for the horizontal position of the basket 120 and drive shaft 122 when a user installs the basket in the cooking chamber.
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In various embodiments, the left-side surface (not shown), right-side surface 124, and outer surface 128 may be a solid sheet, a wire mesh, or a sheet including a plurality of holes or gaps 130. Wherein the left-side surface (not shown), right-side surface 124, and outer surface 128 are wire meshes, the wire may be selected from among a variety of thicknesses ranging from 1 centimeter to 1 millimeter. Further, the wire meshes may be formed from wire stock that is not simple circular cross-section, but is instead oval or rectangular. Wherein the left-side surface (not shown), right-side surface 124, and outer surface 128 are sheets including a plurality of holes or gaps 130, the holes may be any of a variety of shapes including circular, oval, square, rectangular, rhomboid, quadrilateral, or other higher order symmetric and asymmetric geometric shapes. The holes or gaps 130 may range in size from 1 millimeter up to and including 2 centimeters. Further, the spacing between each of the holes 130 and any adjacent holes 130 may provide for 1 millimeter up to 5 centimeters of solid sheet surface between holes 130. In some embodiments, the left-side surface (not shown) may include a door (not shown) and a locking mechanism (not shown). In other embodiments, the right-side surface 124 may include a door (not shown) and a locking mechanism (not shown). In still other embodiments, the outer surface may include a door (not shown) and a locking mechanism (not shown). The locking mechanism may be a press lock.
In one embodiment, the holes 130 are circular and each have a 6 millimeter hole diameter centered about the hole center. In this embodiment, the holes 130 are spaced such that the center of each hole 130 is separated from the center of any adjacent hole by 8.5 millimeters. This hole size allows for effective and efficient heating and cooking of a food product within the basket 120, while securing the food product within the basket and allowing crumbs to exiting the basket during cooking, which eases later cleaning of the interior of the basket 120.
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In one embodiment, the quartz tubular heater 142 comprises a quartz tube housing a resistive filament. The quartz tubular heater 142 emits IR radiation by forcing electricity through the resistive element, which emits black body radiation ranging from visible to far IR, centered about the mid IR range. The quartz tube housing the resistive element absorbs almost all non-IR radiation and re-emits this as IR radiation, far IR radiation, or any combination thereof. The infrared tubular heater 144 comprises a quartz tube that houses a carbon filament sealed in an inert gas environment. The IR tubular heater 144 emits far IR radiation with a similar, but not the same, profile as the quartz tubular heater 142, but at a lower intensity. In this embodiment, the quartz tubular heater 142 heats the food skin or outer layer faster to lead to a crisp skin, e.g. crisp French fries. The IR tubular heater penetrates the food surface to heat the inside of the food more effectively. This combination of heaters results in, for example, French fries with a crisp skin and a soft, moist interior with a faster cooking time than conventional methods and systems.
In various embodiments, the front guard 138 may be fabricated from sheet metal, such as aluminum, steel, and stainless steel; the front guard 138 may also be fabricated from enameled steel or a suitable infrared transparent material such as silicon. The front guard 138 may be a substantially solid sheet lacking holes or including a variety of holes to allow transmittance of heat to the food product in the basket 120 by radiation and convection. The holes may be uniform or variegated and of a variety of sizes ranging from one millimeter to 5 centimeters. The front guard 138 protects the first heating element 114 from damage that may be caused from food objects falling from the basket 120, from handling of the basket 120 by a user during installation of the basket in the combination toaster oven and air fryer 100. Additionally, the front guard 138 shields the first heating element 114 from drippings and other small falling food objects that may coat the first heating element 114 and cause the first heating element 114 to operate inefficiently or cease to operate properly. The rear guard 140 may be fabricated from sheet metal, such as aluminum, steel, and stainless steel; the rear guard 140 may also be fabricated from enameled steel or a suitable infrared transparent material such as silicon. The rear guard 140 may be a substantially solid sheet configured to reflect and direct heat emitted by the first heating element 114 toward the basket 120 to improve efficiency of the first heating element 114.
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In the illustrative embodiment, the first heating element 114 is positioned at one edge of the crumb fall zone, such that a portion of the first heating element 114 encroaches into the crumb fall zone. This positioning allows the first heating element to provide sufficient heat to cook food products within the basket 120, while removing the first heating element 114 from a vast majority of crumbs and food morsels falling from the basket 120. Additionally, any grease or other liquid seeping from the food product in the basket 120 will fall in the center of the crumb fall zone directly under the basket 120, and not on the first heating element 114. Further, the positioning of the front guard 138 deflects the few crumbs that fall at or outside the edge of the crumb fall zone and thereby shields the first heating element 114 from the crumbs and food morsels.
In various embodiments, the first heating element 114 may be positioned entirely outside of the crumb fall zone. Therefore, the first heating element may or may not include the front guard 138. In other embodiments, the first heating element may be positioned entirely within the crumb fall zone.
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In an illustrative example of operation, a user may select a non-zero time on the timer 108c, i.e. 20 minutes, select Broil on the cooking function selector 108b, and a temperature on the temperature selector 108a, i.e. 350 degrees Fahrenheit, to begin a cooking session. While the timer 108c indicates a non-zero time, the timer 108a allows power to flow through the indicator light 162, the fan motor 150, and the cooking function selector 108b. Thus, during operation the indicator light illuminates to indicate that the combination toaster oven and air fryer 100 is pre-heating or cooking; and the fan motor 150 spins the fan 152 to circulate air through the cooking chamber. The Broil mode of the cooking function selector 108b allows power to flow only through the fan motor 150 and the second heating elements 146c and 146d, thereby providing heat only from the top of the cooking chamber, above a food product and the basket 120. The fan motor 150 operates to circulate air through the cooking chamber at all times that the timer 108c indicates a non-zero time. The temperature selector 108a allows power to flow through the second heating elements 146c and 146d until the temperature inside the cooking chamber, determined by the thermostat (not shown), reaches the selected temperature, 350 degrees Fahrenheit. Upon reaching 350 degrees within the cooking chamber, the temperature selector 108a opens the circuits and prevents power from flowing to the second heating elements 146c and 146d. When the temperature inside the cooking chamber, as determined by the thermostat, drops below 350 degrees the temperature selector 108a closes the circuit and allows power to resume flowing through the second heating elements 146c and 146d to maintain the selected temperature within the cooking chamber. In various embodiments, the temperature selector 108a may operate to maintain a temperature range centered about the selected temperature, such as plus or minus 5 degrees Fahrenheit, i.e. 350+/− degrees Fahrenheit. In other embodiments, the temperature range maintained may be plus or minus 1 degree Fahrenheit, plus or minus 10 degrees Fahrenheit, or plus or minus 20 degrees Fahrenheit. The temperature selector 108a operates such that upon reaching a temperature in the cooking chamber that is within the prescribed range of temperatures maintained about the selected temperature, i.e. a temperature within the range 345-355 degrees Fahrenheit, the temperature selector 108a shuts off the second heating elements 146c and 146d; and when the temperature in the cooking chamber drops below the bottom end of the prescribed range of temperatures maintained about the selected temperature, i.e. below 345 degrees Fahrenheit, the temperature selector 108a engages the second heating elements 146c and 146d until the temperature within the cooking chamber reaches a temperature within the prescribed range of temperatures maintained about the selected temperature, i.e. a temperature within the range 345-355 degrees Fahrenheit. Additionally, the temperature selector 108a operates to shut off power to the second heating elements 146c and 146d when the temperature within the cooking chamber exceeds the top end of the prescribed range of temperatures maintained about the selected temperature, i.e. a temperature above 355 degrees Fahrenheit.
Alternatively, a user may select 20 minutes on the timer 108c, select Rotisserie on the cooking function selector 108b, and 350 degrees Fahrenheit on the temperature selector 108a to begin a cooking session. While the timer 108a indicates a non-zero time, the timer 108a allows power to flow through the indicator light 162, the fan motor 150, and the cooking function selector 108b. Thus, during operation the indicator light illuminates to indicate that the combination toaster oven and air fryer 100 is pre-heating or cooking; and the fan motor 150 spins the fan 152 to circulate air through the cooking chamber. The fan motor 150 operates to circulate air through the cooking chamber at all times that the timer 108c indicates a non-zero time. The Rotisserie mode of the cooking function selector 108b allows power to flow through the drive element 136, which causes the basket 120 to rotate during the cooking session; and allows power through only the second heating elements 146c and 146d, thereby providing heat from the top of the cooking chamber, above a food product and the basket 120. The temperature selector 108a allows power to flow through the second heating elements 146c and 146d until the temperature inside the cooking chamber reaches a temperature within the range 345-355 degrees Fahrenheit. Upon reaching a temperature within the range 345-355 degrees Fahrenheit inside the cooking chamber, the temperature selector 108a opens the circuits and prevents power from flowing to the second heating elements 146c and 146d. When the temperature inside the cooking chamber, as determined by the thermostat, drops below the 345 degrees Fahrenheit the temperature selector 108a closes the circuit and allows power to resume flowing through the second heating elements 146c and 146d to maintain the temperature within the cooking chamber within the range 345-355 degrees Fahrenheit. The temperature selector 108a operates such that upon reaching a temperature within the range 345-355 degrees Fahrenheit inside the cooking chamber the temperature selector 108a shuts off the second heating elements 146c and 146d; and when the temperature in the cooking chamber drops below 345 degrees Fahrenheit the temperature selector 108a engages the second heating elements 146c and 146d until the temperature within the cooking chamber reaches a temperature within the range 345-355 degrees Fahrenheit. Additionally, the temperature selector 108a operates to shut off power to the second heating elements 146c and 146d when the temperature within the cooking chamber exceeds 355 degrees Fahrenheit.
Alternatively, a user may select 5 minutes on the timer 108c, select Toast on the cooking function selector 108b, and 400 degrees Fahrenheit on the temperature selector 108a to begin a cooking session. While the timer 108a indicates a non-zero time, the timer 108a allows power to flow through the indicator light 162, the fan motor 150, and the cooking function selector 108b. Thus, during operation the indicator light illuminates to indicate that the combination toaster oven and air fryer 100 is pre-heating or cooking; and the fan motor 150 spins the fan 152 to circulate air through the cooking chamber. The fan motor 150 operates to circulate air through the cooking chamber at all times that the timer 108c indicates a non-zero time. The Toast mode of the cooking function selector 108b allows power to flow only through the second heating elements 146a, 146b, 146c, and 146d, thereby providing heat from the top and from the bottom of the cooking chamber, above and below a food product on a tray or rack (not shown). The temperature selector 108a allows power to flow through the second heating elements 146a, 146b, 146c, and 146d until the temperature inside the cooking chamber reaches a temperature within the range 395-405 degrees Fahrenheit. Upon reaching a temperature within the range 395-405 degrees Fahrenheit inside the cooking chamber, the temperature selector 108a opens the circuits and prevents power from flowing to the second heating elements 146a, 146b, 146c, and 146d. When the temperature inside the cooking chamber, as determined by the thermostat, drops below the 395 degrees Fahrenheit the temperature selector 108a closes the circuit and allows power to resume flowing through the second heating elements 146a, 146b, 146c, and 146d to maintain the temperature within the cooking chamber within the range 395-405 degrees Fahrenheit. The temperature selector 108a operates such that upon reaching a temperature within the range 395-405 degrees Fahrenheit inside the cooking chamber the temperature selector 108a shuts off the second heating elements 146a, 146b, 146c, and 146d; and when the temperature in the cooking chamber drops below 345 degrees Fahrenheit the temperature selector 108a engages the second heating elements 146a, 146b, 146c, and 146d until the temperature within the cooking chamber reaches a temperature within the range 395-405 degrees Fahrenheit. Additionally, the temperature selector 108a operates to shut off power to the second heating elements 146a, 146b, 146c, and 146d when the temperature within the cooking chamber exceeds 355 degrees Fahrenheit.
Alternatively, a user may select 45 minutes on the timer 108c, select Bake on the cooking function selector 108b, and 425 degrees Fahrenheit on the temperature selector 108a to begin a cooking session. While the timer 108a indicates a non-zero time, the timer 108a allows power to flow through the indicator light 162, the fan motor 150, and the cooking function selector 108b. Thus, during operation the indicator light illuminates to indicate that the combination toaster oven and air fryer 100 is pre-heating or cooking; and the fan motor 150 spins the fan 152 to circulate air through the cooking chamber. The fan motor 150 operates to circulate air through the cooking chamber at all times that the timer 108c indicates a non-zero time. The Bake mode of the cooking function selector 108b allows power to flow only through the second heating elements 146a and 146b, thereby providing heat from the bottom of the cooking chamber, below a food product on a tray (not shown). The temperature selector 108a allows power to flow through the second heating elements 146a and 146b until the temperature inside the cooking chamber reaches a temperature within the range 420-430 degrees Fahrenheit. Upon reaching a temperature within the range 420-430 degrees Fahrenheit inside the cooking chamber, the temperature selector 108a opens the circuits and prevents power from flowing to the second heating elements 146a and 146b. When the temperature inside the cooking chamber, as determined by the thermostat, drops below the 420 degrees Fahrenheit the temperature selector 108a closes the circuit and allows power to resume flowing through the second heating elements 146a and 146b to maintain the temperature within the cooking chamber within the range 420-430 degrees Fahrenheit. The temperature selector 108a operates such that upon reaching a temperature within the range 395-405 degrees Fahrenheit inside the cooking chamber the temperature selector 108a shuts off the second heating elements 146a and 146b; and when the temperature in the cooking chamber drops below 420 degrees Fahrenheit the temperature selector 108a engages the second heating elements 146a and 146b until the temperature within the cooking chamber reaches a temperature within the range 420-430 degrees Fahrenheit. Additionally, the temperature selector 108a operates to shut off power to the second heating elements 146a and 146b when the temperature within the cooking chamber exceeds 430 degrees Fahrenheit.
Alternatively, a user may select 15 minutes on the timer 108c, select Air Fryer on the cooking function selector 108b, and 350 degrees Fahrenheit on the temperature selector 108a to begin a cooking session. While the timer 108a indicates a non-zero time, the timer 108a allows power to flow through the indicator light 162, the fan motor 150, and the cooking function selector 108b. Thus, during operation the indicator light illuminates to indicate that the combination toaster oven and air fryer 100 is pre-heating or cooking; and the fan motor 150 spins the fan 152 to circulate air through the cooking chamber. The fan motor 150 operates to circulate air through the cooking chamber at all times that the timer 108c indicates a non-zero time. The Air Fryer mode of the cooking function selector 108b allows power to flow through the drive element 136, which causes the basket 120 to rotate during the cooking session; and allows power through only the first heating element 114, thereby providing heat from behind and below a food product and the basket 120. The temperature selector 108a allows power to flow through the first heating element 114 until the temperature inside the cooking chamber reaches a temperature within the range 345-355 degrees Fahrenheit. Upon reaching a temperature within the range 345-355 degrees Fahrenheit inside the cooking chamber, the temperature selector 108a opens the circuits and prevents power from flowing to the first heating element 114. When the temperature inside the cooking chamber, as determined by the thermostat, drops below the 345 degrees Fahrenheit the temperature selector 108a closes the circuit and allows power to resume flowing through the sec first heating element 114 to maintain the temperature within the cooking chamber within the range 345-355 degrees Fahrenheit. The temperature selector 108a operates such that upon reaching a temperature within the range 345-355 degrees Fahrenheit inside the cooking chamber the temperature selector 108a shuts off the first heating element 114; and when the temperature in the cooking chamber drops below 345 degrees Fahrenheit the temperature selector 108a engages the first heating element 114 until the temperature within the cooking chamber reaches a temperature within the range 345-355 degrees Fahrenheit. Additionally, the temperature selector 108a operates to shut off power to the first heating element 114 when the temperature within the cooking chamber exceeds 355 degrees Fahrenheit.
It is to be understood that the detailed description of illustrative embodiments are provided for illustrative purposes. Thus, the degree of software modularity for the transactional system and method presented above may evolve to benefit from the improved performance and lower cost of the future hardware components that meet the system and method requirements presented. The scope of the claims is not limited to these specific embodiments or examples. Therefore, various process limitations, elements, details, and uses may differ from those just described, or be expanded on or implemented using technologies not yet commercially viable, and yet still be within the inventive concepts of the present disclosure. The scope of the invention is determined by the following claims and their legal equivalents.