Patent Application
20070204856
People around the world are familiar with the taste of flame-grilled foods. The smokey flavor, the texture, and the grill markings, among other attributes, contribute to a person's perception that food has been grilled on an open flame or charcoal. For example, meat products like chicken or steak are often associated with grilled preparation. However, at times it can be less desirable to actually grill on an open flame or charcoal. Alternative cooking methods, such as convective baking, for example, are often selected over open-flame or charcoal grilling as easier, less expensive, safer, or for other reasons.
To accomplish the appearance, taste, and/or texture of grilling, various chemical coloring agents and/or chemical smoke additives have been used in combination with baking processes in an effort to reproduce the attributes of grilled foods. Unfortunately, the taste, texture, and/or appearance achieved with such techniques are readily discernible from those otherwise associated with grilled foods.
One embodiment of the present invention relates to food products characterized by grill markings, wherein the grill markings are generated by a simulated grilling process. The simulated grilling process includes maintaining a food item on a grill rack, the grill rack including a plurality of substantially solid rods, each of the plurality of rods being substantially parallel and laterally spaced from an adjacent rod to define a plurality of spaces between the plurality of rods. The plurality of rods each defines a substantially flat top surface with a non-stick coating over the top surfaces. The process also includes disposing the food product as maintained on the plurality of rods in a convection oven. The oven is convectively heated at or above about 400 degrees F. such that the plurality of rods impart the grill markings on the food product, the grill markings being substantially darker than surrounding portions of the food item.
While some aspects of the invention have been described above, other related products and methods are also disclosed and provide additional advantages.
Embodiments of the invention will be described with respect to the figures, in which like reference numerals denote like elements, and in which:
In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention.
For reference, actual grilling, or natural grilling, is a dry-heat cooking method whereby heat is radiated from below and transferred to a metal grid supporting food to be grilled. Actual grilling is often accomplished over an open flame and/or charcoal heat source and at a relatively high temperature, with food in relatively close proximity to the heat source. Embodiments of the present invention generally address methods of simulated grilling using convection-type ovens as opposed to the traditional radiant heat cooking associated with open flame and/or charcoal heating, for example.
The first and second side members 30, 32 are optionally substantially parallel and laterally opposed to one another. In turn, the first and second end members 34, 36 are also optionally substantially parallel and laterally opposed to one another. The first and second side members 30, 32 extend orthogonally to the first and second end members 34, 36, such that the border 22 defines a substantially rectangular outer profile, if desired. However, it should be noted that other outer profiles are also contemplated, for example circular outer profiles. The border 22 is optionally formed substantially continuously as a single piece. However, separate, connected components are also contemplated. The outer profile of the border 22 defines a width of about 29.5 cm and a length of about 41 cm, for example. In particular, the border 22 is optionally sized and shaped to fit into an industry-standard half-size sheet pan or other pan.
The racking portion 24 includes a plurality of cross members 50, also described as bars, rods, or lattice members. Each of the plurality of cross members 50 is substantially solid and continuously formed with the border 22. The plurality of cross members 50 extend in a first direction D1 to span the interior 38 of the border 22 with each of the plurality of cross members 50 optionally laterally spaced and substantially parallel to an adjacent cross member. Each of the plurality of cross members 50 spans the interior 38 of the border 22 at about 45 degrees, although other angles are contemplated.
For example, the cross member 50a defines a top surface 54 and a bottom surface 56. In turn, all of the plurality of cross members 50 define top surfaces 54 and bottom surfaces 56 substantially similar to the top surface 54 and the bottom surface 56 of the cross member 50a. With such similarity in mind, the cross member 50a also defines a width at the top surface 54, a width at the bottom surface 56, a projection height HP relative to the border 22, and an overall height HO. The cross member 50a also defines a centerline C1, and optionally has rounded top corners 58, 60. In transverse cross-section, the cross member 50a is substantially trapezoidal, tapering in width from the bottom surface 56 to the top surface 54 at a taper angle α.
Use of such tapering optionally enhances convective heat transfer to the cross member 50a by increasing surface area at the bottom surface 56 while heat transfer from the cross member 50a is directed to, and ultimately from, a smaller surface area at the top surface 54. For example, a smaller surface area at the top surface 54 facilitates simulated grilling by reducing frying effects from trapped lipids or other fats, greases or oils at the top surface 54 and by directing heat to a smaller surface of a food item to be “grilled.” Such frying effects result in markings on the food item that are lighter or otherwise discolored, rather than darker marks traditionally associated with grilling. It is also contemplated that the cross member 50a defines other transverse cross-sections including, for example, square or triangular cross-sections. Additionally, both of the top surface 54 and the bottom surface 56 are substantially planar, though other surface shapes are contemplated, for example pointed or rounded.
Referring again to
The first and second directions D1, D2 are optionally substantially orthogonal, such that the first and second support members 70, 72 extend orthogonally relative to the plurality of cross members 50. However, it is contemplated that the first and second support members 70, 72 and the plurality of cross members 50 define a variety of other angles. By disposing the first and second support members at an angle to the plurality of cross members 50, the grill 20 is provided additional structural support without otherwise using a solid backing. This, in turn, reduces weight as well as a thermal mass of the grill 20 allowing for easier handling, faster heating, and/or faster cooling of the grill 20.
In particular, the first support member 70 defines a top surface 76 and a bottom surface 78, a centerline C2, a width WTS at the top surface 76, a width at the bottom surface 78, and an overall height HOC at the centerline C2. The first support member 70 is substantially trapezoidal in transverse cross section, tapering in width from the bottom surface 78 to the top surface 76 at a taper angle β. Use of such tapering optionally enhances overall structural integrity of the grill 20 while reducing overall weight. For example, the bottom surface 78 is sufficiently wide to reduce bending of the grill 20, but tapers to the top surface 76 to reduce a volume of the first support member 70, and therefore overall weight. The top surface 76 is optionally substantially flat, rounded, or angled, for example. By including a non-flat top surface 76, the first support member 70 optionally reduces frying effects such as those referenced above by reducing pooling of greases or other lipids on the top surface 76.
With reference to
With reference to
With reference to
Additionally, where oils, greases, or other lipids collect or otherwise drop onto the surface on which the grill 20 is resting, for example the pan, the height of the leg 28a is optionally selected to reduce or prevent splattering of such substances onto the food item being grilled to reduce discoloration or other undesirable effects. The height of the leg 28a is about 3 cm, for example, with the food item supported at about 3.8 cm above the surface on which the grill 20 is resting, although other dimensions are contemplated. Additionally, in side profile, the top end 90 defines a maximum width of about 3.43 cm, curves toward the bottom end 92 at a radius of about 4.5 cm, and is rounded at the bottom end 92 at a radius of about 0.7 cm. However, other dimensions are also contemplated.
The grill 20 is optionally substantially continuously formed as a single piece, including the border 22, the racking portion 24, the backing portion 26, and the legs 28. The grill 20 is optionally formed of metal, and in particular aluminum, including aluminum alloys such as those amenable to high pressure casting manufacturing techniques. While materials for the grill 20 are selected as desired and in light of a particular application, metals such as aluminum alloys, having a relatively high thermal conductivity, are well-suited for some simulated grilling operations with the grill 20, as will be described in greater detail below.
The grill 20, or portions thereof, optionally includes a non-stick and/or protective coating (not shown). Acceptable coatings include non-stick, oilophobic, and hydrophobic coatings suitable for temperature ranges for simulated grilling, such as fluoropolymer-based coatings. The coating is optionally formed over the plurality of cross members 50 or over a portion of each of the plurality of cross members 50, for example the top surfaces 54 of the plurality of cross members 50 as desired. However, the coating is also optionally formed over an entirety of the grill 20, for example to promote cleanability of the grill 20 and to provide a more uniform coating surface.
With reference to
By way of background, the food item 300 and/or the plurality of food items 302 optionally includes a variety of different foods. For example, the plurality of food items 302 are optionally protein-based or meats. In particular, each of the plurality of food items 302 is optionally chicken including a skin (not shown) and muscle fiber (not shown) covered by the skin. The plurality of food items 302 optionally include natural lipids, such as fats or oils. Where the plurality of food items 302 are chicken, for example, each of the plurality of food items 302 optionally defines a bone side, or a back side, and a skin side, or a front side.
The food item preparation step 220 includes arranging the plurality of food items 302 on a rack 20a.With reference to
The plurality of food items 302 are spaced out and arranged as desired on the rack 20a with the skin side facing up. Seasoning mix (not shown) is applied over the plurality of food items 302 with any excess seasoning optionally dropping through the rack 20a.
With reference to
The rack 20a is optionally removed from the bone side of the plurality of food items 302 before the seasoning mix (not shown) is optionally applied over the plurality of food items 302 with any excess seasoning dropping through the grill 20, for example through the plurality of spaces 86. While one manner of seasoning is described above, the plurality of food items 302 are seasoned on separate and/or different types of racks, trays, or in other manners as desired.
Following seasoning, the plurality of food items 302 are optionally stored on the grill 20, or otherwise. For example, the plurality of food items 302 are placed in a cooler, covered to prevent drying, and marked with a discard time if desired. The plurality of food items 302 need not be stored and optionally proceed directly to the baking step 230.
With reference to
Preparing the oven 400 includes bringing the oven to a desired temperature. For example, the temperature is optionally at or above about 400 degrees F. or other appropriate temperature where for example a protein charring process will begin for a particular type of food item. However, it should be understood that other temperatures are also acceptable in embodiments of the method, including embodiments addressing simulated grilling of non-meat food items.
The plurality of food items 302 are optionally taken to the oven 400 on the grill 20 for loading. A plurality of grills maintaining food items are optionally loaded into the oven 400, if desired. Although the plurality of food items 302 are shown supported on top of the grill 20, it should also be understood that the grill 20 is optionally placed on top of the plurality of food items 302 to impart the grill markings, or that the grill 20 is placed below the plurality of food items 302 with a second grill on top of the plurality of food items 302 to impart grill markings on both sides of the plurality of food items 302.
Regardless, the plurality of grills are optionally substantially similar to the grill 20 and a desired number, for example between one and five, or another number, are loaded into the oven 400. In particular, each of the plurality of grills is optionally supported on a pan (not shown) for catching lipids or other greases, oils, or fats dripping from the plurality of food items 302. If desired, a baking sheet liner appropriate for a selected baking temperature is optionally placed in each of the pans to facilitate cleaning of the pans following the baking process. Where the plurality of food items 302 include chicken, for example, the oven 400 is optionally loaded grill-by-grill from top-down. Following loading, the oven 400 is closed and a timer or other alarm is optionally set to alert the operator or others when a baking cycle has ended.
The oven 400 is set to heat the interior 402 of the oven to a temperature at or above about 400 degrees F., at or above about 425 degrees F., at or above about 450 degrees F., at or above about 475 degrees F. or at any range or temperature implied by those specifically identified above, for example between about 425 degrees F. and about 475 degrees F. Each of the plurality of food items 302 is optionally heated through to at least about 165 degrees F. or higher during baking, although other temperatures are also contemplated, to meet food safety or other regulations. Additionally the plurality of food items 302 are baked for between about 20 to about 30 minutes and at or above about 400 degrees Fahrenheit, or other appropriate temperature, for example to begin a charring process with the plurality of food items 302. It should also be understood that other times and temperatures are also contemplated.
Baking the plurality of food items 302 includes convectively heating the grill 20 and/or the plurality of food items 302. The border 22, the backing portion 26, and/or the racking portion 24 are convectively heated. For example, the border 22, the backing portion 26, and/or the racking portion 24 are convectively heated to a temperature at or above about 400 degrees F., at or above about 425 degrees F., at or above about 450 degrees F., at or above about 475 degrees F. or at any range or temperature implied by those specifically identified above, for example between about 425 degrees F. and about 475 degrees F.
Heat is also conductively translated from the border 22 and/or the backing portion 26 to the racking portion 24, and in particular the plurality of cross members 50 where the grill 20 is formed of a substantially thermally conductive material, such as an aluminum alloy, for example. Where the plurality cross members 50 of the grill 20 define tapered shapes in transverse cross section, heat is also directed to the top surfaces 54 of the plurality of cross members 50 as the plurality of food items 302 are baked in the oven 400. In particular, the plurality of cross members 50 are optionally tapered such that the top surfaces 54 of the plurality of members 50 define a relatively smaller surface area than the bottom surfaces 56 of the plurality of cross members 50. In this manner, the bottom surfaces 56 are able to draw convective heat from the oven across a wider surface area, while the top surfaces 54 have a smaller surface area, or lines of contact with the plurality of food items 302, allowing the top surfaces 54 to effectively form realistic looking grill markings 310 in the plurality of food items 302.
During the baking step 230, convective heating or baking of the grill 20 results in simulated grilling. For example, with reference to
During simulated grilling, the plurality of food items 302 optionally release lipids, including fats, waxes, and/or oils otherwise associated with the plurality of food items 302. For example, with chicken, fat, oils, and “juices” of the chicken liquefy and/or drip from the chicken. As lipids associated with the plurality of food items 302 become liquefied and/or are released from the plurality of food items 302, the lipids drip from the plurality of food items 302 between the plurality of cross members 50, through the plurality of spaces 86, and through the grill 20.
The grill 20 is optionally adapted such that the lipids do not collect or otherwise pool on portions of the grill 20. For example, the top surfaces 54 of the plurality of cross members 50 are optionally substantially flat to prevent pooling of the lipids. In turn, the plurality of spaces 86 also allow the lipids to pass through the grill 20. Additionally, the tapered top surfaces of the first and second support member 70, 72 also facilitate prevention of lipid pooling. As a result, rather than the plurality of food items 302 being fried in their own greases, or otherwise fried with their own lipids, the plurality of food items 302 are instead “grilled” on the top surfaces 54 of the plurality of cross members 50 to impart the grill markings 310.
For example, where the plurality of food items 302 are otherwise fried with lipids on the top surfaces of the plurality of cross members 50, lines of contact between the plurality of cross members 50 and the plurality of food items 302 are substantially lighter, rather than darker, than remaining portions of the plurality of food items 302. If the plurality of food items 302 are fried, rather than grilled, on the plurality of cross members 50, an opposite effect to that desired sometimes results, with lighter, rather than darker markings imparted on the plurality of food items 302.
As the lipids drip over and through the grill 20, they optionally drop onto heating elements of the oven 400, other hot surfaces in the oven 400, over hot surfaces of the grill 20, and/or are carried or otherwise distributed by air currents to other hot surfaces. If the lipids contact sufficiently hot surfaces they are vaporized, or flashed, upon reaching a smoke point, for example, of the lipids. This, in turn, creates smoke, which optionally engenders a smoke flavor in the plurality of food items 302. It should also be noted that the oven 400 is optionally vented to reduce or otherwise control smoke in the oven 400 if desired. As referenced above, the grill 20 is optionally placed on a sheet pan or other pan (not shown) or surface for collecting lipids dripping from the plurality of food items 302, for example.
From the above, it should be understood that the simulated grilling effect is optionally accomplished with or without any artificial coloring agents, such as cocoa butter dextrose paste, for example, and optionally accomplished with or without chemical smoke flavoring or external smoking devices, such as devices known by those of ordinary skill in the art. By removing the use of artificial smoking and/or coloring agents or devices, a more realistic grilled taste and appearance are realized, for example.
The post-processing step 240 includes removing the plurality of food items 302 from the oven, storing the plurality of food items 302, and/or presenting the plurality of food items 302 to a consumer. The operator optionally removes the grill 20 or plurality of grills with associated pans (not shown) from the oven 400. If desired, the operator also uses a rack handle 410 to grasp and remove the grill 20 or plurality of grills, as well as any associated pans, from the oven 400.
Although the plurality of food items 302 are then optionally flipped onto a separate rack, it should also be understood that other methods, including leaving the plurality of food items on the grill 20 until holding, packaging, or distributing the plurality of food items 302 to a consumer, for example, are also contemplated. Regardless, the non-stick coating optionally operates to allow removal of the plurality of food items 302 without sticking and allows relatively easy clean up following simulated grilling, even at relatively high temperatures, for example at or above 400 degrees F. where the plurality of food items 302 or associated lipids might otherwise become securely adhered to the grill 20.
Where flipped, an empty rack (not shown) is placed on top of the plurality of food items 302 to sandwich them between the grill 20 and the rack after removal from the oven 400. The rack is optionally substantially similar to the rack 20a, the grill 20, or another baking implement as desired. The operator flips the plurality of food items 302 onto the rack. Where the grill 20 includes the coating having non-stick properties, the plurality of food items 302 are flipped and release from the grill 20 without substantial portions of the plurality of food items sticking, or remaining adhered to the grill 20.
The grill 20 is then allowed to cool, used again in another the food item preparation step 220, and/or used again in another baking step 230 as desired. If any of the plurality of food items 302 has moved, the operator rearranges the plurality of food items 302 on the rack as desired, using tongs (not shown), for example. The plurality of food items 302 are optionally put into a storage area, for example a moist upright cabinet (not shown), and held for a period of time before packaging or serving to a consumer. The grill 20 is then optionally cleaned. For example, where the grill 20 includes the optional protective and/or non-stick coating, cleaning the grill 20 is facilitated by the coating.
In light of the above, the grill 20, the simulated grilling system, and/or the method of simulated grilling optionally achieve many advantages. For example, frying, as opposed to grilling the food item 300 is possible. In particular, the grill 20 is adapted to prevent pooling of lipids, sometimes termed renderings, on the food item 300, which may otherwise interfere with more realistic grill markings 310 and create a greasy product. Additionally, the food item 300 is removable from the grill 20, for example by flipping the grill 20 or otherwise removing the food item 300 from the grill, without the food item 300 sticking to the grill 20. Coplanar back surfaces of the grill 20 increase surface area for forced-convection heating.
The highly thermally conductive and unitary structure of the grill 20 also facilitates the top surfaces 54 of the plurality of cross members 50 being at a high enough temperature to impart the grill marking on the food item 300. Additionally, the grill 20 allows lipids to be flashed to create smoke in the oven 400 to create a smoke flavor in the food item 300. In particular, the grill markings 310 and smoke flavoring are realizable in the absence of artificially introduced flavoring or coloring agents or devices. As another example, by placing the plurality of cross members 50 at about a 45 degree angle to the border 22 the plurality of food items 302 are optionally placed on the grill 20 in a variety of configurations while still imparting an otherwise random, realistic orientation of the grill markings 310 on the food item 300.
Although the invention has been described with respect to particular embodiments, such embodiments are for illustrative purposes only and should not be construed to limit the invention. Various alternatives and changes will be apparent to those of ordinary skill in the art. For example, although disclosed above as being formed in a particular shape or of a particular size, other suitable shapes and sizes are also contemplated. Other modifications within the scope of the invention and its various embodiments will be apparent to those of ordinary skill.
