Patent Application
20200054032
The present subject matter relates generally to indoor smokers, and more particularly to systems and methods of smoke regulation in indoor smokers.
Conventional smokers include a smoking chamber and a firebox positioned within or fluidly coupled to the smoking chamber. The firebox is filled with a combustible material, such as wood or wood byproducts that are ignited or otherwise heated to generate smoke and/or heat. The heat and smoke are routed into the smoking chamber to impart flavor on and cook food items positioned within the smoking chamber. One or more heating elements may be positioned within the smoking chamber and the firebox to maintain the temperatures necessary both for cooking the food and for generating the desired amount of smoke.
However, conventional smokers use a single firebox containing a single volume of combustible material. Therefore, fireboxes typically are loaded with a single type of wood or a single mixture of wood chips or pellets. In addition, such fireboxes typically include a single heating element or igniter to raise the temperature of the combustible material to the smoldering temperature. Once ignited, the combustible material continues to burn until all the combustible material is consumed or the smoking process is stopped. Therefore, conventional fireboxes provide little flexibility in terms of varying smoking times, wood types and materials, and in the ability to generate differing smoke flavor profiles.
Accordingly, a smoker that has features for improved smoke regulation during a smoking operation would be useful. More specifically, an indoor smoker that has features allowing a user to use different combustible materials and burn schedules during a single smoking process would be particularly beneficial.
Aspects and advantages of the invention will be set forth in part in the following description, may be apparent from the description, or may be learned through practice of the invention.
In one aspect of the present disclosure, an indoor smoker defining a vertical, a lateral, and a transverse direction is provided. The indoor smoker includes a firebox defining a firebox inlet, a firebox outlet, and a smoldering chamber. An air handler is operably coupled with firebox for urging a flow of air through the smoldering chamber and a smoke tray is positioned within the smoldering chamber and includes a plurality of chambers, each of the plurality of chambers being configured for receiving combustible material. A plurality of smoldering heaters is positioned within the smoldering chamber, each of the plurality of smoldering heaters being configured for smoldering the combustible material in one of the plurality chambers.
In another aspect of the present disclosure, a method of operating an indoor smoker is provided. The indoor smoker includes a firebox defining a firebox inlet, a firebox outlet, and a smoldering chamber, an air handler operably coupled with firebox, and a smoke tray positioned within the smoldering chamber and including a first chamber and a second chamber for receiving combustible material. The method includes receiving a command to initiate a smoking process, operating the air handler to urge a flow of air into the smoldering chamber, igniting the combustible material in the first chamber using a first heating element at a first ignition time, and igniting the combustible material in the second chamber using a second heating element at a second ignition time.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
As used herein, the terms “upstream” and “downstream” refer to the relative direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the direction from which the fluid flows, and “downstream” refers to the direction to which the fluid flows. In addition, as used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within a ten percent margin of error. Furthermore, the term “smoke” is generally used to refer to the flow of air, smoke, combustion byproducts, or any combination thereof through an appliance.
Within cabinet 102 is a smoking chamber 120 which is configured for the receipt of one or more food items to be cooked and/or smoked. In general, smoking chamber 120 is at least partially defined by a plurality of chamber walls 122. Specifically, smoking chamber 120 may be defined by a top wall, a rear wall, a bottom wall, and two sidewalls. These chamber walls 122 may define smoking chamber 120 and an opening through which a user may access food articles placed therein. In addition, chamber walls 122 may be joined, sealed, and insulated to help retain smoke and heat within smoking chamber 120. In this regard, for example, in order to insulate smoking chamber 120, indoor smoker 100 includes an insulating gap defined between chamber walls 122 and cabinet 102. According to an exemplary embodiment, the insulation gap is filled with insulating material 124 (see
Indoor smoker 100 includes a door 126 rotatably attached to cabinet 102 in order to permit selective access to smoking chamber 120. A handle 128 is mounted to door 126 to assist a user with opening and closing door 126 and a latch 130 is mounted to cabinet 102 for locking door 126 in the closed position during a cooking or smoking operation. In addition, door 126 may include one or more transparent viewing windows 132 to provide for viewing the contents of smoking chamber 120 when door 126 is closed and also to assist with insulating smoking chamber 120.
Referring still to
Generally, indoor smoker 100 may include a controller 140 in operative communication with user input device 136. User interface panel 134 of indoor smoker 100 may be in communication with controller 140 via, for example, one or more signal lines or shared communication busses, and signals generated in controller 140 operate indoor smoker 100 in response to user input via user input devices 136. Input/Output (“I/O”) signals may be routed between controller 140 and various operational components of indoor smoker 100 such that operation of indoor smoker 100 can be regulated by controller 140.
Controller 140 is a “processing device” or “controller” and may be embodied as described herein. Controller 140 may include a memory and one or more microprocessors, microcontrollers, application-specific integrated circuits (ASICS), CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of indoor smoker 100, and controller 140 is not restricted necessarily to a single element. The memory may represent random access memory such as DRAM, or read only memory such as ROM, electrically erasable, programmable read only memory (EEPROM), or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 140 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.
Although aspects of the present subject matter are described herein in the context of an indoor smoker having a single smoking chamber, it should be appreciated that indoor smoker 100 is provided by way of example only. Other smoking appliances having different configurations, different appearances, and/or different features may also be utilized with the present subject matter, e.g., outdoor smokers, conventional oven appliances, or other suitable cooking appliances. Thus, the example embodiment shown in
Referring now also to
As illustrated, smoking chamber 120 defines a chamber inlet 158 and a chamber outlet 160. During a smoking operation, a flow of smoke (identified in
In order to ensure a desirable cooking temperature within smoking chamber 120, indoor smoker 100 further includes a chamber heater 166 that is positioned within or otherwise in thermal communication with smoking chamber 120 for regulating the temperature in smoking chamber 120. In general, chamber heater 166 may include one or more heating elements positioned within cabinet 102 for selectively heating smoking chamber 120. For example, the heating elements may be electric resistance heating elements, gas burners, microwave heating elements, halogen heating elements, or suitable combinations thereof. Notably, because chamber heater 166 is operated independently of firebox 150 (e.g., as described below), smoking chamber 120 may be maintained at any suitable temperature during a smoking process. More specifically, for example, chamber heater 166 may be turned off or on a very low setting for smoking cheeses or may be turned on high for quickly cooking and smoking meats.
In some embodiments, indoor smoker 100 also includes one or more sensors that may be used to facilitate improved operation of the appliance, such as described below. For example, indoor smoker 100 may include one or more temperature sensors and/or humidity sensors which are generally operable to measure the internal temperature and humidity in indoor smoker 100, e.g., within smoking chamber 120. More specifically, as illustrated, indoor smoker 100 includes a temperature sensor 168 and a humidity sensor 170 positioned within smoking chamber 120 and being operably coupled to controller 140. In some embodiments, controller 140 is configured to vary operation of chamber heater 166 based on one or more temperatures detected by temperature sensor 168 or humidity measurements from humidity sensor 170.
As described herein, “temperature sensor” may refer to any suitable type of temperature sensor. For example, the temperature sensors may be thermocouples, thermistors, or resistance temperature detectors. Similarly, “humidity sensor” may refer to any suitable type of humidity sensor, such as capacitive digital sensors, resistive sensors, and thermal conductivity humidity sensors. In addition, temperature sensor 168 and humidity sensor 170 may be mounted at any suitable location and in any suitable manner for obtaining a desired temperature or humidity measurement, either directly or indirectly. Although exemplary positioning of certain sensors is described below, it should be appreciated that indoor smoker 100 may include any other suitable number, type, and position of temperature and/or humidity sensors according to alternative embodiments.
Referring still to
As best illustrated in
As will be described in more detail below, indoor smoker 100 includes an air handler 190 for urging the flow of air 184 into smoldering chamber 176 through firebox inlet 182 for facilitating the smoldering process and smoke generation. In addition, indoor smoker 100 may further include features for preventing or regulating the flow of air 184 from entering indoor smoker 100 from environment 156 when the flow of such air is not desired. In this regard, for example, indoor smoker 100 may include a firebox check valve 192 which is operably coupled to firebox inlet 182. In general, this check valve prevents the flow of air 184 from entering smoldering chamber 176 when not desired.
For example, firebox check valve 192 may have a “cracking pressure,” which is used herein to refer to the pressure, or more precisely the negative pressure, required within smoldering chamber 176 to open firebox check valve 192. In this manner, firebox check valve 192 may be designed to permit the flow of air 184 only when air handler 190 is operating, thus facilitating the quick and effective asphyxiation of combustible material 178 within smoldering chamber 176 when desired.
Referring still to
As used herein, the verb “smolder” or variations thereof is intended to refer to burning a combustible material (e.g., combustible material 178) slowly such that smoke is generated but little or no flame is generated. In this manner, the combustible material is not expended quickly, but a large amount of smoke is generated for the smoking process. Notably, the burn rate of combustible material and the amount of smoke generated is regulated using smoldering heater 194 positioned within smoldering chamber 176. For typical combustible material used in smokers, e.g., wood and wood byproducts, a typical smoldering temperature is between about 650° F. and 750° F. However, the exact temperature may vary depending on the combustible material used, the air flow rate through smoldering chamber 176, the level of combustible material 178, and other factors.
As mentioned briefly above, indoor smoker 100 further includes an exhaust system 154 which is generally configured for safely discharging the flow of smoke 164 from indoor smoker 100. Specifically, according to the illustrated embodiment, exhaust system 154 generally extends between chamber outlet 160 and a discharge vent 200 defined by cabinet 102 for directing the flow of smoke 164 from smoking chamber 120 to the environment 156. Although an exemplary exhaust system 154 is described below, it should be appreciated that variations and modifications may be made while remaining within the scope of the present subject matter. For example, the routing of ducts, the position of fans and dampers, and the types of sensors used may vary according to alternative embodiments.
As shown, exhaust system 154 includes an exhaust duct 202 that generally extends between and provides fluid communication between chamber outlet 160 and discharge vent 200. Air handler 190 is operably coupled with exhaust duct 202 for urging the flow of smoke 164 through exhaust duct 202 and out of discharge vent 200 to environment 156. According to the illustrated exemplary embodiment, air handler 190 is a tangential fan positioned within exhaust duct 202. However, it should be appreciated that according to alternative embodiments, air handler 190 may be positioned at any other suitable location and may be any other suitable fan type, such as an axial fan, a centrifugal fan, etc. In addition, according to an exemplary embodiment, air handler 190 is a variable speed fan such that it may rotate at different rotational speeds, thereby generating different air flow rates. In this manner, the amount of smoke drawn from smoldering chamber 176 may be continuously and precisely regulated.
As illustrated, indoor smoker 100 further includes a catalytic converter 210 which is positioned within exhaust duct 202 for lowering or removing volatile organic compounds (VOCs) from the flow of smoke 164. As used herein, “catalytic converter” or variations thereof may be used to refer to any component, machine, or device that is configured for removing or lowering volatile organic compounds (VOCs), toxic gases, harmful emissions, pollutants, or undesirable compounds from a flow of air and smoke. For example, according to the illustrated embodiment, catalytic converter 210 generally includes a catalytic element 212 and a catalyst heater 214. In general, catalytic element 212 includes a material that causes an oxidation and a reduction reaction. For example, precious metals such as platinum, palladium, and rhodium are commonly used as catalyst materials, though other catalysts are possible and within the scope of the present subject matter. In operation, the catalytic element 212 may combine oxygen (O2) with carbon monoxide (CO) and unburned hydrocarbons to produce carbon dioxide (CO2) and water (H2O). In addition, according to exemplary embodiments, catalytic element 212 may remove nitric oxide (NO) and nitrogen dioxide (NO2).
Notably, catalytic converters typically require that the catalyst be heated to a suitably high temperature in order to catalyze the necessary chemical reactions. Therefore, catalyst heater 214 is in thermal communication with catalytic element 212 for heating it to a suitable temperature, such as approximately 800° F. According to the illustrated embodiment, catalyst heater 214 is positioned upstream of catalytic element 212 to provide thermal energy through convection. However, it should be appreciated that according to alternative embodiments, catalyst heater 214 may be in direct contact with catalytic element 212 to provide thermal energy through conduction, or may be thermally coupled to catalytic element 212 in any other suitable manner.
Thus, during operation of indoor smoker 100, air handler 190 draws the flow of air 184 into smoldering chamber 176 through firebox inlet 182. The flow of air 184 and combustible material 178 in the smoldering chamber 176 generate the flow of smoke 164 which is drawn into smoking chamber 120 through chamber inlet 158. The flow of smoke 164 passes through smoking chamber 120 for performing a smoking process on food items positioned therein before exiting smoking chamber 120 through chamber outlet 160. Air handler 190 and continues to urge the flow of smoke 164 through catalytic converter 210 and exhaust duct 202 before passing out discharge vent 200.
Referring now to
More specifically, according to the illustrated embodiment, chamber 222 of smoke tray 220 includes a first chamber 224 and the second chamber 226 that are positioned adjacent to each other and extend substantially parallel along an entire depth of firebox 150 (e.g., measured along the transverse direction T). In addition, chambers 224, 226 may have a rectangular cross-sectional areas, e.g., when sectioned along the transverse direction T. However, it should be appreciated that according to alternative embodiments, smoke tray 220 may include any suitable number of chambers 222 having any suitable size, geometry, orientation, etc.
As best shown in
As illustrated, bottom walls 230, sidewalls 232, and divider walls 234 are integrally formed as a single part. More specifically, smoke tray 220 may be a perforated metal sheet that defines a plurality of perforations 236 and is stamped to form walls 230-234 and chambers 222. However, it should be appreciated that according to alternative embodiments, smoke tray 220 may have any other suitable construction and may be formed from any other suitable material or materials. For example, smoke tray 220 may be formed from a plurality of steel mesh sheets that are positioned, oriented, joined together to form chambers 222. Notably the apertures within mesh sheets or perforations 236 may have any size suitable for permitting the flow of air 184 to pass through smoke tray 220 and combustible material 178, while substantially containing or preventing the combustible material 178 from falling through or out of smoke tray 220.
Notably, each chamber 222 of smoke tray 220 may contain a different combustible material 178. For example, first chamber 224 may contain a first type or quantity of combustible material (e.g., cherry wood chips) while second chamber 226 may contain a second type or quantity of combustible material (e.g., pecan chunks). Indeed, smoke tray 220 may contain any suitable wood (e.g., cherry, pecan, oak, etc.) and type (e.g., wood chunks, wood chips, wood pellets, wood resin, etc.) in each chamber 222 to provide a versatile smoking process with distinct flavor profiles.
Referring still to
For example, as best illustrated in
Referring still to
Referring again to
Now that the construction and configuration of indoor smoker 100 has been described according to an exemplary embodiment of the present subject matter, an exemplary method 300 for regulating a flow of smoke within or otherwise operating an indoor smoker will be described according to an exemplary embodiment of the present subject matter. Method 300 can be implemented by controller 140 and may be used to operate indoor smoker 100, or any other smoker or cooking appliance. It should be appreciated that the exemplary method 300 is discussed herein only to describe exemplary aspects of the present subject matter, and is not intended to be limiting.
Referring now to
Step 330 may include igniting the combustible material in a first chamber of a multi-chamber smoke tray using a first heating element at a first ignition time. In addition, step 340 may include igniting combustible material in a second chamber of the multi-chamber smoke tray using a second heating element and a second ignition time. Notably, the first ignition time and the second ignition time may be the same or different. In this regard, according to an exemplary embodiment, there is a time delay between the first ignition time and the second ignition time.
In this regard, continuing the example from above, at step 330, cherry wood chunks positioned within first chamber 224 may be ignited to commence a smoldering process at the start of a smoking process (e.g., at t=0). The cherry chunks may be ignited by first heating element 260 and burn, for example, for approximately four hours. Notably, due to the thermal barrier 240 and multi-chamber configuration of smoke tray 220, the combustible material located in second chamber 226 will not be ignited by the smoking cherry chunks in first chamber 224, unless second heating element 262 is separately energized.
After the combustible material 178 in first chamber 224 has been consumed, it may be desirable to extend the smoking process longer, e.g., with another wood material. Thus, at step 340, pecan chunks positioned within second chamber 226 may be ignited with second heating element 262. The pecan chunks may burn for another time, e.g., four hours to extend the smoke time as well as provide different flavor profiles to the food being smoked.
In addition, although two exemplary wood types and smoking methods are described herein, it should be appreciated that according to alternative embodiments any suitable wood types or materials may be used. In addition, any suitable smoking or ignition schedule may be used to fill the smoking chamber with the desired type of smoke at the desired times during a smoking process. Moreover, other variations and modifications may be in applied while remaining within the scope of the present subject matter.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
