1. Field of the Invention
The present invention is broadly concerned with improved induction heating systems for use in heating or cooking of food products. More particularly, the invention is concerned with such systems, as well as corresponding methods, wherein the systems include heating apparatus with a base adapted for positioning adjacent an induction heating device, and having structure for receiving a cooking container and a drive mechanism to rotate the container during heating. Advantageously, the base and cooking container are separable from the heating device, and the container is equipped with a plurality of temperature sensing assemblies in order to provide continuous temperature information to the induction heating device by way of wireless RFID temperature feedback.
2. Description of the Prior Art
In the commercial preparation of many food products, continuous or near-continuous stirring is required during heating and cooking. To give but one example, the preparation of chilis mandates virtually continuous stirring during cooking to avoid burning or sticking of the food product to the pot or container. This in turn requires significant manual labor and consequent cost. Moreover, in large commercial operations, the occurrence of improperly cooked and stirred final products is still prevalent.
Restaurants often prepare a full day's supply of chili during the morning hours. After cooking, portions of the supply must be cooled and later reheated for sale. Thus, a number of separate cooking containers are simultaneously being heated, which multiplies the problems of manual labor and cost. Further, the cooling of cooked products is inefficient, owing to the fact that the products are static within the cooler or chiller. This can lead to food safety problems if the products are not quickly chilled to temperatures inhibiting microbial growth.
Several attempts have been made to create a cooker that can automatically stir food and maintain a desired temperature of a food container. For instance, U.S. Pat. No. 4,173,925 describes a variable tilt rotating pot cooker and mixer for making possible automatic, continuous mixing or tumbling, with or without simultaneous heating, of a plurality of foods or substances. The device consists of an outer non-rotating shell pivoting on a fixed base. Inside the shell is a pot rotated by a motor attached to the bottom of the shell. A cover is secured over the pot to prevent the contents for spilling out. The shell and its pot are tiltable as a unit to various angular positions from vertical to horizontal. Compartments, dividers, ridges, projections or other shapes inside the rotating pot or on the pot wall and/or bottom, serve to separate, move, mix, and tumble the contents when the tilt angle of the pot is other than at the vertical position. The shell contains a suitable heating system for raising the temperature of the pot. The device is provided with an automatic temperature control, motor speed control and automatic time cycle and function indicators. However, the outer rotating shell and fixed base of this unit will not allow an induction heater separate from the vessel and the rotating mechanism, such as a standard induction cooktop, to heat the inner food-contacting pot and maintain its heated area at a desired temperature. Furthermore, this system cannot be easily moved to the freezer so that the contents can be quickly chilled. Finally, there is no teaching of any wireless temperature feedback of the internal vessel temperature during operation.
U.S. Pat. No. 5,512,733 teaches a rotating and inclining induction heated pot for holding ingredients. This system uses an induction heater to heat the rotating pot. Temperature control of the pot is provided by means of a flexible temperature sensor that is contacting the bottom of the pot such that the sensor can maintain contact with the pot bottom. However, when the pot is inclined to near horizontal, the sensor can no longer measure the temperature of the food contacting surface when the food level falls below the center axis of the pot. Inasmuch as the food level should be below the center axis for optimum stirring, the '733 device is deficient. Furthermore, a sensor of the type used in the '733 patent is very likely to either be quickly destroyed owing to forces on the wire, or to lose thermal contact with the pot.
There is accordingly a need in the art for improved food preparation systems which overcome the deficiencies of the prior art by providing apparatus for holding and rotating a cooking container during induction heating and which can be fully separated along with the container from the induction heating device. Preferably, such systems should also have a food container providing accurate temperature monitoring on a continual basis, with wireless transmission of the temperature data to an induction heating device for control purposes.
The present invention overcomes the problems outlined above, and provides improved systems for heating and cooking of food products requiring stirring during preparation thereof, such as chilis and stews. Broadly speaking, the systems of the invention include an induction heating device and an apparatus cooperable with the heating device in order to provide continuous rotation and consequent stirring during heating and cooking. The apparatus has a base designed to accommodate the induction heating device, as well as structure operable to receive a cooking container holding food product, and a drive mechanism operable to rotate the container during heating. The apparatus is fully separable from the induction heating device at the conclusion of heating/cooking, and can thus be placed in a cooler with the container in place thereon, thereby allowing rotation and stirring of the container during cool-down.
The preferred bases of the invention include a container-receiving cradle shiftable between an upright food product loading and unloading position, and a lowered cooking position wherein the container engages the drive mechanism and is oriented to receive magnetic induction radiation from the associated induction heating device. A releasable locking mechanism on the base serves to hold the container in the lowered cooking position thereof, thereby facilitating bodily movement of the apparatus and container after the conclusion of heating/cooking.
The preferred container of the invention is in the form of a generally cylindrical container body having a bottom wall and a tubular sidewall, with a plurality of temperature sensing assemblies operably secured to the tubular sidewall in circumferentially spaced apart relationship. Each assembly has a temperature sensor operable to sense the temperature of the food product during heating thereof (either directly or indirectly via container temperature), and temperature data-transmitting structure, preferably in the form of an RFID tag, operably coupled with the temperature sensor in order to wireless transmit sensed temperature information to the induction heating device. Each of the data-transmitting structures operates to successively transmit updated temperature information related to the temperature of the food product during rotation of the container. The individual temperature sensing assemblies are preferably mounted in a collar disposed about the container sidewall.
Turning now to the drawings, an apparatus 30 is provided, which is broadly made up of a base 32, with container-receiving structure 34 and drive mechanism 36 mounted on the upper surface of the base. The apparatus 30 is used with a conventional magnetic induction heating device 38 (
The base 32 includes a generally rectangular upper wall 44 and depending, circumscribing sidewall structure 46 designed to receive the heating device 38 with the underside of sidewall structure 46 engaging a support surface, such as a table or counter. It will be observed that the base 32 has a large central through-opening 50 making the base 32 fully permeable to the passage of magnetic induction radiation. Additionally, the forward end of the base 32 includes heavy ballast structure 51.
The container-receiving structure 34 is in the form of a cradle 52, which is pivotally mounted to upper wall 44. Specifically, the cradle 52 includes a lower platform 54 provided with a central projecting stop member 56, as well as a pair of elongated container-supporting arms 58 and 60 and an opposed handle 62 secured to platform 54. The platform 54 is mounted to base 32 by means of a pivot assembly 64. The assembly 64 includes a pair of laterally spaced apart, apertured brackets 66 secured to the underside of platform 54 and receiving a transverse pivot pin 68. The pin 68 is in turn received by bearings 70 and 72 and extends beyond the bearing 72, as shown (
The drive mechanism 36 includes three resilient elastomeric drive wheels 84 located in spaced apart relationship along the length of wall 44 and supported by respective bights 86 secured to upper wall 44. An elongated, axially rotatable drive shaft 88 passes through the individual bights 86 and is secured to the respective drive wheels 84. A selectively operable electrical drive motor 90 is attached to upper wall 44 and is drivingly connected with the adjacent end of shaft 88. The motor 90 has an electrical cord and plug (not shown) to provide electrical power, and is selectively operable via control button 91. In addition, three resilient elastomeric guide or idler wheels 92 are positioned in opposing relationship to the drive wheels 84, and are likewise mounted on bights 94. A shaft 96 is secured to each of the wheels 92 and passes through the bights 94, thereby permitting rotation of the wheels 92. It will be observed that the wheels 84 and 92 are located along the opposite lengths of the opening 50.
The heating device 38 is preferably a magnetic induction heater, including a housing 98 holding the work coil and associated electronics, a cooktop support surface 100, and an RFID reader with its associated RFID antenna 102. In conventional uses, a pot or other cookware is placed on cooktop 100 and is energized in order to create a time-changing magnetic field serving to heat the pot. In the context of this invention, however, the device 38 is situated within the base 32 and serves to heat container 40. The through-opening 50 of base 32 permits unimpeded passage of the magnetic field through the base.
In particularly preferred embodiments, the device 38 is of the type described in U. S. Pat. No. 6,953,919, as noted above. In particular, the device 38 is operable to control heating of food products by use of wireless communication between the device 38 and a temperature sensing assembly on a pot or other container. The temperature sensing assembly normally includes a temperature sensor operably coupled with the pot or container in order to directly or indirectly monitor the temperature of the food products on a continuous or intermittent basis throughout a normal operating range (e.g., −30° C. to 200° C.), with a coupled RFID tag. The device 38 periodically interrogates the temperature sensing assembly to obtain temperature data, and uses such data in a heating control algorithm to regulate the magnetic field produced by the device 38. Such a control system is referred to as a wireless RFID temperature feedback system.
The container 40 in this embodiment is of generally cylindrical configuration including a bottom wall 104 and a continuous circular sidewall 106. The container 40 may be formed of standard metallic materials, such as stainless steel, multiple-ply materials often including inner aluminum layers and outer stainless steel layers. Also, the container 40 may be constructed of carbon composite materials that may include flexible graphite sheeting wrapped about a carbon fiber reinforced plastic (CFRP) composite material shell. Such a design provides increased thermal conductivity and is relatively low in weight. For purposes of the present invention, the container 40 may be formed of any suitable induction heating-compatible material. Preferably, the inner surface of bottom wall 104 and sidewall 106 has anon-stick coating 108, such as Teflon or the like (see
In many instances, the container 40 will have an insulation layer between the inner food-contacting sidewall of the container, and ambient atmosphere. In this regard, the layer may be in the form of a removable, tubular, heat insulative shell cover 114 about the sealer layer 112, formed from any suitable material, such as polymeric foam, fiberglass matting, Aerogel insulation matting, silicate fibrous material, or any other suitable insulative material. Such a cover is maintained on the pot during heating or cooking steps, but is preferably removed during cool-down. Alternately, a permanent insulation layer may be provided between the sidewall of container 40 and an outer shell (not shown) constructed of non-heat-conducting material, such as nylon, propylene, or other material capable of withstanding continuous temperatures of up to approximately 250° F.
As best seen in FIGS. 7 and 16-17, the interior of container 40 maybe equipped with a fin assembly 116, which assists in mixing of ingredients within the container during rotation thereof. The fin assembly 116 may be of variable construction, so long as a plurality of inwardly extending fins 118 are provided. In the illustrated embodiment, the assembly 116 is of unitary construction and includes four spaced apart rings 120 interconnected by means of struts 122. The fins 118 extend from the struts 122, as shown. The assembly 116 is sized so as to mate with the internal surface of sidewall 106.
In order to provide heating control, a collar 124 is permanently secured to the open end of container 40 and extends for a distance beyond the butt open end of sidewall 106. The collar 124 may be made of suitable polymeric or ceramic materials, and is preferably rigid. The collar 124 may be designed for use only with sidewall 106 (see
The collar 124 is used in conjunction with a plurality of sensor assemblies 128 made up of individual temperature sensors and associated RFID tags, the latter communicating with device 38 via antenna 102. Preferably, a plurality of sensor assemblies 128 are provided in circumferentially spaced relationship around collar 124, which successively communicate with device 38 as container 40 rotates.
A variety of different sensor assemblies 128 maybe used in this context, depending upon the heating conditions to be encountered and the type of product to be heated. Most of the various sensor assemblies 128 are used to measure the temperature of the container sidewall 160. For instance, referring to
The base 156 has an upper wall 166 and depending sidewalls 168 defining a recess 170 for removably receiving heating device 154. The container-supporting structure 158 includes a centrally apertured bowl 172 designed to mate with the spherical wall of container 162. Drive assembly 160 includes a plurality of circumferentially spaced apart rotable drive elements 174, which are selectively rotatable by means of a drive motor (not shown). A plurality of sensor assemblies (which may be any of the types of assemblies 128a-128e, described previously) are embedded within the spherical wall of container 162 and are operable to wirelessly communicate sensed temperature information to heating device 154.
Referring to the embodiment of
At this point, the user can select an automatic cooking/warming recipe by either scanning a recipe card over the induction cooktop's RFID antenna (see U.S. Pat. No. 6,953,919), scanning a food package over the induction cooktop's RFID antenna, using the induction cooktop's interface to select a pre-programmed heating recipe, wirelessly communicating the recipe from a computer to the induction cooktop (if that unit has wireless compatibility), or other means. Furthermore, the rotational speed can either be set manually by the user (via the control knob 91) or could be automatically controlled by the induction cooktop's microprocessor via communications with the rotational mechanism.
As the cooking cycle begins, the induction heating device 38 generates appropriate magnetic field, and motor 90 operates so as to rotate drive wheels 84. The fins 118 within container 40 serve to continually lift and mix the food product to enhance even heating thereof.
In order to properly control the temperature of the product during the course of heating, the sensor assemblies 128 come into play. As container 40 rotates, the individual assemblies 128 consecutively rotate into communication range with RFID antenna 102 and thus with the device 38. Referring to
Furthermore, the circumferential portion of the container 40 that starts when one sensor assembly 128 begins communicating temperature information via the RFID antenna 102 and ends when the same sensor assembly 128 has rotated to a point where it no longer can communicate via the RFID antenna 102, is an arc hereafter referred to as a “sensor assembly feedback zone.” It should be evident from
As each “sensor assembly feedback zone” rotates through the heating zone of the induction heater 38 (where the heating zone exists directly above the induction heater's work coil), the feedback provided by the temperature information from the sensor assembly 128 allows the induction heater's microprocessor to make meaningful adjustments to its produced magnetic field that prevent overheating of the container side wall 106 while providing proper energy to the food within the container 40.
While a sensor assembly 128 exists within its sensor assembly feedback zone, wireless communication of temperature data (and other stored data on the sensor assembly whose examples are described in U.S. Pat. No. 6,953,919) occurs typically 16 times per second so that an average temperature can be used once per second to make adjustments to the magnetic field. During each rotation of container 40, the individual assemblies 128 respectively communicate via antenna 102 with the device 38. During such communications, the temperature conditions sensed by the temperature sensors are wirelessly transmitted to heating device 38. The microprocessor controller forming a part of the device 38 then appropriately modulates the magnitude of the induction heating radiation delivered by the heating device. In this fashion, the cooking cycle can be continued until the desired product temperature is reached. Moreover, this arrangement allows the use of a differential schedule of heating over different time periods, e.g., high intensity heating may be continued for periods of time with intermediate lower intensity heating periods.
When the food product within container 40 is heated and cooked to the desired extent, the device 138 is de-energized and motor 90 is stopped. In this condition, with cradle 52 and container 40 still locked in the lowered position thereof, the entire assembly 30 and loaded container 40 can be fully separated from device 38. Thus, the assembly 30 and container 40 can be placed in a cooler, for example, and the product may be rapidly cooled by again initiating operation of motor 90. If it is desired to subsequently reheat the product, the interconnected assembly 30 and container 40 are simply moved back to the initial cooking position over device 38, and a reheating cycle is initiated. When it is desired to remove food product (either hot or cold) from container 40, the cam lock 78 is rotated so as to clear the locking element 74, whereupon handle grip 82 is grasped and the cradle 52 with container 40 is moved upwardly to the loading/unloading position. This movement is assisted by the torsion spring 76. As noted previously, in the upper position the container 40 is slightly over-center, in order to insure against accidental tip over of the container.
The operation of the embodiment of
This application claims the benefit of application Ser. No. 61/192,013, filed Sep. 15, 2008. This prior application is incorporated by reference herein in its entirety.
Number | Date | Country | |
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61192013 | Sep 2008 | US |