FIELD OF THE INVENTION
The inventions relate primarily to countertop ovens with steam and/or rotisserie; and/or infrared features.
BACKGROUND OF THE INVENTION
Countertop ovens may include means for generating steam. See, for example, U.S. Pat. No. 6,100,502, incorporated herein by this reference. Usually, steam is generated exterior to the oven cooking cavity and piped into the oven cavity.
In other examples, water is piped into the oven cavity to or proximate the oven heating element therein in order to produce steam. See, for example, U.S. Pat. Nos. 5,680,810 and 8,233,690, incorporated herein by this reference.
Many prior art systems are unduly complex and expensive. Moreover, water dripping onto or near the oven heating element can cause corrosion and/or cause the oven heating element to cool.
Some countertop ovens include rotisserie features. See, for example, U.S. Pat. No. 6,170,390, incorporated herein by this reference. According to the '390 patent, two large spit plates are loaded into tracks in the oven side walls. In loading and unloading the spit assembly, the food may have to be handled. Moreover, a spit support plate is required to support the food vertically. And, drippings can fall onto the oven cavity floor making cleaning difficult.
U.S. Pat. No. 5,819,639, incorporated herein by this reference, discloses a rotisserie base, a spit support, and a manually wound spit rotation apparatus designed for use in a conventional home oven.
SUMMARY OF THE INVENTION
Featured is a rotisserie system comprising a cooking oven enclosure including a driven gear at one inner wall thereof and a spit assembly support framework including a drip pan and first and second side racks upstanding from the drip pan each including a spit assembly support. A spit assembly comprises a driven wheel with associated gear teeth driven by the driven gear, an inward bushing supported by the spit assembly support, and a socket for a spit rod. The spit assembly also includes a handle assembly with an inward bushing supported by the spit assembly support and a yoke assembly comprising a center spit rod extending into the driven wheel socket and one or more additional spit rods extending at least partially along the length of the center spit rod.
In one example, the cooking oven enclosure includes at least one bottom side track configured to receive the drip pan therein. Preferable, there are opposing bottom side tracks, one for each side of the drip pan. The cooking enclosure has a back wall and a front door and the drip pan preferably extends from the back wall to the front door when loaded in the side tracks. The first and second side racks of the drip pan may be pivotally attached to the drip pan. In one design, the first and second side racks each include a wire with a U-shaped downward bend forming the spit assembly support.
The yoke assembly may include the center spit rod and a spit rod on each side thereof extending along the majority of the length of the center spit rod but stopping short of the drive wheel.
The system may further include a basket with a side axle receivable in the driven wheel socket and an opposite side bushing supported by the spit assembly support. In one example, the basket includes a lid with retractable opposite side tabs biased outwardly and movable finger engagement members each connected to a side tab. The system may further include a tumbler cage rotatably supported by the spit assembly. In one design, the cage includes a top basket hingedly attached to a bottom basket. There may be opposing side openings between the top and bottom baskets for the center spit rod and one or more additional side openings for the additional spit rods. A removable divider for the top and/or bottom baskets can be provided.
The system may further include a kabob assembly rotatably supported by the spit assembly. In one design, the kabob assembly includes first and second spaced kabob rims joined by a hollow axle receiving the center spit rod therethrough and kabob rods removably coupled to the first and second kabob rims.
The system may further include a trussing device. In one design, the trussing device includes a cable with an end member (hook or ball) and multiple links releasably receiving the end member therein for varying the diameter of the trussing device.
In one embodiment, the cooking oven enclosure includes at least one infrared heater. The infrared heater can be automatically energized when power is supplied to the driven gear motor and automatically deenergized when power is not supplied to the motor. In one design, the infrared heater is electrically connected in parallel with a relay for the motor. The system may also include a steam source and preferably the infrared heater has a peak emission absorbed by steam produced by the steam source.
The side racks may include a locking mechanism releasably locking the side rack to the drip pan. One preferred drip pan includes a slot and the locking mechanism includes a lever pivotable with respect to the side rack and with a catch engageable with the drip pan slot. There may also be a mechanism such as a detent holding the lever in position with respect to the side rack. The side rack may further include a tab received in a slot in the drip pan. In one design, the drip pan includes a cutout for the driven wheel and the side rack also includes a cutout for the driven wheel.
The system driven gear may be movable between a load position and a home position and biased to the load position. In one design, an articulating motor is provided for the driven gear. A pivoting bracket for the articulating motor and a spring biases the bracket and the motor forward to bias the driven gear to the load position. In one example, the drip pan is loadable into the cooking oven enclosure so the driven wheel engages the drive gear in its load position and the drip pan then registers in the oven with the driven wheel forcing the drive gear to its home position.
Also featured is a rotisserie system including a cooking oven enclosure and a spit assembly support with a bottom drip pan and first and second side racks upstanding from the drip pan each including a bushing support. The spit assembly includes a driven wheel including an inward bushing rotatably supported on one bushing support, and a handle assembly including an inward bushing rotatably supported on the other bushing support, and one or more spit rods extending from the handle assembly, at least one spit rod received by and removable from the drive wheel. The system may include a center spit rod extending therefrom and a spit rod on each side thereof extending along a majority of the length of the center spit rod but stopping short of the driven wheel.
The subject invention, however, in other embodiments, need not achieve all these objectives and the claims hereof should not be limited to structures or methods capable of achieving these objectives.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Other objects, features, and advantages will occur to those skilled in the art from the following description of a preferred embodiment and the accompanying drawings, in which:
FIG. 1 is a schematic three dimensional front view of an example of a countertop oven in accordance with the invention;
FIG. 2 is a schematic three dimensional view showing the cooking enclosure of the countertop oven shown in FIG. 1;
FIG. 3 is a schematic view showing a spit assembly support framework supporting a spit assembly for use with the countertop oven of FIGS. 1 and 2;
FIG. 4 is a schematic front view showing the spit assembly framework and a spit assembly disposed with the oven cavity of FIGS. 1 and 2;
FIG. 5A is a schematic three dimensional top view of another embodiment of a spit assembly support framework;
FIG. 5B is a schematic three dimensional top view showing the spit assembly support framework of FIG. 5A with the side racks folded down;
FIG. 6 is a schematic three dimensional front view showing another embodiment of a spit assembly support framework with a spit assembly in accordance with examples of the invention;
FIG. 7 is a schematic three dimensional front view of another embodiment of a spit assembly;
FIG. 8 is a schematic three dimensional front view showing another example of a spit assembly in accordance with the invention;
FIG. 9 is a schematic view showing a kabob assembly in accordance with aspects of the invention;
FIG. 10 is a schematic view showing a portion of another kabob assembly in an example of the invention;
FIG. 11 is a schematic view of a trussing subassembly in accordance with the invention;
FIG. 12 is a highly schematic view showing an example of a steam generator subsystem associated with the countertop oven of FIG. 1;
FIG. 13A is a schematic view showing another example of a steam source for a steam infusion subsystem;
FIG. 13 B is a schematic three dimensional view of a steam source cover in accordance with examples of the invention;
FIG. 14 is a flow chart depicting a method associated with the invention and/or the programming and operation of the controller of FIG. 7;
FIG. 15 is a schematic view of a cooking system according to one embodiment of the present disclosure;
FIG. 16 is a schematic view showing the fluid reservoir removed;
FIGS. 17-18 are schematic views of another fluid of a cooking system;
FIG. 19 is a schematic view of another steam source within a cooking enclosure;
FIG. 20 is a schematic view of the steam source of FIG. 14;
FIG. 21 is a schematic view of an air flow system for a cooking system;
FIG. 22 is a schematic view of the air flow system of FIG. 16;
FIGS. 23-25 are tabulated results of the improvements in cooking time and moisture retention with the cooking system according to some embodiments of the present disclosure; and
FIG. 26 is a flow chart depicting the programming associated with the controller of FIG. 7.
FIG. 27 is a schematic three dimensional front view showing one example of a spit assembly in accordance with one preferred embodiment of the subject invention;
FIG. 28 is a schematic three dimensional front view showing the handle yoke and spit rod assembly of FIG. 27;
FIG. 29 is a schematic three dimensional top view showing an example of a rotisserie basket in accordance with the invention;
FIG. 30 is a schematic three dimensional top view showing a lid mechanism for the cooking basket or FIG. 29;
FIG. 31 is a schematic three dimensional view showing a rotisserie tumbler cage supported by a spit assembly handle yoke and spit rod subassembly in accordance with an example of the invention;
FIG. 32 is a schematic view of the rotisserie tumbler cage showing the top cage basket in the open position relative to the bottom cage basket;
FIG. 33 is a schematic three dimensional end view of the rotisserie tumbler of FIGS. 31 and 32;
FIG. 34 is a schematic three dimensional view showing the rotisserie tumbler basket with the internal dividers removed;
FIG. 35 is schematic three dimensional end view of a kabob assembly in accordance with an example of the invention;
FIG. 36 is a schematic three dimensional front view showing the kabob assembly of FIG. 35 supported by the spit assembly;
FIG. 37 is a schematic three dimensional view of a trussing apparatus in accordance with an example of the invention;
FIGS. 38A and 38B are views of one trussing cable adjusted to two different sizes for different size poultry;
FIG. 39 is a schematic three dimensional partially cutaway view showing an infrared heater in the oven enclosure;
FIG. 40 is a schematic three dimensional close-up view of the ceramic heater depicted in FIG. 39;
FIG. 41 is a schematic three dimensional front view showing an example of a rotisserie mode selector in accordance with an example of the invention;
FIG. 42 is a block diagram showing the operation of the infrared heater and the driven oven cavity gear motor in accordance with an example of the invention;
FIG. 43 is a schematic side view showing an example of the spit assembly loaded onto the spit assembly support framework;
FIG. 44 is a schematic view showing one spit assembly support framework side rack decoupled from the drip pan;
FIG. 45 is a schematic view showing the interior of the oven with the spit assembly and the spit assembly support framework partially loaded therein;
FIG. 46 is a schematic three dimensional view similar to FIG. 45 now showing the spit assembly support framework and, in particular, the drip pan in its fully loaded position within the interior of the oven; and
FIG. 47 is a schematic view showing an articulating drive gear motor and a bracket therefore in accordance with examples of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Aside from the preferred embodiment or embodiments disclosed below, this invention is capable of other embodiments and of being practiced or being carried out in various ways. Thus, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. If only one embodiment is described herein, the claims hereof are not to be limited to that embodiment. Moreover, the claims hereof are not to be read restrictively unless there is clear and convincing evidence manifesting a certain exclusion, restriction, or disclaimer.
FIG. 1 depicts countertop oven 10 with controls 12a, 12b, and 12c, e.g., temperature controls, a timer, and mode settings (e.g., rotisserie, steam infusion, toasting, broiling, baking, convection) and the like.
The cooking enclosure 15, FIG. 2, includes spaced interior side walls 14a, 14b, bottom and top surfaces 16a, 16b, rear wall 18 and front door 20, FIG. 1 with a glass window.
One or more racks are typically provided as shown FIG. 1 removably retained in the cooking enclosure at different heights via side tracks. There may be a top heating element as show at 22 in FIG. 2 within the enclosure secured to top surface 16a. A bottom heating element, one or more side heating elements, a rear wall heating element, and the like are possible adjacent to or within the oven walls.
In a rotisserie model, lower side tracks 26a and 27b are preferably associated with side walls 14a and 14b and added near the bottom of the cooking enclosure. The tracks can be grooves in the side walls or indents formed in a structure added to the side walls. The tracks may be continuous or include discrete support members.
The side tracks preferably receive the side rails 30a, 30b of drip pan 32, FIGS. 3-4. The drip pan may sit on the bottom of the cooking enclosure or may be elevated slightly off the bottom by virtue of the pan side rails being supported by oven enclosure lower side tracks. A drip pan front portion 44a and a rear portion 44b preferably engage the front and rear of the cooking enclosure respectively, e.g., rear wall 18, FIG. 2 and front door 20, FIG. 1. Also, the side tracks may form a step to retain the drip pan in place in the enclosure.
The drip pan 32, FIGS. 3-4, is preferably a component of a spit assembly support framework also including side racks 40a and 40b each including a spit assembly support (e.g., a top U-shaped channel as show at 42a formed in side rack 40a). The bushings of spit assembly 50 are supported (rotatably supported or otherwise) in these U-shaped channels as shown for spool shaped or grooved bushing 52a supported in the top support 42a of side rack 40a. Spool shaped bushing 52b, FIG. 4 is supported in the top support of side rack 40b. The side racks may be pivotably attached to the drip pan and/or removably attached to drip pan. Preferably, the side racks pivot inward and fold over each other adjacent the bottom floor of the drip pan.
As shown in FIG. 4 spit rod 60 extends between the center of each bushing 52a, 52b. Adjustable forks 61a and 61b, FIG. 3, may be provided each with two or more spits. Gear wheel 70 may be attached to bushing 52a, FIG. 4, and handle member 72 may be attached to bushing 52b. In such a design, the smaller diameter handle member 72 is preferably configured to support the spit assembly vertically on a countertop or on the drip pan for loading the spit assembly with food and/or for seasoning the same and/or during removal/disassembly operations. In one embodiment, drip pan 32 may include a recess or cavity as shown at 74, FIG. 3 for receiving round handle 72 and/or gear wheel 70 therein.
The cooking enclosure in this embodiment preferably includes motor (M) driven gear 78, FIGS. 2-3 proximate side wall 14b in order to drive (rotate) gear wheel 70, FIG. 3. In other designs, the spit assembly spit rod 60 extends through bushing 42 and into a socket associated with an exterior mounted barbeque type rotisserie motor. Bushings 52a and 52b may rotate with spit rod 60 or may be stationary with respect to spit rod 60 which then rotates with respect to the bushings.
FIG. 5A shows an embodiment where side racks 40a′ and 40b′ are wire members pivotably and removably attached to pan 32′. The bushing supports 42a and 42b are U-shaped downward bends in the wire which also extends upwardly and inwardly at an angle from the front corner and rear corner of pan 32′. In this way, the side racks are configured to fold down one over the other into the interior of the drip pan. FIG. 5B show the wire side racks folded inwardly.
FIG. 6 shows another drip pan 32″, wire side racks 40a′ and 40b′, and spit assembly 50′ with gear wheel 70 having handle cutouts 80a and 80b for handling the gear wheel. Gear wheel 70 is attached to spool shaped bushing 51a which is attached to yoke member 90 having spaced sockets 92a and 92b. Handle 72′ is attached to spool shaped bushing 52b. Spit rod assembly 60′ is a U-shaped fork like member with end 96 co-joined to spits 98a and 98b the distal ends of which are removably received in sockets 92a and 92b, respectively. Clamp member 100 connects U-shaped end 96 to bushing 52b.
In some preferred embodiments, the drip pan is always used during rotisserie cooking since it supports the spit assembly. The drip pan thus keeps the interior of the cooking enclosure clean. The drip pan is also used to support the spit assembly during assembly, during food preparation, during disassembly, and the like. The food itself need not be handled in order to load the food into the oven or to remove it from the oven. A separate spit assembly support is not required as the drip pan functions to support the food before and after cooking, for seasoning, carving, and the like all the while catching any seasonings and/or drippings from the food. The drip pan, with the rotisserie supports removed, can be used to serve the food. It can also be used as a baking pan
Also, the drip pan is simply slid into and out of the oven. The lower oven enclosure side tracks position the drip pan for proper engagement of the spit assembly gear wheel with the interior oven cavity drive gear and the drip pan extends fore and aft in the oven enclosure sufficiently to prevent movement of the drip pan during rotisserie operations since a drip pan rear portion abuts the oven enclosure rear wall and a drip pan front portion abuts the drip pan front door or frame.
In other embodiments, a different type of drip pan/oven enclosure registration means may be used, such as a clamp or clamps securing the drip pan with respect to the oven interior and/or a drip pan which, because of its configuration (size and/or shape), lodges in place within the cooking enclosure properly engaging the spit assembly gear wheel or equivalent with the gear in the oven enclosure driven by a motor.
FIG. 7 shows a spit assembly with yoke 61 attached to bushing 52b of handle 72′ supporting center spit rod 60 and two prongs 98a′ and 98b′ extending about 75% of the length of rod 60. Center spit rod 60 has a square cross section and tapered distal end 63 is received in square socket 65 extending from the bushing of gear wheel 70.
FIG. 8 show a spit assembly with center spit rod 60 received in socket 67 extending from bushing 52b of handle 72 and received in socket 65 of gear wheel 70. Forks 61a and 61b are adjustable with respect to spit rod 60 via spring member 69a and 69b each having an inner side fixed to a respective fork member and an outer tab 71 with an orifice therethrough for the spit rod 60. Urging the two tabs 71b and 73b together allows sliding of fork 61b along rod 60. Releasing the tabs locks the fork in place on rod 60.
FIG. 9 shows a kabob assembly with three kabob forks 100a, 100b, and 100c slid onto spit rod 60 and each including two kabob holders (e.g., kabob holders 102a and 102b for kabob fork 100a) having distal ends received in kabob retainer 104 with spaced peripheral sockets for the distal ends of the kabob holders. Retainer 104 is slid on spit rod 60 as shown.
FIG. 10 shows a kabob retainer 104′ with peripheral slots 106 which receive kabob holders such as kabob holder 102′ in a snap lock configuration. End 110 has a cone profile and/or a groove received in slot 106 and opening 114 with tang 112 residing in slot 106. The other end of each kabob holder may include another similar retainer, the retainer shown in FIG. 9, or an equivalent structure.
FIG. 11 shows trussing 120 for food 122. The trussing may be made of rope, braided metal, silicon material, or the like and/or combinations of such material. Hooks may be included to secure the trussing to the food. The ends of a wire trussing can be used to twist tie the netting securing it to the food. If the truss is made of rope, the ends may extend beyond the net and can be tied to secure the trussing to the food.
For steam infusion with or without rotisserie operations, cooking enclosure 15, FIG. 12 has a cooking heater element (as shown at 22 in FIG. 2, for example) and a separate steam source such as trough shaped metal (e.g., cast aluminum) Teflon coated pan 200, FIG. 12 or 200′, FIG. 13A which may be affixed near the bottom rear corner of right side wall 14b within the cooking enclosure. A steam source heater heats the trough shaped pan. In FIG. 12, the heater 202 is secured to the bottom of pan 200. In FIG. 13A, the heater element is within the curved side wall 204 of pan 200′, e.g. molded therein. Cover 211FIG. 13B may be included for pan 210′ with steam exit hole 213. Cover 211 keeps drippings and the like from contaminating the interior of pan 200′
Fluid reservoir 206 is typically attached externally to the cooking enclosure and can be filled with water by the user. The fluid reservoir can be removed from the countertop oven in some embodiments in order to be filled at the sink. Conduit 208 leads from reservoir 206 to the steam source as shown with distal end 210, FIGS. 12 and 13 just above pans 200 and 200′.
In this way, the problems associated with dripping water on the oven heating element are avoided. This prevents corrosion of the oven heating element and/or cooling of the oven heating element during cooking operations when the steam infusion mode is selected. Steam is generated independent of the main oven heating element(s). One benefit of such a feature is to provide a low temperature (e.g., 140° F.) steam filled environment for functions such as bread proofing, keeping food warm and moist, and the like. Another benefit is the steam source heater can be de-energized if the oven temperature (by virtue of the oven heater element(s)) is hot enough to heat the steam source to a temperature sufficient to create steam when water drips on it.
The water may be gravity fed to the steam source or a pump 212 may be included and/or one or more valves 214 may be included. Controller 216 may control valve 214 and/or pump 212 to deliver water to the steam source sufficient to produce steam at a rate between about 6-7 grams per minute. Controller 216 may be a microcontroller, one or more processors, an application specific integrated circuit, a field programmable gate array, or may include analog and/or digital circuitry. In some embodiments, controller 216 is distributed amongst a plurality of devices and/or electronic chips and/or subassemblies or subsystems. A microcontroller may control the oven heater element, a fan, valve 214, and/or pump 212 based on input from selector controls 12, FIG. 1. Various relays, thyristors, and/or a thermostat may also be used. Valve 214 may be a manually controlled orifice or an electronically activated gate to provide a pulsed or variable flow of fluid.
Controller 216 controls the oven heater controls as shown in FIG. 12 based on input from a temperature sensor to control the oven temperature as desired based on selector control 12.
Controller 216 also functions to sense the desired input from a selector control 12 (see FIG. 1) for the steam infusion mode. When the oven is sufficiently hot, the steam source heater need not be activated since the cooking enclosure heater will sufficiently heat the pan 200, 200′, FIGS. 12-13 to a temperature necessary to produce steam as water in conduit 208 drips onto the pan.
In other cooking modes, the oven temperature may be lower and the steam source is not hot enough to produce steam or to produce steam at a sufficient rate without energizing the steam source heater.
Accordingly, temperature sensor 220, FIG. 12 (e.g., an NTC thermistor) is included and provides to controller 216 the temperature of the steam source pan 200, 200′.
As shown in FIG. 14, controller 216 is configured (e.g., programmed) to detect whether the steam mode is selected, step 230 and if so, to activate pump 212, FIG. 12, and/or open valve 214, step 232, FIG. 14. If the steam mode is not selected, the pump is not activated and/or the valve remains closed. The temperature as provided by the thermistor is measured and/or sensed, step 234 and if the temperature is above a predetermined temperature T1, step 236, then the steam source heater element (202, FIG. 12) is de-energized (or turned on low), step 238 or left de-energized if already de-energized. If the temperature measured by the temperature sensor is below T1, step 236, then the steam source heater element is energized (or turned on high), step 240. In cases where the temperature measured by the temperature sensor exceeds another predetermined temperature T2, step 242, an alert signal may be output, step 244 (e.g., to an audible alarm, an indicator lamp, or the like). Such a high temperature could indicate a problem with the operation of the countertop oven or the need to fill the fluid reservoir. In one embodiment, T1 is 220° F. and T2 is 250° F. Thereafter, the steam source heater and pump are periodically turned on (and/or the valve is opened) and the temperature read. If the temperature falls below T2, that indicates water has been added to the reservoir. Normal operation then resumes. If the temperature does not fall below T2, the pump is turned off (and/or the valve is closed) and the heater is turned off. The steps of periodically turning the heater and pump on (and/or opening the valve) and reading the temperature continue. LED indicators can be energized to flash throughout this cycle until the temperature falls below T2.
In some embodiments, the temperature of the steam pan is maintained at a predetermined set point by control of the steam source heater and/or controlling the amount of water supplied to the pan.
FIG. 15 shows a removable fluid reservoir 206 and piston pump 212 driven by an AC motor. Cast aluminum steam source 200″ is also shown. Fan 300 is also shown. Also shown is temperature sensor 220 for the steam source heater. The temperature sensor for the oven is preferably near the top right side front of the oven cavity.
FIG. 16 show fluid reservoir 206 removed from side wall receptacle 207 for filling. When the reservoir is removed, valve 214 automatically closes. Reservoir 206 may be made of clear or otherwise see-through plastic so the user can monitor the fluid level within the reservoir. Reservoir 206 may have markings indicating the water level as shown at 205 to dictate a desired steam duration.
Because of independent steam trough heater 202, FIG. 12, controller 216 can be programmed to provide steam independent of the control of the oven temperature. In one example, a steam bake with browning may be selected via selector control 12. Controller 216 then controls the oven temperature to about 375° F. and supplies steam at a rate of 6-9 g/min for about 20 minutes. Then, the steam ceases and the food product is browned at 375° F. for the final 10 minutes of cooking. In other examples, the steam rate is lowered for the final 10 minutes of cooking.
In another example, steam alone is used at the beginning of the cooking cycle or a low oven temperature is maintained (e.g., 120° F.) and, at the end of the cooking cycle, no steam is used and the oven is maintained at a higher temperature of 400° F.
Thus, controller 216 controls whether or not steam is used, the rate of steam infusion, and the time steam is used as well as whether or not the oven heating element(s) are turned on, the power supplied to them (oven temperature), and the length of time they are on.
In this way, the steam source heater can also be protected from overheating, water will not be introduced into the cooking chamber that will not be boiled away by the steam source (boiler), and the like.
In one example, if the temperature of the steam source exceeds a predetermined temperature (e.g., 375° F.), the steam source heater can be turned off and/or cycled on and off. In some examples, the pump is left on. When the reservoir is refilled, water again strikes the steam source. When the steam source heater is cycled on and the temperature decreases, that indicates the reservoir has been refilled and now the steam source heater can be left on (in the steam infusion mode).
If the temperature is less than a predetermined temperature (e.g., 175° F.), the pump is turned off as shown at 300 in FIG. 26 so water does not contaminate the cooking enclosure and/or leak therefrom. The steam source heater may be left on or turned off.
FIG. 17 is a perspective view of a cooking system according to one embodiment. As shown, the cooking system can include one or more control knobs 12 for manipulating temperature and/or time within the cooking system. The control knobs 12 may also be used for controlling other features of the cooking system 10 as can be appreciated by one skilled in the art. In some instances, the control knobs 12 can also include predetermined timing and/or cooking programs. In one embodiment, the cooking system is a convection oven with steam infusion capabilities. As shown, the cooking system includes a stainless steel handle 314 on a front glass door panel 316 for access to the interior of the cooking system 10. As can be appreciated by one skilled in the art, handle 314 and the door panel 316 can be formed of any suitable material and can come in a variety of configurations (e.g., side of the oven, top of the oven). In one embodiment, the cooking system includes a right side water reservoir 206′ for providing water to the interior of the cooking system.
FIG. 18 is a perspective close-up view of the water reservoir 206′. As shown, the water reservoir 206′ can be detached for refilling with water as necessary. In some instances, the water reservoir 206′ can be integrated to the cooking system. Water within the water reservoir 206′ can be provided to the interior of the cooking system 10 via a water inlet 322 that is in communication with the modular water reservoir 206′. Additional pipes and/or valves (not shown) may be used to direct the water throughout the interior of the cooking system as necessary.
FIG. 19 is a perspective view of a heating system within the cooking system. As shown, the heating system can be housed within chamber 330. In one embodiment, the heating system includes a heating element 332 that can be powered by a power supply (not shown) within the cooking system via an electrical outlet (not shown) and controlled by controller 216, FIG. 12. At least one steam source channel 334 can be found adjacent to an underside of the heating element 332. In one embodiment, the channel 334 can be substantially disposed about and surround the underside of the heating element 332. In another embodiment, the channel 334 can be integrated with the heating element 332. In yet another embodiment, the channel 334 can be detachably coupled to the heating element 332. In some embodiments, the channel 334 is able to maintain fluid communication with the heating element 332.
In one embodiment, an apparatus 336 can be in communication with the heating element 332 to deliver water to the channel 334. The water for the apparatus 336 can be retrieved from the water reservoir via pipes and/or valves. In one example, the objective is to deliver water from the apparatus 336 to the channel 334. The water is converted to steam. In one embodiment, the heating element 332 is operable to convert water along the length of the channel 334 to steam.
In some embodiments, the rate at which water can be delivered to the steam source may be capable of producing steam rates in the range of about 2 grams per minute, or about 3 grams per minute, or about 4 grams per minute, or about 5 grams per minute, or about 6 grams per minute. In other embodiments, the steam rate can be in the range of between about 2 grams per minute to about 6 grams per minute. In some instances, the steam rate can be less than 10 grams per minute, or less than 5 grams per minute. In other instances, the steam rate can be greater than 1 gram per minute, or greater than 3 grams per minute, or greater than 7 grams per minute. 6-7 grams per minute may be preferred.
In one embodiment, the bottom heating element can have a substantially linear configuration. In another embodiment, the heating element can have a substantially serpentine configuration. The serpentine configuration may minimize the amount of cold sections in the cooking system and eliminate cold spots that can develop in the cooking system. In yet other embodiments, the heating element can have a combination of linear and serpentine configuration, among other suitable configuration as can be appreciated by one skilled in the art. In some embodiments, the objective of the heating element is to provide a better heat distribution and cooking uniformity throughout the cooking system. The heating element is also capable of providing cooking, baking and broiling functions, among others, to food products within the cooking system.
The cooking system can also include an air flow system 330 such as a fan to facilitate air flow within the cooking system. This will be described in more detail in subsequent figures and discussion.
FIG. 20 is a schematic view of a heating system. As shown, the chamber can house the serpentine heating element 332 as well as the removable water collar channel 334. In one embodiment, the disclosed cooking system is capable of introducing steam throughout the chamber for cooking food products contained therein via a water delivery apparatus 36, the heating element 332 and the channel 334 to add humidity. Optionally, the chamber 30 can be a convection oven capable of cooking food products with or without the infusion of steam provided by the water delivery apparatus. In other words, the cooking system can function like a traditional convection oven in one instance. In other instances, the cooking system can function like a convection oven with steam infusion to provide enhanced cooking capabilities to the food products.
FIG. 21 is a schematic view of an air flow system of the cooking system. In one embodiment, the air flow system includes a housing 350 where the housing 350 is capable of receiving food products therein. Like above, the food products can include the likes of bread, rice, pasta, vegetables, fruits, dairy products, meats, fish and poultry, among others.
As shown, the housing 350 includes at least one top wall 352 and at least one side wall 354. In one embodiment, the air flow system includes an apparatus 300 adjacent one of the side walls 354. In operation, the apparatus 300 is capable of facilitating air flow throughout the air flow system.
In one embodiment, the apparatus 300 is capable of facilitating movement of the air flow out of the housing 350 at a first orientation 342. The air flow may subsequently move up the side wall 354 at a second orientation 344, followed by movement along the top wall 352 at a third orientation 346. Finally, the air flow may be redirected back into the housing 350 at a fourth orientation 348. In this instance, the four orientations 342, 344, 346, 348 are able to form a substantially circular air flow pathway within the housing 350 to facilitate cooking of the food products contained therein. Although the air flow has been disclosed as moving in a counterclockwise direction, it will be appreciated by one skilled in the art that the air flow pathway can also flow in a clockwise direction, or a combination of the two different directions as necessary depending on the design of the cooking system. Preferably, the airflow is proximate the heating elements (top and/or bottom).
In one embodiment, the apparatus 300 is a fan, which can be powered by a power supply out to an electrical outlet similar to that of the heating element 332 as discussed above. In another embodiment, the fan has a blade diameter in the range of from about 25 mm to about 125 mm. In some embodiments, the blade diameter of the fan can be less than about 200 mm, or less than about 150 mm, or less than about 100 mm, or less than about 50 mm, or less than about 25 mm. In other embodiments, the blade diameter of the fan can be greater than about 10 mm, or greater than about 35 mm, or greater than about 75 mm, or greater than about 125 mm, or greater than about 225 mm. It will be appreciated by one skilled in the art that a variety of fan blade lengths and thicknesses may be utilized in the presently disclosed cooking system. In operation, the fan is able to provide an increase of at least about 50% in volumetric capacity with greater air flow and enhanced convective heat transfer. In some instances, the increase can be at least about 10%, or at least about 20%, or at least about 30%.
FIG. 22 is a perspective view of an air flow system. In one embodiment, the top wall 352 of the housing 350 may include a plurality of apertures 360 to facilitate air flow throughout the housing 350. Furthermore, in some embodiments, additional heating elements 332 may be disposed adjacent the top wall 350 to facilitate additional heating of food products within the housing 350 as necessary. In operation, the plurality of apertures 360 may facilitate greater uniformity and/or distribution of the air flow and subsequently the heat transfer distribution throughout the housing 350 for enhanced cooking of the food products contained therein.
In some embodiments, the cooking system can include a combination of the air flow system and the heating system disclosed above. For example, the air flow system can include the addition of a heating element within the housing as shown in the figure. And like above, in one embodiment, adjacent an underside of the heating element 332 includes at least one channel 334, the channel 334 configured to receive water from a water delivery apparatus 336. In operation, water from the apparatus 336 can be delivered to the heating element 332 which can be flashed to produce steam for the housing 350. In some embodiments, the channel 334 can also receive excess water not instantaneously converted to steam by the heating element 332. In other words, the channel 334 can help to maintain the cleanliness of the housing 350 by ensuring that water not flash steamed does not buildup at the bottom of the housing 350. In addition, the removable channel 334 may also minimize, reduce or in some instances, eliminate scaling issues.
In one embodiment, the substantially circular air flow pathway helps to facilitate circulation of at least one of heat and steam within the housing 350. And like above, steam can be introduced into the housing 350 of the air flow system without the use of a boiler or steam generator.
FIGS. 23-25 are tabulated results of the improvements in cooking time and moisture with the convection oven with steam infusion according to one embodiment of the present disclosure. The results in FIG. 23 are indicative of a cooking system according to one embodiment of the present disclosure with the addition of steam to provide enhanced faster cooking times. For example, the currently disclosed cooking system is able to cook frozen lasagna in about half the time (e.g., time reduction of about 49%) as compared to a traditional convection oven without the addition of steam. In other instances, the cooking system is able to cook yellow cake with an improvement of about 11 minutes (e.g., time reduction of about 35%).
In one embodiment, the substantially circular air flow pathway, in combination with the heating system and steam generation without the use of a boiler or steam generator, can reduce the cooking time of food products by at least about 10%, in comparison to a traditional convection oven without the addition of steam. In some embodiments, the improvement in cook time may be in the range of from about 20% to about 50%, or from about 10% to about 50%, or from about 30% to about 50%, or from about 25% to about 60%. In other embodiments, the improvement in cook time may be greater than about 15%, or greater than about 20%, or greater than about 25%, or greater than about 30%, or greater than about 35%, or greater than about 50%.
FIG. 24 shows the results of a cooking system, according to one embodiment of the present disclosure with steam versus the cooking system 10 without the addition of steam. As shown by the data, cooking time within the currently disclosed cooking system can be faster with the addition of steam than without. For example, frozen lasagna can take about 90 minutes to cook using the currently disclosed cooking system without the infusion of steam, in contrast to about 80 minutes with the additional introduction of steam to the cooking system for an improvement in cooking time reduction of about 11%. Similarly, pork chop can be cooked in about 20% less time (e.g., 24 minutes with steam versus 30 minutes without steam).
FIG. 25 shows the results of a cooking system according to one embodiment of the present disclosure with steam versus the cooking system without the addition of steam. As shown by the data, moisture loss within the currently disclosed cooking system can be less with the addition of steam than without. For example, frozen lasagna can suffer a weight loss of about 38 grams using the currently disclosed cooking system without the infusion of steam, in contrast to a weight loss of about 7 grams if cooked with the additional introduction of steam to the cooking system for an improvement in weight loss reduction of about 81%. Similarly, fish can be cooked with about 26% less weight loss (e.g., 28 grams of weight loss with steam versus 38 grams of weight loss without steam).
In one embodiment, the substantially circular air flow pathway, in combination with the heating system and steam generation without the use of a boiler or steam generator, can enhance the moisture content of the food products by at least about 10%, in comparison to a traditional convection oven without the addition of steam. In some embodiments, the enhancement in moisture content may be in the range of from about 20% to about 50%, or from about 10% to about 50%, or from about 30% to about 50%, or from about 25% to about 60%. In other embodiments, the enhancement in moisture content may be greater than about 15%, or greater than about 20%, or greater than about 25%, or greater than about 30%, or greater than about 35%, or greater than about 50%.
In some instances, electronic controllers may be included with the currently disclosed cooking system for controlling the steam rate delivery (e.g., for controlling the amount of water delivered from the apparatus). In other instances electronic controllers may be utilized for controlling temperature, among other variables, to provide better uniformity and expanded functionality. For example, tighter temperature control may lead to better uniformity of the cooking products by minimizing temperature swings. In some instances, defrosting of food products can be better produced by tighter temperature control in combination with steam infusion. In other instances, the currently disclosed cooking system can be used for proofing bread or dough products, the cooking system capable of delivering a reduction in proofing time of at least about 15% for a similar dough rise at ambient temperature.
In some embodiments, the currently disclosed cooking system may also have increased capabilities including holding function (e.g., warming drawer), proofing function (e.g., low temperature control with humidity), defrost function, and the potential to toast products with the addition of toaster rack and/or pizza tray, among other functions. In other embodiments, the cooking system may defrost food products without dehydrating the same with the infusion of steam. In other words, the currently disclosed cooking system with steam infusion can accelerate the defrosting process without over-dehydrating the food products. In one example, instead of losing water defrosting (e.g., ambient air) through condensation (e.g., losing 0.5 gram of water), a piece of steak may instead gain water (e.g., gaining 2 grams of water) during defrosting (e.g., high temperature) using the currently disclosed cooking system 10.
In one aspect, rotisserie cooking enclosure 18, FIG. 2 includes motor driven gear at inner wall 14b (see also FIG. 39) and the spit assembly support framework, FIG. 5A includes drip pan 32′ and first 40a′ and second 40b′ side racks each including a spit assembly support 42a, 42b, respectively.
One spit assembly, FIG. 27 includes driven or gear wheel 70 with associated (here peripheral) teeth driven by the enclosure inside driven gear when the spit assembly and support are loaded into the oven enclosure. Gear wheel 70 includes inward bushing 52a rotatably supported on side rack support 42a, FIG. 5A. Gear wheel 70, FIG. 27 further includes center spit rod socket 65.
Handle 72′ includes inward bushing 52b rotatably supported by spit assembly support framework support 42b, FIG. 5A. These bushings could be wheels with grooves as shown or other types of members (even just a Teflon piece or portion) depending on the design of the spit assembly supports which may also vary in design. Attached to handle 72′ through bushing 52b is yoke 61 supporting central spit rod 60 (here square in cross section) having a distal sharpened end received in inward socket 65 of gear wheel 70 and side (here round) spit rods 98′ and 98b′ which extend about ¾-⅞ of the length of center spit rod 60 and then terminate in sharpened ends. FIG. 28 show the handle yoke and spit rod subassembly removed from the gear wheel for loading an item to be cooked and the like.
One optional accessory is basket 400, FIGS. 29-30 with left side bushing 402 rotatably supported in the spit assembly framework support (42b, FIG. 5A). The right side of basket 400 includes axle 404, FIG. 30 received in inward socket 65, FIG. 29 of gear wheel 70. Gear wheel 70 inward bushing 52b is rotatably supported in the other spit assembly framework support (42a, FIG. 5A) and food can be loaded into the basket and rottiseried in the oven cavity. Gear wheel 70 is thus more versatile than in some prior art rotisserie ovens.
Basket lid 406 is preferably adjustable up and down with respect to basket container 408. In this particular design, lid 406 includes retractable side tabs 410a and 410b biased outward and received in container sidewall slots such as slots 412. Tab 410a is connected to movable wire tab finger member 414a and tab 410b is connected to movable wire tab finger member 414b. Urging members 414a and 414b together withdraws tabs 410a and 410b out of their respective basket container slot (412) and releasing members 414a and 414b registers each tab in a side wall slot to reposition lid 406 up or down depending on the size and/or configuration of the food loaded into container basket 400.
FIG. 31 shows tumbler cage 420 as another possible accessory rotatably supported by the spit assembly center 60 and side spit rods 98a and 98b. Gear wheel 70, FIG. 27 is not shown. Cage 420 includes top basket 422a hingedly attached to bottom basket 422b, FIGS. 32-34 and releasably secured together via outer clasp 424. The sides of each basket portion, where they join together when closed, form center opening (see opening 426, FIG. 33) for the center spit rod. Top basket portion 422a also includes side opening 428 for one side spit rod and bottom basket 422b includes side opening 430 for the other side spit rod. There may be similar openings on the other side of the tumbler cage.
Also included are removable dividers 432a and 432b for the top and bottom basket portions 422a and 422b, respectively. FIG. 34 best shows the retaining channels 434a-434c inside upper basket portion 422 for removably positioning a divider therein. In this way, the internal configuration of the tumbler cage can be reconfigured from fully open (with both dividers removed), divided into two compartments (with both dividers installed), or a partial compartment (with only one divider installed).
FIGS. 35-36 show kabob assembly 450 also rotatably supported by the spit assembly. First 452a and second 452b kabob rims are joined by hollow axle 454 which receives the center spit rod therethough. Kabob rods 456 are removably coupled to kabob rims 452a and 452b as shown. In this specific design, rim 452b includes circumferential holes 458 for the distal end of the kabob rods and rim 452a includes circumferential slots 460a for the head end of the kabob rods which here includes spring loop 464 removably retained in the slot edges. FIG. 36 shows the kabob assembly 450 loaded on to the spit assembly where the side spit rods are received through cut outs in one kabob rim.
FIGS. 37-38 depict an example of a trussing system with cables 480a and 480b connected to bar 482. Each cable includes an end member 484a (e.g., a ball or a hook or the like) and multiple links 486a releasably receiving the end member therein for varying the diameter of the trussing as shown in FIGS. 38A-39B depending on the size of the food product to be rotisseried and/or the location of the trussing as applied to the food product. In FIG. 38A, each end member is releasably locked in the third cable loop resulting in a smaller diameter trussing. In FIG. 38B, the end member is releasably locked in the last loop resulting in a larger diameter trussing.
FIG. 39 shows oven enclosure 18′ with infrared heater 500 in the top rear of the enclosure. Also shown are conventional resistance heaters 502a-502d (two near the top and two near the bottom). Stainless steel guard 508, FIG. 40 may surround infrared heater 500 and shield/reflector assembly 510 may also be included.
Preferably, when selector 12a, FIG. 41 is rotated to the rotisserie function, the infrared heater and the driven rotisserie gear motor are automatically turned on. Resistance heater element 502a may also be turned on automatically. Heaters 502b, 502c, and 502d are preferably left off in the rotisserie mode.
FIG. 42 shows drive gear motor 512 (which powers gear 78, FIGS. 2 and 39) connected to power supply 514 through relay 516 which also connects power supply 514 to infrared heater element 500. Thus, the infrared heater is electrically connected in parallel with the driven gear motor relay. In this way, when the rotisserie function is selected, relay 516 is closed and infrared heater element 500 is automatically turned on with motor 512 which drive (rotates) the spit assembly gear wheel (70, FIG. 27) and the food product or products mounted thereon. Preferably, when another function is selected, (e.g., toasting), relay 516 opens and the infrared heater 500 and motor 512 are automatically turned off.
As noted previously, the rotisserie oven preferably includes a steam source as discussed above with respect to FIGS. 12-20. Selecting the rotisserie function may also automatically energize the steam source.
Moreover, infrared heater 500, FIG. 39-40 may be selected such that it has a peak emission wavelength readily absorbed by steam inside the oven enclosure. One result is less heating of the drip pan (32′, FIG. 5A) and thus less charring of food drippings captured by the drip can and also less smoke in the oven enclosure. Better quality steam may also be produced.
In one example, a quartz infrared element with a peak wavelength at ˜3 μm corresponds to a wavelength which is readily absorbed by water. Little smoking was observed in the oven cavity during a rotisserie test of chicken. A halogen infrared heater element, in contrast, has a peak wavelength at ˜1 μm which is a wavelength not readily absorbed by water. More smoke was observed during a similar rotisserie test using a halogen element. Moreover, the quartz infrared heater element also produced a large amount of visible light which enabled the user to more easily view the progress of the cooking food product.
FIG. 43 shows the spit assembly loaded onto the spit assembly support framework and side rack 40b with locking mechanism 602 releasably locking the side rack to drip pan 32. In this particular example, the locking mechanism includes lever 604 with catch 606 engageable with drip pan slot 608 in side rail 610 of drip pan 32. The other side rack is typically configured the same way. Lever 604 may have a ball 612 and side rack 40b may have a detent 614 (see FIG. 44) serving as a mechanism to hold lever 604 in place with respect to the side rack in the locked position. In this way, the side racks can be decoupled from the drip pan for shipping, cleaning, and the like but secured in a reliable fashion thereto when needed using the locking mechanism or a similar locking mechanism. Side rack 40b may further include a tab 618 received in side rack 40b slot 620. Both drip pan 32 and side rack 40b include a cut out 620, 622, respectively, in this particular example, for clearance of drive wheel 70, FIG. 43.
In the design of FIGS. 45-47, drive gear 78 may move slightly from a forward load position shown in FIG. 45 as drip pan 32 is partially loaded into oven 10 but the front corners have not yet dropped down behind step 23 in the side tacks as shown for side track 26a′. In FIG. 45, drip pan 32 is fully loaded and registered with the interior of oven 10 and drive gear 78 has moved reward. Drive gear 78 is biased in the more forward load position so the drive gear engages the driven wheel 70 of the spit assembly during drip pan loading and remains biased against the driven spit assembly wheel during rotisserie operations to ensure engagement between the drive gear and the driven wheel. As discussed before, the drip pan is configured such that when it is fully loaded in the interior of the oven and the oven door is closed, the drip pan registers in the oven and does not move with respect to the interior of the oven. If a front step is included in the opposing side tracks, the oven door can be opened and still the drip pan remains fixed in place. The rear of the drip pan (e.g. 44b, FIG. 43) may engage the rear wall of the oven. To remove the drip pan, the door is opened and the front of the drip pan is lifted slightly. The drip pan can then be slid out of the oven enclosure.
To facilitate the moving slideable drive gear, motor M in FIG. 47 is connected to drive gear 78, FIGS. 46-47 and is mounted in an articulating fashion on the outside of the oven interior wall using bracket 630 which pivots about pivot point 632 with respect to base bracket 634 but is biased forward via a coil spring (not shown). Motor M can thus be pushed 8 mm rearward and forward but its home biased position is forward. In this way the drip pan is loadable into the cooking oven enclosure so that driven wheel engages the drive gear in its load position and the drip pan then registers in the oven with the driven wheel forcing the drive gear to its home position and in that position biased against the spit assembly driven wheel.
Although specific features of the invention are shown in some drawings and not in others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention. The words “including”, “comprising”, “having”, and “with” as used herein are to be interpreted broadly and comprehensively and are not limited to any physical interconnection. Moreover, any embodiments disclosed in the subject application are not to be taken as the only possible embodiments.
In addition, any amendment presented during the prosecution of the patent application for this patent is not a disclaimer of any claim element presented in the application as filed: those skilled in the art cannot reasonably be expected to draft a claim that would literally encompass all possible equivalents, many equivalents will be unforeseeable at the time of the amendment and are beyond a fair interpretation of what is to be surrendered (if anything), the rationale underlying the amendment may bear no more than a tangential relation to many equivalents, and/or there are many other reasons the applicant can not be expected to describe certain insubstantial substitutes for any claim element amended.
Other embodiments will occur to those skilled in the art and are within the following claims.
Patent Application
20140216271
