U.S. patent application number 11/366061 was filed with the patent office on 2007-09-06 for grill rack and method.
This patent application is currently assigned to KFC CORPORATION. Invention is credited to Lonita Barron, Mauriee E. Edwards, Eric S. Elwell, Michael E. Harlamert, Esther Chui Lian Ang, John C. Murray, Paul Shuter.
Application Number | 20070204856 11/366061 |
Document ID | / |
Family ID | 38470419 |
Filed Date | 2007-09-06 |
United States Patent
Application |
20070204856 |
Kind Code |
A1 |
Elwell; Eric S. ; et
al. |
September 6, 2007 |
Grill rack and method
Abstract
Food products are characterized by grill markings, wherein the
grill markings are generated by a simulated grilling process. The
simulated grilling process includes maintaining a food item on a
grill rack, the grill rack including a plurality of substantially
solid rods, each of the plurality of rods being substantially
parallel to, and laterally spaced from, an adjacent rod to define a
plurality of spaces between the plurality of rods. The plurality of
rods each define a substantially flat top surface and include a
non-stick coating over the substantially flat top surfaces. The
process also includes disposing the food product as maintained on
the plurality of rods in a convection oven. The oven is
convectively heated at or above about 400 degrees F such that the
plurality of rods impart the grill markings on the food product,
the grill markings being substantially darker than surrounding
portions of the food item.
Inventors: |
Elwell; Eric S.;
(Shepherdsville, KY) ; Lian Ang; Esther Chui;
(Louisville, KY) ; Barron; Lonita; (New Albany,
IN) ; Edwards; Mauriee E.; (Louisville, KY) ;
Harlamert; Michael E.; (Louisville, KY) ; Murray;
John C.; (Louisville, KY) ; Shuter; Paul;
(Louisville, KY) |
Correspondence
Address: |
STITES & HARBISON, PLLC
400 W MARKET ST
SUITE 1800
LOUISVILLE
KY
40202-3352
US
|
Assignee: |
KFC CORPORATION
|
Family ID: |
38470419 |
Appl. No.: |
11/366061 |
Filed: |
March 2, 2006 |
Current U.S.
Class: |
126/337R |
Current CPC
Class: |
F24C 15/16 20130101 |
Class at
Publication: |
126/337.00R |
International
Class: |
F24C 15/16 20060101
F24C015/16 |
Claims
1. A grill comprising: a border defining a bottom surface and
forming an outer perimeter and an interior; a plurality of cross
members secured to the border, each of the plurality of cross
members: being solid, substantially parallel, and laterally spaced
from an adjacent cross member, defining a bottom surface and a
substantially planar top surface, protruding above the border, and
spanning the interior of the border in a first direction; and a
plurality of support members secured to the border, each of the
plurality of support members: being solid, substantially parallel,
and laterally spaced from an adjacent support member, defining a
bottom surface and a top surface, and spanning the interior of the
border in a second direction to intersect with at least one of the
plurality of cross members; wherein the grill is formed
substantially continuously, as a single piece, of a substantially
thermally conductive material, and such that the bottom surface of
the border, the bottom surface of the plurality of cross members,
and the bottom surface of the plurality of support members are
substantially coplanar.
2. The grill of claim 1, wherein each of the plurality of cross
members defines a quadrilateral shape in transverse cross
section.
3. The grill of claim 1, wherein each of the plurality of cross
members tapers in width from the bottom surface of each of the
plurality of cross members to the top surface of each of the
plurality of cross members.
4. The grill of claim 1, wherein the border, the plurality of cross
members, and the plurality of support members are formed of
aluminum alloy.
5. The grill of claim 1 further comprising: a coating formed over
the top surface of each of the plurality of cross members, the
coating including a fluoropolymer-based coating.
6. The grill of claim 1, wherein the border comprises: a first side
member; a second side member extending substantially parallel to
and opposed to the first side member; a first end member extending
orthogonally to and between the first and second side members; and
a second end member extending substantially parallel to and opposed
to the first end member; wherein the first direction at which the
plurality of cross members span the interior of the border is
disposed at an angle of about 45 degrees relative to each of the
first and second side members.
7. The grill of claim 6, wherein each of the plurality of cross
members extends orthogonally relative to each of the plurality of
support members.
8. A method of simulated grilling in an oven comprising: supporting
a food item on a rack including a plurality of bars, each of the
plurality of bars extending substantially parallel to, and
laterally spaced from, an adjacent bar and defining a substantially
flat top surface, wherein the food item is supported on the top
surfaces of the plurality of bars; disposing the rack and the food
item in a convection oven; and convectively heating the oven at or
above about 400 degrees F. to impart darkened grill markings on the
food item with the rack, wherein the darkened grill markings are
imparted free of actual grilling and substantially correspond to
lines of contact between the plurality of bars and the food
item.
9. The method of claim 8, further comprising: removing the food
item from the rack after convectively heating the rack with the
rack being substantially free of portions of the food item sticking
to the rack.
10. The method of claim 8, wherein the food item comprises meat
including muscle fiber, and skin covering the muscle fiber, and
further wherein the method further comprises: imparting the
darkened grill markings into the skin and the muscle fiber.
11. The method of claim 8, wherein the food item includes lipids
and the method further comprises: releasing the lipids from the
food item; and substantially preventing the released lipids from
collecting on the top surfaces of the plurality of bars.
12. The method of claim 11, further comprising: engendering a smoke
flavor in the food item by generating smoke from the released
lipids.
13. The method of claim 12, wherein engendering a smoke flavor in
the food item is generated entirely by the released lipids such
that the method is characterized by the absence of chemical or
artificially introduced smoke flavoring.
14. The method of claim 8, wherein imparting the darkened grill
markings is characterized by the absence of frying the food
item.
15. The method of claim 8, including convectively heating the rack
to a temperature where protein charring is initiated.
16. The method of claim 8, wherein imparting the darkened grill
markings is characterized by the food item being free of
artificially introduced coloring agents.
17. A food product characterized by grill markings, wherein the
grill markings are generated by a simulated grilling process
including: maintaining a food product on a grill rack including a
plurality of substantially solid rods, each of the plurality of
rods being substantially parallel and laterally spaced from an
adjacent rod and defining a substantially flat top surface, wherein
each of the rods includes a non-stick coating over the top surfaces
of the rods; disposing the food product as maintained on the
plurality of rods in a convection oven; convectively heating the
oven at or above about 400 degrees F such that the plurality of
rods impart the grill markings on the food product, the grill
markings being substantially darker than surrounding portions of
the food product.
18. The food item of claim 17, wherein the food item is
chicken.
19. A grill comprising: a frame defining a bottom surface and
forming a substantially rectangular outer perimeter and an
interior, the frame including a first side member, a second side
member opposing the first side member, a first end member, and a
second end member opposing the first end member; a plurality of
rods secured to the frame, each of the plurality of rods: being
solid, substantially parallel, and laterally spaced from an
adjacent rod, defining a bottom surface and a substantially planar
top surface, protruding above the border, and spanning the interior
of the border; and a first support member and a second member, each
of the support members: being solid, substantially parallel, and
laterally spaced from an adjacent support member, defining a bottom
surface and a top surface, residing below the top surfaces of the
plurality of rods, intersecting with at least one of the plurality
of rods, wherein the first support member extends from the first
end member of the frame to the first side member of the frame
across the interior of the border and the second support member
extends from the second side member of the frame to the second end
member of the frame across the interior of the border; wherein the
grill is formed substantially continuously, as a single piece, of a
substantially thermally conductive material.
20. The grill of claim 19, wherein each of the plurality of rods
includes a protective, non-stick coating disposed over the top
surfaces of each of the plurality of rods.
Description
BACKGROUND OF THE INVENTION
[0001] People around the world are familiar with the taste of
flame-grilled foods. The smokey flavor, the texture, and the grill
markings, among other attributes, contribute to a person's
perception that food has been grilled on an open flame or charcoal.
For example, meat products like chicken or steak are often
associated with grilled preparation. However, at times it can be
less desirable to actually grill on an open flame or charcoal.
Alternative cooking methods, such as convective baking, for
example, are often selected over open-flame or charcoal grilling as
easier, less expensive, safer, or for other reasons.
[0002] To accomplish the appearance, taste, and/or texture of
grilling, various chemical coloring agents and/or chemical smoke
additives have been used in combination with baking processes in an
effort to reproduce the attributes of grilled foods. Unfortunately,
the taste, texture, and/or appearance achieved with such techniques
are readily discernible from those otherwise associated with
grilled foods.
SUMMARY OF THE INVENTION
[0003] One embodiment of the present invention relates to food
products characterized by grill markings, wherein the grill
markings are generated by a simulated grilling process. The
simulated grilling process includes maintaining a food item on a
grill rack, the grill rack including a plurality of substantially
solid rods, each of the plurality of rods being substantially
parallel and laterally spaced from an adjacent rod to define a
plurality of spaces between the plurality of rods. The plurality of
rods each defines a substantially flat top surface with a non-stick
coating over the top surfaces. The process also includes disposing
the food product as maintained on the plurality of rods in a
convection oven. The oven is convectively heated at or above about
400 degrees F. such that the plurality of rods impart the grill
markings on the food product, the grill markings being
substantially darker than surrounding portions of the food
item.
[0004] While some aspects of the invention have been described
above, other related products and methods are also disclosed and
provide additional advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Embodiments of the invention will be described with respect
to the figures, in which like reference numerals denote like
elements, and in which:
[0006] FIG. 1 is a perspective view of a grill, according to an
embodiment of the present invention;
[0007] FIG. 2 is a top view of the grill of FIG. 1, according to an
embodiment of the present invention;
[0008] FIG. 3 is a bottom view of the grill of FIG. 1, according to
an embodiment of the present invention;
[0009] FIG. 4 is an enlarged cross-sectional view along line 4-4 of
FIG. 2, according to an embodiment of the present invention;
[0010] FIG. 5 is an enlarged cross-sectional view along line 5-5 of
FIG. 2, according to an embodiment of the present invention;
[0011] FIG. 6 is an enlarged cross-sectional view along line 6-6 of
FIG. 2, according to an embodiment of the present invention;
[0012] FIG. 7 is a side view of the grill of FIG. 1, according to
an embodiment of the present invention;
[0013] FIG. 8 is a front view of the grill of FIG. 1, according to
an embodiment of the present invention;
[0014] FIG. 9 is a diagram of a method using the grill of FIG. 1,
according to an embodiment of the present invention;
[0015] FIGS. 10-12 are illustrative of a method of baking,
according to an embodiment of the present invention; and
[0016] FIG. 13 is a top view of a grilled food item, according to
an embodiment of the present invention.
DETAILED DESCRIPTION
[0017] In the following detailed description, reference is made to
the accompanying drawings which form a part hereof, and in which is
shown by way of illustration specific embodiments in which the
invention may be practiced. In this regard, directional
terminology, such as "top," "bottom," "front," "back," "leading,"
"trailing," etc., is used with reference to the orientation of the
Figure(s) being described. Because components of embodiments of the
present invention can be positioned in a number of different
orientations, the directional terminology is used for purposes of
illustration and is in no way limiting. It is to be understood that
other embodiments may be utilized and structural or logical changes
may be made without departing from the scope of the present
invention.
[0018] For reference, actual grilling, or natural grilling, is a
dry-heat cooking method whereby heat is radiated from below and
transferred to a metal grid supporting food to be grilled. Actual
grilling is often accomplished over an open flame and/or charcoal
heat source and at a relatively high temperature, with food in
relatively close proximity to the heat source. Embodiments of the
present invention generally address methods of simulated grilling
using convection-type ovens as opposed to the traditional radiant
heat cooking associated with open flame and/or charcoal heating,
for example.
[0019] FIG. 1 shows a grill 20, which is otherwise described as a
rack, a grill rack, a cooking utensil, or a baking framework, for
example. Generally speaking, the grill 20 includes a border 22,
also described as a frame, a racking portion 24, a backing portion
26, and a plurality of legs 28. As will be described in greater
detail below, the grill 20 is generally used in a baking operation,
or baking process, to simulate open-flame grilling.
[0020] FIG. 2 illustrates the grill 20 from a top view. With
reference to FIG. 2, the border 22 includes a plurality of frame
members, for example a first side member 30, a second side member
32, a first end member 34, and a second end member 36. The border
22 defines an interior 38 centrally located relative to the first
and second side members 30, 32, and the first and second end
members 34, 36. The border 22 also defines an inner surface 40
(FIG. 3) proximate the interior 38, a top surface 42, a bottom
surface 44 (FIG. 3), and a thickness between the top and bottom
surfaces 42, 44.
[0021] The first and second side members 30, 32 are optionally
substantially parallel and laterally opposed to one another. In
turn, the first and second end members 34, 36 are also optionally
substantially parallel and laterally opposed to one another. The
first and second side members 30, 32 extend orthogonally to the
first and second end members 34, 36, such that the border 22
defines a substantially rectangular outer profile, if desired.
However, it should be noted that other outer profiles are also
contemplated, for example circular outer profiles. The border 22 is
optionally formed substantially continuously as a single piece.
However, separate, connected components are also contemplated. The
outer profile of the border 22 defines a width of about 29.5 cm and
a length of about 41 cm, for example. In particular, the border 22
is optionally sized and shaped to fit into an industry-standard
half-size sheet pan or other pan.
[0022] The racking portion 24 includes a plurality of cross members
50, also described as bars, rods, or lattice members. Each of the
plurality of cross members 50 is substantially solid and
continuously formed with the border 22. The plurality of cross
members 50 extend in a first direction D.sub.1 to span the interior
38 of the border 22 with each of the plurality of cross members 50
optionally laterally spaced and substantially parallel to an
adjacent cross member. Each of the plurality of cross members 50
spans the interior 38 of the border 22 at about 45 degrees,
although other angles are contemplated.
[0023] FIG. 4 illustrates a portion of a cross-section of the grill
20 along line 4-4 shown in FIG. 2. With reference to FIG. 4, each
of the plurality of cross members 50 projects vertically above top
surface 42, and is substantially coplanar with the bottom surface
44 of the border 22. For reference, individual features of each of
the plurality of cross-members 50 are described in greater detail
below with reference to a cross member 50a of the plurality of
cross members 50, as each of the plurality of cross members 50
optionally includes substantially similar features to those
described in association with the cross member 50a.
[0024] For example, the cross member 50a defines a top surface 54
and a bottom surface 56. In turn, all of the plurality of cross
members 50 define top surfaces 54 and bottom surfaces 56
substantially similar to the top surface 54 and the bottom surface
56 of the cross member 50a. With such similarity in mind, the cross
member 50a also defines a width at the top surface 54, a width at
the bottom surface 56, a projection height H.sub.P relative to the
border 22, and an overall height H.sub.O. The cross member 50a also
defines a centerline C.sub.1, and optionally has rounded top
corners 58, 60. In transverse cross-section, the cross member 50a
is substantially trapezoidal, tapering in width from the bottom
surface 56 to the top surface 54 at a taper angle .alpha..
[0025] Use of such tapering optionally enhances convective heat
transfer to the cross member 50a by increasing surface area at the
bottom surface 56 while heat transfer from the cross member 50a is
directed to, and ultimately from, a smaller surface area at the top
surface 54. For example, a smaller surface area at the top surface
54 facilitates simulated grilling by reducing frying effects from
trapped lipids or other fats, greases or oils at the top surface 54
and by directing heat to a smaller surface of a food item to be
"grilled." Such frying effects result in markings on the food item
that are lighter or otherwise discolored, rather than darker marks
traditionally associated with grilling. It is also contemplated
that the cross member 50a defines other transverse cross-sections
including, for example, square or triangular cross-sections.
Additionally, both of the top surface 54 and the bottom surface 56
are substantially planar, though other surface shapes are
contemplated, for example pointed or rounded.
[0026] Referring again to FIGS. 2 and 3, the backing portion 26
includes a first support member 70 and a second support member 72.
The first and second support members 70, 72 are substantially solid
and project from the inner surface 40 of the border 22 across the
interior 38 of the border 22. Each of the first and second support
members 70, 72 is optionally substantially parallel to the other.
Additionally, the first and second support members 70, 72 are also
laterally spaced from the other. While the plurality of cross
members 50 extend in the first direction D.sub.1, the first and
second support members 70, 72 optionally extend in a second
direction D.sub.2 across the interior 38 relative to the first
direction D.sub.1.
[0027] The first and second directions D.sub.1, D.sub.2 are
optionally substantially orthogonal, such that the first and second
support members 70, 72 extend orthogonally relative to the
plurality of cross members 50. However, it is contemplated that the
first and second support members 70, 72 and the plurality of cross
members 50 define a variety of other angles. By disposing the first
and second support members at an angle to the plurality of cross
members 50, the grill 20 is provided additional structural support
without otherwise using a solid backing. This, in turn, reduces
weight as well as a thermal mass of the grill 20 allowing for
easier handling, faster heating, and/or faster cooling of the grill
20.
[0028] FIG. 5 illustrates a portion of a cross-section of the grill
20 along line 5-5 shown in FIG. 2. In particular, with reference to
FIG. 5, a cross-section of the first support member 70 is shown in
greater detail. For reference, individual features of each of the
first and second support members 70, 72 are described with
reference to the first support member 70, as each of the first and
second support members 70, 72 optionally include substantially
similar features.
[0029] In particular, the first support member 70 defines a top
surface 76 and a bottom surface 78, a centerline C.sub.2, a width
W.sub.TS at the top surface 76, a width at the bottom surface 78,
and an overall height H.sub.OC at the centerline C.sub.2. The first
support member 70 is substantially trapezoidal in transverse cross
section, tapering in width from the bottom surface 78 to the top
surface 76 at a taper angle .beta.. Use of such tapering optionally
enhances overall structural integrity of the grill 20 while
reducing overall weight. For example, the bottom surface 78 is
sufficiently wide to reduce bending of the grill 20, but tapers to
the top surface 76 to reduce a volume of the first support member
70, and therefore overall weight. The top surface 76 is optionally
substantially flat, rounded, or angled, for example. By including a
non-flat top surface 76, the first support member 70 optionally
reduces frying effects such as those referenced above by reducing
pooling of greases or other lipids on the top surface 76.
[0030] With reference to FIGS. 2, 3, and 5, the first and second
support members 70, 72, the plurality of cross members 50, and the
border 22 are optionally substantially continuously formed as a
single piece. However, separate, connected components are also
contemplated. Regardless, the plurality of cross members 50, the
support members 70, 72, and the border 22 intersect to define a
plurality of spaces 86 through the grill 20. Each of the plurality
of spaces 86 defines a length, with lengths of each space varying
from space to space. Each of the plurality of spaces 86 defines a
width, for example the same width as the other spaces. As shown
more clearly in FIG. 3, each of the plurality of spaces 86
optionally has rounded ends 88.
[0031] With reference to FIGS. 3 and 5, the bottom surface 78 of
the first support member 70 is coplanar with the bottom surface 56
of the cross member 50a. Additionally, the bottom surface 44 of the
border 22 is coplanar with the bottom surface 78 of the first
support member 70, as well as the bottom surface 56 of the cross
member 50a. The second support member 72 and a remainder of the
plurality of cross-members 50 also define coplanar bottom surfaces
with the bottom surface 44 of the border 22. In this manner, the
racking portion 24 and the backing portion 26 are optionally
substantially coplanar with the bottom surface 44 of the border 22.
In turn, the plurality of cross-members 50 of the racking portion
24 optionally protrude above the border 22 and the backing portion
26, with the top surfaces 54 of the plurality of cross members
defining a greater height than the border portion 22 and the
backing portion 26.
[0032] FIG. 6 shows several intersections between the plurality of
cross members 50 and the first support member 70 along the
centerline C.sub.2 of the first support member 70. In particular,
FIG. 6 illustrates a portion of a cross-section of the grill 20
along line 6-6 shown in FIG. 2. With reference to FIG. 6, the cross
member 50a and the first support member 70 are optionally fluidly
formed, smoothly transitioning into one another. With reference to
FIG. 4, the border 22 and the plurality of cross-members 50 are
also optionally fluidly formed together, smoothly transitioning
into one another. In particular, various intersections between the
first and second support members 70, 72, the plurality of cross
members 50, and the border 22 include fillets or are otherwise
rounded.
[0033] With reference to FIG. 3, the plurality of legs 28a-28d are
shown. In general terms, each of the plurality legs 28 projects
from bottom surface 44 of the border 22. Each of the plurality of
legs 28 is substantially continuously formed with the border 22 as
a single piece. However, separate, connected pieces are also
contemplated. Additionally, each of the plurality of legs 28 is
optionally spaced, or inset from the outer perimeter defined by the
border potion 22.
[0034] FIGS. 7 and 8 illustrate the grill 20 from side and front
views, respectively. With reference to FIGS. 7 and 8, the plurality
of legs 28, including legs 28a-28d, are optionally substantially
similar to the leg 28a, and are described cumulatively in
association with the leg 28a. Generally, the leg 28a defines a
centerline M, a top end 90 and a bottom end 92. More specifically,
when viewed in side profile as shown in FIG. 7, the leg 28a is
optionally bell-shaped, with the top end 90 being substantially
flat and the bottom end 92 being substantially rounded from the
side profile. The leg 28a also defines a height which is optionally
selected to support a food item being grilled a desired height
above a surface on which the grill 20 is resting. For example, the
grill 20 is optionally resting on a pan (not shown), such as an
industry-standard half-size sheet pan, for catching lipids or other
greases, fats, or oils (sometimes described as renderings) dripping
from food items. The height is optionally selected to ensure
sufficient heat transfer to the grill 20, or otherwise allow hot
air to flow under the grill 20 (and over any optional pan) as
desired.
[0035] Additionally, where oils, greases, or other lipids collect
or otherwise drop onto the surface on which the grill 20 is
resting, for example the pan, the height of the leg 28a is
optionally selected to reduce or prevent splattering of such
substances onto the food item being grilled to reduce discoloration
or other undesirable effects. The height of the leg 28a is about 3
cm, for example, with the food item supported at about 3.8 cm above
the surface on which the grill 20 is resting, although other
dimensions are contemplated. Additionally, in side profile, the top
end 90 defines a maximum width of about 3.43 cm, curves toward the
bottom end 92 at a radius of about 4.5 cm, and is rounded at the
bottom end 92 at a radius of about 0.7 cm. However, other
dimensions are also contemplated.
[0036] The grill 20 is optionally substantially continuously formed
as a single piece, including the border 22, the racking portion 24,
the backing portion 26, and the legs 28. The grill 20 is optionally
formed of metal, and in particular aluminum, including aluminum
alloys such as those amenable to high pressure casting
manufacturing techniques. While materials for the grill 20 are
selected as desired and in light of a particular application,
metals such as aluminum alloys, having a relatively high thermal
conductivity, are well-suited for some simulated grilling
operations with the grill 20, as will be described in greater
detail below.
[0037] The grill 20, or portions thereof, optionally includes a
non-stick and/or protective coating (not shown). Acceptable
coatings include non-stick, oilophobic, and hydrophobic coatings
suitable for temperature ranges for simulated grilling, such as
fluoropolymer-based coatings. The coating is optionally formed over
the plurality of cross members 50 or over a portion of each of the
plurality of cross members 50, for example the top surfaces 54 of
the plurality of cross members 50 as desired. However, the coating
is also optionally formed over an entirety of the grill 20, for
example to promote cleanability of the grill 20 and to provide a
more uniform coating surface.
[0038] With reference to FIG. 9, a method 200 of baking a food item
300 (FIG. 10), also described as a food product, or a plurality of
food items 302 (FIG. 10), in a simulated grilling system 350
including an oven 400 (FIG. 12) and a grill 20, is described below.
The method 200 optionally includes a food item preparation step
220, a baking step 230, and a post-processing step 240.
[0039] By way of background, the food item 300 and/or the plurality
of food items 302 optionally includes a variety of different foods.
For example, the plurality of food items 302 are optionally
protein-based or meats. In particular, each of the plurality of
food items 302 is optionally chicken including a skin (not shown)
and muscle fiber (not shown) covered by the skin. The plurality of
food items 302 optionally include natural lipids, such as fats or
oils. Where the plurality of food items 302 are chicken, for
example, each of the plurality of food items 302 optionally defines
a bone side, or a back side, and a skin side, or a front side.
[0040] The food item preparation step 220 includes arranging the
plurality of food items 302 on a rack 20a.With reference to FIG.
10, the plurality of food items 302 are brought to a table or other
suitable surface and placed on a rack 20a. The rack 20a is
optionally substantially similar to the grill 20, but it is also
contemplated that other types of grills, trays, and/or other
implements are used during the food item preparation step 220.
Excess fat, skin, or other identified portions of the plurality of
food items 302 are optionally trimmed and/or removed as desired.
Where the food item 300 or the plurality of food items 302 includes
skin, the skin is optionally smoothed. Such smoothing helps prevent
the plurality of food items 302 from drying out during baking and
also covers the muscle tissue to enhance visibility and/or
impartation of grill markings on the food items 302.
[0041] The plurality of food items 302 are spaced out and arranged
as desired on the rack 20a with the skin side facing up. Seasoning
mix (not shown) is applied over the plurality of food items 302
with any excess seasoning optionally dropping through the rack
20a.
[0042] With reference to FIG. 11, the plurality of food items 302
are flipped individually or together. For example, the plurality of
food items 302 are optionally flipped by sandwiching the plurality
of food items 302 between the grill 20 and the rack 20a and
flipping both the grill 20 and the rack 20a. In particular, the
grill 20 is optionally placed onto the plurality of food items 302,
for example over the meat side 306, to sandwich the plurality of
food items 302 between the rack 20a and the grill 20. Rather than
the grill 20, another rack, tray, or other implement is optionally
used if desired. Regardless, with a sandwiched configuration, the
operator grasps the rack 20a and the grill 20 and flips the rack
20a and the grill 20 over so that the plurality of food items 302
are supported on the grill 20, for example on the top surfaces 54
with the skin side down.
[0043] The rack 20a is optionally removed from the bone side of the
plurality of food items 302 before the seasoning mix (not shown) is
optionally applied over the plurality of food items 302 with any
excess seasoning dropping through the grill 20, for example through
the plurality of spaces 86. While one manner of seasoning is
described above, the plurality of food items 302 are seasoned on
separate and/or different types of racks, trays, or in other
manners as desired.
[0044] Following seasoning, the plurality of food items 302 are
optionally stored on the grill 20, or otherwise. For example, the
plurality of food items 302 are placed in a cooler, covered to
prevent drying, and marked with a discard time if desired. The
plurality of food items 302 need not be stored and optionally
proceed directly to the baking step 230.
[0045] With reference to FIG. 12, the baking step 230 includes
preparing an oven 400, loading the oven 400 with the plurality of
food items 302, baking the plurality of food items 302, and
removing the plurality of food items 302 from the oven 400. The
oven 400 is optionally a forced convection oven adapted to
convectively heat an interior 402 of the oven 400. Use of an oven,
such as the oven 400, for simulated grilling is advantageous in
many respects. For example, the high thermal conductivity and/or
low thermal mass of an embodiment of the grill 20 allow the
simulated grilling process to be optionally batch continuous. In
other words, grills and food items are optionally added to those
already baking in the oven 400 at any time without stopping the
baking process. Such batch continuity is advantageous from the
standpoint of labor savings. Additionally, by departing from
conventional grilling and moving to a simulated grilling process in
an oven, environmental impact in restaurant or other cooking area
is improved and a more controlled process is facilitated.
[0046] Preparing the oven 400 includes bringing the oven to a
desired temperature. For example, the temperature is optionally at
or above about 400 degrees F. or other appropriate temperature
where for example a protein charring process will begin for a
particular type of food item. However, it should be understood that
other temperatures are also acceptable in embodiments of the
method, including embodiments addressing simulated grilling of
non-meat food items.
[0047] The plurality of food items 302 are optionally taken to the
oven 400 on the grill 20 for loading. A plurality of grills
maintaining food items are optionally loaded into the oven 400, if
desired. Although the plurality of food items 302 are shown
supported on top of the grill 20, it should also be understood that
the grill 20 is optionally placed on top of the plurality of food
items 302 to impart the grill markings, or that the grill 20 is
placed below the plurality of food items 302 with a second grill on
top of the plurality of food items 302 to impart grill markings on
both sides of the plurality of food items 302.
[0048] Regardless, the plurality of grills are optionally
substantially similar to the grill 20 and a desired number, for
example between one and five, or another number, are loaded into
the oven 400. In particular, each of the plurality of grills is
optionally supported on a pan (not shown) for catching lipids or
other greases, oils, or fats dripping from the plurality of food
items 302. If desired, a baking sheet liner appropriate for a
selected baking temperature is optionally placed in each of the
pans to facilitate cleaning of the pans following the baking
process. Where the plurality of food items 302 include chicken, for
example, the oven 400 is optionally loaded grill-by-grill from
top-down. Following loading, the oven 400 is closed and a timer or
other alarm is optionally set to alert the operator or others when
a baking cycle has ended.
[0049] The oven 400 is set to heat the interior 402 of the oven to
a temperature at or above about 400 degrees F., at or above about
425 degrees F., at or above about 450 degrees F., at or above about
475 degrees F. or at any range or temperature implied by those
specifically identified above, for example between about 425
degrees F. and about 475 degrees F. Each of the plurality of food
items 302 is optionally heated through to at least about 165
degrees F. or higher during baking, although other temperatures are
also contemplated, to meet food safety or other regulations.
Additionally the plurality of food items 302 are baked for between
about 20 to about 30 minutes and at or above about 400 degrees
Fahrenheit, or other appropriate temperature, for example to begin
a charring process with the plurality of food items 302. It should
also be understood that other times and temperatures are also
contemplated.
[0050] Baking the plurality of food items 302 includes convectively
heating the grill 20 and/or the plurality of food items 302. The
border 22, the backing portion 26, and/or the racking portion 24
are convectively heated. For example, the border 22, the backing
portion 26, and/or the racking portion 24 are convectively heated
to a temperature at or above about 400 degrees F., at or above
about 425 degrees F., at or above about 450 degrees F., at or above
about 475 degrees F. or at any range or temperature implied by
those specifically identified above, for example between about 425
degrees F. and about 475 degrees F.
[0051] Heat is also conductively translated from the border 22
and/or the backing portion 26 to the racking portion 24, and in
particular the plurality of cross members 50 where the grill 20 is
formed of a substantially thermally conductive material, such as an
aluminum alloy, for example. Where the plurality cross members 50
of the grill 20 define tapered shapes in transverse cross section,
heat is also directed to the top surfaces 54 of the plurality of
cross members 50 as the plurality of food items 302 are baked in
the oven 400. In particular, the plurality of cross members 50 are
optionally tapered such that the top surfaces 54 of the plurality
of members 50 define a relatively smaller surface area than the
bottom surfaces 56 of the plurality of cross members 50. In this
manner, the bottom surfaces 56 are able to draw convective heat
from the oven across a wider surface area, while the top surfaces
54 have a smaller surface area, or lines of contact with the
plurality of food items 302, allowing the top surfaces 54 to
effectively form realistic looking grill markings 310 in the
plurality of food items 302.
[0052] During the baking step 230, convective heating or baking of
the grill 20 results in simulated grilling. For example, with
reference to FIG. 13, the food item 300 is characterized by grill
markings 310. The grill markings 310, also described as grill
lines, correspond to lines of contact between the food item 300 and
the plurality of cross members 50. Regardless, the grill markings
310 are imparted across the food item 300 with light areas 320
interspersed between the grill markings 310.
[0053] During simulated grilling, the plurality of food items 302
optionally release lipids, including fats, waxes, and/or oils
otherwise associated with the plurality of food items 302. For
example, with chicken, fat, oils, and "juices" of the chicken
liquefy and/or drip from the chicken. As lipids associated with the
plurality of food items 302 become liquefied and/or are released
from the plurality of food items 302, the lipids drip from the
plurality of food items 302 between the plurality of cross members
50, through the plurality of spaces 86, and through the grill
20.
[0054] The grill 20 is optionally adapted such that the lipids do
not collect or otherwise pool on portions of the grill 20. For
example, the top surfaces 54 of the plurality of cross members 50
are optionally substantially flat to prevent pooling of the lipids.
In turn, the plurality of spaces 86 also allow the lipids to pass
through the grill 20. Additionally, the tapered top surfaces of the
first and second support member 70, 72 also facilitate prevention
of lipid pooling. As a result, rather than the plurality of food
items 302 being fried in their own greases, or otherwise fried with
their own lipids, the plurality of food items 302 are instead
"grilled" on the top surfaces 54 of the plurality of cross members
50 to impart the grill markings 310.
[0055] For example, where the plurality of food items 302 are
otherwise fried with lipids on the top surfaces of the plurality of
cross members 50, lines of contact between the plurality of cross
members 50 and the plurality of food items 302 are substantially
lighter, rather than darker, than remaining portions of the
plurality of food items 302. If the plurality of food items 302 are
fried, rather than grilled, on the plurality of cross members 50,
an opposite effect to that desired sometimes results, with lighter,
rather than darker markings imparted on the plurality of food items
302.
[0056] As the lipids drip over and through the grill 20, they
optionally drop onto heating elements of the oven 400, other hot
surfaces in the oven 400, over hot surfaces of the grill 20, and/or
are carried or otherwise distributed by air currents to other hot
surfaces. If the lipids contact sufficiently hot surfaces they are
vaporized, or flashed, upon reaching a smoke point, for example, of
the lipids. This, in turn, creates smoke, which optionally
engenders a smoke flavor in the plurality of food items 302. It
should also be noted that the oven 400 is optionally vented to
reduce or otherwise control smoke in the oven 400 if desired. As
referenced above, the grill 20 is optionally placed on a sheet pan
or other pan (not shown) or surface for collecting lipids dripping
from the plurality of food items 302, for example.
[0057] From the above, it should be understood that the simulated
grilling effect is optionally accomplished with or without any
artificial coloring agents, such as cocoa butter dextrose paste,
for example, and optionally accomplished with or without chemical
smoke flavoring or external smoking devices, such as devices known
by those of ordinary skill in the art. By removing the use of
artificial smoking and/or coloring agents or devices, a more
realistic grilled taste and appearance are realized, for
example.
[0058] The post-processing step 240 includes removing the plurality
of food items 302 from the oven, storing the plurality of food
items 302, and/or presenting the plurality of food items 302 to a
consumer. The operator optionally removes the grill 20 or plurality
of grills with associated pans (not shown) from the oven 400. If
desired, the operator also uses a rack handle 410 to grasp and
remove the grill 20 or plurality of grills, as well as any
associated pans, from the oven 400.
[0059] Although the plurality of food items 302 are then optionally
flipped onto a separate rack, it should also be understood that
other methods, including leaving the plurality of food items on the
grill 20 until holding, packaging, or distributing the plurality of
food items 302 to a consumer, for example, are also contemplated.
Regardless, the non-stick coating optionally operates to allow
removal of the plurality of food items 302 without sticking and
allows relatively easy clean up following simulated grilling, even
at relatively high temperatures, for example at or above 400
degrees F. where the plurality of food items 302 or associated
lipids might otherwise become securely adhered to the grill 20.
[0060] Where flipped, an empty rack (not shown) is placed on top of
the plurality of food items 302 to sandwich them between the grill
20 and the rack after removal from the oven 400. The rack is
optionally substantially similar to the rack 20a, the grill 20, or
another baking implement as desired. The operator flips the
plurality of food items 302 onto the rack. Where the grill 20
includes the coating having non-stick properties, the plurality of
food items 302 are flipped and release from the grill 20 without
substantial portions of the plurality of food items sticking, or
remaining adhered to the grill 20.
[0061] The grill 20 is then allowed to cool, used again in another
the food item preparation step 220, and/or used again in another
baking step 230 as desired. If any of the plurality of food items
302 has moved, the operator rearranges the plurality of food items
302 on the rack as desired, using tongs (not shown), for example.
The plurality of food items 302 are optionally put into a storage
area, for example a moist upright cabinet (not shown), and held for
a period of time before packaging or serving to a consumer. The
grill 20 is then optionally cleaned. For example, where the grill
20 includes the optional protective and/or non-stick coating,
cleaning the grill 20 is facilitated by the coating.
[0062] In light of the above, the grill 20, the simulated grilling
system, and/or the method of simulated grilling optionally achieve
many advantages. For example, frying, as opposed to grilling the
food item 300 is possible. In particular, the grill 20 is adapted
to prevent pooling of lipids, sometimes termed renderings, on the
food item 300, which may otherwise interfere with more realistic
grill markings 310 and create a greasy product. Additionally, the
food item 300 is removable from the grill 20, for example by
flipping the grill 20 or otherwise removing the food item 300 from
the grill, without the food item 300 sticking to the grill 20.
Coplanar back surfaces of the grill 20 increase surface area for
forced-convection heating.
[0063] The highly thermally conductive and unitary structure of the
grill 20 also facilitates the top surfaces 54 of the plurality of
cross members 50 being at a high enough temperature to impart the
grill marking on the food item 300. Additionally, the grill 20
allows lipids to be flashed to create smoke in the oven 400 to
create a smoke flavor in the food item 300. In particular, the
grill markings 310 and smoke flavoring are realizable in the
absence of artificially introduced flavoring or coloring agents or
devices. As another example, by placing the plurality of cross
members 50 at about a 45 degree angle to the border 22 the
plurality of food items 302 are optionally placed on the grill 20
in a variety of configurations while still imparting an otherwise
random, realistic orientation of the grill markings 310 on the food
item 300.
[0064] Although the invention has been described with respect to
particular embodiments, such embodiments are for illustrative
purposes only and should not be construed to limit the invention.
Various alternatives and changes will be apparent to those of
ordinary skill in the art. For example, although disclosed above as
being formed in a particular shape or of a particular size, other
suitable shapes and sizes are also contemplated. Other
modifications within the scope of the invention and its various
embodiments will be apparent to those of ordinary skill.
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