U.S. patent application number 13/210181 was filed with the patent office on 2011-12-08 for heated compressed air broiler system.
This patent application is currently assigned to NIECO CORPORATION. Invention is credited to Matthew J. Baker, Patrick D. Baker, Mohsen Sarfehjoo.
Application Number | 20110297140 13/210181 |
Document ID | / |
Family ID | 44358456 |
Filed Date | 2011-12-08 |
United States Patent
Application |
20110297140 |
Kind Code |
A1 |
Baker; Matthew J. ; et
al. |
December 8, 2011 |
HEATED COMPRESSED AIR BROILER SYSTEM
Abstract
An oven and broiler for cooking foods using convection and
radiant heat, including a housing defining a cooking chamber with
an inlet for introducing uncooked foods into the cooking chamber,
an outlet for discharging cooked foods and a conveyor for conveying
food product from the inlet to the outlet, an array of heating
elements, and a compressed air injection system for providing a
bank of moving air over the food product during the early stages of
cooking so as to break up the blanket of cold air over the food
product.
Inventors: |
Baker; Matthew J.; (Windsor,
CA) ; Baker; Patrick D.; (Windsor, CA) ;
Sarfehjoo; Mohsen; (Franklin, TN) |
Assignee: |
NIECO CORPORATION
Windsor
CA
|
Family ID: |
44358456 |
Appl. No.: |
13/210181 |
Filed: |
August 15, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11849854 |
Sep 4, 2007 |
7997189 |
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13210181 |
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60824419 |
Sep 1, 2006 |
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Current U.S.
Class: |
126/41R |
Current CPC
Class: |
F23D 14/10 20130101;
F23D 14/14 20130101; F23D 14/70 20130101; A21B 1/26 20130101; F23D
14/76 20130101; F23D 2900/21003 20130101 |
Class at
Publication: |
126/41.R |
International
Class: |
F24C 3/08 20060101
F24C003/08 |
Claims
1. A method of rapidly cooking frozen food, comprising the steps
of: (a) providing a cooking apparatus with a cooking chamber with
convective and radiant heating elements, a source of pressurized
air, an air plenum in fluid communication with the source of
pressurized air disposed above at least one heating element in the
cooking chamber, the underside of the air plenum having a plurality
of air outlets for directing a body of moving heated air down and
toward food product, and a food conveyor for conveying food product
through the cooking chamber; (b) introducing frozen food into the
cooking chamber on the food conveyor; (c) exposing the frozen food
first to radiant heating in the initial stages of the cooking
process; (d) simultaneously with step (c), also directing a moving
bank of air toward the food to break the protective blanket of cold
air surrounding the frozen food; (e) continuing the cooking process
as the food is conveyed by the conveyor using convective and
radiant heating with at least one gas burner having a radiant
reflector cap shaped to confine and control the shape of the heat
cone produced by the burner flames; (f) conveying the food from the
cooking chamber when it is properly cooked and browned.
2. The method of claim 1, wherein step (e) includes deflecting
flame away from the burner so as to reduce burner temperature while
simultaneously creating a radiant heating surface with the radiant
reflector cap.
3. The method of claim 1, further including the step of injecting
low pressure air into the heat cones produced by the gas burners to
shape and control the flame field characteristics.
4. A cooking system, comprising: a cooking chamber having an inlet
end, and outlet end, an upper portion, a lower portion, and a
product conveyor disposed between said upper and lower portions; at
least one gas burner or electric heating element in said lower
portion; at least one gas burner or electric heating element in
said upper portion; an automatic food product feeder for conveying
food product through said cooking chamber from said inlet end to
said outlet end; and an air plenum disposed in said upper portion
of said cooking chamber above said at least one gas burner or said
electric heating element in said upper portion, said air plenum
having an interior volume in fluid communication with a source of
pressurized air and having a plurality of air outlets for directing
a body of heated moving air onto and over food product in an
initial quick thaw stage of cooking.
5. The system of claim 4, wherein said air plenum is height
adjustable such that the volume and velocity of air directed onto
food product can be tailored to the particular product cooking
requirements.
6. The system of claim 4, wherein said air plenum comprises a box
and wherein said at least one gas burner or heating element is
disposed immediately under said air plenum.
7. The system of claim 4, wherein said cooking platform is a moving
food product conveyor belt or grid.
8. The system of claim 4, wherein said at least one gas burner or
electric heating element is a gas burner, and further including air
injection apparatus coupled to a source of air for injecting air
into heat cones produced by said gas burner, such that the heat
cones can be shaped and controlled to create desired flame and heat
cone characteristics.
9. The system of claim 8, wherein said air injection apparatus
comprises at least one air injection nozzle.
10. The system of claim 8, wherein said gas burner comprises: an
elongate tube body having a top portion, a bottom, and a gas inlet
portion for insertion of a gas jet nozzle, and a burner portion
having a burner orifice array disposed on said bottom of said tube
body, said burner portion further including a support element
running substantially the entire length of said burner portion of
said tube body; and a reflector cap having a medial channel
disposed over said top portion of said tube body, and wing elements
angled upwardly and away from said channel portion.
11. The oven and broiler of claim 10, wherein said tube body has a
bottom which exposes the burner orifice array, such that said
burner outlet array and said reflector cap configuration confine
and control the shape of the heat cone from said gas burners to
minimize indirect heating of the burner and maximize the production
of radiant heat.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. Utility
patent application Ser. No. 11/849,854, filed Sep. 4, 2007 (Sep. 4,
2007,) which claims the benefit of U.S. Provisional Patent
Application Ser. No. 60/824,419, filed Sep. 1, 2006, (Sep. 1,
2006.)
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT
DISC
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates generally to broiler systems
for the rapid cooking of food products, and more particularly to a
broiler system combining different kinds of heating methods and
including a novel gas burner design and the introduction of heated
compressed air into the first stage of cooking The system is
adapted for cooking a variety of food products through the
combination of radiant and convection heat.
[0006] 2. Discussion of Related Art Including Information Disclosed
Under 37 CFR .sctn..sctn.1.97, 1.98
[0007] To prepare certain foods, such as hamburger patties,
sausages, hot dogs, and chicken and fish fillets, and the like, as
well as their respective buns, high output commercial food
purveyors (i.e., fast food restaurants) utilize broiler systems
that rapidly and continually cook the food products. The systems
typically comprise a housing having a horizontal conveyor for
moving food product from an input end to an output end. During the
cooking process the food passes between a number of spaced-apart
cooking elements, typically either electric resistance elements or
gas burners. As may be readily appreciated, the profitability of
utilizing such a system hinges on a number of factors, including
the rapidity and efficiency with which the food product can be
cooked, the minimization of energy and/or fuel utilized in cooking,
the ease with which the system can be serviced and cleaned, the
quality (and therefore desirability) of the cooked food products,
and so forth.
[0008] The present invention improves on prior art broiler systems
by providing a system which includes a combination of electric
heating elements, a compressed air system which distributes and
directs low pressure air through a plenum disposed above the
cooking food product into an electric heating element portion of
the broiler, an array of novel gas burners, and heat reflecting
surfaces (i.e., radiant heat/infrared heating elements) on both the
underside of the air plenum and on wings extending outwardly from
the gas burner elements, all of which create a combination
convention/radiant heat broiling system. The system provides
rapidly cooked food products of uniform doneness, high quality, and
moisture content.
[0009] Several rapid cooking broiler systems have been developed
for use in the fast food industry, including those described in the
following U.S. patents.
[0010] U.S. Pat. No. 4,936,286, to Baker, discloses a broiler
system having at least two side-by-side broiling conveyors, and
broiler units mounted adjacent to the conveyors extending across
the combined widths of the two conveyors. To permit different
heating conditions on the two conveyors while still permitting the
broiler units to be interchangeable and made of interchangeable
parts, a broiler unit is provided with a shield which blocks off
the heated face of the broiler unit where the broiler unit faces
one of the conveyors. The shield preferably carries a portion which
extends towards the adjacent edges of two conveyors to prevent
lateral heat radiation between the conveyors.
[0011] U.S. Pat. No. 4,188,868, to Baker et al, shows a broiler
system having a food passageway restricted by baffles, including an
entrance shield of heat-reflecting material formed as a fitting
over the entrance burner housing and including a baffle sheet
extending from the entrance burner housing through most of the gap
toward the entrance opening, and an exit shield of similar
heat-reflecting material formed as a fitting over the exit burner
housing and having a baffle sheet extending from the exit burner
housing through most of the gap toward the exit opening. In
addition, there is an intermediate shield including a horizontal
sheet of similar material resting on adjacent burner housings and
having a vertical sheet depending from said horizontal sheet. The
entrance shield, the exit shield and the intermediate shield define
the upper limits of the passageway through the burner and tend to
reflect heat away from the entrance and exit openings and to limit
air circulation within and through the passageway.
[0012] U.S. Pat. No. 4,121,509, to Baker et al., teaches a housing
having a passageway through which a continuous food conveyor
operates, taking food products from an inlet end to an outlet end.
Within the passageway the food products are exposed to infrared
radiation from heaters, hot air blown from a fan through a supply
duct and through groups of nozzles onto the patties, and steam or
hot water vapor provided through the air supply. By using three
different types of heat supply--direct infrared radiation, warm
air, and water vapor--the system provides a quickly cooked food
product having a relatively high moisture content.
[0013] U.S. Pat. No. 3,987,718 to Lang-Ree et al., discloses a
hamburger patty and bun cooker having a frame supporting lower and
upper heated platens. A product conveyor, typical of such systems,
moves food product from the inlet to the outlet. At least one of
the platens is provided with a low-friction layer between it and an
advancing patty. The layer is constituted by jets of hot air
discharged over the platen surface or by a Teflon-coated thin,
metal foil sheet or by a Teflon-carrying thin, fiber glass sheet,
the sheets being readily changeable. Bun portions for the
individual patties are advanced on the same frame in paths parallel
to the hamburger patties by comparable endless conveyors and are
heated by individual platens on the frame as the bun portions
advance.
[0014] The foregoing patents reflect the current state of the art
of which the present inventors are aware. Reference to, and
discussion of, these patents is intended to aid in discharging
Applicants' acknowledged duty of candor in disclosing information
that may be relevant to the examination of claims to the present
invention. However, it is respectfully submitted that none of the
above-indicated patents disclose, teach, suggest, show, or
otherwise render obvious, either singly or when considered in
combination, the invention described and claimed herein.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention is an improved convection and radiant
heating oven and broiler system which combines several novel
elements. Most notable among those novel elements is the provision
and use of a heated compressed air system employed during the first
stage of cooking The compressed air is delivered through a plenum
disposed over the food product conveyor in the electric resistance
heating element portion of the broiler, and low pressure compressed
air passing through a plurality of holes in the underside of plenum
is directed downwardly toward the food product so as to break up
the water vapor envelope that typically covers and insulates the
food product as it initially thaws and begins heating. This
facilitates cooking and enhances browning.
[0016] The inventive system additionally includes a novel gas
burner element with a novel wing design that directs and
distributes gas flames so as to spread the heat provided by the
elements and to include radiant heating surface on the underside of
the wings.
[0017] It is therefore an object of the present invention to
provide a new and improved oven and broiler system that cooks
frozen foods rapidly using both convective and radiant heat.
[0018] It is another object of the present invention to provide a
new and improved oven and broiler system that utilizes an air
source to break the protective blanket of cold air surrounding
frozen food products so as to expose the food surfaces to cooking
heat early in the cooking process.
[0019] A further object or feature of the present invention is a
new and improved oven and broiler system that improves uniform and
aesthetically pleasing browning of rapidly cooked foods.
[0020] An even further object of the present invention is to
provide a novel oven and broiler system that shapes flames provided
by gas burners by using compressed air injected across the flame
region.
[0021] The foregoing summary broadly sets out the more important
features of the present invention so that the detailed description
that follows may be better understood, and so that the present
contributions to the art may be better appreciated. There are
additional features of the invention that will be described in the
detailed description of the preferred embodiments of the invention
which will form the subject matter of the claims appended
hereto.
[0022] Accordingly, before explaining the preferred embodiment of
the disclosure in detail, it is to be understood that the
disclosure is not limited in its application to the details of the
construction and the arrangements set forth in the following
description or illustrated in the drawings. The inventive apparatus
described herein is capable of other embodiments and of being
practiced and carried out in various ways.
[0023] Also, it is to be understood that the terminology and
phraseology employed herein are for descriptive purposes only, and
not limitation. Where specific dimensional and material
specifications have been included or omitted from the specification
or the claims, or both, it is to be understood that the same are
not to be incorporated into the appended claims.
[0024] As such, those skilled in the art will appreciate that the
inventive concept set out in may readily be used as a basis for
designing other structures, methods, and systems for carrying out
the several purposes of the present invention. It is important,
therefore, that the inventive concept be regarded as including such
equivalent constructions as far as they do not depart from the
spirit and scope of the present invention. For a better
understanding of the present invention, its advantages and the
specific objects attained by its uses, reference should be made to
the accompanying drawings and descriptive matter in which there is
described and illustrated the preferred embodiment.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0025] The invention will be better understood and objects other
than those set forth above will become apparent when consideration
is given to the following detailed description thereof. Such
description makes reference to the annexed drawings wherein:
[0026] The invention will be better understood and the objects of
the invention will become apparent when consideration is given to
the following detailed description thereof. Such description makes
reference to the annexed drawings wherein:
[0027] FIG. 1 is a perspective view of the inventive heated
compressed air broiler system, showing the system with the top
cover removed and the upper catalytic converter partly cut away to
reveal the upper gas burner array;
[0028] FIG. 2 is a partial cross-sectional top plan view showing
the burner array, upper catalytic unit, and air supply plenum;
[0029] FIG. 3 is a cross-sectional side view in elevation of the
upper portion of the broiler housing and heating system taken along
the Section lines 3-3 shown in FIG. 2;
[0030] FIG. 4 is a perspective view of the novel gas burner and
radiant cap for the gas burners as employed in the present
inventive broiler system;
[0031] FIG. 5 is a top plan view of the gas burner of FIG. 4;
[0032] FIG. 6 is side view in elevation of the gas burner of FIGS.
4 and 5; and
[0033] FIG. 7 is an end view in elevation of the gas burner and
radiant cap.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Referring to FIGS. 1 through 6, wherein like reference
numerals refer to like components in the various views, there is
illustrated therein a new and improved multi-product broiler
system, generally denominated 100 herein.
[0035] FIGS. 1-3 illustrate the general structural and operative
elements of a first preferred embodiment of the heated compressed
air oven of the present invention 100, showing that the inventive
apparatus includes: a support frame and carriage 110; a housing 120
(preferably stainless steel); an automatic food product feeder 130;
a cooking control panel 140 presenting a consolidated plurality of
control dials, button, switches, and the like; an upper catalytic
converter 150; and an upper gas burner array 160.
[0036] Food products, such as hamburger patties 170, are conveyed
into the inlet end 180 of the oven and broiler system housing using
the automatic product feeder, and via an inlet product conveyor
190, the food product is passed on to a product conveyor belt or
grid 200, which moves the food product through the cooking chamber
210 and to the outlet end 220 of the housing.
[0037] In the most general terms, the cooking chamber includes a
constellation of electric resistance heating elements, gas burners,
each in spaced-apart arrays and disposed both above and below the
product belt, as well as a plurality of reflective surfaces, all of
which combine to provide both radiant and convective heat tailored
to produce a continuous output of highly desirable food products in
minimal time. More specifically, the cooking chamber includes a
plurality of lower gas burners 230 disposed in the lower portion
240 of the cooking chamber to provide convective heat to the
chamber. Optionally, at least one electric heating element can be
positioned in the lower portion of the cooking chamber to introduce
a measure of radiant heat in the initial cooking stages. Disposed
immediately above the lower burners are drip shields 250, which
protect the lower burner flames and prevent flare ups.
[0038] The first stage of broiling in the upper portion 260 of the
heating chamber is provided by a plurality of radiant electric
elements 270 disposed transversely above the product conveyor belt.
These elements preheat the food product or initiate a quick thaw if
frozen product is used. As will be immediately appreciated, this
effect is complemented by the heat provided by the lower heating
elements and burners. The heat output 275 of the electric heating
elements can be varied by using an automated percentage timer to
vary wattage, as is well known in the art.
[0039] The second stage of upper broiling and cooking is provided
by a plurality of gas burners 300, each provided with a novel
radiant reflector cap 310 and having an array of orifices or ports
320 (not shown) disposed on each side of the gas burner body
between the radiant reflector cap and the bottom side 330 of the
burner body. The radiant reflector cap is attached to the
cylindrical burner body with a plurality of spot welds 320 and
deflects flame from away from the burner and further reduces burner
temperature while simultaneously creating a surface that
contributes to radiant heat to accelerate cooking Preferably, while
the upper burners may be on a common gas supply with the lower
burners, they are on a discrete control circuit so that they can be
adjusted for output independently from the lower burners.
[0040] Optionally, a low pressure air source (roughly 5 psi) 500
can be provided to inject air into some or all of the heat cones
produced by the gas burners to shape and control the flame field
characteristics and cooking effects. Optimally, the air source is
either an air pump or small compressor, rather than a fan, and is
injected through a plurality of air injector nozzles 510 having
tips tailored to create the desired flame and heat cone
characteristics.
[0041] Disposed at the top of the cooking chamber is a catalytic
converter 150, which may optionally be placed under negative air
pressure, and which removes grease and smoke. However, the unit is
also provided with a reflective lower surface 155 which is a
primary producer of radiant heat in the cooking chamber.
Accordingly, in addition to cleaning and conditioning vented gases,
the catalytic converter improves the heat profile, saves energy,
and reduces cooking time.
[0042] Next, a box-shaped air plenum 700 is provided and disposed
above resistance elements 270. The plenum is in fluid communication
with an air source through an air inlet 710. The plenum includes a
plurality of small air outlet orifices so as to provide a gentle
moving bank of air over the food product in the initial "quick
thaw" stage of cooking The moving air breaks the blanket of
protective cold air that typically rests on frozen food product as
it first enters a cooking apparatus, thereby exposing the surfaces
of the food product to effective heating temperatures at an early
stage of cooking in the cooking chamber. The plenum is height
adjustable so that the volume and velocity of air directed onto the
food product may be tailored to the particular food product cooking
requirements.
[0043] The above-described upper burner system also allows the
burners to be positioned at an optimum height above the food
product, so that a single height setting can be employed for a
variety of products. This eliminates the need for multiple broiling
systems or machine having multiple chambers with differing heating
element heights. By eliminating the need to adjust burner heights,
the changeover to cooking food products having widely different
broiling requirements is streamlined and simplified. Most of the
cooking differences can be addressed with easy adjustments to
either or both upper and lower burner sets.
[0044] FIGS. 4 through 6 show details of the gas burner 300 and
radiant reflector cap 310 employed in the inventive oven system.
These views show that the burner has a generally cylindrical
elongate tube body 340 having a gas inlet portion 350 for insertion
of a gas jet nozzle 360, and a burner portion 370 disposed below
the radiant reflector cap 310. The radiant reflector cap is affixed
to the burner body with a plurality of spot welds 320 disposed
below the radiant reflector cap. The burner portion further
includes a vertically disposed I-beam support element 380 running
substantially the entire length of the burner portion of the tube
body. This provides increased structural integrity which resists
deformation under high heat.
[0045] The radiant reflector cap 310 comprises a medial channel
portion 390 which is disposed over the top portion 400 of the tube
body. Angling upwardly from the lower edges of the channel portion
are generally symmetrical wing portions 410, 420, which curve into
substantially vertical walls 430, 440, at the level of top of the
tube body. The tube body portion includes a burner orifice array
disposed below the radiant reflector cap. The burner outlet array
and radiant reflector cap configuration confines and controls the
shape of the heat cone to minimize indirect heating of the burner
and maximize the production of radiant heat.
[0046] The above disclosure is sufficient to enable one of ordinary
skill in the art to practice the invention, and provides the best
mode of practicing the invention presently contemplated by the
inventor. While there is provided herein a full and complete
disclosure of the preferred embodiments of this invention, it is
not desired to limit the invention to the exact construction,
dimensional relationships, and operation shown and described.
Various modifications, alternative constructions, changes and
equivalents will readily occur to those skilled in the art and may
be employed, as suitable, without departing from the true spirit
and scope of the invention. Such changes might involve alternative
materials, components, structural arrangements, sizes, shapes,
forms, functions, operational features or the like.
[0047] Therefore, the above description and illustrations should
not be construed as limiting the scope of the invention, which is
defined by the appended claims.
* * * * *