U.S. patent application number 14/547237 was filed with the patent office on 2015-08-20 for cooking oven.
The applicant listed for this patent is New American Ovens, Inc.. Invention is credited to John Creel.
Application Number | 20150233585 14/547237 |
Document ID | / |
Family ID | 53797777 |
Filed Date | 2015-08-20 |
United States Patent
Application |
20150233585 |
Kind Code |
A1 |
Creel; John |
August 20, 2015 |
COOKING OVEN
Abstract
In various embodiments, an oven includes a cooking chamber floor
including a ceramic blanket; and walls, the walls and cooking
chamber floor defining a cooking chamber. In various embodiments,
an oven includes walls including a panel; and a frame including an
extruded corner post, the extruded corner post including an inner
wall and an outer wall defining a channel, a portion of the panel
positioned in the channel of the extruded corner post.
Inventors: |
Creel; John; (Kennesaw,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
New American Ovens, Inc. |
Kennesaw |
GA |
US |
|
|
Family ID: |
53797777 |
Appl. No.: |
14/547237 |
Filed: |
November 19, 2014 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61939874 |
Feb 14, 2014 |
|
|
|
Current U.S.
Class: |
126/19R ;
29/428 |
Current CPC
Class: |
F24B 1/22 20130101; Y10T
29/49826 20150115 |
International
Class: |
F24C 15/34 20060101
F24C015/34 |
Claims
1. An oven comprising: a cooking chamber floor including a ceramic
blanket; and walls, the walls and cooking chamber floor defining a
cooking chamber.
2. The oven of claim 1, wherein a portion of the cooking chamber
floor defines a ledge extend through at least one wall of the walls
of the oven to an exterior of the oven.
3. The oven of claim 1, wherein the cooking chamber floor includes
a hollow shell, the ceramic blanket enclosed within the hollow
shell.
4. The oven of claim 1, wherein the ceramic blanket is formed from
ceramic fibers.
5. The oven of claim 1 further comprising a ceramic roof having a
vent, the roof further defining the cooking chamber.
6. The oven of claim 1, wherein the walls include a ceramic side
panel.
7. The oven of claim 6, wherein the side panel includes
cordierite.
8. The oven of claim 1 further comprising a fire box removable from
the oven.
9. The oven of claim 1 further comprising an oven floor, wherein
the oven floor, cooking chamber floor, and walls define a heating
chamber below the cooking chamber floor.
10. The oven of claim 9, wherein the oven floor includes a hollow
shell and a ceramic blanket enclosed within the hollow shell.
11. An oven comprising: walls including a panel; and a frame
including an extruded corner post, the extruded corner post
including an inner wall and an outer wall defining a channel, a
portion of the panel positioned in the channel of the extruded
corner post.
12. The oven of claim 11, wherein: the extruded corner post is a
first extruded corner post and the frame includes a second extruded
corner post including an inner wall and an outer wall defining a
channel sized to accept a portion of the panel; the panel includes
a first lateral end and a second lateral end distal from the first
lateral end; and the first lateral end is positioned in the channel
of the first extruded corner post and the second lateral end is
positioned in the channel of the second extruded corner post.
13. The oven of claim 11 further comprising a roof including a
ceramic material, the roof positioned on a top of the frame.
14. The oven of claim 11, further comprising a cooking chamber
floor, the cooking chamber floor and the walls defining a cooking
chamber, the cooking chamber floor supported by at least one
support clip mounted on the frame.
15. The oven of claim 11, wherein the inner wall of the extruded
corner post defines a plurality of fastener holes and a groove
sized to accept a gasket.
16. The oven of claim 11, wherein: the extruded corner post is a
first extruded corner post and the frame includes a second extruded
corner post, a third extruded corner post, a fourth extruded corner
post, a top cap, and a bottom cap, the top cap and the bottom cap
each attached to the first extruded corner post, second extruded
corner post, third extruded corner post, and fourth extruded corner
post; the panel is a first side panel and the walls include a
second side panel, a back panel, and a front wall; and the first
side panel is connected to the first extruded corner post and the
second extruded corner post, the second side panel is connected to
the third extruded corner post and the fourth extruded corner post,
the back panel is connected to the second extruded corner post and
the third extruded corner post, and the front wall is connected to
the first extruded corner post and the fourth extruded corner
post.
17. A method of assembling an oven comprising: fastening an
extruded corner post to a frame of the oven through at least one
fastener hole defined in an end of the extruded corner post; and
sliding a lateral end of a panel into a channel defined between a
inner wall and an outer wall of the extruded corner post.
18. The method of claim 17, further comprising mounting a cooking
chamber floor to the frame with at least one support clip, the
cooking chamber floor including a ceramic blanket.
19. The method of claim 17, further comprising placing a gasket in
a groove defined in the inner wall of the extruded corner post.
20. The method of claim 17 further comprising positioning a ceramic
roof on a top of the frame of the oven.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 61/939,874, filed Feb. 14, 2014, which is hereby
specifically incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] This disclosure related to cooking More particularly, this
disclosure relates to ovens for cooking
BACKGROUND
[0003] Cooking in an oven such as a brick oven involves maintaining
proper air and cooking surface temperatures. A brick oven typically
includes a heat source within the cooking chamber of the brick oven
and situated at one side of the cooking chamber, and therefore
cooking food such as pizza on a cooking surface in the brick oven
typically requires turning of the food within the oven on the
cooking surface to avoid overcooking one side of the food and
undercooking the other side of the food. In addition, cooking
multiple food items in succession requires maintaining the
temperature of the cooking surface between removing cooked food and
adding food to be cooked, often requiring the use of multiple
removable baking stones. Baking stones typically require preheating
to a certain temperature, so typically a single baking stone cannot
be used to cook two food items in succession.
SUMMARY
[0004] Disclosed is an oven comprising a cooking chamber floor
including a ceramic blanket; and walls, the walls and cooking
chamber floor defining a cooking chamber.
[0005] Also disclosed is an oven comprising walls including a
panel; and a frame including an extruded corner post, the extruded
corner post including an inner wall and an outer wall defining a
channel, a portion of the panel positioned in the channel of the
extruded corner post.
[0006] Also disclosed is a method of assembling an oven comprising
fastening an extruded corner post to a frame of the oven through at
least one fastener hole defined in an end of the extruded corner
post; and sliding a lateral end of a panel into a channel defined
between a inner wall and an outer wall of the extruded corner
post.
[0007] Various implementations described in the present disclosure
may include additional systems, methods, features, and advantages,
which may not necessarily be expressly disclosed herein but will be
apparent to one of ordinary skill in the art upon examination of
the following detailed description and accompanying drawings. It is
intended that all such systems, methods, features, and advantages
be included within the present disclosure and protected by the
accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The features and components of the following figures are
illustrated to emphasize the general principles of the present
disclosure. Corresponding features and components throughout the
figures may be designated by matching reference characters for the
sake of consistency and clarity.
[0009] FIG. 1 is a perspective view of a cooking oven.
[0010] FIG. 2 is a perspective view of a frame of the cooking oven
of FIG. 1.
[0011] FIG. 3 is a perspective view of the cooking oven of FIG. 1
with a front wall and a fire box of the cooking oven removed.
[0012] FIG. 4 is a perspective view of the cooking oven of FIG. 1
with an oven door and a fire box of the oven removed.
[0013] FIG. 5 is a sectional view of the cooking oven of FIG. 1
taken along line 5-5 of FIG. 1.
[0014] FIG. 6 is a side view of a side panel of the cooking oven of
FIG. 1.
[0015] FIG. 7 is a top view of a corner post of the cooking oven of
FIG. 1.
[0016] FIG. 8 is a perspective close-up view of a corner of the
oven with a roof and an oven door of the oven removed.
[0017] FIG. 9 is a top view of a support clip.
[0018] FIG. 10 is a top view of a support clip installed in the
oven of FIG. 1.
[0019] FIG. 11 is a bottom view of a second support clip installed
in the oven of FIG. 1.
[0020] FIGS. 12A through 12G are various views of the cooking
chamber floor of the oven of FIG. 1.
[0021] FIG. 13 is a perspective view of an upper plate of the
cooking chamber floor of FIG. 12A.
[0022] FIG. 14 is a perspective view of a lower plate of the
cooking chamber floor of FIG. 12A.
[0023] FIG. 15 is a perspective view of the oven of FIG. 1 from a
bottom side of the oven with the roof and several panels of the
oven removed.
[0024] FIG. 16 is a perspective close-up view of the support clip
of FIG. 9 holding up the cooking chamber floor of FIG. 12A.
[0025] FIG. 17 is another perspective close-up view of the support
clip of FIG. 9 holding up the cooking chamber floor of FIG.
12A.
[0026] FIG. 18 is a perspective view of an oven floor of the oven
of FIG. 1.
[0027] FIG. 19 is a perspective view of the oven floor of FIG. 18
resting on a bottom cap of the frame of FIG. 2.
[0028] FIG. 20 is a bottom view of the oven floor of FIG. 18
resting on the bottom cap of the frame of FIG. 2.
[0029] FIG. 21 is a perspective view of a fire box of the oven of
FIG. 1.
[0030] FIG. 22 is a top view of the fire box of FIG. 21.
[0031] FIG. 23 is another perspective view of the fire box of FIG.
21.
[0032] FIG. 24 is a perspective view of a vent cap of the fire box
of FIG. 21.
[0033] FIG. 25 is a perspective back-side view of the cooking oven
of FIG. 1 with the back panel of the oven removed.
[0034] FIG. 26 is a sectional view of the cooking oven of FIG. 1
taken along line 26-26 of FIG. 1.
[0035] FIG. 27 is a sectional view of the cooking oven of FIG. 1
taken along line 27-27 of FIG. 1.
[0036] FIG. 28 is a perspective view of another embodiment of a
cooking oven with a roof of the cooking oven removed.
DETAILED DESCRIPTION
[0037] Disclosed is a cooking oven, or hearth, and associated
methods, systems, devices, and various apparatus. It would be
understood by one of skill in the art that the disclosed cooking
oven is described in but a few exemplary embodiments among many. No
particular terminology or description should be considered limiting
on the disclosure or the scope of any claims issuing therefrom.
[0038] One embodiment of an oven 100 is disclosed and described in
FIG. 1. The oven 100 includes a front wall 110, side panels 120a,b
(120b shown in FIG. 3), a back panel 130 (shown in FIG. 10), a roof
140, a frame 150, a fire box 160, an oven door 170 with a handle
172, and a cooking chamber floor 180. Front wall 110, side panels
120a,b, and back panel 130 define walls of the oven 100. In various
embodiments, the walls of the oven 100 may be formed from a single
or multiple curved panels, multiple flat panels, or a combination
of curved and flat panels, and the disclosure of front wall 110,
side panels 120a,b, and back panel 130 should not be considered
limiting on the configuration of the walls of the oven 100 in the
current disclosure.
[0039] A vent cap 142 is placed over a hole 540 (shown in FIG. 5)
defining a vent in the roof 140. The vent cap 142 includes a
rotating top plate 144 for opening and closing the vent cap 142.
The top plate 144 includes a tab 148 that can be used to rotate the
top plate 144. The top plate 144 and vent cap 142 are connected by
a bolt 146 extending through bolt holes (not shown) in the top
plate 144 and vent cap 142 and tightened sufficiently to allow the
top plate 144 to rotate relative to the vent cap 142. The vent cap
142, including the rotating top plate 144, may be constructed from
aluminum or aluminized steel, or other materials in various
embodiments.
[0040] FIG. 2 shows a perspective view of the frame 150. The frame
150 includes four corner posts 250a,b,c,d, a top cap 252, and a
bottom cap 254. The top cap 252 includes four top frame pieces
256a,b,c,d, each top frame piece 256a,b,c,d including an L-shaped
cross-section. The bottom cap 254 includes four bottom frame pieces
258a,b,c,d, each bottom frame piece 258a,b,c,d including an
L-shaped cross-section. Each top frame piece 256a,b,c,d includes a
plurality of fastener holes 266, two fastener holes 266 at each end
of each top frame piece 256a,b,c,d. Top frame piece 256a includes
four fastener holes 266a, top frame piece 256b includes four
fastener holes 266b, top frame piece 256c includes four fastener
holes 266c, and top frame piece 256d includes four fastener holes
266d. Each bottom frame piece 258a,b,c,d includes a plurality of
fastener holes 268 (shown in FIG. 15), two fastener holes 268 at
each end of each bottom frame piece 258a,b,c,d. Bottom frame piece
258a includes four fastener holes 268a, bottom frame piece 258b
includes four fastener holes 268b, bottom frame piece 258c includes
four fastener holes 268c, and bottom frame piece 258d includes four
fastener holes 268d. Bottom frame piece 258a also defines a notch
262. The top cap 252 is connectable to the four corner posts
250a,b,c,d by a plurality of self-tapping screws through the
plurality of fastener holes 266, and the bottom cap 254 is
connectable to the four corner posts 250a,b,c,d by a plurality of
self-tapping screws through the plurality of fastener holes 268. In
various embodiments, the top cap 252 and bottom cap 254 may be
connected to the four corner posts 250a,b,c,d by other connections
in various embodiments, including non-self-tapping screws, bolts,
welding, adhesives, or being formed integrally with each other, and
the manner of connection should not be considered limiting.
[0041] FIG. 3 is a perspective view of the oven 100 with the front
wall 110, back panel 130, the fire box 160, and the oven door 170
removed. As shown in FIG. 3, the cooking oven 100 also includes an
oven floor 300 resting on the bottom cap 254. The oven floor 300
includes guide rails 310a,b for guiding the fire box 160 into and
out of the oven 100. The oven 100 defines a heating chamber 330
below the cooking chamber floor 180 and further defines a cooking
chamber 320 above the cooking chamber floor 180. The cooking
chamber floor 180 fills the space between the side panels 120a,b,
leaving a small air gap between the cooking chamber floor 180 and
each of the side panels 120a,b to allow for heated air to move from
the heating chamber 330 to the cooking chamber 320. The cooking
chamber floor 180 also defines a cooking surface 384 facing upwards
into the cooking chamber 320.
[0042] FIG. 4 shows a perspective view of the oven 100 with the
back panel 130, the fire box 160, and the oven door 170 removed. As
shown in FIG. 4, the front wall 110 defines an upper opening 410
and a lower opening 412. The upper opening 410 provides access to
the cooking chamber 320 and the lower opening 412 provides access
to the heating chamber 330 and is sized to accept the fire box 160.
The cooking chamber floor 180 also defines a ledge 382 extending
through the upper opening 410 of the front wall 110 and resting on
the front wall 110.
[0043] Further, as shown in FIG. 4, the front wall 110 includes a
plurality of clip holes 2612 around the upper opening 410 and a
pair of gasket holes 2614a,b, one on each side of the upper opening
410. The clip holes 2612 are sized to accept a series of clips on a
clip gasket (not shown) and the gasket holes 2614a,b are sized to
accept each end of the clip gasket, so that the clip gasket can be
mounted around the upper opening 410 to seal the oven door 170 in
combination with a tadpole gasket 2590 (shown in FIG. 25) when the
oven door 170 is closed. A clip gasket, or oven door gasket, is a
rope-shaped gasket typically used around oven doors to provide a
thermal seal around the oven door and typically include a series of
wire clips extending radially from the gasket which may be pushed
into a clip hole to mount the clip gasket around an oven door.
[0044] Likewise, shown in FIG. 4, the front wall 110 includes a
plurality of clip holes 2616 around the lower opening 412 and a
gasket hole 2618 centered below the lower opening 412. The clip
holes 2616 are sized to accept a series of clips on a second clip
gasket (not shown) and the gasket hole 2618 is sized to accept each
end of the second clip gasket, so that the second clip gasket can
be mounted around the lower opening 412 to seal a front panel 2140
(shown in FIG. 21) of the fire box 160 against the front wall 110
when the fire box 160 is in a closed position inside the oven
100.
[0045] FIG. 5 shows a sectional view of the oven 100 from the back
side of the oven 100, with the back panel 130 removed. As shown in
FIG. 5, a hinge mount 510 and a door latch 520 are mounted on the
front wall 110 on either side of the upper opening 410. A door
hinge 2670 is mounted on the hinge mount 510, mounting the oven
door 170 on the front wall 110 and allowing the oven door 170 to be
opened and closed. FIG. 5 also shows a thermometer sensor hole 550
defined in the front wall 110. The thermometer sensor hole 550 is
sized to accept a thermometer with a temperature gauge (not shown)
situated outside the cooking chamber 320 and with a temperature
sensor extending through the thermometer sensor hole 550 into the
cooking chamber 320 to read the temperature in the cooking chamber
320 during operation. In various embodiments, a gauge hole (not
shown) is included on the outside of front wall 110 in order to
house the entire temperature gauge. In various other embodiments, a
gauge hole is not present. In various embodiments, a humidity
sensor (not shown) for measuring the relative humidity of the
cooking chamber 320 will be included with the oven 100.
[0046] FIG. 6 shows a side view of side panel 120a. In the current
embodiment, side panels 120a,b and back panel 130 (shown in FIG.
10) are rectangular ceramic panels sized to slide into the top of
frame 150 after top cap 252 is removed. In the current embodiment,
side panels 120a,b, back panel 130, and roof 140 are cordierite,
though other materials may be used in various embodiments. The
front wall 110 is formed from metal such as aluminized steel or
aluminum in the current embodiment, though other materials such as
ceramic, including cordierite, may be used in various
embodiments.
[0047] FIG. 7 shows a top view of a corner post 250 of the oven
100. As shown in FIG. 6, the corner post 250 includes an outer wall
710 having an L-shaped cross-section. The corner post 250 also
includes an inner wall 720. The inner wall 720 includes a
protrusion 730 having a first arm 732 and a second arm 734. The
inner wall 720 defines a plurality of fastener holes 722. Two
fastener holes 722a,b are defined on the first arm 732 and the
second arm 734, respectively, and two fastener holes 722c,d are
defined on the inner wall 720 in a cavity 740 defined between the
outer wall 710 and the inner wall 720. The inner wall 720 also
defines a pair of grooves 760a,b adjacent to the protrusion 730.
The grooves 760a,b are each sized to accept a gasket such as a hog
gasket. A hog gasket is a fiberglass tube-shaped gasket with a
metal mesh inside it to keep it open or expanded. It may be stapled
at one or each end to allow the gasket to be pushed into place with
a wood dowel. The inner wall 720 also defines a pair of stop
shoulders 724a,b adjacent to the outer wall 710. The outer wall 710
of corner post 250 defines a plurality of grooves 770. In various
embodiments, grooves 770 represent aesthetic design features. In
various embodiments, one or more grooves 770 prevent or hide sink
marks that could otherwise be visible in outer wall 710 where outer
wall 710 intersects with inner wall 720. Sink marks can become
visible on extruded and molded parts that cool after exiting the
mold or die, especially in areas of a part where part thickness
changes abruptly such as at an intersection of two walls. The
corner post 250 is symmetrical across a plane 750 extending
diagonally through the corner post 250 to allow for easy
manufacture of the corner posts 250a,b,c,d by producing and cutting
a single extruded element, which lowers the cost of individual
components and the cost of assembly of the oven 100. In various
embodiments, corner post 250 is fabricated from aluminum or an
alloy thereof, but the disclosure of aluminum and aluminum alloys
for corner post 250, as well as the shape of corner post 250,
should not be considered limiting, and various other materials or
shapes may be present in various embodiments.
[0048] FIG. 8 shows a perspective close-up view of the oven 100
showing the interaction of the side panel 120a, the front wall 110,
and the corner post 250a. The side panel 120a is slid into the
space defined between the outer wall 710 and first arm 732 of the
inner wall 720, which thereby define a channel sized to accept a
portion of the side panel 120a, the side panel 120a resting against
the stop shoulder 724a. The front wall 110 is slid into the space
defined between the outer wall 710 and second arm 734 of the inner
wall 720, which thereby define a channel sized to accept a portion
of the front wall 110, the front wall 110 resting against the stop
shoulder 724b. Prior to sliding the side panel 120a and the front
wall 110 into place, gaskets may be placed into the grooves 760a,b.
Side panel 120a rests in a similar arrangement with corner post
250b and front wall 110 rests in similar arrangement with corner
post 250d. Side panel 120b is slid into corner posts 250c,d
similarly to side panel 120a, and back panel 130 is slid into
corner posts 250b,c similarly to side panels 120a,b. After sliding
front wall 110, side panels 120a,b, and back panel 130 into corner
posts 250a,b,c,d, the top cap 252 may be connected to corner posts
250a,b,c,d, and the roof 140 may thereafter be placed on top of the
oven 100 with the roof 140 positioned on the top cap 252 of the
frame 150.
[0049] FIG. 9 shows a top view of a support clip 900. The support
clip 900 includes a clip body 910 and a bolt 950. The clip body 910
has a U-shaped cross-section includes an upper plate 920 and a
lower plate 930 (shown in FIG. 16) extending from a base 940. The
bolt 950 extends through a threaded hole (not shown) defined in the
base 940 of the clip body 910. In the current embodiment, the bolt
950 is square-headed, but may be round-headed or hexagonal or any
other shape in various embodiments. The bolt 950 may be replaced
with a screw or other fastener in various other embodiments.
Turning the bolt 950 moves the bolt 950 axially through the
threaded hole relative to the clip body 910. The upper plate 920
and the lower plate 930 define a pair of grooves 912a,b and a
flared portion 914. A support clip 900a is mounted on corner post
250b and a support clip 900b is mounted on corner post 250c. In
various embodiments, support clip 900 is made from stainless steel.
In various embodiments, support clip 900 is formed from one or more
materials other than stainless steel including, but not limited to,
aluminum or non-stainless steel. In the current embodiment, support
clip 900 is formed from a flat blank into the shape disclosed. In
various other embodiments, support clip 900 is formed into a solid
shape from one or more processes including, but not limited to,
machining, casting, extruding, and molding, with a hole for bolt
950 that is deeper than when support clip 900 is bent from a flat
blank. In various embodiments, the threads of support clip 900 are
of a different material or part of a separate fastener that is
joined to clip body 910 of support clip 900.
[0050] FIG. 10 shows a top view of the oven 100 over the corner
post 250c with the roof 140 removed. As shown in FIG. 10, the
cooking chamber floor 180 rests on the upper plate 920 of the
support clip 900b, which is mounted on corner post 250c. To install
the support clip 900b on the corner post 250c, the support clip
900b is slid onto the top of corner post 250 with the flared
portion 914 between the first arm 732 and the second arm 734 and
with the grooves 912a,b surrounding the fastener holes 722a,b,
respectively. The support clip 900b is slid to position the support
clip 900b such that the cooking chamber floor 180 is in a
horizontal position parallel with the oven bottom (and also with
the ground in various embodiments) when the cooking chamber floor
180 is resting on the support clips 900a,b and the upper opening
410 of the front wall 110. The bolt 950 is thereafter tightened,
contacting and digging into inner wall 720 and thereby pushing the
flared portion 914 into first arm 732 and second arm 734 and thus
preventing further sliding of the support clip 900b relative to the
corner post 250c.
[0051] FIG. 11 shows support clip 900a from the bottom installed on
corner post 250b similarly to support clip 900b on corner post
250c.
[0052] FIGS. 12A through 12G show various views of the cooking
chamber floor 180. FIG. 12A shows a top view of the cooking chamber
floor 180. FIG. 12B shows a cross-sectional view of the cooking
chamber floor 180 taken along line 12B-12B in FIG. 12A. FIG. 12C
shows a front side view of the cooking chamber floor 180. FIG. 12D
shows a cross-sectional view of the cooking chamber floor 180 taken
along line 12D-12D in FIG. 12C. FIG. 12E shows a perspective view
of the cooking chamber floor 180. FIG. 12F shows a right side view
of the cooking chamber floor 180. FIG. 12G shows a detail
cross-sectional view of the cooking chamber floor 180 taken from
detail 12G in FIG. 12B.
[0053] As shown in FIGS. 12B and 12D, the cooking chamber floor 180
is filled with a ceramic blanket 1200. The ceramic blanket 1200 is
a blanket formed from ceramic fibers. In the current embodiment,
the ceramic blanket 1200 is one inch thick, has a density of eight
pounds per cubic foot, and is rated up to 2,800 degrees Fahrenheit,
though the thickness, density, and temperature rating of the
ceramic blanket 1200 may be different in various embodiments and
the disclosed thickness, density, and temperature rating of the
ceramic blanket 1200 should not be considered limiting on the
current disclosure. Ceramic blanket 1200 may be formed with a
variety of ceramic fiber materials, such as alumina, zirconia,
silica, polycrystalline mullite, or other ceramic fiber materials
or any combination thereof in various embodiments, and the material
composition of the ceramic blanket 1200 should not be considered
limiting on the current disclosure.
[0054] As shown in FIGS. 12A and 12D, the cooking chamber floor 180
defines a pair of notches 1280a,b adjacent to the ledge 382. In the
current embodiment, the ceramic blanket 1200 does not extend into
the ledge 382, but in other various embodiments the ceramic blanket
1200 may extend into and fill the ledge 382. In various embodiments
the cooking chamber floor 180 may not include ledge 382 extending
through the front wall 110 or may not include the pair of notches
1280a,b and still extend through the front wall 110 to provide a
wider ledge 382.
[0055] As shown in FIG. 12G, the cooking chamber floor 180 includes
an upper plate 1210 and a lower plate 1220. The lower plate 1220 is
nested within the upper plate 1210, forming a hollow shell. A
slight gap between the upper plate 1210 and the lower plate 1220 in
FIG. 12G is shown for purpose of illustrating the upper plate 1210
and the lower plate 1220, and the upper plate 1210 and the lower
plate 1220 are in contact with no gap in the current embodiment. In
various other embodiments, a gap will be present between upper
plate 1210 and lower plate 1220 in order to allow the lower plate
1220 to expand more than the upper plate 1210 while maintaining the
shape of cooking chamber floor 180. The ceramic blanket 1200 is
placed within the upper plate 1210 and the lower plate 1220. The
cooking surface 384 is defined on the upper plate 1210. In the
current embodiment, the upper plate 1210 is cooking-grade stainless
steel (including, but not limited to, stainless steel grades
meeting minimum National Sanitation Foundation (NSF) Standard 51
requirements) and the lower plate 1220 is aluminum or aluminized
steel. In various embodiments, the upper plate 1210 will be made
from a material other than stainless steel or the lower plate 1220
will be made from a material other than aluminum or aluminized
steel. In various embodiments, the upper plate 1210 and the lower
plate 1220 will be made from the same material. In various
embodiments, the side panels 120a,b, back panel 130, front wall
110, and roof 140 each may be formed from a ceramic blanket in a
metal shell or a shell made from other material, with the shell
including one or more plates enclosing the ceramic blanket.
[0056] In various embodiments, the cooking chamber floor 180 may
have a one or more through holes for the placement of one or more
anti-expansion bolts through the cooking chamber floor 180, each
anti-expansion bolt having a head tightened against the upper plate
1210 by a nut threaded onto each anti-expansion bolt and tightened
against the lower plate 1220. The anti-expansion bolts may have
dome-shaped heads that blend with the cooking surface 384, or the
anti-expansion bolts may have heads that otherwise lie flush with
the cooking surface 384, so as to prevent the anti-expansion bolts
from interfering with insertion or removal of food from the cooking
chamber 320 or with use of cooking utensils within the cooking
chamber 320. In various embodiments, one or more anti-expansion
bolts will be replaced with a fastener, such as an internal stud
welded to the inside of upper plate 1210, that is not exposed to
the cooking chamber 320 or otherwise visible from the top side of
cooking chamber floor 180 but will be partial or completely
internal to cooking chamber floor 180. The anti-expansion bolts
prevent the upper plate 1210 and the lower plate 1220 from moving
away from each other during thermal expansion of the stainless
steel of the upper plate 1210 relative to thermal expansion of the
aluminum of the lower plate 1220, maintaining the shape of the
cooking chamber floor 180. In various embodiments, through-holes
and anti-expansion bolts are not required because the shape of
cooking chamber floor 180 is sufficiently maintained without
through-holes and anti-expansion bolts. One example among others of
this embodiment would include cooking chamber floor 180 having
upper plate 1210 and lower plate 1220 made out of the same
material. In this example, upper plate 1210 and lower plate 1220
can be expected to expand at the same rate when heated and
therefore maintain the shape of cooking chamber floor 180.
[0057] FIG. 13 is a perspective view of the upper plate 1210 of the
cooking chamber floor 180. The upper plate 1210 includes a top
panel 1310 and a downwardly-extending wall 1320 around an outer
edge of the top panel 1310. The wall 1320 includes a front portion
1322 and a back portion 1324. The wall 1320 defines a pair of gaps
1326a,b between the front portion 1322 and the back portion 1324,
though gaps 1326a,b may not be present in various embodiments or
may be in different locations along the wall 1320 in various other
embodiments. The wall 1320 defines a plurality of holes 1330 spaced
around the wall 1320, though there may be any number of holes 1330,
including zero holes 1330, in various embodiments.
[0058] In various embodiments, internal corners or intersections
between surfaces may be given a radius or surfaces may be given a
raised lip or radii may otherwise be added to corners or edges
exposed inside cooking chamber 320 or heating chamber 330 in order
to reduce or eliminate traps for food and to facilitate cleaning In
various embodiments, these radii may be formed through one or more
processes including, but not limited to, welding, caulking, metal
forming, and molding,
[0059] FIG. 14 is a perspective view of the lower plate 1220 of the
cooking chamber floor 180.
[0060] The lower plate 1220 includes a bottom panel 1410 and an
upwardly-extending wall 1420 around an outer edge of the bottom
panel 1410. The wall 1420 includes a front portion 1422 and a back
portion 1424. The wall 1420 defines a pair of gaps 1426a,b between
the front portion 1422 and the back portion 1424, though gaps may
not be present in various embodiments or may be in different
locations along the wall 1420 in various other embodiments. The
wall 1420 defines a plurality of holes 1430 spaced around the wall
1420, though there may be any number of holes 1430, including zero
holes 1430, in various embodiments. The top panel 1310 is sized
larger than bottom panel 1410 so that wall 1420 of lower plate 1220
nests inside or inboard of wall 1320 of the upper plate 1210.
[0061] The plurality of holes 1430 of the lower plate 1220 are
positioned along the wall 1420 such that the holes 1430 align with
the holes 1330 of the upper plate 1210 along the wall 1320. The
holes 1330 and 1430 are sized to accept a fastener to attach the
upper plate 1210 to the lower plate 1220 to form cooking chamber
floor 180. Fasteners may include nuts and bolts, pins, screws, or
any other type of fastener. The upper plate 1210 may be attached to
the lower plate 1220 by other types of fasteners that do not use
holes 1330,1340, such as adhesives, welding, or clips. In various
embodiments, upper plate 1210 and the lower plate 1220 may be
formed from a single piece of sheet metal or may be formed by
injection molding, extrusion, machining, or other methods, and the
disclosed methods of forming or assembling cooking chamber floor
180 should not be considered limiting on the current
disclosure.
[0062] FIG. 15 shows a perspective view of the oven 100 showing the
cooking chamber floor 180 resting on the support clips 900a,b (900a
not shown) and the upper opening 410 of the wall 110. The ledge 382
of the cooking chamber floor 180 rests on a support ledge 1500
defined at a bottom edge of the upper opening 410.
[0063] FIG. 16 and FIG. 17 show perspective close-up views of the
support clip 900a holding up the cooking chamber floor 180. As
shown in FIG. 16, the bolt 950 extends through base 940 of the body
910.
[0064] FIG. 18 shows the oven floor 300. Similarly to cooking
chamber floor 180, the oven floor 300 includes a lower plate 1820
(shown in FIG. 20) nested in an upper plate 1810 with the space
between the upper plate 1810 and the lower plate 1820 filled with a
ceramic blanket 1800 (shown in FIG. 5) similar to ceramic blanket
1200. The upper plate 1810 includes a plurality of holes 1830 that
align with a plurality of holes (not shown) in the lower plate
1820, all of which are sized to accept a fastener such as a pin,
bolt, or screw, similar to upper plate 1210 and lower plate 1220 of
cooking chamber floor 180. Upper plate 1810 and lower plate 1820
may be attached to each other by any method, include the methods
previously described relating to upper plate 1210 and lower plate
1220, and the disclosed methods of forming or assembling oven floor
300 should not be considered limiting on the current disclosure. In
the current embodiment, the upper plate 1810 and the lower plate
1820 are both aluminum or aluminized steel, though other materials
including, but not limited to, stainless steel may be used in
various embodiments. In various embodiments, the oven floor 300 may
not be filled with a ceramic blanket 1800 and may be hollow or
filled with another insulation material. The oven floor 300 may
also be constructed of a solid material such as the materials of
the side panels 120a,b, including cordierite.
[0065] FIG. 19 shows a perspective view of the oven floor 300
resting on the bottom cap 254.
[0066] The oven floor 300 is sized to rest on an inner edge of the
bottom cap 254.
[0067] FIG. 20 shows a bottom view of the oven floor 300 resting on
the bottom cap 254. In various embodiments, a gasket may be placed
between the oven floor 300 and the bottom cap 254. To attach the
bottom cap 254 to corner posts 250a,b,c,d, self tapping screws are
screwed through the plurality of fastener holes 268 into the
plurality of fastener holes 722 of each corner post 250a,b,c,d.
Bottom frame pieces 258a,b,c,d also include fastener holes
2022a,b,c,d, respectively. To attach the bottom cap 254 to the oven
floor 300, fasteners such as screws or bolts may be inserted
through fastener holes 2022a,b,c,d into oven floor 300, which may
have corresponding fasteners holes (not shown). Bottom cap 254 may
also define four adjustment leg holes 2024a,b,c,d between each
bottom frame piece 258a,b,c,d, respectively. The four adjustment
leg holes 2024a,b,c,d may accept four adjustment legs (not shown)
which may be used to level the oven 100.
[0068] FIG. 21 shows a perspective view of the fire box 160. The
fire box 160 includes a body 2110, a grate 2120, a vent box 2130, a
front panel 2140, a vent cap 2150, a handle 2160, and wheels
2170a,b (2170a shown in FIG. 22). The body 2110 includes side
panels 2180a,b and a back panel 2190. The vent cap 2150 covers a
vent hole 580 (shown in FIG. 5) defined in the front panel 2140 and
is movable to uncover the vent hole 580 to allow air to enter the
heating chamber 330. The vent cap 2150 includes a vent cap handle
2152 for moving the vent cap 2150 to cover and uncover the vent
hole 580. The vent box 2130 provides a spacer between the front
panel 2140 and the grate 2120 to prevent ash from escaping the vent
hole 580 and to direct air flow through the vent hole 580 and under
the grate 2120 to combustible materials on the grate 2120 during
use. The wheels 2170a,b allow the fire box 160 to slide easily in
and out of the heating chamber 330 by pulling and pushing the
handle 2160. In the current embodiment, the handle 2160 is a
grip-style handle that can be accessed from above or below. In the
current embodiment, the handle 2160 is formed from a coiled metal
wire and is also hollow, though other handles may be present in
various embodiments. In various embodiments, it is be possible for
a hollow handle 2160 to remain at a lower temperature, especially
if made from a material that has a lower coefficient of thermal
conductivity such as stainless steel for metals and any one or more
of a number of non-metallic materials. In various embodiments, the
handle has a coating or a cover for aesthetic or functional
reasons. One functional reason for a coating or a cover would be to
insulate against a handle which may be too hot to touch for some
for some users.
[0069] FIG. 22 shows a top view of the fire box 160. As shown in
FIG. 22, an axle 2270 extends through the body 2110 underneath the
grate 2120 between the wheels 2170a,b. The grate 2120 defines a
pattern of slots 2220 to hold combustible material above bottom
floor of the body 2110. Any pattern of slots 2220 may be present in
various embodiments and the specific pattern of slots 2220 shown in
FIG. 22 should not be considered limiting on the current
disclosure.
[0070] FIG. 23 shows a perspective view of the fire box 160 from
the back side of the fire box 160. The vent box 2130 includes a
back panel 2330. The back panel 2330 has a lower edge 2730 (shown
in FIG. 27) that is raised above the body 2110 and is about level
with the grate 2120 to allow air flow from the vent hole 580 under
the lower edge 2730 and under the grate 2120 to the combustible
material.
[0071] FIG. 24 shows a perspective view of the vent cap 2150. The
vent cap 2150 includes a vent cover plate 2400 and a guide post
2450. In the current embodiment, the guide post 2450 has a square
cross-section and a plurality of teeth 2452 defined along a bottom
face of the guide post 2450 proximate the vent cover plate 2400.
The number of teeth 2452 varies widely in various embodiments. In
various embodiments, there will be a relatively large number of
teeth 2452 spaced closely together to allow for fine positioning of
the vent cap 2150. In various other embodiments, the teeth will be
larger and/or spaced apart for fewer adjustment positions of vent
cap 2150. The guide post 2450 is placed in a guide slot defined in
a protrusion 582 (shown in FIG. 5) extending from the front panel
2140 into the center of the vent hole 580. In the current
embodiment, the guide slot includes teeth so that the guide post
2450 may be held in various positions to allow various degrees of
venting.
[0072] The guide post 2450 is inserted into the guide slot and over
a support post 2760 (shown in FIG. 27) attached to the front panel
2140 and into a stop collar 2750 (shown in FIG. 27) fastened to the
support post 2760. When the vent cover plate 2400 covers the vent
hole 580, the guide post 2450 rests on the support post 2760 and
the teeth 2452 of the guide post 2450 engage a matching set of
teeth on the support post 2760 (shown in FIG. 27) to prevent the
vent cap 2150 from being pulled out of the vent hole 580. To
uncover the vent hole 580, the guide post 2450 must be lifted and
slid out by lifting the handle 2152. The stop collar 2750 prevents
the guide post 2450 from being lifted too far and aligns the guide
post 2450 with the support post 2760.
[0073] In various embodiments, the guide post 2450 may be a
threaded shaft and the guide slot may be a threaded hole to allow
the vent cap 2150 to be turned by the vent cap handle 2152 to move
the vent cap 2150 towards and away from the vent hole 580. In
embodiments where the guide post 2450 is threaded, the vent cap
handle 2152 being angled with respect to the guide post 2450 as
shown in the current embodiment may act as an indicator of the
degree to which the vent cap 2150 is distanced from the vent hole
580 so that a user may consistently set the amount of venting
during subsequent uses of the oven 100, though in other embodiments
the vent cap handle 2152 may not be angled and may extend straight
outward from the vent cap 2150 to allow for easy turning of the
handle 2152. In the current embodiment, the individual parts of
fire box 160 are fabricated from stainless steel although the
disclosure of stainless steel should not be considered limiting. In
various other embodiments, other materials including, but not
limited to, non-stainless steel may be used.
[0074] FIG. 25 shows a perspective view of the oven 100 from the
back side of the oven 100, with the back panel 130 removed. As
shown in FIG. 25, the fire box 160 is placed in the heating chamber
330 by rolling the fire box 160 into the heating chamber 330 on the
wheels 2170a,b. In various embodiments and depending on the height
and shape of back panel 2190 of fire box 160 relative to the height
of lower opening 412, fire box 160 may be tilted during
installation. The guide rails 310 guide the wheels 2170a,b of the
fire box 160 into the heating chamber 330. In various embodiments,
the guide rails 310 may surround the wheels 2170a,b on the top and
the bottom and include a safety catch at ends of the guide rails
310a,b proximate the lower opening 412 to prevent the fire box 160
from accidentally being pulled completely out of the heating
chamber 330 during use. In various embodiments, at least a portion
of the back panel 2190 of fire box 160 is taller than lower opening
412 to prevent the fire box 160 from accidentally being pulled
completely out of the heating chamber 330 during use. In various
embodiments, the fire box 160 may be placed on a track system
rather than on wheels 2170a,b to allow for the fire box 160 to be
pulled out and pushed into the oven 100, with the track system
connected to the oven floor 300 and with track interaction elements
connected to the fire box 160. In various other embodiments, the
fire box 160 may be placed directly on the oven floor 300 and slide
over the oven floor 300 by metal-on-metal contact between the oven
floor 300 and the body 2110.
[0075] FIG. 25 also shows the oven door 170 in the closed position
covering the upper opening 410. The oven door 170 includes a door
latch catch 2520 which latches with the door latch 520 when the
oven door 170 is in the closed position. The door latch catch 2520
is connected to the handle 172 to allow the door latch catch 2520
to be lowered by lifting on the handle 172 to unlatch the door
latch catch 2520 from the door latch 520. The oven door 170 also
includes a window 2570 mounted in a window frame 2580 on the oven
door 170. The oven door 170 also includes a tadpole gasket 2590
along a bottom of the oven door 170 to help seal the oven door 170
when in the closed position.
[0076] FIG. 26 shows a cross-sectional view of the oven 100 taken
along line 26-26 in FIG. 1. As shown in FIG. 26, the fire box 160
rests on the oven floor 300 between the guide rails 310a,b. The
wheels 2170a,b contact the oven floor 300 beside the guide rails
310a,b, which keep the fire box 160 in place laterally between the
side panels 120a,b. Also shown in FIG. 26 is the axle 2270
extending through the fire box 160 from wheel 2170a to wheel
2170b.
[0077] FIG. 26 also shows the cooking chamber floor 180 resting on
the support clips 900a,b, which are attached to corner posts
250b,c, respectively. The cooking chamber floor 180 is shown spaced
apart from side panels 120a,b, allowing air and smoke to flow from
heating chamber 330 to cooking chamber 320.
[0078] FIG. 27 shows a cross-sectional view of the oven 100 taken
along line 27-27 in FIG. 1.
[0079] As shown in FIG. 27, the vent box 2130 includes the back
panel 2330 having a lower edge 2730 that defines an air path from
the vent hole 580 into the vent box 2130 and below the lower edge
2730 to under the grate 2120 and then through the slots 2220 to
combustible material resting on the grate 2120.
[0080] Also shown in FIG. 27 is the cooking chamber floor 180
resting on the support ledge 1500 and the support clip 900b. The
handle 172 is also shown connected to the door latch catch 2520
through the oven door 170. The interaction between the door latch
catch 2520 and the door latch 520 is also shown.
[0081] FIG. 28 shows a perspective view of another embodiment of an
oven 2600 with the roof 140 removed. The oven 2600 includes side
panels 120a,b, front wall 110, back panel 130, and oven door 170.
As shown in FIG. 28, the oven door 170 includes the door hinge
2670. As previously discussed, the door hinge 2670 is mounted on
the hinge mount 510, mounting the oven door 170 on the front wall
110 and allowing the oven door 170 to be opened and closed.
Further, as shown in FIG. 28, the front wall 110 includes the
plurality of clip holes 2612 around the upper opening 410 and the
pair of gasket holes 2614a,b, one on each side of the upper opening
410. The clip holes 2612 are sized to accept a series of clips on a
clip gasket (not shown) and the gasket holes 2614a,b are sized to
accept each end of the clip gasket, so that the clip gasket can be
mounted around the upper opening 410 to seal the oven door 170 in
combination with the tadpole gasket 2590.
[0082] Oven 2600 also includes a cooking chamber floor 2680. The
cooking chamber floor 2680 is similar to cooking chamber floor 180
and further includes a plurality of notches 2682 adjacent side
panels 120a,b and back panel 130 to increase air flow from the
heating chamber 330 to cooking chamber 320. Oven 2600 also includes
corner covers 2690a,b,c,d for firmly holding the cooking chamber
floor 2680 in place and covering the corner posts 250a,b,c,d.
Cooking chamber floor 2680 also includes corner chamfers 2684 to
interface with the corner covers 2690a,b,c,d.
[0083] Oven 2600 also includes a fire box 2860. In the current
embodiment, the fire box 2860 includes a front panel 2840, a vent
cap 2850, and a handle 2865 mounted below the vent cap 2850 on the
front panel 2840. The vent cap 2850 covers a vent hole (not shown)
defined in the front panel 2840 and is movable to uncover the vent
hole. In the current embodiment, the vent cap 2850 is hinged and
includes a handle fastener hole 2852 sized to accept a fastener on
a vent cap handle (not shown). Hinge of the vent cap 2850 may be
oriented at an upper side, a lower side, a right side, or a left
side of the vent cap 2850. In various embodiments, the vent cap
2850 may be configured to pull outward from the front panel 2840
similar to a drawer to uncover the vent hole.
[0084] To use the oven 100, a heat source including combustible
materials such as charcoal, including lump or briquette charcoal,
or wood is placed on the grate 2120 of the fire box 160 and lit,
and the fire box 160 is slid into the heating chamber 330 to begin
heating the heating chamber 330 and the cooking chamber 320. In
various embodiments, a gas heat source such as propane may be used
instead of combustible materials within the fire box 160 and the
fire box 160 may not be present. In various other embodiments, the
fire box 160 may not be present and the grate 2120 may be placed
directly on the oven floor 300. The top plate 144 of the vent cap
142 and the vent cap 2150 are opened to allow air flow through the
oven 100. The side panels 120a,b, and the back panel 130, and the
cooking chamber floor 180 heat to a desired temperature. When the
side panels 120a,b and the back panel 130 are formed from
cordierite or other ceramics, the side panels 120a,b and the back
panel 130 maintain a steady temperature even when the oven door 170
is opened. The ceramic blanket 1200 in the cooking chamber floor
180 also maintains a steady temperature, even after food is removed
from the cooking surface 384. Because the ceramic blanket 1200 is
composed of ceramic fibers and includes space between the fibers,
the ceramic blanket 1200 also maintains a lower temperature than
the side panels 120a,b and the back panel 130, shedding excess heat
to prevent the temperature of the cooking chamber floor 180 from
rising above a desired cooking temperature and thereby preventing
food from overheating and burning. After heating up the oven 100,
food may be placed in the cooking chamber 320 for cooking Baking
stones are not required and food does not need to be rotated on the
cooking surface 384 because the temperature of the cooking chamber
floor 180 and the air within the cooking chamber 320 is even across
the cooking chamber floor 180 and the air within the cooking
chamber 320. In addition, food can be placed in the cooking chamber
320 in succession without waiting for the temperature within the
cooking chamber 320 to return to the desired temperature after a
first use.
[0085] One should note that conditional language, such as, among
others, "can," "could," "might," or "may," unless specifically
stated otherwise, or otherwise understood within the context as
used, is generally intended to convey that certain embodiments
include, while other embodiments do not include, certain features,
elements and/or steps. Thus, such conditional language is not
generally intended to imply that features, elements and/or steps
are in any way required for one or more particular embodiments or
that one or more particular embodiments necessarily include logic
for deciding, with or without user input or prompting, whether
these features, elements and/or steps are included or are to be
performed in any particular embodiment.
[0086] It should be emphasized that the above-described embodiments
are merely possible examples of implementations, merely set forth
for a clear understanding of the principles of the present
disclosure. Any process descriptions or blocks in flow diagrams
should be understood as representing modules, segments, or portions
of code which include one or more executable instructions for
implementing specific logical functions or steps in the process,
and alternate implementations are included in which functions may
not be included or executed at all, may be executed out of order
from that shown or discussed, including substantially concurrently
or in reverse order, depending on the functionality involved, as
would be understood by those reasonably skilled in the art of the
present disclosure. Many variations and modifications may be made
to the above-described embodiment(s) without departing
substantially from the spirit and principles of the present
disclosure. Further, the scope of the present disclosure is
intended to cover any and all combinations and sub-combinations of
all elements, features, and aspects discussed above. All such
modifications and variations are intended to be included herein
within the scope of the present disclosure, and all possible claims
to individual aspects or combinations of elements or steps are
intended to be supported by the present disclosure.
* * * * *