U.S. patent application number 15/350815 was filed with the patent office on 2017-03-02 for refractory cooking devices.
The applicant listed for this patent is Timothy M. Case. Invention is credited to Timothy M. Case.
Application Number | 20170055770 15/350815 |
Document ID | / |
Family ID | 49912863 |
Filed Date | 2017-03-02 |
United States Patent
Application |
20170055770 |
Kind Code |
A1 |
Case; Timothy M. |
March 2, 2017 |
REFRACTORY COOKING DEVICES
Abstract
A cooking device may include a refractory oven and a housing.
The refractory oven may define a cooking chamber that may be
configured to receive thermal energy from an external heat source.
The refractory oven may further define an opening configured to
allow foodstuffs to be introduced into the cooking chamber. The
refractory oven may be further configured to substantially surround
the foodstuffs while the foodstuffs are positioned inside the
cooking chamber. The housing may at least partially surround the
refractory oven. The housing and the refractory oven may define a
heated volume between an external surface of the refractory oven
and an internal surface of the housing. The heated volume may be
configured to receive thermal energy from the external heat source
and to reduce transfer of thermal energy from the cooking chamber
through refractory oven.
Inventors: |
Case; Timothy M.; (Mission
Viejo, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Case; Timothy M. |
Mission Viejo |
CA |
US |
|
|
Family ID: |
49912863 |
Appl. No.: |
15/350815 |
Filed: |
November 14, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13941176 |
Jul 12, 2013 |
9491951 |
|
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15350815 |
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|
61671725 |
Jul 14, 2012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24B 1/003 20130101;
Y02A 40/928 20180101; A47J 37/0704 20130101; A47J 37/0759 20130101;
A21B 1/00 20130101; A47J 37/0658 20130101; A21B 1/52 20130101; A47J
37/0786 20130101 |
International
Class: |
A47J 37/06 20060101
A47J037/06; A21B 1/52 20060101 A21B001/52; A47J 37/07 20060101
A47J037/07; F24B 1/00 20060101 F24B001/00 |
Claims
1. A cooking device comprising: a refractory oven that includes a
refractory top piece, two refractory side pieces, a refractory rear
piece, and a refractory bottom piece, wherein: the refractory oven
defines a cooking chamber configured to receive thermal energy from
an external heat source that is adjacent to an external surface of
the refractory bottom piece; the refractory oven defines a vent at
least partially between an end surface of the refractory bottom
piece and the refractory rear piece; the vent is configured to
enable transfer of convective thermal energy from the external heat
source to the cooking chamber; the refractory oven further defines
an opening opposite the refractory rear piece; and the refractory
oven is configured to allow foodstuffs to be introduced into the
cooking chamber and to allow at least a portion of the convective
thermal energy to exit the cooking chamber.
2. The cooking device of claim 1, wherein the refractory top piece,
the two refractory side pieces, and the refractory rear piece are a
single piece.
3. The cooking device of claim 1, wherein the refractory bottom
piece contacts the two refractory side pieces.
4. The cooking device of claim 2, wherein the refractory rear piece
is secured relative to the two refractory side pieces.
5. The cooking device of claim 4, further comprising: a housing
that surrounds external surfaces of the refractory top piece, the
two refractory side pieces, and the refractory rear piece when the
refractory oven is positioned in the housing; and a volume defined
between the external surfaces of at least one of the refractory top
piece, the two refractory side pieces, and the refractory rear
piece and an internal surface of the housing when the refractory
oven is positioned in the housing.
6. The cooking device of claim 5, wherein the volume is configured
to: receive thermal energy from the external heat source; and
reduce transfer of thermal energy from the cooking chamber.
7. The cooking device of claim 5, wherein the housing includes:
side portions that when the refractory oven is positioned in the
housing and centered therein are apart from the refractory side
pieces such that two side sub-volumes are defined between the side
portions and the refractory side pieces; a top portion that when
the refractory oven is positioned in the housing and centered
therein is apart from the refractory top piece such that a top
sub-volume is defined between the refractory top piece and the top
portion; and the volume includes the two side sub-volumes and the
top sub-volume.
8. The cooking device of claim 5, wherein: the housing includes a
front panel that defines a front panel opening; and the front panel
opening corresponds to the opening defined by the refractory oven
and positioned substantially adjacent to a front surface of the
refractory bottom piece, front surfaces of the two refractory side
pieces, and a front surface of the refractory top piece.
9. The cooking device of claim 8, wherein: the housing further
includes a rear panel and two side panels; the rear panel is
adjacent to the refractory rear piece; the two side panels are
positioned apart from the refractory side pieces; and the volume is
configured to receive thermal energy from areas between the side
panels and the refractory side pieces.
10. The cooking device of claim 9, wherein: the two side panels are
oriented substantially parallel to the refractory side pieces, and
the housing includes a top cover positioned apart from an external
surface of the refractory top piece.
11. The cooking device of claim 9, further comprising a support
brace that is attached to the two side panels, wherein the support
brace is configured to at least partially secure the refractory
oven to the housing.
12. The cooking device of claim 5, further comprising an insulative
insert that is affixed to the housing.
13. The cooking device of claim 1, wherein: the refractory oven
includes an internal surface that is configured as a boundary of
the cooking chamber; and the refractory oven is configured to
transfer thermal energy from the internal surface to the foodstuffs
via thermal radiation during heating of the foodstuffs while
positioned inside the cooking chamber.
14. The cooking device of claim 1, wherein the refractory oven
includes a cooking surface on which the foodstuffs are positioned
during cooking and which is configured to transfer thermal energy
to the foodstuffs via thermal conduction.
15. The cooking device of claim 1, wherein the external heat source
includes a charcoal grill, a wood grill, a natural gas grill, or a
propane grill.
16. The cooking device of claim 1, wherein: the external heat
source includes a grilling surface and a lid; and the cooking
device is configured to be positioned on the grilling surface with
the lid placed in a closed position or partially closed position
over the cooking device.
17. The cooking device of claim 1, wherein the refractory bottom
piece, the two refractory side pieces, the refractory rear piece,
and the refractory top piece are substantially rectangular.
18. The cooking device of claim 1, wherein the refractory top
piece, the two refractory side pieces, and the refractory rear
piece is a single piece.
19. The cooking device of claim 1, wherein one or both of the
refractory oven and the refractory bottom piece include
Cordierite.
20. The cooking device of claim 1, wherein: the refractory bottom
piece is configured to absorb a first portion of the thermal energy
received from the external heat source and to transfer the first
portion of the thermal energy to the foodstuffs in contact with the
refractory bottom piece via thermal conduction; the refractory top
piece, the two refractory side pieces, and the refractory rear
piece are configured to absorb a second portion of the thermal
energy received from the external heat source and to transfer the
second portion of the thermal energy to the foodstuffs via thermal
radiation; and the vent is configured to receive a third portion of
the thermal energy from the external heat source into the cooking
chamber and to transfer the third portion of the thermal energy to
the foodstuffs or to the refractory top piece, the two refractory
side pieces, the refractory rear piece, and the refractory bottom
piece via thermal convection.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of and priority
to U.S. patent application Ser. No. 13/941,176, filed Jul. 12,
2013, now U.S. Pat. No. 9,491,951, which claims priority to U.S.
Provisional Patent Application No. 61/671,725, filed Jul. 14, 2012,
both of which are incorporated herein by reference in their
entireties.
FIELD
[0002] The embodiments discussed herein are related to refractory
cooking devices.
BACKGROUND
[0003] Properly cooking certain foods may include the introduction
of the foods into a high-heat environment for a short period. By
applying the high-heat for the short period, specific
characteristics of the food may be achieved. For example, properly
cooking a New York style pizza and/or a Neapolitan style pizza may
include introducing an uncooked pizza into an oven with a
temperature between about 600 degrees Fahrenheit (F) and about 1100
degrees F. for between three and six minutes. The high-heat
environment may scorch the crust of the pizza while simultaneously
heating toppings and melting cheese.
[0004] However, creating a high-heat environment is difficult,
expensive, and inefficient in residential and small-scale
situations. Typically, high-heat environments are produced in large
ovens that may cost thousands of dollars and may occupy large
spaces. The large ovens may inefficiently consume fuel during the
heating and lose much of the heat following use. Additionally,
cooking using the large oven may involve learning "hot spots" and
"cool spots" which may be geometrically or environmentally
determined.
[0005] The subject matter claimed herein is not limited to
embodiments that solve any disadvantages or that operate only in
environments such as those described above. Rather, this background
is only provided to illustrate one example technology area where
some embodiments described herein may be practiced.
SUMMARY
[0006] According to an aspect of an embodiment, a cooking device is
disclosed. The cooking device may include a refractory oven and a
housing. The refractory oven may define a cooking chamber that may
be configured to receive thermal energy from an external heat
source. The refractory oven may further define an opening
configured to allow foodstuffs to be introduced into the cooking
chamber. The refractory oven may be further configured to
substantially surround the foodstuffs while the foodstuffs are
positioned inside the cooking chamber. The housing may at least
partially surround the refractory oven. The housing and the
refractory oven may define a heated volume between an external
surface of the refractory oven and an internal surface of the
housing. The heated volume may be configured to receive thermal
energy from the external heat source and to reduce transfer of
thermal energy from the cooking chamber through the refractory
oven.
[0007] The object and advantages of the embodiments will be
realized and achieved at least by the elements, features, and
combinations particularly pointed out in the claims.
[0008] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory and are not restrictive of the invention, as
claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Example embodiments will be described and explained with
additional specificity and detail through the use of the
accompanying drawings in which:
[0010] FIGS. 1A and 1B illustrate example cooking systems;
[0011] FIGS. 2A-2C illustrate an example cooking device that may be
implemented in the cooking system of FIGS. 1A and 1B;
[0012] FIGS. 3A-3C are sectional views that illustrate example
thermodynamic characteristics of the cooking device of FIGS.
2A-2C;
[0013] FIGS. 4A-4C illustrate an example refractory oven that may
be implemented in the cooking device of FIGS. 2A-2C; and
[0014] FIGS. 5A and 5B illustrate an example housing that may be
implemented in the cooking device of FIGS. 2A-2C, all in accordance
with at least one embodiment described herein.
DESCRIPTION OF SOME EXAMPLE EMBODIMENTS
[0015] Some embodiments discussed herein are related to refractory
cooking devices. An example embodiment includes a cooking device
that may include a refractory oven and a housing. The refractory
oven may define a cooking chamber that may be configured to receive
thermal energy from an external heat source. The cooking device may
create a high-heat environment that may be suitable to cook
foodstuffs such as New York style pizza Neapolitan style pizza,
steaks, casseroles, cookies, cakes, etc. As used herein, high-heat
may generally refer to an environment having a temperature between
about 600 degrees Fahrenheit (F) and about 1100 degrees F.
[0016] The refractory oven may also define an opening and a vent.
The opening may be configured to allow foodstuffs to be introduced
into the cooking chamber. The refractory oven may be configured to
absorb thermal energy received from the external heat source and
transfer the thermal energy to foodstuffs in contact with a cooking
surface of the refractory oven via thermal conduction. The
refractory oven may be configured to absorb the thermal energy and
transfer the thermal energy to the foodstuffs via thermal
radiation. Additionally, the vent and the opening may be configured
to allow the thermal energy from the external heat source to enter
the cooking chamber through the vent. The thermal energy is then
transferred to the foodstuffs via thermal convection.
[0017] The housing may at least partially surround the refractory
oven. The housing and the refractory oven may define a heated
volume between an external surface of the refractory oven and an
internal surface of the housing. The heated volume may be
configured to receive thermal energy from the external heat source
and to reduce transfer of thermal energy from the cooking chamber
through the refractory oven. Some additional embodiments will be
explained with reference to the accompanying drawings in which like
item numbers indicate like structures.
[0018] FIGS. 1A and 1B illustrate example cooking systems 100A and
100B in accordance with at least one embodiment described herein.
The cooking systems 100A and 100B may include an external heat
source 102 that may be configured to produce thermal energy that
may be received by a cooking device 104. Generally, the cooking
device 104 may be configured to be positioned relative to the
external heat source 102 such that the thermal energy produced by
the external heat source 102 may be received by the cooking device
104. The cooking device 104 may be configured to then transfer the
thermal energy to foodstuffs positioned inside the cooking device
104. Thus, the cooking device 104 may use the thermal energy
produced by the external heat source 102 to create a high-heat
environment.
[0019] In the cooking systems 100A and 100B, the cooking device 104
may be positioned on top of or generally above the external heat
source 102. The thermal energy produced by the external heat source
102 may accordingly heat a bottom portion of the cooking device
104. In some alternative embodiments, the cooking device 104 may be
positioned to the side of, in front of, below, or within the
external heat source 102. In these embodiments, the cooking device
104 may receive the thermal energy along a side portion, a rear
portion, the bottom portion, a top portion or any combination
thereof. For example, in FIG. 1B, the external heat source 102 may
include a lid 112. In FIG. 1B, the lid 112 is depicted in an open
position. However, the cooking device 104 may be positioned on a
grilling surface 114 of the external heat source 102 and the lid
112 may be moved to a closed position. In this circumstance, the
cooking device 104 may be substantially within the external heat
source 102. In an alternative example, the external heat source 102
may include a rotisserie cooking element, or the like, that is
positioned along a rear portion of the cooking device 104. In the
alternative example, the cooking device 104 may receive thermal
energy from a bottom portion and/or along a rear portion.
[0020] Additionally, in some embodiments a user may disassemble the
cooking device 104. When disassembled, the user may introduce some
alternative external heat sources to the cooking device 104 or may
enable direct heating through a disassembled portion of the cooking
device 104. For example, in the example above with the rotisserie
cooking element, a user may remove a rear portion of the cooking
device 104 to allow the thermal energy from the rotisserie cooking
element to more directly heat the cooking device 104.
[0021] Referring to FIGS. 1A and 1B, the cooking device 104 may be
removable from the external heat source 102. The removability of
the cooking device 104 may enable the cooking device 104 to be
positioned relative to one or more different external heat sources
and may enable use of the external heat source 102 without the
cooking device 104. For example, in the cooking system 100B in FIG.
1B, the external heat source 102 may include a propane grill. When
the cooking device 104 is positioned relative to the external heat
source 102, the cooking device 104 may substantially cover the
grilling surface 114. Thus, to otherwise use grilling surface 114
of the external heat source 102, a user may remove the cooking
device 104 from the external heat source 102.
[0022] Alternatively, in the cooking system 100A in FIG. 1A, the
cooking device 104 may be removable or may be attached to the
external heat source 102. In the embodiment depicted in FIG. 1A,
the cooking system 100A includes the cooking device 104, which may
be positioned next to an independent grill 106. The cooking device
104 and the independent grill 106 may share a support structure
108. In embodiments in which the cooking device 104 is attached to
the external heat source 102, the cooking device 104 may be secured
to the support structure 108 during a substantial portion of the
useful life of the cooking system 100A. In embodiments in which the
cooking device 104 is removable, the cooking device 104 may be
removed from the support structure 108 between uses to enable
another application of the external heat source 102.
[0023] The cooking system 100A includes the independent grill 106,
which may include, but is not limited to, a propane grill, a
natural gas grill, a charcoal grill, a wood grill, an electrical
grill, etc. However, the configuration of the cooking system 100A
is not meant to be limiting. In some alternative embodiments, the
cooking system 100A may only include the cooking device 104, which
may be attached to the support structure 108. Alternatively still,
the cooking device 104 may be paired with another appliance or
device.
[0024] In the cooking systems 100A and 100B, the cooking device 104
and the external heat source 102 may share a fuel and/or a fuel
source (not shown). For example, in the cooking system 100A of FIG.
1A, the independent grill 106 may use propane gas as a fuel. One or
more knobs 110A may control a supply of the fuel to the independent
grill 106, while one or more other knobs 110B may control a supply
of the fuel to the cooking device 104. In some alternative
embodiments, the independent grill 106 and the cooking device 104
may be fueled by different fuel sources. For example, the
independent grill 106 may be charcoal or wood grill while the
cooking device 104 may be heated by burning propane gas.
[0025] In the cooking system 100B of FIG. 1B, the cooking device
104 may essentially take the place of foodstuffs being heated on
the grilling surface 114. Thus, the external heat source 102 may
generate thermal energy using the fuel source and the thermal
energy may then be directly transferred to the cooking device 104.
In some embodiments, the cooking device 104 may be sized such that
the cooking device 104 covers a substantial portion of the grilling
surface 114. In these and other embodiments, a majority of the
thermal energy produced by the external heat source 102 may be
transferred to the cooking device 104. Alternatively, the cooking
device 104 may be sized to cover only a portion of the grilling
surface 114. In these and other embodiments, sizing the cooking
device 104 to cover only a portion of the grilling surface 114 may
enable use of the cooking device 104 with foodstuffs positioned on
a remainder of the grilling surface 114, for instance.
[0026] The external heat source 102 may include, but is not limited
to, a charcoal grill, a wood grill, a wood smoker, a gas smoker, a
pellet stove, a natural gas grill, an electric grill, an electric
oven, a gas oven, or a propane grill. Accordingly, a fuel source of
the external heat source 102 may include any fuel that generates
thermal energy that may be transferred to the cooking device 104.
For example, the fuel source may include, but is not limited to,
propane gas, natural gas, wood, wood pellets, charcoal,
electricity, etc.
[0027] In some embodiments, the external heat source 102 may be
configured for residential or outdoor settings. For example, in
embodiments in which the external heat source 102 is a propane
grill, the external heat source 102 may be configured for use on a
deck or a patio or in a backyard of a user. Accordingly, the
cooking device 104, when used in conjunction with the external heat
source 102 may enable creation of a high-heat environment at a
residence of a user. This may enable the efficient use of the
external heat source 102, may allow creation of the high-heat
environment without heating the interior of a house of the user,
and may efficiently use and re-purpose an external heat source 102
that the user already owns. In some embodiments, the external heat
source 102 may be configured for a commercial charbroiler or gas
grill. In these and other embodiments, the cooking device 104 may
be used in conjunction with the external heat source 102 to enable
creation of a high-heat environment at a commercial kitchen or
restaurant. Again, use of the cooking device 104 may enable the
efficient use of the external heat source 102, may allow creation
of the high-heat environment without heating an entire restaurant,
and may efficiently use and re-purpose an external heat source 102
that the user already owns.
[0028] FIGS. 2A-2C illustrate an example cooking device 104 that
may be implemented in the cooking systems 100A and 100B of FIGS. 1A
and 1B in accordance with at least one embodiment described herein.
Specifically, FIG. 2A is a perspective view of the cooking device
104, FIG. 2B is a second perspective view of the cooking device
104, and FIG. 2C is a partially exploded view of the cooking device
104. The cooking device 104 may generally be configured to receive
thermal energy from an external heat source such as the external
heat source 102 of FIGS. 1A and 1B, and to transfer the thermal
energy to foodstuffs positioned inside the cooking device 104. The
cooking device 104 may be suitable for cooking foodstuffs that are
properly cooked in a high-heat environment through efficient
retention and transfer of thermal energy to the foodstuffs. For
example, the cooking device 104 may be configured to substantially
surround foodstuffs while foodstuffs are positioned inside the
cooking device 104 and may use a combination of thermal conduction,
thermal convection, and thermal radiation to heat the
foodstuffs.
[0029] The cooking device 104 may include a refractory oven 202.
The refractory oven 202 may be used in combination with a housing
206 or may be used without the housing 206. For instance, with
combined reference to FIGS. 1B and 2C, the refractory oven 202 may
be positioned on the grilling surface 114 of the external heat
source 102 without the housing 206. The lid 112 may be placed in
the closed position over the refractory oven 202, may be placed in
a partially closed position, may be left in the open position, or
aluminum foil may be used to cover the refractory oven 202. The
refractory oven 202 may receive thermal energy from the external
heat source 102. Alternatively, the refractory oven 202 may be
positioned within the housing 206. The refractory oven 202 and the
housing 206 may then be positioned on the grilling surface 114 as
shown in FIG. 1B.
[0030] Referring back to FIGS. 2A-2C, when the housing 206 is used
with the refractory oven 202, the housing 206 may at least
partially surround the refractory oven 202. In some embodiments,
the refractory oven 202 may be introduced into the housing 206
through a bottom opening 208. With reference to FIGS. 2B and 2C,
for instance, with the housing 206 held in a constant position, the
refractory oven 202 may be moved in the arbitrarily defined
positive y-direction and thus be introduced into the housing
206.
[0031] In some embodiments, one or more support braces 218 may be
included in the cooking device 104. The one or more support braces
218 (FIGS. 2B and 2C only) may be configured to at least partially
secure the refractory oven 202 to the housing 206. Additionally,
the support braces 218 may lift the refractory oven 202 some
distance off a grilling surface. For example, with combined
reference to FIGS. 1B, 2B, and 2C, when the cooking device 104 is
positioned on the grilling surface 114, the support braces 218 may
lift the refractory oven 202 a distance from the grilling surface
114. For example, a bottom surface 220 (FIG. 2B only) of the
support braces 218 may be in contact with the grilling surface,
which may lift the refractory oven 202 the distance from the
grilling surface. In this and other examples, the distance may be
about equal to a height 222 (FIGS. 2B and 2C only) of the support
braces 218. By lifting the refractory oven 202, a portion of the
thermal energy that may have otherwise been received by the
refractory oven 202 may escape to a surrounding environment and/or
be received by a heated volume 210 (discussed below), which may be
defined between the housing 206 and the refractory oven 202.
Additionally, lifting the refractory oven 202 from the grilling
surface 114 may decrease wear imposed on the grilling surface 114
that may result from having the refractory oven 202, after being
heated, in direct contact with the grilling surface 114.
[0032] Referring back to FIGS. 2A-2C, the cooking device 104 may
generally define two volumes. A first volume, which is referred to
herein as a cooking chamber 204, may be defined by the refractory
oven 202. For example, the cooking chamber 204 may include a volume
that is substantially bordered by an internal surface 226 and a
cooking surface 216 of the refractory oven 202.
[0033] The cooking chamber 204 may be configured to receive thermal
energy from an external heat source (e.g., the external heat source
102 of FIGS. 1A and 1B). In some embodiments, the cooking chamber
204 may receive multiple types of thermal energy, which may be
transferred to foodstuffs that are positioned inside the cooking
chamber 204. Specifically, the refractory oven 202 may be
configured to absorb and to retain thermal energy in the structure
of the refractory oven 202. The internal surface 226 of the
refractory oven 202 may then transfer the absorbed thermal energy
to foodstuffs positioned therein via thermal radiation.
Additionally, when foodstuffs are positioned inside the refractory
oven 202, the foodstuffs may be positioned in contact with the
cooking surface 216. While positioned in contact with the cooking
surface 216, thermal energy may be transferred to the foodstuffs
via thermal conduction. Additionally still, while foodstuffs are
positioned inside the refractory oven 202, a heated gas may be
passed over the foodstuffs. Thermal energy in the heated gas may be
transferred to the foodstuffs via thermal convection. The heated
gas may include heated ambient air and/or exhaust gases that may
result from combustion of a flammable gas, charcoal, wood, wood
pellets, etc.
[0034] For example, with specific reference to FIG. 2B, the
refractory oven 202 may define an opening 250 and a vent 224. The
opening 250 may be configured to allow foodstuffs to be introduced
into and removed from the cooking chamber 204. The vent 224 may be
positioned in relationship to the opening 250 to receive a portion
of the thermal energy in a heated gas into the cooking chamber 204
and to allow the portion of the heated gas to flow across the
foodstuffs toward the opening 250. The opening 250 may be
configured to allow the portion of the thermal energy to exit the
cooking chamber 204. The opening 250 may be left open or may be
selectively covered by a door (not shown). In embodiments without a
door, or positioning the door in an open position, may allow
monitoring and adjustment of foodstuffs through the opening
250.
[0035] In some embodiments, the opening 250 may be positioned
opposite the vent 224. In these and other embodiments, the vent 224
may allow a heated gas to enter the cooking chamber 204 then pass
over foodstuffs positioned inside the refractory oven 202. The
opening 250 may be configured to allow the heated gas or thermal
energy included therein to exit the cooking chamber 204. As the
heated gas passes over the foodstuffs positioned between the vent
224 and the opening 250, thermal energy may be transferred to the
foodstuffs via thermal convection.
[0036] In this and other embodiments, the refractory oven 202
defines one vent 224, the vent 224 is substantially rectangular,
the vent 224 spans essentially a width of the refractory oven 202,
and the vent 224 is defined towards a rear portion (opposite the
opening 250) of the refractory oven 202. This configuration of the
vent 224 is not meant to be limiting. For example, some embodiments
may include multiple vents that include various shapes and that may
be defined at one or more other locations on the refractory oven
202. Additionally, in this and other embodiments, the heated gas
may exit through the opening 250. However, this is not meant to be
limiting. In some embodiments, the heated gas may exit through one
or more other openings and/or one or more vents defined in the
refractory oven 202.
[0037] Referring back to FIGS. 2A-2C, the second volume included in
the cooking device 104, which is referred to herein as the heated
volume 210, may be defined by the housing 206 and the refractory
oven 202. The heated volume 210 may be defined between an external
surface 212 (FIGS. 2B and 2C only) of the refractory oven 202 and
an internal surface 214 (FIGS. 2B and 2C only) of the housing 206.
The heated volume 210 may also be defined to be bordered by the
bottom opening 208 of the housing 206. The heated volume 210 may be
configured to receive thermal energy from an external heat
source.
[0038] With reference to FIG. 2B, the internal surface 214 of the
housing 206 and the external surface 212 of the refractory oven 202
may be separated by distances 228. The distances 228 may run along
the length 230 of the housing 206, which may create an area of the
bottom opening 208 in which thermal energy may enter the heated
volume 210. For example, with combined reference to FIGS. 1B and
2B, when the cooking device 104 is positioned on the grilling
surface 114, a portion of the grilling surface 114 may be
positioned beneath the area of the bottom opening 208 between the
internal surface 214 of the housing 206 and the external surface
212 of the refractory oven 202. The external heat source 102 may
accordingly transfer thermal energy to the heated volume 210.
[0039] In this and other embodiments, the distances 228 may be
essentially constant along the length 230 of the housing 206.
However, in some alternative embodiments, the distances 228 may
vary along the length of the housing 206. The distances 228 may be
based on the shapes of the refractory oven 202 and the housing 206,
for instance. Additionally, in this and other embodiments, the
refractory oven 202 and the housing 206 may be configured such that
the distances 228 may only exist on a left side, which is generally
indicated in FIG. 2B by 252, and a right side, which is generally
indicated in FIG. 2B by 254, of the refractory oven 202. However,
in alternative embodiments, the refractory oven 202 and the housing
206 may be configured such that distances 228 may exist on the left
side 252, the right side 254, a front, which is generally indicated
in FIG. 2B by 256, a back, which is generally indicated in FIG. 2B
by 258, or any combination thereof. Additionally, in this and other
embodiments, the distances 228 may be essentially equal on the left
side 252 and on the right side 254 of the refractory oven 202,
which may essentially center the refractory oven 202 with respect
to the housing 206 in the x-direction. However, in some
embodiments, the distances 228 on the right side 254 of the
refractory oven 202 may be different from the left side 252 of the
refractory oven 202.
[0040] Referring back to FIGS. 2A-2C, the heated volume 210 may be
configured to reduce the transfer of thermal energy from the
cooking chamber 204 through the refractory oven 202. As mentioned
above, the structure of the refractory oven 202 may absorb thermal
energy, which may be transferred to foodstuffs through thermal
radiation. By lowering a thermal gradient at the external surface
212 of the refractory oven 202 (i.e., by heating the heated volume
210), the thermal energy absorbed by the thermal energy may be
retained in the structure of the refractory oven 202. Some
additional details of the heated volume 210 are provided with
reference to FIGS. 3A-3C.
[0041] In this and other embodiments, the cooking device 104 may be
generally rectangular. For example, the refractory oven 202 may
include substantially rectangular surfaces (e.g., 212, 216, and
226) and the bottom opening 208 into which the refractory oven 202
may be introduced may be substantially rectangular. The rectangular
shape of the cooking device 104 may correspond to external heating
devices that include grilling surfaces (e.g., the grilling surface
114 of FIG. 1B) that may be rectangular. Accordingly, the cooking
device 104 may receive thermal energy from a substantial portion of
a grilling surface and/or may not hang off the edges of the
grilling surface. In alternative embodiments, the cooking device
104 may be generally circular, oval, square, or "D"-shaped. In
these and other alternative embodiments, the vent 224, the opening
250, the distances 228, the heated volume 210, the cooking chamber
204, etc. may include different shapes than those shown in FIGS.
2A-2C, and may perform one or more similar functions.
[0042] Additionally, the cooking device 104 may include one or more
thermometers 232. The thermometer 232 may be used to monitor the
temperature of the heated volume 210 and/or the cooking chamber
204. The thermometer 232 may include a bi-metal thermometer, an
infrared thermometer, a resistance thermometer, a thermocouple, a
pyrometer, or any other type of suitable temperature measuring
device.
[0043] Additionally, the cooking device 104 may include one or more
lid supports 234. The lid supports 234 may be used to support a lid
such as the lid 112 of FIG. 1B. For example, when the cooking
device 104 is positioned relative to an external heat source that
includes a lid, the lid may be positioned in a partially closed
position in which the lid rests on the lid supports 234.
[0044] Additionally, the cooking device 104 may include a firebox
(not shown). The firebox may be constructed from expanded sheet
metal, perforated metal, or the like. The firebox may be positioned
in the cooking chamber 204. A fire may be started in the firebox to
introduce additional radiant heating to foodstuffs positioned in
the cooking chamber 204. Additionally or alternatively, the firebox
may be configured to receive woods or wood chips that may be used
to introduce smoke into the cooking chamber 204. The smoke may
flavor the foodstuffs.
[0045] The refractory oven 202, or some portion thereof, may be
composed of a material selected for thermal conductivity, strength,
density, and thermal shock resistance properties. For example, the
refractory oven 202 may be composed of Cordierite and
FibraMent.RTM..
[0046] FIGS. 3A-3C are sectional views of the cooking device 104
that illustrate example thermodynamic characteristics of the
cooking device 104 in accordance with at least one embodiment
described herein. Specifically, FIG. 3A is a sectional view
generated using a first plane labeled 3A in FIG. 2A. FIG. 3B is a
second sectional view generated using a second plane labeled 3B in
FIG. 2A. FIG. 3C is a third sectional view generated using a third
plane labeled 3C in FIG. 2A. Generally, the first, second, and
third sectional views are substantially orthogonal to one another.
FIGS. 3A-3C illustrate the cooking device 104 described with
reference to FIGS. 1A-2C. Accordingly, multiple components and
features (e.g., 202, 204, 206, 208, 224, 228, 230, and 250)
described with reference to FIGS. 1A-2C are included in FIGS.
3A-3C. Some details of these components and features are not
repeated with reference to FIGS. 3A-3C.
[0047] In FIGS. 3A-3C, thermal energy may be transferred from an
external heat source to the cooking device 104. The thermal energy
transferred from the external heat source is represented in FIGS.
3A and 3B by block arrows 302. As best illustrated in FIG. 3A, the
thermal energy 302 may be received by the refractory oven 202 and
the heated volume 210. The thermal energy 302 received by the
refractory oven 202 may be used to heat foodstuffs 304 positioned
within the cooking chamber 204 and the thermal energy 302 received
by the heated volume 210 may be used to reduce thermal energy
transfer from the cooking chamber 204 through the refractory oven
202.
[0048] As mentioned above, heating the foodstuffs 304 may occur in
multiple modes of thermal energy transfer. The multiple modes of
thermal energy transfer may combine to create a high-heat
environment in the cooking chamber 204 as well as combine to heat
the foodstuffs 304 while positioned inside the cooking chamber
204.
[0049] A first mode may include thermal radiation. The thermal
radiation is represented in FIGS. 3A-3C by dashed, curved, thin
arrows 306. Generally, thermal radiation 306 may occur when the
refractory oven 202 absorbs thermal energy. The thermal radiation
306 may be emitted by the internal surface 226 and/or the cooking
surface 216 of the refractory oven 202. As shown in FIGS. 3A-3C,
thermal energy may be transferred to the foodstuffs 304 via thermal
radiation 306 that may originate throughout the refractory oven
202. Accordingly, a substantial portion of the foodstuffs 304
and/or multiple surfaces of the foodstuffs 304 may be heated by the
thermal radiation 306.
[0050] A second mode of thermal energy transfer may include thermal
conduction. In FIGS. 3A and 3B, the thermal conduction is
represented by solid arrows 308. Generally, thermal conduction 308
may occur when two objects having differing temperatures contact
one another. In the cooking device 104, the foodstuffs 304 may be
positioned to contact the cooking surface 216. The cooking surface
216 may have been heated by the thermal energy 302 received from
the external heat source. Accordingly, when the foodstuffs 304
contacts the cooking surface 216, the cooking surface 216 may
transfer thermal energy to the foodstuffs 304 via thermal
conduction 308.
[0051] A third mode of thermal energy transfer may include thermal
convection. In FIGS. 3B and 3C the thermal convection is
represented by dashed, curved thick arrows 310. Generally, thermal
convection 310 may occur when a heated gas moves through the
cooking chamber 204. In this and other embodiments, the thermal
energy 302 may heat air or another gas in the cooking chamber 204
or may emit a heated fluid. The heated gas may enter the cooking
chamber 204 through the vent 224 and exit the cooking chamber 204
through the opening 250. As the heated gas passes over and/or
around the foodstuffs 304, thermal energy may be transferred to the
foodstuffs via thermal convection 310.
[0052] In this and other embodiments, the heated volume 210 may
include a volume that partially surrounds the refractory oven 202.
Specifically, the heated volume 210 may include multiple
sub-volumes 318, 320, and 322. As best illustrated in FIG. 3A, the
sub-volumes 318, 320, and 322 may each be heated by the thermal
energy 302 received from the external heat source.
[0053] A first sub-volume 318 of the heated volume 210 may be
defined between a first panel 326 of the housing 206, a first side
portion 324 of the refractory oven 202, and a top cover 332 of the
housing 206. Thus, the first sub-volume 318 may include a width
substantially equal to the distance 228, a height substantially
equal to a height 314 of the housing 206, and a length
substantially equal to the length 230 of the housing 206. The
height 314 of the housing 206 may vary along the length 230.
[0054] Likewise, a second sub-volume 320 may be defined between a
second panel 328 of the housing 206, a second side portion 330 of
the refractory oven 202, and a top cover 332 of the housing 206.
Thus, the second sub-volume 320 may include a width substantially
equal to the distance 228, a height substantially equal to the
height 314 of the housing 206, and a length substantially equal to
the length 230 of the housing 206.
[0055] A third sub-volume 322 may be defined between the first and
second sub-volumes 318 and 320 and between a top portion 334 of the
refractory oven 202 and the top cover 332 of the housing 206. A
second distance 312 may be defined as a distance between the top
portion 334 and the top cover 332. In this and other embodiments,
the top cover 332 may be curved in the yz-plane, thus the second
distance 312 (and the height 314 of the housing 206) may vary along
the length 230 of the housing 206 and may be constant along a width
316 of the housing 206. Additionally or alternatively, the top
cover 332 may be curved in the xy-plane. In these and other
embodiments, the second distance 312 (and the height 314 of the
housing 206) may vary along the width 316 and/or the length 230 of
the housing 206.
[0056] In some embodiments, to heat the heated volume 210, the
thermal energy 302 may enter the first and second sub-volumes 318
and 320. The thermal energy 302 may then heat the third sub-volume
322. When the sub-volumes 318, 320, and 322 are heated, the heated
volume 210 may reduce transfer of thermal energy from the cooking
chamber 204 through the refractory oven 202. For example, with
reference to FIG. 3B, the heated volume 210 may be heated to reduce
a thermal gradient between the cooking chamber 204 and the heated
volume 210 across the top portion 334. Thus, thermal energy
transfer through the top portion 334 may be reduced.
[0057] In effect, by reducing transfer of thermal energy from the
cooking chamber 204, the heated volume 210 additionally reduces a
thermal gradient within the cooking chamber 204. For example,
without the housing 206 and/or the heated volume 210, thermal
energy may be lost through the refractory oven 202. Consequently,
the top portion 334, the first side portion 324, and the second
side portion 330, other portions, or some combination thereof of
the refractory oven 202 may be at a low temperature when compared
to a bottom portion 336 of the refractory oven 202. The lower
temperatures of some portion of the refractory oven 202 may create
temperature gradients within the cooking chamber 204. Additionally,
the lower temperature of the top portion 334, the first side
portion 324, and the second side portion 330 may reduce the
transfer of thermal energy to the foodstuffs 304 via the thermal
radiation 306.
[0058] In some embodiments, configurations of the heated volume 210
and/or the cooking chamber 204 may control one or more thermal
characteristics of the cooking device 104. In particular, the
configurations of the heated volume 210 and/or the cooking chamber
204 may determine the distance 228, the second distance 312, a
variation of the distances 228 along the length 230, a variation of
the second distance 312 along the width 316 and/or the length 230,
or some combination thereof. For example, in some embodiments, the
distances 228 and the second distance 312 may be configured such
that when the cooking surface 216 is above about 600 degrees F.,
the temperature gradients within the cooking chamber 204 may be
maintained between about 75% and about 100% of the temperature of
the cooking surface 216. Additionally or alternatively, the heated
volume 210 and/or the cooking chamber 204 may be configured to
maintain the temperatures of the refractory oven 202 within about
100 degrees F. when the cooking surface 216 is between about 600
degrees F. and about 1100 degrees F.
[0059] As best illustrated in FIGS. 3B and 3C, the housing 206 may
be separated from the refractory oven 202 along the side portions
324 and 330 and the top portion 334, thereby creating the heated
volume 210. Additionally, the housing 206 may be substantially
adjacent to the refractory oven 202 along a rear portion 340 and
around a perimeter of the opening 250. In these and other
embodiments, the heated volume 210 may, accordingly, not include
sub-volumes along the rear portion 340 and/or around the perimeter
of the opening 250. However, this configuration of the heated
volume 210 is not meant to be limiting. In some alternative
embodiments, the heated volume 210 may include sub-volumes along
the rear portion 340 and/or around the perimeter of the opening
250.
[0060] FIGS. 4A-4C illustrate an example refractory oven 400 that
may be implemented in the cooking device 104 of FIGS. 2A-2C in
accordance with at least one embodiment described herein. The
refractory oven 400 may be substantially similar to the refractory
oven 202 discussed with reference to FIGS. 2A-3C. For example, the
refractory oven 400 may define the cooking chamber 204, the vent
224, and the opening 250. Additionally, the refractory oven 400 may
receive thermal energy from an external heat source such as the
external heat source 102 of FIGS. 1A and 1B. Some details of the
cooking chamber 204, the vent 224, and the opening 250 or the
general functions of the refractory oven 400 are not repeated with
reference to FIGS. 4A-4C.
[0061] In some embodiments, the refractory oven 400 may include a
refractory top piece 406, two refractory side pieces 408 and 412, a
refractory rear piece 414, and a refractory bottom piece 410
(collectively, refractory pieces). With combined reference to FIGS.
3A-4C, the refractory top piece 406 may be substantially similar to
and/or correspond to the top portion 334, two refractory side
pieces 408 and 412 may be substantially similar to and/or
correspond to two side portions 324 and 330, the refractory bottom
piece 410 may be substantially similar to and/or correspond to the
bottom portion 336, the refractory rear piece 414 may be
substantially similar to and/or correspond to the rear portion 340,
or any combination thereof.
[0062] The refractory top piece 406, the two refractory side pieces
408 and 412, the refractory rear piece 414, and the refractory
bottom piece 410 may be combined to define the cooking chamber 204.
The refractory bottom piece 410 may include the cooking surface 216
described above and a heated surface 416 (FIG. 4B only). When the
refractory oven 400 is positioned adjacent to an external heat
source, the heated surface 416 may be oriented towards the external
heat source. Additionally, the vent 224 may be defined between an
end surface 418 (FIG. 4C only) of the refractory bottom piece 410
and the refractory rear piece 414. Additionally, in the refractory
oven 400, the opening 250 may be defined opposite the refractory
rear piece 414. As above, the opening 250 may be configured to
enable introduction and removal of foodstuffs from the cooking
chamber 204 and to allow thermal energy to exit the cooking chamber
204.
[0063] Functionally, in the refractory oven 400, the refractory
bottom piece 410 may be configured to absorb a first portion of the
thermal energy received from the external heat source. The
refractory bottom piece 410 may be further configured to transfer
the absorbed first portion of the thermal energy to foodstuffs in
contact with the refractory bottom piece 410 via thermal
conduction. Additionally, the refractory top piece 406, the two
refractory side pieces 408 and 412, and the refractory rear piece
414 may be configured to absorb a second portion of the thermal
energy received from the external heat source. The refractory top
piece 406, the two refractory side pieces 408 and 412, and the
refractory rear piece 414 may be configured to transfer the
absorbed thermal energy to the foodstuffs via thermal radiation.
Additionally, the vent 224 may be configured to receive a third
portion of the thermal energy from the external heat source as it
enters the cooking chamber 204. The thermal energy may then be
transferred to the foodstuffs via thermal convection. Additionally
or alternatively, the thermal energy may be transferred to the
refractory top piece 406, the two refractory side pieces 408 and
412, the refractory rear piece 414, and/or the refractory bottom
piece 410 via thermal convection. Additionally or alternatively,
the thermal energy may exit the cooking chamber 204 through the
opening 250.
[0064] In some embodiments, one or more of the refractory pieces
may be secured to one another. As best illustrated in FIG. 4C, one
or more of the refractory pieces may include interlocking
protrusions 428 (FIG. 4C only) and slots 430 (FIGS. 4B and 4C only)
that may enable the refractory pieces to be secured with respect to
one another. For example, in this and other embodiments, the
refractory bottom piece 410 may be secured to the two refractory
side pieces 408 and 412, the refractory top piece 406 may be
secured to the two refractory side pieces 408 and 412, and the
refractory rear piece 414 may be secured to the two refractory side
pieces 408 and 412.
[0065] In some alternative embodiments, one or more of the
refractory pieces may be a single piece. For example, in some
embodiments, the two refractory side pieces 408 and 412, the
refractory top piece 406, and the refractory rear piece 414 may be
a single piece referred to as a refractory enclosure 402 (FIG. 4B
only). In these and other embodiments, the interlocking protrusions
428 and the slots 430 between the two refractory side pieces 408
and 412, the refractory top piece 406, and the refractory rear
piece 414 may be omitted and the refractory enclosure 402 may be
manufactured as a single piece.
[0066] The refractory enclosure 402 may be positioned with respect
to the refractory bottom piece 410 to define the cooking chamber
204. In particular, the refractory enclosure 402 may be positioned
with respect to the refractory bottom piece 410 such that the
internal surface 226 of the refractory enclosure 402 and a cooking
surface 216 of the refractory bottom piece 410 define the cooking
chamber 204. In some alternative embodiments, the refractory
enclosure 402 may include another combination of the refractory
pieces, without limitation.
[0067] In this and other embodiments, the refractory oven 400 is
substantially rectangular. Specifically, the refractory bottom
piece 410, the two refractory side pieces 408 and 412, the
refractory top piece 406 and the refractory rear piece 414 are
substantially rectangular. As used herein with reference to the
refractory oven 400, the term "substantially rectangular" may refer
to the overall or general shape of the refractory oven 400 or the
refractory pieces 410, 408, 412, 406, and 414, which may include
the interlocking protrusions 428 and the slots 430. However, this
is not meant to be limiting. In some alternative embodiments, the
refractory oven 400 may take other shapes such as a dome or
pyramidal shaped. In these alternative embodiments, one or more of
the refractory bottom piece 410, the two refractory side pieces 408
and 412, the refractory top piece 406 and the refractory rear piece
414 may be curved and/or non-rectangular.
[0068] In some embodiments, one or more of the refractory pieces
may be composed of a material selected for thermal conductivity,
strength, density, and thermal shock resistance properties. For
example, one or more of the refractory pieces may be composed of
Cordierite and FibraMent.RTM..
[0069] FIGS. 5A and 5B illustrate an example housing 500 that may
be implemented in the cooking device 104 of FIGS. 2A-2C in
accordance with at least one embodiment described herein.
Specifically, FIG. 5A is a perspective view of the housing 500 and
FIG. 5B is a partially exploded view of the housing 500. The
housing 500 may be substantially similar to and/or correspond to
the housing 206 of FIGS. 2A-3C. Accordingly, one or more components
or features (e.g., 218) of the housing 206 may be included in the
housing 500. Some details of these components and features are not
repeated with reference to FIGS. 5A and 5B. As discussed above, the
housing 500 may be configured to surround or partially surround a
refractory oven such as the refractory oven 400 of FIGS. 4A-4C
and/or the refractory oven 202 of FIGS. 2A-3C.
[0070] In this and other embodiments, the housing 500 may be
composed of a metal. For example, the housing 500 may be composed
of a carbon steel or an aluminum. In some alternative embodiments,
the housing 500 or some portion thereof may be composed of a
ceramic material. Additionally, some alternative embodiments may
include a metallic housing 500 that is coated with insulation
and/or includes insulative inserts that are attached or affixed to
the metallic housing 500.
[0071] The housing 500 may include one or more panels 502, 504,
506, 508, and 510 that may be attached and/or formed as a single
piece. In particular, in this and other embodiments, the housing
500 may include a front panel 504, a rear panel 508, two side
panels 506 and 510, and a top cover 502. The top cover 502 and the
front panel 504 may be formed as a single piece in this and other
embodiments, and the rear panel 508 and the two side panels 506 and
510 may be attached to the top cover 502 and the front panel 504
using one or more fasteners. This configuration of the housing 500
is not limiting. For example, two or more of the panels 502, 504,
506, 508, and 510 may be formed as a single piece and/or attached
to the remaining panels 502, 504, 506, 508, and 510 without
limitation. Additionally, the panels 502, 504, 506, 508, and 510
may be attached to one another through any suitable means such as
welding, adhering with adhesives, end rolling, etc.
[0072] In some embodiments, the front panel 504 may define a front
panel opening 512. The front panel opening 512 may be configured to
correspond to an opening defined in a refractory oven. For example,
with combined reference to FIGS. 4B and 5A-5B, the front panel
opening 512 may correspond to the opening 250 defined by the
refractory oven 400. Additionally, in some embodiments, the front
panel 504 may be positioned substantially adjacent to a front
surface 424 of the refractory bottom piece 410, front surfaces 422
and 426 of the two refractory side pieces 408 and 412, and a front
surface 420 of the refractory top piece 406.
[0073] Additionally, in these and other embodiments the rear panel
508 may be positioned substantially adjacent to the refractory rear
piece 414, the two side panels 506 and 510 may be positioned a
distance (e.g., the distance 228 of FIGS. 2A-3C) from the two
refractory side pieces 408 and 412, and the top cover 502 may be
positioned a second distance (e.g., the second distance 312 of
FIGS. 3A-3C) from the external surface 212 of the refractory top
piece 406. Thus, the housing 500 may surround the external surface
212 of the refractory top piece 406, the two refractory side pieces
408 and 412, and the refractory rear piece 414. The housing 500
combined with the refractory top piece 406, the two refractory side
pieces 408 and 412, and the refractory rear piece 414, may define a
heated volume (discussed above) that may be configured to reduce
transfer of thermal energy from the cooking chamber through the
refractory top piece 406, the two refractory side pieces 408 and
412, and the refractory rear piece 414.
[0074] In some embodiments, the two refractory side pieces 408 and
412 and the two side panels 506 and 510 may be substantially
parallel when the refractory oven 400 is positioned inside the
housing 500. In this and other embodiments, the refractory oven 400
and the housing 500 are generally rectangular. However, this is not
meant to be limiting. In some embodiments, the refractory oven 400
and/or the housing 500 may be circular, oval, D-shaped, etc. In
each of these embodiments, refractory side pieces of a refractory
oven may be substantially parallel to the side panels of a
housing.
[0075] Additionally, in this and other embodiments, the support
braces 218 may be attached to the two side panels 506 and 510. The
support braces 218 may additionally or alternatively be attached to
any other of the panels 502, 504, 506, 508, and 510 or may be
omitted in some embodiments.
[0076] The present invention may be embodied in other specific
forms without departing from its spirit or characteristics. The
described embodiments are to be considered in all respects only as
illustrative and not restrictive. The scope of the invention is,
therefore, indicated by the appended claims rather than by the
foregoing description. All changes which come within the meaning
and range of equivalency of the claims are to be embraced within
their scope.
* * * * *