U.S. patent application number 15/441853 was filed with the patent office on 2017-08-31 for article with reinforced nonstick food preparation surface.
This patent application is currently assigned to Meyer Intellectual Properties Ltd.. The applicant listed for this patent is Meyer Intellectual Properties Ltd.. Invention is credited to Stanley Kin Sui Cheng.
Application Number | 20170245677 15/441853 |
Document ID | / |
Family ID | 59678832 |
Filed Date | 2017-08-31 |
United States Patent
Application |
20170245677 |
Kind Code |
A1 |
Cheng; Stanley Kin Sui |
August 31, 2017 |
ARTICLE WITH REINFORCED NONSTICK FOOD PREPARATION SURFACE
Abstract
Cookware surfaces of metal, such as aluminum, may include a
nonstick coating and embedded hard metal mesh. The mesh protects
the nonstick coating between interior regions within the mesh from
being cut or abraded by knives and other tools.
Inventors: |
Cheng; Stanley Kin Sui;
(Hillsborough, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Meyer Intellectual Properties Ltd. |
Kowloon |
|
HK |
|
|
Assignee: |
Meyer Intellectual Properties
Ltd.
Kowloon
HK
|
Family ID: |
59678832 |
Appl. No.: |
15/441853 |
Filed: |
February 24, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62299669 |
Feb 25, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47J 36/025
20130101 |
International
Class: |
A47J 36/02 20060101
A47J036/02; C23C 26/00 20060101 C23C026/00 |
Claims
1. A cookware article comprising: (a) a base material layer having
at least a first base surface along a first side; (b) at least a
first mesh layer disposed on the first base surface, the first mesh
layer comprising a plurality of first network segments embedded in
the first base surface and extending outward therefrom to a planar
outer first mesh surface and defining a plurality of first interior
regions between adjacent first network segments; and (c) a nonstick
coating layer disposed on the first base surface, within the first
interior regions between the adjacent first network segments, and
extending outward therefrom to an outer nonstick coating surface
adjacent to the outer first mesh surface, wherein the outer first
mesh surface is disposed outward of the first base surface farther
than the adjacent outer nonstick coating surface such that the
nonstick coating surface is disposed below the outer first mesh
surface.
2. The cookware article of claim 1, wherein each of the first and
second portions of the first base surface are planar.
3. The cookware article of claim 1, wherein the outer nonstick
coating surface comprises a plurality of discrete surfaces
interspersed between the first network segments.
4. The cookware article of claim 3, wherein the first network
segments are interconnected and laterally surround the plurality of
first interior regions.
5. The cookware article of claim 1, wherein the base material layer
comprises aluminum and the first mesh layer comprises stainless
steel first network segments.
6. The cookware article of claim 1, wherein the cookware article is
one of a pot, pan, tray, platter, platen, grill, griddle surface,
baking tray, roasting pan, or pizza pan.
7. The cookware article of claim 1, wherein the adjacent first
network segments define one of parallelogram, hexagonal, or
rhomboidal first interior regions.
8. The cookware article of claim 1, wherein the adjacent first
network segments define hexagonal interior regions.
9. The cookware article of claim 1, wherein the interior regions
have a surface dimension between about 0.8 mm and about 2 mm.
10. The cookware article of claim 1, wherein the network segments
have a width of between about 0.3 mm and about 0.5 mm.
11. The cookware article of claim 1, wherein the network segments
have a thickness between about 0.5 mm to about 1 mm normal to the
cookware article surface.
12. The cookware article of claim 11, wherein the base material
layer is between 3 mm and 4 mm thick.
13. The cookware article of claim 1, wherein the interior regions
have a surface dimension between about 0.8 mm and about 2 mm and
the network segments have a width of between about 0.3 mm and about
0.5 mm.
14. The cookware article of claim 13, wherein the network segments
have a thickness between about 0.5 mm to about 1 mm normal to the
cookware article surface.
15. The cookware article of claim 1, wherein the base material
layer comprises a second base surface along a second side, opposite
the first side, and wherein the cookware article further comprises:
(d) a second mesh layer disposed on the second base surface, the
second mesh layer comprising a plurality of second network segments
embedded in the second surface and extending outward therefrom to a
planar outer second mesh surface and defining a plurality of second
interior regions between adjacent second network segments.
16. The cookware article of claim 15, wherein the second base
surface within the second interior regions defined by the adjacent
second network segments comprise an outer second base surface
disposed outward beyond adjacent second base surfaces in which the
second network segments are embedded.
17. The cookware article of claim 16, wherein the outer second mesh
surface is disposed outward at least as far as adjacent outer
second base surfaces.
18. The cookware article of claim 17, wherein each of the first and
second base surfaces are planar.
19. The cookware article of claim 17, wherein the outer nonstick
coating surface comprises a plurality of discrete surfaces
interspersed between the first network segments, and wherein the
outer second base surface comprises a plurality of discrete
surfaces interspersed between the second network segments.
20. The cookware article of claim 17, wherein the first network
segments are interconnected and laterally surround the plurality of
first interior regions, and wherein the second network segments are
interconnected and laterally surround the plurality of second
interior regions.
21. The cookware article of claim 17, wherein at least one of the
first network segments, the second network segments, or both
comprise stainless steel.
22. The cookware article of claim 17, wherein the first network
segments comprise stainless steel and the second network segments
comprise magnetic stainless steel alloy.
23. The cookware article of claim 22, wherein the base material
layer comprises aluminum.
24. The cookware article of claim 17, wherein the adjacent first
network segments define hexagonal first interior regions.
25. A method of making a surface of a cookware article, the method
comprising: (a) providing a base material comprising a metal or
metal alloy; (b) coating at least one planar surface of the metal
or metal alloy with an organic nonstick material; and (c)
compressing a mesh comprising a plurality of network segments
comprising a metal or metal alloy onto the coated surface to embed
the network segments into the base material, wherein the network
segments define a plurality of interior regions between adjacent
network segments, and wherein the network segments extend outward
of the base material beyond the nonstick material.
26. The method of claim 25, wherein the method further comprises
(d) compressing a mesh comprising a plurality of network segments
comprising a metal or metal alloy onto another surface of the base
material located on an opposite side thereof, wherein the network
segments define a plurality of interior regions between adjacent
network segments, and wherein the network segments extend outward
of the base material at least as far as outer surfaces of the base
material layer within the interior regions defined between the
network segments.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of the filing
date under 35 U.S.C. .sctn.119(e) to U.S. Provisional Patent
Application No. 62/299,669, filed on Feb. 25, 2016, the contents of
which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The present invention relates to cookware and surfaces
thereof, such as food preparation surfaces and induction heating
features of pots, pans, platens, griddles and grills.
BACKGROUND
[0003] Some foods tend to stick to cookware surfaces. This tendency
is particularly common with heated cookware surfaces when preparing
such foods. To combat this tendency, cookware articles may be
outfitted with what is often referred to as "nonstick" or "easy
release" cooking surfaces. These surfaces typically include coated
metal surfaces including fluorocarbons, such as PTFE; vitreous
enamel; silicones; and ceramics.
SUMMARY
[0004] In one aspect, a cookware article includes a base material
layer, a mesh layer, and a nonstick coating layer. The base
material layer may have at least a first base surface along a first
side. At least a first mesh layer may be disposed on the first base
surface. The first mesh layer may include a plurality of first
network segments embedded in the first base surface and that extend
outward therefrom to a planar outer first mesh surface. The first
network segments may define a plurality of first interior regions
between adjacent first network segments. The nonstick coating layer
may be disposed on the first base surface, within the first
interior regions between the adjacent first network segments, and
extend outward therefrom to an outer nonstick coating surface
adjacent to the outer first mesh surface. The outer first mesh
surface may be disposed outward of the first base surface farther
than the adjacent outer nonstick coating surface such that the
nonstick coating surface is disposed below the outer first mesh
surface.
[0005] The first base surface and layers thereon may employ a
variety of configurations. For example, in various embodiments,
each of the first and second portions of the first base surface are
planar. In further embodiments, the outer nonstick coating surface
may include a plurality of discrete surfaces interspersed between
the first network segments. The first network segments may be
interconnected and laterally surround the plurality of first
interior regions. In one embodiment, the base material layer
comprises aluminum and the first mesh layer comprises stainless
steel first network segments. Adjacent first network segments may
define one of parallelogram, hexagonal, or rhomboidal first
interior regions. For example, adjacent first network segments may
define hexagonal interior regions.
[0006] In various embodiments, the base material layer may include
a second base surface along a second side, opposite the first side.
The cookware article may further include a second mesh layer
disposed on the second base surface. The second mesh layer may
include a plurality of second network segments embedded in the
second surface and extending outward therefrom to a planar outer
second mesh surface and defining a plurality of second interior
regions between adjacent second network segments.
[0007] In one embodiment, the second base surface within the second
interior regions defined by the adjacent second network segments
has an outer second base surface disposed outward beyond adjacent
second base surfaces in which the second network segments are
embedded. In this or another embodiment, the outer second mesh
surface may be disposed outward at least as far as adjacent outer
second base surfaces. Each of the first and second base surfaces
may be planar. In further embodiments, the outer nonstick coating
surface may include a plurality of discrete surfaces interspersed
between the first network segments, and the outer second base
surface may include a plurality of discrete surfaces interspersed
between the second network segments. The first network segments may
be interconnected and laterally surround the plurality of first
interior regions, and the second network segments may be
interconnected and laterally surround the plurality of second
interior regions.
[0008] The layers may include various materials. In one example, at
least one of the first network segments, the second network
segments, or both include stainless steel. In a further example,
the first network segments include stainless steel and the second
network segments include magnetic stainless steel alloy. In some
embodiments, the base material layer may include aluminum. The base
material layer may also include copper or other suitable metal or
alloy.
[0009] The network segments may include various shapes, sizes, and
patterns. For example, in one embodiment, the adjacent first
network segments define hexagonal first interior regions.
[0010] The features of the cookware article surface may be
configured with various dimensions. For example, interior regions
may have a surface dimension between about 0.8 mm and about 2 mm.
In this or another embodiment, network segments have a width of
between about 0.3 mm and about 0.5 mm. In any of the above or
another embodiment, network segments may have a thickness between
about 0.5 mm to about 1 mm normal to the cookware article surface.
In any of the above or a further embodiment, the base material
layer is between 3 mm and 4 mm thick.
[0011] Various cookware articles employing the inventive surface
features may include a pot, pan, tray, platter, platen, grill,
griddle surface, baking tray or pizza pan.
[0012] In another aspect, a method of making a surface of a
cookware article may include providing a base material including a
metal or metal alloy and coating at least one planar surface of the
metal or alloy with an organic nonstick material. The method may
further include compressing a mesh comprising a plurality of
network segments including a metal or metal alloy onto the coated
surface to embed the network segments into the base material. The
network segments may define a plurality of interior regions between
adjacent network segments. The network segments may also extend
outward of the base material beyond the nonstick material.
[0013] In various embodiments, the method may further include
compressing a mesh comprising a plurality of network segments
including a metal or metal alloy onto another surface of the base
material located on an opposite side thereof. The network segments
may define a plurality of interior regions between adjacent network
segments. The network segments may extend outward of the base
material at least as far as outer surfaces of the base material
layer within the interior regions defined between the network
segments.
[0014] The above and other objects, effects, features, and
advantages of the present invention will become more apparent from
the following description of the embodiments thereof taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Novel features of the present invention are set forth with
particularity in the appended claims. However, the various
embodiments of the present invention described herein, both as to
organization and manner of operation, may be best understood by
reference to the following description, taken in conjunction with
the accompanying drawings in which:
[0016] FIG. 1A is a schematic cross-sectional elevation view of an
upper portion of a cookware article surface according to various
embodiments described herein, whereas FIG. 1B is a top plan view
thereof.
[0017] FIG. 2A is a schematic cross-sectional elevation view of an
upper portion of a cookware article surface according to various
embodiments described herein, whereas FIG. 2B is a top plan view
thereof.
[0018] FIG. 3 is a schematic cross-sectional elevation view of a
portion of a cookware article surface according to various
embodiments described herein.
[0019] FIG. 4A is a cross-sectional elevation of a cookware article
surface according to various embodiments described herein, where
FIG. 4B is the cookware article surface of FIG. 4A formed into a
cooking pan.
DESCRIPTION
[0020] Nonstick or easy release cooking surfaces are typically
deployed as coatings. The durability of these coatings may be
enhanced through chemistry, particulate reinforcement, and layers.
However, even when enhanced, nonstick or easy release coatings may
still be easily scratched or cut by hard tools or other cookware,
such as cookware utensils including sharp tools like knives and
circular pizza cutters, or with similar sharp instruments. Thus,
this lack of durability also limits cross-use of cookware articles
that may damage a coating of either article.
[0021] According to various embodiments, the present disclosure
describes reinforced nonstick cookware article surfaces, generally
denominated article surface 100 in FIGS. 1A-4B, wherein like
reference numerals refer to like components in the various views.
The cookware article surface 100 may comprise one or more layers of
materials. The cookware article surface 100 may be embodied in any
cookware article, such as pots, pans, platens, griddles, grills,
roasting pans, utensils, and the like. The surface 100 may be
constructed to allow users to cut and slice food on the article
surface 100, without damaging the nonstick finish. In some
embodiments, for example, the surface 100 comprises a cut resistant
nonstick construction for cookware articles such as pots, pans,
platens, griddles, grills, roasting pans, and the like. While
referred to herein as surface 100, it should be understood that the
layered material of the surface 100 may form an expanse of a wall,
through the thickness of the wall, of a cookware article or may be
further layered onto another material to form an expanse of a wall
of a cookware article.
[0022] With reference to FIGS. 1A & 1B, the cookware article
surface 100 may include a base material layer 110. The base
material layer 110 will typically include a thermally conductive
material such as a metal. The base material layer 110 may
preferably be a malleable metal, such as a soft metal, e.g.,
aluminum, copper, or alloys thereof. In one embodiment, for
example, the base material 110 is aluminum.
[0023] The cookware article surface 100 may also include a mesh
layer 120 disposed over at least a portion of a surface 111 of the
base material layer 110. The portion of the surface 111 onto with
the mesh layer 120 is disposed will typically be planar. Thus, the
mesh layer 120 may be disposed over a planar surface portion of the
surface 111. The mesh layer 120 includes a plurality of network
segments 121 arranged along the surface 111 of the base material
layer 110 that extend outward therefrom to together define a
generally planar outer mesh surface 122 above the base material
surface 111. Adjacent network segments 121 along the mesh layer 120
may define a plurality interior regions 123. The interior regions
123 may have various shapes and sizes as described in more detail
below. The interior regions 123 may be patterned to include
consistent sizes, shapes, and alignments. The network segments 121
may be interconnected to laterally surround interior regions 123 or
may be partially or entirely disconnected to partially laterally
surround interior regions 123. The mesh layer 120 may embed within
the surface 111 of the base material layer 110. For example, as
shown, inwardly positioned portions of the network segments 121
that interface with the surface 111 may embed in the base material
layer 110.
[0024] The cookware article surface 100 may also include a nonstick
coating layer 130 that coats a portion of the surface 111 of the
base material layer 110 between the adjacent network segments 121
within the interior regions 123. The nonstick coating layer 130 may
extend outward of the base material layer 110 to an outer nonstick
coating surface 132 adjacent to the planar outer mesh surface 122.
Thus, the nonstick coating layer 130 may be interspersed among the
network segments 121 to together with the mesh layer 120 provide an
outer surface comprising a plurality of outer nonstick coating
surface 132 regions disposed between outer mesh surface 122
regions. In various embodiments, the outer nonstick coating surface
132 may include discrete or interconnected regions. In the
embodiment illustrated in FIG. 1B, the mesh layer 120 includes a
plurality of interconnected network segments 121 positioned over a
planar portion of the surface 111 of the base material layer 110
that are arranged to laterally surround interior regions 123 and,
hence, discrete portions of the nonstick coating layer 130 disposed
therein.
[0025] Interior regions 123 may preferably have a spacing dimension
between network segments 121 or surface dimension such as diameter
between about 0.8 mm and about 2 mm. Smaller dimensions or larger
dimensions may also be used. The width of the network segments 121
between the interior regions 123 may preferably be between about
0.3 mm and about 0.5 mm, although smaller or larger width
dimensions may also be used. The thickness of the network segments
121 may also preferably be between about 0.5 mm to about 1 mm
normal to the cookware article surface 100; however, smaller or
larger thicknesses may be used. In various embodiments, the base
material layer 110 may preferably be between 3 mm and 4 mm thick,
although smaller or larger thicknesses may be used.
[0026] It has been discovered that the ranges of dimensions of the
interior regions 123 and the network segments 121 provide the
benefits of easy food release even from the surface 123 which is
not coated with non-stick material in regions 130. At the same
time, the surface 123 also protects the non-stick surface 132 from
damage by cutting and food preparation utensils, such as knives,
spatulas, tongs and the like.
[0027] It has also been discovered that the corrugation pattern
enhances food browning with a small quantity of cooking oil being
used for this purpose.
[0028] The base material layer 120 may be coated with the nonstick
coating layer 130 according to any suitable method. For example,
various US patents teach compositions of matter and methods of
applying organic based and nonstick coatings to cookware vessels.
These include U.S. Pat. No. 3,986,993 to Vassiliou (issued Oct. 19,
1976); U.S. Pat. No. 4,118,537 to Vary, et al. (issued Oct. 3,
1978); U.S. Pat. No. 4,321,177 to Wilkinson (issued Mar. 23, 1982);
U.S. Pat. No. 5,691,067 to Patel (issued Oct. 25, 1997) and U.S.
Pat. No. 6,133,359 to Bate, et al. (issued Oct. 17, 2000), all of
which are incorporated herein by reference. The nonstick coating
layer 130 may typically contain one or more low surface energy
polymers of resin, particularly fluorinated resins or fluorinated
silicone resins, and silicone resins, including, PTFE
(polytetrafluoroethylene), FEP (fluorinated ethylene propylene),
PFA (Perfluoroalkoxy) and combinations thereof, along with
reinforcing fillers such as glass, aluminum oxide titanium oxide,
silicon carbide, and the like, and may preferably be deposited as
multilayer coatings with varying compositions so the exposed outer
surface, though softer, is more chemically inert and water and oil
repellent. The nonstick coating layer 130 may also include one or
more binder resins such as polyamide-imide (PAI), polyphenylene
sulphide (PPS), polyether sulphone (PES), or a silicone and
possibly also pigments.
[0029] In various embodiments, the mesh layer 120 may be embedded
into the base material layer 110 by force. For example, surface 111
of the base material layer 110 may be coated with the nonstick
coating layer 130 and the mesh layer 120 may be forced against the
exposed nonstick coating layer 130. As the mesh layer 120 is
embedded by force into the base material layer 110 it penetrates
the nonstick coating layer 130 which is then exposed within the
interior regions 123 between the network segments 121 of the mesh
layer 120. The embedding process may result in the planar outer
mesh surface 122 being disposed no lower than the outer nonstick
coating surface 132 positioned within the interior regions 123
along the outer surface. In some embodiments, the outer mesh
surface 122 is approximately level with the outer nonstick coating
surface 132. In other embodiments, the outer mesh surface 122
extends beyond the outer nonstick coating surface 132, such as
between 0 mm and about 0.01 mm, or between about 0.01 mm and about
0.1 mm.
[0030] The mesh layer 120 preferably comprises a metal material,
including alloys thereof, harder than the organic nonstick coating
material of the nonstick coating layer 130 and the base material of
the base material layer 110. For example, a mesh layer 120 formed
of stainless steel network segments 121 may be readily embedded
into an aluminum base material after a nonstick coating layer 130,
as stainless steel network segments 121 are harder than both the
aluminum base material and the nonstick coating material. The
planar outer mesh surface 122 extending beyond or level with the
nonstick coating outer surface 132 provides a network of protective
shields that prevent hard surfaces, such as sharp steel tool
surfaces, from digging into the nonstick coating 130 within the
interior regions 123.
[0031] FIGS. 2A & 2B illustrate another embodiment of the
cookware article surface 100 comprising a base material layer 110,
mesh layer 120, and a nonstick coating layer 130. The layers 110,
120, 130 may be arranged in a manner similar to that described with
respect to FIGS. 1A & 1B. As shown in FIG. 1A and FIG. 2A,
network segments 121 of 10 the mesh layer 120 may be arranged to
define various shaped interior regions 123. For example, interior
regions 123 may have hexagonal shapes, e.g., as shown in FIG. 1A,
or rectangular, parallelogram, or rhombus shapes. Other shapes may
include arcuate, geometric, nongeometric, regular, or irregular
shapes. In one embodiment, networks segments 121 define rhomboid or
diamond shaped interior regions 123, e.g., as shown in FIG. 2A. As
introduced above, the interior regions 123 may be patterned along
the cookware article surface 100 to include consistent or
inconsistent sizes, shapes, and alignments. In one embodiment,
network segments 121 define interior regions 123 of multiple
shapes, sizes, or both.
[0032] The mesh layer 120 may be formed by casting, forming,
assembly, material removal techniques such as excising material
from sheets, or other suitable fabrication techniques to form the
network segments 121. In one example, the arrangement of the
network segments 121 of the mesh layer 120 illustrated in FIG. 2A
may be formed by introducing rows of discrete slits in a metal
sheet and then expanding the sheet such that each slit may then be
opened to form connected network segments 121 wherein adjacent
segments 121 define interior regions 123.
[0033] In various embodiments, a cookware article comprises the
cookware article surface 100. The cookware article surface 100 may
optionally be any portion of a pot, pan, tray, platter, platen,
grill, or griddle surface, for example. In one embodiment, the
cookware article surface 100 is a portion of a nonstick surface of
a baking tray, or pizza pan wherein the mesh layer 120 protects the
outer nonstick surface 132 from a knife blade, such as a mezzaluna,
or circular pizza cutting wheel.
[0034] With reference to FIG. 3, in some embodiments, the cookware
article surface 100 includes a base material layer 110 having
multiple surfaces 111, 111' upon which mesh layers 120, 120' are
disposed. In such embodiments, the base material layer 110 may be
coated along at least one of the surfaces 111, 111' with a nonstick
coating layer 130. Surfaces 111, 111' including the nonstick
coating layer 130 will typically be surfaces 111, 111' that are
intended to or in which it is foreseeable will contact food during
use.
[0035] In the illustrated embodiment, the cookware article surface
100 comprises a base material layer 110, first and second mesh
layers 120, 120', and a nonstick coating layer 130 wherein the
first mesh layer 120 and the nonstick coating layer 130 are
disposed on a first surface 111 of the base material layer 110 and
the second mesh layer 120' is disposed on a second surface 111' of
the base material layer 110, generally opposite the first surface
111. The first mesh layer 120 includes a plurality of first network
segments 121 embedded in the first surface 111 and extending to a
first outer mesh surface 122. The nonstick coating layer 130 is
disposed within interior regions 123 defined by the first network
segments 121 and extends outward from the first surface 111 to a
plurality of outer nonstick coating surfaces 132 in an arrangement
similar to that described with respect to FIGS. 1A-2B.
[0036] The second mesh layer 120' includes a plurality of second
network segments 121' embedded in the second surface 111' and
extending to a generally planar second outer mesh surface 122'. The
second network segments 121' are arranged to define interior
regions 123' between adjacent segments 121' within which the second
surface 111' of the base material layer 110 is exposed to form an
outer base material surface 112. In various embodiments, the base
material layer 110 may preferably be between 3 mm and 4 mm thick,
although smaller or larger thicknesses may be used. While the base
material layer 110 is illustrated as the same across and through
the thickness of the expanse of the cookware article surface 100,
in various embodiments a same base material layer may not form both
the first and second surfaces 111, 111'. For example, the base
material layer 110 may comprise multiple base materials layers
110.
[0037] The second network segments 121' of the second mesh layer
120' are illustrated as being embedded deeper in the base material
layer 110 than the first network segments 121 of the first mesh
layer 120. In other embodiments the first network segments 121 may
be embedded the same depth or deeper than the second network
segments 121'. The second outer mesh surface 122' is disposed no
lower than the outer base material surface 112. Thus, the second
outer mesh surface 122' may extend outward beyond the outer base
material surface 112 along the second surface 111'. The outer base
material surface 112 may also be level with second outer mesh
surface 122. The thickness of the second network segments 121' may
be similar to the thickness of the first network segments. For
example, in some embodiments, the thickness of the second network
segments 121' may be between about 0.5 mm to about 1 mm normal to
the cookware article surface 100; however, smaller or larger
thicknesses may be used. For example, first or second network
segments 121, 121' having larger thicknesses may be used to
increase strength and durability.
[0038] The second network segments 121' may be interconnected to
laterally surround interior regions 123' or may be partially or
entirely disconnected to partially laterally surround interior
regions 123'. Similarly, the outer base material surface 112 may be
interconnected or comprise discrete regions. For example, the outer
base material surface 112 may include a discrete surface region
within each interior region 123' between interconnected second
network segments 121'.
[0039] The second network segments 121' of the second mesh layer
120' are illustrated as having a width similar to the first network
segments 121 of the first mesh layer 120. For example, the width of
the second network segments 121' between the interior regions 123'
may preferably be between about 0.3 mm and about 0.5 mm. In other
embodiments, the first network segments 121 may have larger or
smaller widths than the second network segments 121'. For example,
the second network segments 121' may include thicknesses larger
than 0.5 mm to increase induction capacity, when applicable, or the
structural strength and durability therealong.
[0040] The second network segments 121' may define interior regions
123' having any shape, such as parallelogram, rhomboidal,
hexagonal, arcuate, geometric, nongeometric, regular, or irregular
shapes. The second network segments 121' may also defined interior
regions having shapes, sizes, or in arrangements similar to or
different than the shapes, sizes, or arrangements defined by the
first network segments 121. In some embodiments, the second network
segments are illustrated as defining interior regions 123' having
similar diameters as the interior regions 123 defined by the first
network segments 121. For example, the interior regions 123 may
have a spacing dimension between network segments 121 or surface
dimension such as diameter between about 0.8 mm and about 2 mm.
However, in other embodiments, second network segments 121' define
interior regions 123' having smaller or larger diameters than the
interior regions 123 defined by the first network segments 121.
[0041] The outer base material surface 112 may correspond to the
outer nonstick coating surface 132 in size, shape, or location.
However, in other embodiments, outer base material surface 112 may
not correspond to the outer nonstick coating surface 132 with
respect to one or more of size, shapes, or location.
[0042] The second mesh layer 120' and second network segments 121'
thereof may comprise materials and be fabricated in a manner
similar to that described with respect to the first mesh layer 120.
In various embodiments, the second network segments 121' may
comprise a material harder than the base material along the second
surface 111', such as a hard metal or alloy. In some embodiments,
the second network segments 121' comprise stainless steel. In some
embodiments, the second mesh layer 120' may be configured to
provide induction heating features. For example, the second network
segments 121' may comprise a ferromagnetic material. In one
embodiment, the second mesh layer 120' comprises magnetic stainless
steel for induction heating of the first outer surfaces
122/132.
[0043] FIGS. 4A & 4B illustrate a cookware article surface 100
and the cookware article surface 100 employed in a cookware article
10 comprising a pan (FIG. 4B) according to various embodiments. The
cookware article surface 100 may be similar to the cookware article
surface 100 described with respect to FIG. 3. For example, the
cookware article surface 100 comprises a base material layer 110,
first and second mesh layers 120, 120', and a nonstick coating
layer 130 wherein the first mesh layer 120 and the nonstick coating
layer 130 are disposed on a first surface 111 of the base material
layer 110 and the second mesh layer 120' is disposed on a second
surface 111' of the base material layer, generally opposite the
first surface 111. The first mesh layer 120 includes a plurality of
first network segments 121 embedded in the first surface 111 and
extending to a first outer mesh surface 122. The nonstick coating
layer 130 is disposed within interior regions 123 defined by the
first network segments 121 and extends outward from the first
surface 111 to a plurality of outer nonstick coating surfaces 132
in an arrangement similar to that described with respect to FIGS.
1A-2B. The second mesh layer 120' includes a plurality of second
network segments 121' embedded in the second surface 111' and
extending to a generally planar second outer mesh surface 122'. The
second network segments 121' are arranged to define interior
regions 123' between adjacent segments 121' within which the second
surface 111' of the base material layer 120 is exposed to form an
outer base material surface 112.
[0044] The second network segments 121' disposed along the
underside of the pan are preferably magnetic stainless steel for
induction heating of the outer surfaces 122/132. The first and
second network segments 121, 121' may define interior regions 123,
123' of any shape. In one embodiment, the first network segments
121, the second network segments 121', or both define hexagonal,
parallelogram, rectangular, or rhomboidal shaped interior regions
123, 123' with a spacing dimension between network segments 121 or
surface dimension such as diameter between about 0.8 mm and about 2
mm. The width of the network segments 121, 121' between the
interior regions 123, 123' may preferably be between about 0.3 mm
and about 0.5 mm. The thickness of the network segments 121, 121'
may also preferably be between about 0.5 mm to about 1 mm normal to
the cookware article surface 100. The base material layer may
preferably be between 3 mm and 4 mm thick. The base material layer
110 along the second surface 111' may comprise similar base
materials as described above with respect to FIGS. 1A-3. For
example, the base material layer 110 along the second surface 111'
may comprise aluminum.
[0045] The dish shape of the cookware article 10 may be formed
before or after embedding the first mesh layer 120, second mesh
layer 120, or both. For example, the network segments 121, 121' may
be embedded when a pot or pan is formed. Side surfaces 104, 104'
surround the planar cooking article surface 100. In various
embodiments, interior or exterior side surfaces 104, 104' may also
include a mesh layer 120, 120', nonstick layer 130, or both. For
example, in the illustrated embodiment, the interior side surface
104 includes a nonstick layer. The cookware article 10 is
preferably made by embedding network segments 121, 121' in a
respective surface 111, 111' of the base material layer 110 after
an organic nonstick material is coated onto the at least one
surface 111, 111'. The network segments 121, 121' will first
penetrate through the nonstick coating layer 130, but thereafter
from a protective barrier from cutting tool, such as knives,
mezzalunas, cutting wheels, spatulas and the like.
[0046] It will be appreciated that the embodiments illustrated in
FIGS. 1A-2B may have a similarly configured opposite surfaces. For
example, the embodiments illustrated in FIGS. 1A-2B may also
include an opposite surface comprising base material with embedded
mesh disposed between interior regions of base material similar to
that described with respect to FIGS. 3-4B. In another example, the
embodiments illustrated in FIGS. 1A-2B may include an opposite
surface comprising a nonstick material layered over the base
material layer and a mesh layer embedded in the base material and
arranged in a manner similar to the base material layer 110, mesh
layer 120, and nonstick layer 130 along the other surface. In any
of the above or another embodiment, an outer mesh surface along the
opposite surface may extend outward beyond an outer base surface or
outer nonstick surface. In another embodiment, an outer base
surface along the opposite surface may be level with or extend
outwardly beyond the mesh surface portion. In yet another
embodiment, the second surface 111' may have a protective layer or
coating over the base material.
[0047] While the invention has been described in connection with a
preferred embodiment, it is not intended to limit the scope of the
invention to the particular form set forth, but on the contrary, it
is intended to cover such alternatives, modifications, and
equivalents as may be within the spirit and scope of the invention
as defined by the appended claims.
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