COOKING SYSTEM

A cooking system including a housing assembly provided with lid, which define a plurality of cooking zones and a thermal energy zone. One of the cooking zones is located beneath the thermal energy zone to utilize convection thermal energy transfer and radiant thermal energy transfer during operation of the cooking system. A blower assembly of the cooking system forces a fluid through at least one fluid flow path of the housing assembly and the thermal energy zone, to provide a superheated fluid having a temperature of about 800° F. to about 1200° F. to at least one of the cooking zones.

FIELD

The disclosure relates to a cooking system, and more particularly to a multi-function cooking system.

BACKGROUND

Outdoor grills and cooking appliances are used for the preparation of food utilizing solid fuel (charcoal or wood) or gaseous fuel sources.

Maximum temperature achievable for gas-fueled outdoor grilling products is typically 550° F. and materials of construction vary between ferrous and nonferrous metals such as stainless steel. Higher temperature searing appliances exist that utilize an infrared spectrum of heat generated from the gas burner. Gas fueled outdoor grilling products have adjustable temperatures in whole or by zone and have burners located below the grill or cooking surface.

Solid fuel sources such as charcoal burn at a maximum temperature of 2000° F. in atmospheric conditions and 2300° F. if supplied with excess air.

Maximum temperature achievable for solid fueled (charcoal) outdoor grilling products is typically 700° F. and materials of construction vary between ferrous and nonferrous metals such as stainless steel as well as ceramic and refractory materials. Elevated temperatures are reached through increased convection air flow up through the solid fuel bed which is located below the grill or cooking surface.

High-temperature (800° F.-1200° F.) searing and cooking of foods creates desirable results found in restaurants. In a professional kitchen, chefs use specialized cooking devices such as salamander broilers to reach high temperatures for searing, broiling and cooking foods. In the market today, only specialized commercial cooking devices are capable of reaching 800° F.-1200° F. and are impractical for home use in terms of cost, service and space requirements.

Further, conventional grilling arrangements generally are not able to provide a multi-functional approach to barbecue cooking. Such systems generally are specialized in their nature, and are incapable of performing multiple levels of barbecue grilling.

There is a need for an arrangement that employs conventional charcoal fuel and which can effect barbecue-style cooking in conventional and searing modes of operation.

Therefore, it would be desirable to provide a cooking system that is multi-functional and can advantageously be employed in conventional barbecue, cooking, and searing modes of operation.

SUMMARY

In concordance and agreement with the presently described subject matter, a cooking system that is multi-functional and can advantageously be employed in conventional barbecue, cooking, and searing modes of operation, wherein a weight, a cost, and complexity thereof is minimized, has surprisingly been discovered.

High-temperature (800° F.-1200 F) searing and cooking of foods creates desirable results found in restaurants. In a professional kitchen chefs use specialized cooking devices such as salamander broilers to reach high temperatures for searing, broiling and cooking foods.

Home-based cooking enthusiasts desire the same professional high-temperature results but traditional gas or solid fuel cooking products cannot reach 800° F.-1200° F. temperatures.

The presently disclosed subject matter is an outdoor broiling, searing and grilling device with four separate cooking zones consisting of a high-temperature broiler-oven, a traditional grill, an elevated and rotating grill, and a warming center. The round metal body of the cooking system contains a thermal energy source that sits on a screened surface located above the broiler-oven and a traditional grill which is located above the thermal energy source. The lid of the cooking system is designed to hold a 12″ cooking device for food warming and cooking utilizing the convection waste heat rising above the cooking system. The elevated and rotating grill rack attaches to an exterior of the device and is adjustable up and down, as well as rotatable away from the thermal energy source.

To create optimal broiling or searing temperatures of 800° F.-1200° F. in the broiler-oven, an adjustable blower assembly, provided with the cooking system, pushes pressurized air into the grill area. With the lid closed, the natural upward convection air flow is reversed and air is forced downward through the thermal energy source, which sits on the screen member. The screen member allows downward flow of superheated air utilized for high-temperature cooking. The superheated air then passes through the screen member into the broiler-oven creating optimal broiling and searing temperatures of 800° F.-1200° F. Utilizing the adjustable air blower assembly also creates balanced, sustainable high-temperature conditions for long periods of time. In traditional barbeque grilling, rising convection air upward through the thermal energy source is adjustable, by manual damper, to accommodate all styles of traditional barbeque cooking and grilling. A user of the presently disclosed subject matter benefits from the flexibility of uses to prepare a wider variety of foods at varying temperatures with desirable results at each temperature range and cooking zone. The user will furthermore benefit from reduced time it takes for the presently disclosed subject matter to reach desired high temperatures as well as the ability to transition quickly to different temperatures and cooking zones based on the desired cooking method during operation of the cooking system. The user will also benefit from consistent, stable cooking conditions over longer periods of time due to the powered airflow and damper adjustments.

In one embodiment, a cooking system, comprises: a housing assembly having a plurality of cooking zones and at least one thermal energy zone provided therein, wherein the at least one thermal energy zone is located between a pair of the cooking zones.

In some embodiments, the cooking zones generate temperatures in range of about 200° F. to about 1200° F.

In some embodiments, at least one of the cooking zones generates a temperate of at least 1100° F.

In some embodiments, at least one of cooking zones of the cooking system utilizes convection thermal energy transfer and radiant thermal energy transfer.

In some embodiments, the at least one thermal energy zone is provided with a thermal energy source and a thermal energy assembly configured to contain the thermal energy source therein.

In some embodiments, the housing assembly provides four cooking zones.

In another embodiment, a cooking system, comprises: a housing assembly having at least one cooking zone; and a thermal energy assembly disposed within the housing assembly, wherein the thermal energy assembly is configured to permit a flow of a fluid therethrough while militating against particulate material entering the at least one cooking zone.

In some embodiments, the housing assembly includes an inner housing structure and an outer housing structure.

In some embodiments, at least a portion of the inner housing structure is formed from a cast aluminum.

In some embodiments, the inner housing structure has a circular cross-sectional shape.

In some embodiments, the thermal energy assembly includes a screen member and a support rack.

In some embodiments, the screen member is configured to filter the particulate material with a size of at least 180 microns.

In some embodiments, the screen member is produced from a woven nickel alloy wire.

In some embodiments, the thermal energy assembly is removable disposed within a chamber of the housing assembly.

In some embodiments, the at least one cooking zone generates a temperate of at least 1100° F.

In some embodiments, the at least one cooking zone utilizes convection thermal energy transfer and radiant thermal energy transfer.

In yet another embodiment, a cooking system, comprises: a housing assembly having a plurality of cooking zones and a plurality of fluid flow paths; and at least one thermal energy source in fluid communication with the fluid flow paths to provide a heated fluid to at least one of the cooking zones.

In some embodiments, the cooking system further comprises a blower assembly in fluid communication with at least one fluid flow path.

In some embodiments, the blower assembly is configured to force a fluid through the at least one fluid flow path and the at least one thermal energy source to at least one of the cooking zones.

In some embodiments, the fluid is superheated to a temperature of at least about 800° F.

DETAILED DESCRIPTION

All documents, including patents, patent applications, and scientific literature cited in this detailed description are incorporated herein by reference, unless otherwise expressly indicated. Where any conflict or ambiguity may exist between a document incorporated by reference and this detailed description, the present detailed description controls.

FIGS.1-3illustrate a cooking system10in accordance with an embodiment of the present disclosure. The cooking system10may be provided with additional cooking devices12(e.g. a frying pan, an iron skillet12a, etc.), as desired. The cooking system10shown may be an outdoor broiling, cooking, and grilling device that has a plurality of distinct cooking zones, which a user may employ substantially simultaneously or individually during food preparation. More preferably, the cooking system10, as shown inFIG.7, may be configured to provide four distinct cooking zones13,14,15,16and a thermal energy zone17disposed between two of the cooking zones13,14,15,16. In some embodiments, the cooking zones13,14,15,16may be a broiler-oven zone, a traditional grill zone, a warming center zone, and an elevated and adjustable grill zone, respectively. The cooking zones13,14,15,16are heated by the thermal energy zone17that is centrally located within a vertically stacked configuration. It is understood that the cooking system10may be suitable for other cooking applications as desired.

In some embodiments, the cooking system10may include a housing assembly20provided with a lid21. In certain embodiments, the lid21may include one or more openings19and an associated damper18to selectively permit and control a flow of a heated fluid (e.g. heated air) from the cooking zone14along a fluid flow path indicated by arrow “A” shown inFIG.10. A handle27may be provided on the closure member40to assist the user with a positioning, opening, and closing of the lid21. Although the lid21shown is coupled to the housing assembly20by a hinged connection, it is understood that the lid21may be movably and/or removably coupled to the housing assembly20by any method as desired. It is also understood that the lid21may be unconnected and freely disposed on the housing assembly20, if desired. In some embodiments, the lid21and/or the damper18may be configured to receive one of the cooking devices12thereon to provide the cooking zone15shown inFIG.7.

As best seen inFIG.3, the housing assembly20may comprise an inner housing structure22and an outer housing structure23formed to surround the inner housing structure22. In one embodiment shown inFIG.4, the inner housing structure22may include a generally cylindrical body portion24defining a chamber25therein, an inlet/outlet portion26coupled to the body portion24, and a base portion28coupled to the body portion24and the inlet/outlet portion26. It is understood that the body portion24may be formed from a cast aluminum material, if desired. It should be appreciated that the housing structures22,23may be produced from any combination of ferrous or nonferrous alloys; however, aluminum may be used primarily for its lightweight properties and ability to transfer heat quickly away from the cooking system10while in operation. Important to overall performance, the cooking system10, and more particularly the inner housing structure22, may have a generally circular cross-sectional shape, which creates optimal fluid conditions of balance and flow. Such shape is essential in allowing superheated fluid flows to perform cooking tasks quickly and efficiently and then exiting the cooking system10immediately to militate against premature corrosion and damage caused by excess heat conditions resulting from trapped superheated fluid flow.

It should also be appreciated that the body portion24, the inlet/outlet portion26, and the base portion28may be coupled together by any suitable method as desired such as by mechanical fasteners, a welding process, and the like, for example.

The body portion24may include an aperture29formed therein and a rim32extending radially outwardly from an upper portion thereof. As shown inFIG.4, the rim32may be supported by an array of spaced apart ribs34extending radially outwardly from the outer circumferential surface of the body portion24. As shown inFIG.5, a support rack33may be disposed on and supported by the rim32. In a non-limiting example, the support rack33may include a ring member31with a plurality of spaced-apart cross-members37extending across a diameter thereof. It is understood that any number of cross-members37may be disposed on the ring member60in any configuration as desired to permit a flow of the heated fluid from the thermal energy zone17to the cooking zone14. It is further understood that the support rack33may be formed from any suitable heat-resistant and/or heat-tolerant material as desired. In certain embodiments, the support rack33may also be configured to be removable from the housing assembly20to allow the thermal energy source50to be removed and/or replaced and the support rack33and other components within the housing assembly20to be cleaned. At least one handle39may extend upwardly from the support rack33may be employed to facilitate such removal from the housing assembly20.

The body portion24may further include a relatively large opening30formed in a front, lower portion thereof. The opening30may be surrounded by the inlet/outlet portion26, which has a generally arcuate cross-sectional shape and may be configured to cooperate with at least a part of the opening30and an outer surface of the body portion24. The inlet/outlet portion26may define a passageway35between the chamber25of the housing assembly20and the atmosphere. As depicted, the base portion28maybe generally planar to further define the chamber25of the housing assembly20and the passageway35of the inlet/outlet portion26.

Now turning toFIGS.3and5, the chamber25of the housing assembly20and the passageway35of the inlet/outlet portion26may be configured to receive one or more of the cooking devices12therein. In a non-limiting example, a lower portion of the chamber25of the housing assembly20, which forms the cooking zone13shown inFIG.7, and the passageway35of the inlet/outlet portion26may be of a suitable size and shape to receive at least one of a collection pan12b, a grill member12c, and at least one piece of stoneware12d(e.g. a pizza stone). It should be appreciated that the grill member12cmay be rotatably disposed on or rotatably coupled to the collection pan12band/or the base portion28to facilitate even cooking and permit the user to easily place and remove food therefrom. It is also understood that the grill member12cmay be sized and shaped to receive and support the piece of stoneware12dthereon.

Referring back toFIGS.1-3, the housing assembly20may further include a closure member40configured to be at least partially disposed in the passageway35to militate against access to the chamber25and a flow of fluid therethrough and into the cooking zone13. It is understood, however, that in some embodiments the closure member40may include an opening42and an associated damper44to selectively permit and control a flow of the heated fluid from the cooking zone13along a fluid flow path indicated by arrow “B” inFIG.8and a flow of the fluid from the atmosphere through the passageway35of the inlet/outlet portion26and into the chamber25along a fluid flow path indicated by arrow “C” shown inFIGS.9and10. A handle46, shown inFIG.1, may be provided on the closure member40to assist the user with a positioning, an insertion, and/or a removal of the closure member40in the inlet/outlet portion26.

As best seen inFIGS.5-7, the thermal energy zone17may be located in an upper portion of the chamber25of the housing assembly20. In certain embodiments, the thermal energy zone17may be provided with at least one thermal energy source50disposed in a thermal energy assembly51. As more clearly shown inFIG.6, the thermal energy assembly51may comprise a screen member52and a support rack54. Although the thermal energy source50shown is a solid source, it is understood that the thermal energy source50may be any suitable type of thermal energy producer as desired. As a non-limiting example, the thermal energy source50may be charcoal, briquettes or lump, and/or wood chips for flavor, if desired. The properties of charcoal are advantageous for the cooking system10because charcoal produces temperatures in excess of 2300° F. when the fluid is caused to flow therethrough. As illustrated, the thermal energy source50may be disposed in the screen member52whose position is maintained by the support rack54. The screen member52is configured to cause back pressure to the flow of fluid therethrough during the operation of the cooking system10, which in turn, balances the flow of the fluid through the thermal energy source50and into the cooking zone13. In preferred embodiments, the screen member52may be configured to contain the thermal energy source50and permit the flow of the fluid therethrough during an operation of the cooking system10, while militating against contaminants and particulates (e.g. charcoal dust) from entering the cooking zone13located beneath the thermal energy zone17. For example, the screen member52may include an upstanding rim56and a bottom58constructed of woven nickel alloy wire capable of filtering contaminants and/or particulates having a size of at least 180 microns. It is understood, however, that the screen member52may be formed from any suitable material with the aforementioned characteristics as desired.

In some embodiments, the support rack54may be configured to maintain a position of the screen member52and permit the flow of the fluid therethrough during the operation of the cooking system10. As shown inFIG.5, the support rack54may be disposed on and supported by a plurality of ribs59that extend radially inward from an inner circumferential surface of the body portion24into the chamber25. In a non-limiting example, the support rack54may include a ring member60with a plurality of spaced-apart cross-members62extending across a diameter thereof. As shown inFIG.6, one or more of the cross-members62may extend across the diameter of the ring member60in a first direction and one or more of the cross-members62may extend across the diameter of the ring member60in a perpendicular second direction. It is understood that any number of cross-members62may be disposed on the ring member60in any configuration as desired. It is further understood that the support rack54may be formed from any suitable heat-resistant and/or heat-tolerant material as desired. In certain embodiments, the screen member52and/or the support rack54may also be configured to be removable from the chamber25to allow the thermal energy source50to be removed and/or replaced and the screen member52to be cleaned. A handle64extending upwardly from the support rack54may be employed to facilitate such removal from the housing assembly20.

Referring back toFIGS.1-3and5, the outer housing structure23has a generally circular cross-sectional shape and may further include a relatively large opening70formed in a front, lower portion thereof to accommodate the inlet/outlet portion26of the inner housing structure22. A space72may be formed between the outer housing structure23and the inner housing structure22to permit a flow of the fluid from the atmosphere to flow around and provide cooling to the outer housing structure23. The fluid in the space72may be permitted to exit the space72via one or more openings74, shown inFIG.2, formed in the outer housing structure23. Preferably, a distance between the housing structures22,23is about 1 inch. However, it is understood that the distance may be more or less if desired. In some embodiments, an additional space76may be formed between the outer housing structure23and the inlet/outlet portion26to perform as a vent and militate against a heated fluid from flowing into a face and body of the user.

In preferred embodiments, the cooking system10may further include an adjustable support rack assembly77. As shown, the support rack assembly77may comprise a support rack78rotatably coupled to an adjustable arm member79. In comes embodiments, the support rack78may be configured to be selectively positionable between 0 and 360 degrees about the arm member79. As such, the support rack78may be vertically aligned with, slightly offset, or completely removed away from the thermal energy zone17. Additionally, the arm member79may be configured to be selectively positionable between a first vertical position within the cooking zone14adjacent the support rack33and a second vertical position within the cooking zone16above the lid21and the cooking zone15. It is understood that the arm member79may be movably coupled to the housing assembly20by any suitable method as desired. As shown inFIGS.1-3and5, the support rack78may include a ring member81with a plurality of spaced-apart cross-members83extending across a diameter thereof. It is understood that any number of cross-members83may be disposed on the ring member81in any configuration as desired to permit a flow of the heated fluid from the thermal energy zone17to surround the food being prepared. It is further understood that the support rack78may be formed from any suitable heat-resistant and/or heat-tolerant material as desired. In certain embodiments, the support rack78may also be configured to be removable from the housing assembly20. At least one handle85may extend upwardly from the support rack78may be employed to facilitate positioning relative to the housing assembly20and removal therefrom.

A blower assembly80may also be removably or fixedly coupled to the housing assembly20, and more particularly, the outer housing structure23. The blower assembly80shown includes a passageway82to permit a flow of the fluid therethrough. The passageway82may be in fluid communication with the atmosphere and a plenum84formed between the housing structures22,23. As more clearly shown inFIG.5, the plenum84may be in fluid communication with the thermal energy zone17via the aperture29formed in the body portion24of the inner housing structure22. In some embodiments, the blower assembly80includes a blower (not depicted), for example a rotatable fan blade, configured to draw the fluid from the atmosphere and force the fluid to flow along a fluid flow path indicated by arrows D inFIG.8through the passageway82, through the plenum84, into an interior of the lid21where the fluid is mixed with the heated fluid from the thermal energy zone17and pressurized, through the thermal energy zone17wherein the mixed fluid is superheated, and into the cooking zone13. The blower assembly80may be in electrical communication with a power source such as a battery, for example, to provide an electric current thereto. A rate of the flow of the fluid into the blower assembly80and through the fluid flow path indicted by arrows D may be selectively adjusted and controlled. In certain embodiments, the rate of flow of the fluid may be directly adjusted and controlled by the user via a control element86and/or wirelessly via an application accessible on an electronic device. In other embodiments, the cooking system10may further include a controller100configured to automatically adjust and control the rate of flow of the fluid through the fluid flow paths A, B, C, D of the cooking system10. Preferably, the cooking system10may be configured to automatically control the rate of flow of the fluid through the fluid flow paths A, B, C, D of the cooking system10depending on parameters set by the user such as type and amount of food being prepared, which of the cooking zones13,14,15,16being utilized, and the like, for example.

In certain embodiments, the housing assembly20may yet further include a deflector90and a heat-resistant and/or heat-tolerant base structure92. The deflector90and the base structure92may be coupled to the inner housing structure22and/or the outer housing structure23by any suitable method as desired such as mechanical fasteners, a welding process, and the like, for example. As shown, the deflector90may be disposed between the base portion28and the base structure92of the housing assembly20. The deflector90may have a generally planar shape and capable of deflecting thermal energy emitted from the chamber25back through the base portion28and away from a supporting structure (not depicted) such as a tabletop, for example. The base structure92may also be generally planar and include one or more receptacles94extending upwardly therefrom. Each of the receptacles94may be configured to receive a corresponding one of protuberances96extending downwardly from the base portion28therein. The base structure92may be formed from a material, for example silicone, that is capable of absorbing and/or slowing the flow of the thermal energy to militate against a transfer of the thermal energy to the supporting structure.

It is understood that any of the components of the cooking system10may be formed from any suitable material such as non-ferrous, high-temperature nickel alloys or ceramic materials, for example.

Operating the cooking zone13in a broiler-oven mode is shown inFIG.8. During high-temperature operation the adjustable blower assembly80, powered by battery or external power source, is operating and pushing fluid through the passageway82and the plenum84, through the aperture29, and into the cooking zone14with the lid21closed. The pressurized fluid flows downward through the thermal energy zone17, where the fluid is superheated to about 800° F. to about 1200° F. The superheated fluid then flows from the thermal energy zone17into and through the cooking zone13for use in high-temperature searing or broiling in a balanced and continuous manner. As such, the cooking zone13utilizes convection thermal energy transfer and radiant thermal energy because of its location beneath the thermal energy zone17.

Operating the cooking zone14in a traditional grill mode is shown inFIG.9. With the lid21open and the blower assembly80turned off, the user can control fluid flow from below the thermal energy zone17with the manually operated closure member40and the damper44. The operating characteristics in this mode of operation are typical to charcoal grill in terms of temperature and cooking capability which ranges from low temperature to high temperature.

Operating the cooking zone16in an elevated and adjustable grill mode is also shown inFIG.9. With the lid21open and the blower assembly80turned off, the user can control air flow from below the thermal energy zone17with the manually operated closure member40and the damper44. The operating characteristics in this mode of operation are the ability to grill using the cooking zone14while also grilling, cooking or warming food above that surface on the adjustable support rack assembly77in the cooking zone16. The adjustable support rack assembly77can also be rotated out of the cooking zones14,16to prevent further cooking and hold food temperature.

Operating the cooking zone15in a warming center mode is shown inFIG.10. With the lid21closed, the user can put a cooking device12onto the damper18. Rotating the damper18increases or decreases a volume of waste heat from the chamber25, allowing for either warming or cooking of food in the cooking device12.

In other embodiments shown inFIGS.11and12, the cooking system10may be configured for use with the following: (1) a ferrous or nonferrous metal stand110(shown inFIG.11) that supports the cooking system10and acts storage for tools and accessories; (2) side mount work tables150(shown inFIGS.11and12) which may be added to the cooking device10to hold unprepared and prepared foods as well as utensils; and/or (3) a metal framework200(shown inFIG.12) which may be used to attach the cooking system10(and optionally an umbrella250) to a trailer hitch to create a mobile outdoor cooking space.

The presently disclosed cooking system10is unique in that it is structurally different from other known devices. More specifically, the cooking system10is unique to the presence of: (1) the blower assembly80that pushes pressurized fluid through the thermal energy source50to create a sustained and stable source of superheated convection cooking fluid; (2) multiple cooking zones that places a highest-temperature cooking zone13below the thermal energy source50, the traditional cooking zone14above the thermal energy source50, and the warming center zone16located above the entire housing assembly20to harvest waste heat for warming and cooking; (3) an overall circular cross-sectional shape to mix and balance fluid flow, heat and cooking capability throughout the cooking system; (4) instantly switchable cooking zones13,14,15,16through managing the blow assembly80and convection fluid flow through the cooking system10; (5) the outer housing structure23that allows cool fluid to flow through the housing assembly20to facilitate a cooling thereof; and (6) the use of cast aluminum for the body portion24for heat dissipation.

The presently disclosed cooking system10is superior to other known methods and systems because: (1) a user can broil and sear foods at 800° F.-1200° F. while also traditionally grilling and warming food in one device; (2) a user can switch quickly between cooking zones13,14,15,16within the cooking system10to prepare a wide range of foods and varying temperatures in one device at the substantially simultaneously or individually.

As to a further discussion of the manner of usage and operation of the presently disclosed subject matter, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided. With respect to the above description, it is to be realized that the optimum dimensional relationships for the parts of the presently disclosed subject matter, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the presently disclosed subject matter. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions and methods can be made within the scope of the present technology, with substantially similar results.