Double-walled baking tray having improved baking characteristics

A baking tray includes a top sheet and a bottom sheet. The top sheet has a first top side, a first bottom side, and a first outer perimeter. The first top side includes a first horizontal surface configured for supporting food for cooking in an oven. The bottom sheet has a second top side, a second bottom side, and a second outer perimeter. The second bottom side includes a second horizontal surface configured for supporting the baking tray upon an oven rack. The bottom sheet is attached to the top sheet at an interface adjacent to the first outer perimeter and the second outer perimeter. The second horizontal surface comprises dimple portions and flat portions. The flat portions separate the dimple portions and are spaced from the top sheet. Each of the dimple portions is indented toward the top sheet.

TECHNICAL FIELD

The present invention relates to cooking implements, and more particularly to trays to facilitate the baking of food in an oven.

BACKGROUND OF THE INVENTION

Single-layer bakeware is formed from a single sheet of metal. In use, food is placed on the sheet and the sheet is then inserted into an oven such that it rests upon an oven rack. As the sheet contacts both the food and the oven rack, heat is directly conducted from the oven rack to the bottom of the food, and the bottom of the food is thereby prone to burning.

Conventional insulated bakeware is typically formed by attaching two sheets of metal together in a parallel and spaced relationship so that one of the sheets serves as a top sheet and the other of the sheets serves as a bottom sheet. In use, food is placed on the top sheet and the bakeware is then inserted into an oven with the bottom sheet resting upon an oven rack. As the space between the top sheet and the bottom sheet is filled with air, heat is not directly conducted from the oven rack to the bottom of the food, and the bottom of the food can thereby be prevented from burning. However, as compared to single-layer bakeware, required baking times are undesirably increased when conventional insulated bakeware is employed.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the present invention, a baking tray comprises a top sheet and a bottom sheet. The top sheet has a first top side, a first bottom side, and a first outer perimeter. The first top side includes a first horizontal surface configured for supporting food for cooking in an oven. The bottom sheet has a second top side, a second bottom side, and a second outer perimeter. The second bottom side includes a second horizontal surface configured for supporting the baking tray upon an oven rack. The bottom sheet is attached to the top sheet at an interface adjacent to the first outer perimeter and the second outer perimeter. The second horizontal surface comprises dimple portions and flat portions. The flat portions separate the dimple portions and are spaced from the top sheet. Each of the dimple portions are indented toward the top sheet. The dimple portions are substantially evenly distributed across the entirety of the second horizontal surface, such that the first horizontal surface is substantially evenly heated by the second horizontal surface when the baking tray is placed into a heated oven, and such that the first horizontal surface is heated more rapidly than that of a baking tray of similar construction but not having the substantially evenly distributed dimple portions.

In accordance with another embodiment of the present invention, a baking tray comprises a top sheet and a bottom sheet. The top sheet has a first top side, a first bottom side, and a first outer perimeter. The first top side includes a first horizontal surface configured for supporting food for cooking in an oven. The bottom sheet has a second top side, a second bottom side, and a second outer perimeter. The second bottom side includes a second horizontal surface configured for supporting the baking tray upon an oven rack. The bottom sheet is attached to the top sheet at an interface adjacent to the first outer perimeter and the second outer perimeter. The second horizontal surface comprises dimple portions and flat portions. The flat portions separate the dimple portions and are spaced from the top sheet. Each of the dimple portions are indented toward the top sheet. Each of the dimple portions has substantially the same diameter and is spaced from every other adjacent one of the dimple portions by a distance no greater than about five times the diameter.

DETAILED DESCRIPTION OF EMBODIMENTS

The present invention and its operation are hereinafter described in detail in connection with the views ofFIGS. 1-7, wherein like numbers indicate the same or corresponding elements throughout the views. Bakeware in accordance with the teachings of the present invention include at least two spaced apart metal sheets, wherein one sheet includes multiple dimple portions as described in further detail below. Through use of bakeware in accordance with the teachings of the present invention, required baking times can be reduced while still providing the reduction in food burning provided by conventional insulated bakeware.

It will be appreciated that the term “baking tray” is inclusive of a variety of baking implements (i.e., bakeware) including but not limited to baking pans and baking sheets. A baking pan can be configured in any of a variety of specific configurations such as a cake pan, pie pan, muffin pan, loaf pan, pizza pan, or a jelly roll pan. Likewise, a baking sheet can be configured in any of a variety of specific configurations such as a cookie sheet or biscuit sheet, with or without one or more raised edges.

FIGS. 1-3depict a baking pan20in accordance with one embodiment of the present invention. The baking pan20is formed by attaching a top sheet22to a bottom sheet32, as best shown inFIG. 3. The attachment can occur at an interface42adjacent to a first outer perimeter28of the top sheet22and a second outer perimeter38of the bottom sheet32. The attachment can comprise crimping (as shown), welding, gluing, rolling, and/or any of a variety of alternatives.

In one embodiment of the present invention, the top sheet22and the bottom sheet32can each comprise sheets of the same type of material (e.g., steel or aluminum). However, in another embodiment, the top sheet22can be formed from a different material from the bottom sheet32. In the embodiment shown, both the top sheet22and the bottom sheet32comprise aluminum. The thickness of the top sheet22may or may not be the same as the thickness of the bottom sheet32. It will be appreciated that one or more coatings can be provided on one or both of the top sheet22and the bottom sheet32to improve properties of use (e.g., a Teflon ® a coating or other coating which reduces sticking).

The top sheet22includes a first top side24and a first bottom side26. A portion of the first top side24provides a first horizontal surface30which is suitable to support food for cooking. The bottom sheet32includes a second top side34and a second bottom side36. A portion of the second bottom side36provides a second horizontal surface40which is suitable to contact an oven rack during use. The second horizontal surface40includes dimple portions44and flat portions46, notwithstanding that the dimple portions44technically render the second horizontal surface40not entirely planar or horizontal. It will be appreciated that the first and second horizontal surfaces30,40can assume any of a variety of shapes (e.g., square, rectangular, circular, oval, or hexagonal), although they are depicted inFIGS. 1-2as being substantially rectangular.

Each of the dimple portions44comprises an indentation in the bottom sheet32which is directed toward the top sheet22. The indentation can assume any of a variety of shapes including but not limited to a spherical indentation, spheroidal indentation, ellipsoidal indentation, or otherwise. Some or all of the dimple portions44may indent sufficiently to contact the top sheet22to provide underlying support for the top sheet22. For example, in one configuration, at least some of the dimple portions can be configured to continuously touch the top sheet (e.g., seeFIGS. 3 and 6). However, in an alternate configuration, at least some of the dimple portions44might touch the top sheet only when a weight (e.g., food) is placed on the first horizontal surface30of the top sheet22(e.g., seeFIG. 7). In still another configuration, a baking tray can be configured such that none of its dimple portions contacts the top sheet under conditions of normal use.

The flat portions46of the bottom sheet32can be spaced from and substantially parallel with corresponding portions of the top sheet22, as shown inFIG. 3. Adjacent dimple portions44are separated by the flat portions46and can be arranged in any of a variety of specific configurations. The dimple portions44can be provided to have a substantially uniform size and shape and/or can be substantially evenly distributed across the entirety of the second horizontal surface40, as shown inFIG. 2, for example. In one embodiment of the present invention, substantially evenly distributed can mean that, for any given dimple portion, more than one dimple portion adjacent to that given dimple portion are spaced the same distance from that given dimple portion. It will be appreciated that an adjacent dimple portion can be one that resides closest to a given dimple portion. Dimple portions distributed substantially evenly across the entirety of the second horizontal surface can extend across the entire second horizontal surface of a baking tray in each direction, as shown inFIG. 2, for example.

The dimple portions44can be arranged in substantially straight rows and in substantially straight columns. In one particular embodiment, a baking tray can include at least thirty-two dimple portions. In another particular embodiment, a baking tray can include at least sixty-four dimple portions arranged into at least eight rows and at least eight columns (e.g., as shown inFIG. 2). However, it will be appreciated that a baking tray having dimple portions provided in substantially straight rows and in substantially straight columns may have absent certain dimple portions. For example, as shown inFIG. 2, the corner dimple portions (e.g.,150inFIG. 5) might not be provided in order to facilitate easier bending of the bottom sheet32during manufacturing.

The dimple portions44can cover a significant portion of the surface area of the second horizontal surface40. For example, in one embodiment, at least about 5% of the surface area of the second horizontal surface40is provided by the dimple portions44. In another embodiment, at least about 10% of the surface area of the second horizontal surface40is provided by the dimple portions44. In still another embodiment, at least about 15% of the surface area of the second horizontal surface40is provided by the dimple portions44. In further embodiments, at least about 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, and/or 90% of the surface area of the second horizontal surface is provided by the dimple portions.

It will be appreciated that each dimple portion44contributes a surface area to the second horizontal surface40which is larger than the surface area which would otherwise be contributed by a corresponding portion of the second horizontal surface40not having a dimple portion44formed therein. Accordingly, the addition of each dimple portion44to the second horizontal surface40increases the total surface area of the second horizontal surface40, and correspondingly increases the ability of the second horizontal surface40to capture heat from an oven. By capturing more heat from an oven, more heat can be transferred to the food being cooked, and the food can accordingly be cooked more quickly. However, because at least a significant portion of this heat can be transferred from the bottom sheet32to the top sheet22through an air gap (e.g.,52, shown inFIG. 3) as opposed to via direct conduction, the food resting upon the first horizontal surface30is unlikely to burn.

The spacing of the dimple portions can, in some circumstances, relate to the overall size of the baking tray and/or its second horizontal surface. For example, as shown inFIG. 2, the second horizontal surface40can have a surface area which extends along perpendicular axes A1and A2. The surface area of the second horizontal surface40is shown to extend a distance D1along axis A1, and a distance D2along axis A2. Each of the dimple portions can be spaced from every other adjacent one of the dimple portions by a distance (e.g., D3, also shown inFIG. 3) which, in some circumstances, is no greater than about 10% of the shortest span of the surface area along either of the axes A1and A2. Hence, in the example depicted inFIGS. 2-3, each of the dimple portions44is spaced by a distance D3which is no greater than about 10% of the shorter of D1and D2. In another embodiment, each of the dimple portions is spaced from every other adjacent one of the dimple portions by a distance (e.g., D3, also shown inFIG. 3) which, in some circumstances, is no greater than about 15% of the shortest span of the surface area along either of the axes A1and A2, and hence is no greater than about 15% of the shorter of D1and D2.

Additionally, dimple portions can be provided within a certain distance from each edge of the second horizontal surface40, wherein that distance (e.g., shown as D5inFIG. 2) does not exceed about 10% of the shortest span of the surface area along either of the axes A1and A2, and hence is no greater than about 10% of the shorter of D1and D2. In another embodiment, that distance is no greater than about 15% of the shortest span of the surface area along either of the axes A1and A2, and hence is no greater than about 15% of the shorter of D1and D2. By providing dimple portions44sufficiently closely spaced to each other and/or the edges of the second horizontal surface40as described herein, heat can transfer substantially uniformly from the second horizontal surface40to the first horizontal surface30during use of the baking pan20within an oven. This substantially uniform transfer of heat helps to ensure that no “hot spots” are present on the first horizontal surface30, and that food thereon can accordingly be evenly heated.

The spacing of the dimple portions can, in some circumstances, relate to the diameter of the dimple portions. For example, in the example ofFIG. 3, each of the dimple portions44has substantially the same diameter D4and is spaced from every other adjacent one of the dimple portions by a distance no greater than about five times the diameter D4. In other embodiments, each of the dimple portions is spaced from every other adjacent one of the dimple portions by a distance no greater than about three times the diameter of the dimple portions. The quantity of dimple portions present on a baking tray can increase as the size (e.g., dimensions D1and D2) of the second horizontal surface increases. Hence, a larger baking tray can include more dimple portions than a smaller baking tray.

By providing a bottom sheet having a significant quantity of dimple portions which are substantially evenly distributed (as shown inFIG. 2, for example) the first horizontal surface of a baking tray can be substantially evenly heated by the second horizontal surface when the baking tray is placed into a heated oven. Additionally, in this configuration, the first horizontal surface can be heated more rapidly (e.g., up to about 15% faster) than that of a conventional baking tray of similar construction but not having the substantially evenly distributed dimple portions. Hence, when a baking tray in accordance with the teachings of the present invention is placed within a heated oven for a predetermined amount of time, its first horizontal surface can reach a desired temperature more quickly than would that of a conventional insulated baking tray when placed within the same oven for the same amount of time. Accordingly, when baking food (e.g., cookies) on a baking tray in accordance with the teachings of the present invention, the food can finish baking more quickly than if the same food were baked on a conventional insulated baking tray, and the bottom of the food would not typically be burned.

An alternative baking tray in accordance with the teachings of the present invention is depicted inFIGS. 4-6to comprise a baking sheet120. The baking sheet120is shown to include a top sheet122and a bottom sheet132which are attached at an interface142adjacent to a first outer perimeter128of the top sheet122and a second outer perimeter138of the bottom sheet32. The top sheet122includes a first top side124and a first bottom side126. A portion of the first top side124provides a first horizontal surface130which is suitable to support food for cooking. The bottom sheet132includes a second top side134and a second bottom side136. A portion of the second bottom side136provides a second horizontal surface140which is suitable to contact an oven rack during use. The second horizontal surface140includes dimple portions144and flat portions146. The dimple portions144can be sized, spaced, and provided in such quantity as discussed above.

FIG. 7depicts a portion of a baking tray220in accordance with another embodiment of the present invention, wherein an alternate suitable arrangement of dimple portions is provided. In particular, a top sheet222is shown to include a first top side224and a first bottom side226. A portion of the first top side224provides a first horizontal surface230which is suitable to support food for cooking. A bottom sheet232is shown to include a second top side234and a second bottom side236. A portion of the second bottom side236provides a second horizontal surface240which is suitable to contact an oven rack during use. The second horizontal surface240includes dimple portions244and flat portions246. When the top sheet222is attached to the bottom sheet232as shown inFIG. 7, an air gap252can remain between the top sheet222and the bottom sheet232. Even though the dimple portions244might not indent insofar as to touch the top sheet222, the baking tray220can still achieve the improved baking performance discussed herein as compared to conventional insulated bakeware.

The foregoing description of embodiments and examples of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed and others will be understood by those skilled in the art. The embodiments were chosen and described in order to best illustrate the principles of the invention and various embodiments as are suited to the particular use contemplated. The scope of the invention is, of course, not limited to the examples or embodiments set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art. Rather it is hereby intended the scope of the invention be defined by the claims appended hereto.