Abstract:
Cookware formed from carbon steel having a handle comprising two tangs cut from a peripheral flange surrounding a formed body of the cookware, such as a fry pan, wherein end portions of the tangs are integral with the formed body, the tangs being bent to form the handle configuration.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation of provision U.S. Patent Application No. 61/811,945, filed on Apr. 15, 2013, of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates generally to cookware and, more particularly, to a method of making a carbon steel cookware such as a fry pan with an integral handle or handles as well as to the cookware which is useful for cooking outdoors on a grill, for example. 
     Description of Related Art 
     It is well known to use carbon steel cookware when cooking food outdoors on a gas or charcoal grill due to the high temperatures involved in such outdoor cooking environments. It is known to form a pan-shaped object and separately forming one or more handles and then attaching the handles to the pan by rivets, for example. 
     SUMMARY OF THE INVENTION 
     Cookware preferably in the form of an outdoor fry pan and a method of making same are disclosed herein. A circular disc or blank of carbon steel is provided of a diameter of sufficient size to accommodate the forming of a fry pan, for example, with an integral handle(s). The blank diameter is sufficient to accommodate on its outer perimeter or flange sufficient material to form the integral handle or handles. The carbon steel disc-shaped blank is first drawn to form the body or pan shape of the fry pan or skillet. The outer perimeter flange of the drawn blank is then preferably laser cut to form the outline (in two dimensions) of opposed handle tangs. A remaining opposite portion of the flange may be laser cut to form an additional loop-type handle outline. The pre-cut tang portions of the blank are then bent upwardly and rearwardly and then bent toward each other to form a stick-type handle for the pan. The opposed handle tangs may then be secured together through pre-formed holes also formed by laser cutting and secured by rivets, for example, to provide the finished formed handle, integral with the fry pan body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a drawn blank of carbon steel in the shape of a fry pan body having a peripheral flange integral therewith in accordance with step 1 of the present invention; 
         FIG. 2  is a perspective view of the drawn blank of  FIG. 1  showing a laser cut pattern along the flange thereof according to the present invention; 
         FIG. 3  is a perspective view showing a 180° bend of the handle tangs as previously pre-cut in  FIG. 2 ; 
         FIG. 4  is a perspective view showing one of the handle tangs bent at 90° on one side of the fry pan according to the present invention; 
         FIG. 5  is a perspective view showing the handle tang on the other side being bent at 90°; 
         FIG. 6  is a side elevation view of the drawn blank of  FIG. 1  with exemplary dimensions; 
         FIG. 7  is a plan view of the laser cut drawn blank of  FIG. 2 ; 
         FIG. 8  is a photograph in perspective of an embodiment of the fry pan according to the invention; and 
         FIG. 9  is a photograph of a presently preferred embodiment of the present invention showing a cooking tool resting in the handle thereof. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to the drawings, a drawn blank  2  is shown in  FIG. 1  and  FIG. 6 . In this first step, the round blank is drawn in a press, for example, for forming a fry pan body  4 . The body  4  comprises a flat bottom wall defining a cooking surface  6  of the fry pan with integral sidewall  8  flaring upwardly therefrom. The outer perimeter of the drawn blank  2  carries an outwardly extending flange  10  on its perimeter. The drawn blank  2  is preferably made from carbon steel of a thickness between 0.080 and 0.125 inch in thickness. A nominal thickness of about 0.10 inch is found to be acceptable. 
     With reference to  FIG. 2 , the drawn blank  2  is next subjected to a second step for laser cutting of the flange  10 . Laser cut lines  12  are formed through the flange  10  to form a first handle tang  14  on one side of the fry pan body  4  and a second handle tang  16  formed on the other side. Holes  18  are also laser cut through the handle tangs. A loop handle  20  is also laser cut from the flange. Scribed lines  12 ′ are also formed at ends of the handle tangs which provide a guide for bending the handle tangs  14  and  16 , which will be described hereinafter. The scribed lines  12 ′ define a solid region of the flange identified as  22  which will remain on the fry pan to connect with the ends of the handle tangs  14  and  16 . 
     Alternatively, the drawn blank and blank cutting operations may be combined in a single step by a hydro forming operation such as a so-called “flow down” hydro forming step, wherein the drawing and cutting of the blank are carried out together. 
     Step 3 in the forming operation is shown in  FIG. 3  in which the handle tangs  14  and  16  are bent at an angle of approximately 180° rearwardly of the fry pan body  4 . 
     Step 4 in the forming operation is shown in  FIG. 4  which shows handle tang  16  being bent on one side of the fry pan body upwardly at a 90° bend. 
       FIG. 5  shows the opposed handle tang  14  being bent upwardly at 90° to match that of handle tang  16 . The formed handle, designated by numeral  24 , is shown in its completed shape in  FIG. 5 . To complete the handle  24 , rivets or the like (not shown) are inserted through the matching holes  18  formed in the respective tangs  14  and  16  to join the handle tangs in a spaced-apart relationship. As seen in  FIG. 5 , the solid portion  22  which was uncut from the flange  10  is integrally connected to the respective handle tangs  14  and  16  to firmly and securely hold the handle  24  to the fry pan body  4 . 
     The plan view of the drawn blank  2  depicted in  FIG. 7  shows in greater detail the laser cut lines  12  used in forming the handle tangs  14  and  16  from the flange  10 . As can be appreciated from  FIG. 7  as well as the remaining figures, the material usage in the manufacture of the fry pan of the present invention is quite efficient in that relatively little scrap is generated because the handles are integral with the body of the fry pan. 
       FIGS. 8 and 9  show the fry pan of the present invention in a completed state with the handle rivets  26  or like fasteners in place on the finished handle  24 . 
     As seen in  FIG. 9 , the handle tangs  14  and  16  in the bent formed position define an opening  30  therebetween which provides for a convenient nesting area for a cooking tool for use during cooking. 
     As shown in a number of the drawing figures, such as  FIGS. 2, 3, 4, 5, and 7 , an outwardly extending protruding portion  32  is laser cut on each of the handle tangs  14  and  16 . As shown in the formed handle  24 , as in  FIGS. 5 and 8 , these outwardly protruding portions  32  form a convenient guide portion for the user when gripping the handle to engage the user&#39;s thumb. In this manner, the user&#39;s hand will remain a safe distance from the hot fry pan body. We have also noted, in use, that the solid portion  22  between the handle tangs  14  and  16  acts as a heat shield to deflect radiant heat from the cooking fire flames away from the handle  24  to prevent it from getting too hot. The thin handle tangs extending upwardly from the top of the pan also tend to remain cooler due to its configuration and also due to the fact that there is an air gap between the two spaced-apart tangs providing a cooling effect on each of the handle tangs. The spacer rivets  26  between the handle tangs contribute to this effect. 
     While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. The presently preferred embodiments described herein are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.