Abstract:
A new style commercial salamander/cheese melter that will normally be off until product is placed under a gas burner, a heating time is selected and a start button is pressed. The burner lights, heats to infrared within 5 seconds (fast heat up), melts cheese or finishes a dish quickly, and then shuts off completely when a timing cycle has expired, freeing up the operator to do other activities and preventing over cooking of the product being finished.

Description:
RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/332,467, filed on May 7, 2010, the entire contents of which are incorporated herein. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    This disclosure relates to a food finishing appliance that provides a finish to a food product, e.g., by melting, browning a surface or toasting the food product. 
       BACKGROUND OF THE DISCLOSURE 
       [0003]    In restaurants, current food finishing appliances, such as commercial cheesemelters/salamander broilers, are turned on at the beginning of the day and left on throughout the day operating at a minimum or a low fired setting. When a food product is placed under the burner for finishing, the operator must turn the heat control from low to high. The operator also must watch the food product during finishing making sure it is not overdone. When the finishing is done, the operator then must remove the food and turn the heat setting from high to low. The disadvantages of the current food finishing appliances are that the appliance must be left on all day so as to be ready to use without a long heat-up time, thereby consuming energy and expelling heat into the kitchen. 
         [0004]    There is a need for a food finishing appliance and method that address the disadvantages of the current food finishing appliances. 
       SUMMARY OF THE DISCLOSURE 
       [0005]    The food finishing appliance of the present disclosure overcomes the aforementioned problems with an instant on burner that is turned on for a timed interval during which the food product is finished and then automatically turns off. 
         [0006]    An embodiment of a food finishing appliance of the present disclosure comprises a food finishing cavity comprising an opening through which the food product to be finished is inserted and removed. An infrared gas heater is disposed within the food finishing cavity. A control circuit turns on the infrared gas heater and starts a finishing time interval and turns the infrared gas heater off when the finishing time interval ends. The infrared gas heater consumes energy only during the finishing time interval. 
         [0007]    In another embodiment of a food finishing appliance of the present disclosure a control panel includes a finishing time interval selector that selects the finishing time interval and a start button that provides electrical energy to turn on the infrared gas heater and start the finishing time interval. 
         [0008]    In another embodiment of a food finishing appliance of the present disclosure the control circuit connects and disconnects the infrared gas heater to one or more sources of energy as the finishing time interval starts and ends, respectively, so that the infrared gas heater consumes energy only during the finishing time interval. 
         [0009]    In another embodiment of a food finishing appliance of the present disclosure the energy is a member of the group consisting of: gas and gas and electrical. 
         [0010]    In another embodiment of a food finishing appliance of the present disclosure the infrared gas heater comprises an infrared gas burner that comprises a metal fiber mat within which combustion takes place. 
         [0011]    In another embodiment of a food finishing appliance of the present disclosure the infrared gas burner further comprises a plenum that is in fluid communication with the metal fiber mat. 
         [0012]    In another embodiment of a food finishing appliance of the present disclosure the plenum comprises a surface with a plurality of apertures to provide the fluid communication with the metal fiber mat. 
         [0013]    In another embodiment of a food finishing appliance of the present disclosure the metal fiber mat comprises a surface of the plenum. 
         [0014]    In another embodiment of a food finishing appliance of the present disclosure the food finishing cavity comprises a first food finishing area in which the opening and the infrared gas heater are disposed and a second food finishing area separate from the first food finishing area. The food finishing appliance further comprises an additional opening, an additional infrared gas heater is disposed in the second food finishing area, and an additional control circuit controls the finishing of an additional food product in the second area. 
         [0015]    An embodiment of a method of the present disclosure comprises: 
         [0016]    providing a food finishing cavity comprising an opening through which the food product to be finished is inserted and removed; 
         [0017]    disposing an infrared gas heater within the food finishing cavity; and 
         [0018]    providing a control circuit that turns on the infrared gas heater and starts a finishing time interval and turns the infrared gas heater off when the finishing time interval ends, wherein the infrared gas heater consumes energy only during the finishing time interval. 
         [0019]    Another embodiment of the method of the present disclosure further provides a control panel that includes a finishing time interval selector that selects the finishing time interval and a start button that provides electrical energy to turn on the infrared gas heater and start the finishing time interval. 
         [0020]    In another embodiment of the method of the present disclosure the control circuit connects and disconnects the infrared gas heater to one or more sources of energy as the finishing time interval starts and ends, respectively, so that the infrared gas heater consumes energy only during the finishing time interval. 
         [0021]    In another embodiment of the method of the present disclosure the energy is a member of the group consisting of: gas and gas and electrical. 
         [0022]    In another embodiment of the method of the present disclosure the heater comprises an infrared gas burner that comprises a metal fiber mat within which combustion takes place. 
         [0023]    In another embodiment of the method of the present disclosure the infrared gas burner further comprises a plenum that is in fluid communication with the metal fiber mat. 
         [0024]    In another embodiment of the method of the present disclosure the plenum comprises a surface with a plurality of apertures to provide the fluid communication with the metal fiber mat. 
         [0025]    In another embodiment of the method of the present disclosure the metal fiber mat comprises a surface of the plenum. 
         [0026]    In another embodiment of the method of the present disclosure the food finishing cavity comprises a first food finishing area in which the opening and the infrared gas heater are disposed and a second food finishing area separate from the first food finishing area. The food finishing appliance further comprises an additional opening, an additional infrared gas heater is disposed in the second food finishing area, and an additional control circuit controls the finishing of an additional food product in the second area. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]    Other and further objects, advantages and features of the present invention will be understood by reference to the following specification in conjunction with the accompanying drawings, in which like reference characters denote like elements of structure and: 
           [0028]      FIG. 1  is a lower left perspective view of a food finishing appliance of the present disclosure; 
           [0029]      FIG. 2  is a lower right perspective view of the food finishing appliance of  FIG. 1 ; 
           [0030]      FIG. 3  is a front perspective view of the food finishing appliance of  FIG. 1 ; 
           [0031]      FIG. 4  is a block diagram of a finish control circuit of the food finishing appliance of  FIG. 1 ; 
           [0032]      FIG. 5  depicts an alternative embodiment of the control panel of the food finishing appliance of  FIG. 1 ; 
           [0033]      FIG. 6  is a lower left perspective view of the food finishing appliance of  FIG. 1  with a divider partition; 
           [0034]      FIG. 7  is a perspective view of the infrared burner of the food finishing appliance of  FIG. 1 ; 
           [0035]      FIG. 8  is a perspective view of the infrared burner of  FIG. 7  with burner surface material removed; and 
           [0036]      FIG. 9  is a perspective view of the food finishing appliance of  FIG. 1  with front and side walls removed. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0037]    Referring to  FIGS. 1-3  and  9 , a food finishing appliance  30  of the present disclosure comprises a top wall  32 , a bottom wall  34 , side walls  36  and  38  and a front wall  40  arranged in a box like structure. Front wall  40  comprises an opening  42  to a food-finishing cavity  44 . A heater  46 , a heater  48  and a shelf  50  are disposed within food finishing cavity  44 . Heaters  46  and  48  are located just below top wall  32  and shelf  50  is located below heaters  46  and  48  by a distance that allows a food product to be placed on shelf  50  for finishing. 
         [0038]    Heater  46  is supported by a mount  52  on side wall  36  and a mount  54  on top wall  32  as shown in  FIG. 1 . Heater  48  is supported by a mount  56  on side wall  38  and a mount  58  on top wall  32  as shown in  FIG. 2 . Shelf  50  is supported by mounts  60  and  62  on side walls  36  and  38  as shown in  FIG. 3 . Shelf  50  may be any suitable shelf, and though shown as a solid shelf, could also have perforations or be formed with wire or rods, as, e.g., a standard food rack. 
         [0039]    In the embodiment shown in  FIGS. 1-3  and  9 , heaters  46  and  48  are arranged side by side so as to provide two separate finishing areas so as to accommodate two separate food products for finishing. Referring also to  FIG. 6 , food finishing appliance  30  is shown with a divider partition  49  disposed in food finishing cavity  44  between heaters  46  and  48  to minimize heat transfer from one area to another. It will be apparent to those of skill in the art that the food finishing appliance of the present disclosure can have more or less than two heaters to provide a corresponding number of food product finishing areas. 
         [0040]    A control panel  72  and a control panel  74  are mounted on front wall  40  below shelf  50  for the control of heaters  46  and  48 , respectively. Control panel  72  carries a start button  76  and an interval timer adjustment selector  78  for heater  46 . Control panel  74  carries a start button  80  and an interval timer adjustment selector  82  for heater  48 . Control circuitry associated with control panels  72  and  74  is located in a compartment  70  that is disposed below shelf  50  within the interior of food finishing appliance  30 . Other control components may also be disposed in compartment  70 . 
         [0041]    Heaters  46  and  48  are preferably gas burners, such as infrared burner  102 , as shown in FIGS.  4  and  7 - 9 , that comprise an infrared metal matrix burner surface. The burner surface can achieve surface temperatures in excess of 1500° F. without surface material breakage (unlike standard ceramic tile burners that are prone to fracture) or puncture. When shut off, the burner surface material cools quickly almost instantly stopping radiant heat. 
         [0042]    In operation, the operator places a food product to be finished in food finishing cavity  44  on shelf  50  below heater  46  or  48 . The operator provides operator input by operating start button  76  and timer adjustment selector  78 , which are connected in a finish control circuit  90 . The operator uses timer adjustment selector  78  to select a finishing time interval. Then the operator activates start button  76  to provide a connection to electrical power or energy, which initiates a heating cycle by lighting the burner with an igniter  100  ( FIGS. 1 and 9 ), which, for example, may be any suitable igniter, such as a pilot, a spark, a hot surface igniter, or the like. The burner heats up to an infrared state within five seconds and begins the finishing process. When the finishing time interval has ended or expired, finish control circuit  90  automatically shuts off the burner such that heating of the food product is stopped so as to prevent over cooking. A similar control circuit  92  is provided for controlling heater  48 . 
         [0043]    After activating start button  76 , the operator can then walk away and do something else. After the finishing time has ended, the operator can then come back to food finishing appliance  30  to remove the food product, which has not been over cooked. Food finishing appliance  30  is completely off when food is not being finished, thereby saving energy and heat load to the kitchen. 
         [0044]    Each heater  46  and  48  has an associated finish control circuit  90  and  92 , respectively, which are substantially identical to one another. Therefore, only the finish control circuit  90  for heater  46  will be described. Referring to  FIG. 4 , finish control circuit  90  for heater  46  comprises a main power switch  94 , interval timer adjustment selector  78 , start button  76 , an interval timer  96 , an ignition module  98 , an igniter  100 , an infrared burner  102  and a valve  104 . Infrared burner  102  is a preferred heater for and corresponds to heater  46 . A gas supply  106  is connected to valve  104  via a gas fitting  84  ( FIGS. 1 and 6 ) and a gas manifold  86  ( FIG. 9 ). Valve  104  is connected to infrared burner  102  by a pipe or tube  88  ( FIG. 9 ). Finish control circuit  90  controls valve  104  to supply gas from gas supply  106  to infrared burner  102  during a finish cycle. Valve  104  may be any suitable valve and preferably is a solenoid valve. 
         [0045]    When main power switch  94  is closed, finish control circuit  90  is connected in circuit with alternating current (AC) power from a power grid or generator. When a food product to be finished is placed below infrared burner  102 , the operator uses interval timer adjustment selector  78  to set or select a finish time interval (a finish time cycle) for finishing the food product. The operator then actuates start button  76  to connect interval timer  96  in circuit with the AC power via main switch  94  and interval timer adjustment  78 . Interval timer  96  initiates the selected finish time interval by providing electrical energy to ignition module  98  and an optional burner air supply blower  108 . Ignition module  98  provides electrical energy to open valve  104  to allow gas from gas supply  106  to flow to infrared burner  102 . Ignition module  98  also provides electrical energy to igniter  100  to ignite the gas, which is entrained with ambient air. Burner air supply blower  108  can optionally be used to provide air under pressure for mixing with gas at infrared burner  102 . Interval timer  96  at the end of the finish time interval removes electrical energy or power from optional air blower  108  and from ignition module  98 , which in turn closes gas valve  104  and igniter  100 . 
         [0046]    Interval timer adjustment selector  78  may comprise a variable resistor, such as a rheostat or potentiometer, a slider or other suitable selector such as the arrangement of food icons shown in  FIG. 5  and described hereinafter. Interval timer  96  may be any suitable interval timer. For example, interval timer  96  may be interval timer module  4310  available from Artisan Controls Corporation of Randolph, N.J. 
         [0047]    Referring to  FIGS. 7 ,  8  and  9 , infrared burner  102  comprises a plenum  120  that receives an air and gas mixture from valve  104  (see also  FIG. 4 ) via a gas orifice fitting  122  that is joined to a combustion air tube  124 . The air-gas mixture is then evenly distributed to a burner surface  130 . Combustion air tube  124 , for example, provides pressurized air from burner air supply blower  108  via an air hose  132  shown in  FIG. 9 . As shown in  FIG. 8 , plenum  120  is structured to hold a top sheet  126  that has a pattern of apertures  128  in fluid communication with the combustible air-gas mixture. Apertures  128  are preferably slots, but may have any other suitable shape. Top sheet  126  is covered with a metal fiber mat  130  shown in  FIG. 7 . Combustion takes place within metal fiber mat  130 . Metal fiber mat  130  has a metal matrix surface that produces radiant infrared heat. Metal fiber mat  130 , for example, is available from Micron Fiber-Tech of Debary, Fla. Some metal fiber mats come with a metallic backing and would not need metallic sheet  126 . 
         [0048]    In an alternate embodiment (not shown) infrared burner  102  is provided gas through gas orifice fitting  122  and entrains ambient air into plenum  120 . The air-gas mixture is then evenly distributed to burner surface  130 . 
         [0049]    Referring to  FIG. 5 , an alternate embodiment of the control panel  150  for food finishing apparatus  30  comprises a start button  152  and separate icon buttons  154 ,  156 ,  158 ,  160  and  162  for food products cheese fries, notchoes, cheese burger, sub, and potato skins, respectively. Associated with each icon button is a time interval value, which when selected causes the time interval to be used by finish control circuit  90 . These values can be represented by separate resistors for interval timer  96  described above. In an alternate embodiment, the values may be digital values that operate a counter to count up or down to establish the time interval for control of ignition module  98 , igniter  100  and valve  104  and/or burner air supply blower  108 . Alternatively, the digital values may address a lookup table that stores the time intervals. The food finishing appliance of the present disclosure is characterized by (a) a fast heat up infrared metal matrix burner surface that heats up to infrared within five seconds of lighting, burner surface temperatures in excess of 1500° F., (c) burner surface material that will not break (unlike standard ceramic tile burners that are prone to fracture) and cannot be punctured easily, (d) upon shut off, the burner surface material cools quickly so as to almost instantly stop radiant heat, (e) large energy saving over current cheese melters/finishers which need to maintain a minimum operating temperature whether or not in use, (f) pre-heat is unnecessary, (g) burner operation between heating cycles is unnecessary, (h) reduced heat load to the kitchen, (i) once time setting is selected and started, operator can walk away and do something else without over cooking food, (j) more comfortable to work around, when finishing, most of the radiant heat is going to the food and not to the operator, and when finished, no radiant heat is output to the kitchen, (k) can be mounted on a wall, used as a pass-through, or mounted over a range, and (l) extended life of the food finishing appliance (compared to current food finishing appliances) 
         [0050]    The table set forth below gives exemplary finish cycles for various food products using food finishing appliance  30 . 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
             
           
               
                   
               
               
                   
                 Product Temp Prior 
                 Quantity/ 
                   
               
               
                 Product 
                 to Cooking 
                 Weight 
                 Time 
               
               
                   
               
             
             
               
                 Penne pasta 
                 Pasta hot sauce, 
                 Single 
                 40 sec 
               
               
                 with 
                 hot cheese chilled 
                 serving 
               
               
                 marinara and 
                 to 45 F. 
               
               
                 mozzarella 
               
               
                 Chili cheese 
                   
                 Family style 
                 48 sec 
               
               
                 fries 
                   
                 platter 
               
               
                 Nachos 
                 Chips, pickled 
                 Family style 
                 50 sec 
               
               
                   
                 jalapenos, scallions 
                 platter 
               
               
                   
                 and cilantro - 
               
               
                   
                 ambient, cheese 45 F. 
               
               
                 Texas Toast 
                 Thawed, refrigerated 
                 Two pieces 
                 1 m:15 sec 
               
               
                   
                 41 F.-43 F. 
               
             
          
           
               
                 Garlic bread 
                 Thawed refrigerated 
                 0.5 
                 loaf 
                 1 m:23 sec 
               
               
                   
                 store bought 
               
               
                 Cheese burger 
                 Burger 150 F. 
                 6 
                 oz burger 
                 30 sec 
               
               
                 and bun 
                 Cheese 41 F. 
                 1 
                 oz cheese 
               
               
                   
                 Bun ambient 
                 1 
                 bun 
               
               
                 Meatball sub 
                 Meat balls 160 F. 
                 30 
                 sec 
               
               
                   
                 Held in food holding 
               
               
                   
                 cabinet with sauce 
               
               
                   
                 Cheese 41 F. 
               
             
          
           
               
                 Chicken parm 
                 Fried 165 F. 
                 3 pieces on 
                 1 m:10 sec 
               
               
                   
                 Sauce 150 F. 
                 platter 
               
               
                   
                 Cheese 41 F. 
               
               
                   
               
             
          
         
       
     
         [0051]    Alternate embodiments of the food finishing appliance of the present disclosure include, but are not limited to, a back wall and/or mounted to a wall, an adjustable shelf, one or more bottom burners, a digital programmable controller, a single burner unit with a smaller footprint, an adjustable shelf or rack, a divided food finishing cavity (e.g., a divider wall disposed between heaters  46  and  48  to divide food finishing cavity  44  into two separate units, a horizontal toaster/finisher configuration with conveyor and burner units off when no food product is present, and a horizontal conveyor with top and bottom burners and a control that when initiated lights the burners and then starts the conveyor, varies the conveyor speed relative to the internal condition in the unit (single runs vs. continuous cooking) and shuts off the burners and conveyor when the last product has completed a cooking event or cycle. 
         [0052]    The present invention having been thus described with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications may be made therein without departing from the spirit and scope of the present invention as defined in the appended claims.