Abstract:
A compact rice cooker with excellent rice cooking performance while preventing boiling-over is presented. This rice cooker comprises a main body, a lid for covering the top of the main body, an inner pan detachably accommodated in the main body, a bottom heating coil for induction heating of the inner pan, a control unit for controlling high frequency power to be supplied to the bottom heating coil, and a rice gruel detector disposed in a steam tube of the lid, and therefore electric power supply is controlled by the control unit depending on the detection state by the rice gruel detecting means. The rice gruel detector makes use of move of the float due to rice gruel, the lid is formed in a compact size, and boiling-over is prevented, so that tasty rice can be cooked.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a rice cooker having a microcomputer for general household or professional use. 
     BACKGROUND OF THE INVENTION 
     Recently, rice cookers for cooking rice with high power for enhancing the rice cooking performance have been developed and distributed widely. There are also rice cookers capable of cooking rice at different levels of softness by the same amount of water. 
     Conventionally, this kind of rice cooker was composed as shown in FIG.  12 . In FIG. 12, a body (rice cooker main body)  1  is a cylindrical structure having an open top, and inside of the body  1  is disposed a protective frame  2  which accommodates an inner pan  3 . The protective frame  2  is a cylindrical structure with a bottom made of nonmetallic material, and the upper end of the protective frame  2  is engaged with the inner circumference of the upper end of the body  1 . 
     The inner pan  3  has a flange  4  projecting outside at the opening of the upper end, and this inner pan  3  is disposed detachably in the protective frame  2 , by mounting the flange  4  on the top of an upper frame  5  in a suspended state. At the outside of the protective frame  2 , an induction coil  6  for heating the inner pan  3  is disposed, and this induction coil  6  is supported by a coil cover  7  formed of a heat resistant resin material in the lower part of the outer circumference of the protective frame  2  so that the distance to the outer circumference of-the inner pan  3  may be constant. In the center of the induction coil  6 , a pan sensor  8  for detecting the temperature of the inner pan  3  is disposed. 
     An outer lid  9  made of synthetic resin is rotatably supported on a hinge member  10  formed integrally on the top of the upper frame  5  through a pin  11 . An inner cover  12  is affixed at the inside of the outer lid  9 . A heat releasing plate  13 , being a heating element, is fixed to the inner cover  12 , and an induction coil  15  supported by a coil support stand  14  is positioned on the top of this heat releasing plate  13 . By the electromagnetic action of this induction coil  15 , the heat releasing plate  13  generates heat. To this heat releasing plate  13 , a lid sensor  16  for detecting the temperature of the heat releasing plate  13  is directly adhered with an aluminum tape, and the temperature of the heat releasing plate  13  is detected. 
     An engaging member  17  is positioned on the opposite side of the hinge member  10  and is formed integrally on the upper end of the protective frame  2 , and confronting to this engaging member  17 , an engaging lever  18  is rotatably supported on the outer lid  9  through a lever pin  19 . A pan packing  20  is to enclose the inner pan  3  by pressing to the flange  4  of the inner pan  3  when the outer lid  9  is closed. A steam tube  21  provided in the center of the outer lid  9  is to prevent rice gruel from boiling over to outside. 
     A control board  22  is to control power feed to the induction coils  6 ,  12 , and also control input and output of signals from the pan sensor  8  and lid sensor  16  and signal of operation display unit  23  provided before the top of the body  1 . A cooling fan  24  is to cool the induction coil  6  and control board  22 . The control board  22  judges the amount of rice and water in the inner pan  3  in the rice cooking amount judging process while cooking rice by the temperature detection signal from the lid sensor  16 , and determines the power feed state to the induction coil  6  depending on the result of judging. 
     In the conventional rice cooker having such constitution, however, the size of the body  1  is large for the inner pan  3  of the rice cooker, and it is not convenient for carrying or installing, or owing to the recent increase in the number of cooking software, the number of operation keys increases and when large keys are used for the ease of handling, the size of the entire rice cooker further becomes larger. 
     On the other hand, when much water is used in cooking rice, it boils over, and the power supply in cooking is stopped before boiling over. However, unless power is supplied in cooking, the temperature rise of rice is not sufficient, and the taste may be sometimes slightly inferior. 
     Besides, when detaching or attaching the inner pan  3 , it is necessary to open or close the outer lid  9 , and particularly when closing the outer lid  9 , the front side of the body  1  on the top of the outer lid  9  must be held down, and if the operation display unit  23  is located on the top of the outer lid  9  in a range possibly held by hand, an operation key may be pressed by mistake. 
     Moreover, since the heat is high, to cook the rice soft, in particular, if more water is added than usual for cooking rice, it often causes boiling-over. 
     SUMMARY OF THE INVENTION 
     It is hence a first object of the invention to realize a rice cooker of compact structure which does not boil over. 
     It is a second object of the invention to realize a rice cooker constituted so as to prevent wrong operation if the operation unit is touched by mistake when closing the lid. 
     It is a third object of the invention to realize a rice cooker capable of preventing boiling-over, without lowering the rice cooking performance, by detecting rice gruel rising over the inner pan. 
     To achieve the objects, the rice cooker of the invention comprises a rice cooker main body (hereinafter called main body), an inner pan detachably accommodated in the main body, a lid to cover the upper opening of the main body, and rice gruel detecting means for detecting flow of rice gruel in cooking rice. Preferably, the rice gruel detecting means is composed of a float and a float detecting unit, and the rice gruel detecting means is preferably provided in the lid, or in a passage of rice gruel, that is, in the steam tube of the lid or in the upper part of the inner pan. 
     In this constitution, the entire rice cooker is made compact, and the convenience of installation and carrying is much improved, and since the steam tube can be easily detached from the lid and cleaned, so that an easy-to-clean and easy-to-handle rice cooker is presented. Still more, by adjusting the heating amount depending on the rising state of rice gruel, boiling-over can be prevented, and a favorable rice cooking performance is always obtained. 
     In the rice cooker of the invention, it is preferred to be constituted so as to supply electric power to the inner pan continuously until the rice gruel detecting means operates, to supply again when rice gruel is no longer possible to flow out of the rice cooker. In this constitution, when finishing cooking, sufficient heating can be applied to rice and water, and tasty rice is cooked, and the taste of the cooked rice is improved. 
     The rice cooker of the invention is preferred to comprise a bottom heating coil for induction heating of the inner pan, control means for controlling supply of high frequency power to the bottom heating coil, a steam tube disposed in the lid for exhausting the steam generated in the inner pan, and rice gruel detecting means disposed in the steam tube. By controlling the power supply amount to the bottom heating coil depending on the detecting state of the rice gruel detecting means, boiling-over of rice gruel can be effectively prevented in a compact steam tube size. 
     Preferably, the rice gruel detecting means is constituted so as to make use of the move of a float moving due to opening and closing of the lid and expansion and contraction of rice gruel generated in the inner pan. As a result, generation of rice gruel can be detected in a simple constitution. Preferably, the rice gruel detecting means comprises a float made of columnar or spherical ferrite disposed so as to roll over a slope provided in the bottom of the steam tube, and a float detecting unit composed of a lead switch for detecting the float. Moreover, preferably, the slope has a groove for flow of rice gruel, and also has a convex portion for the float to move along the groove. Therefore, the structure is also suited to counter-flow of rice gruel. When the float has such a weight as not to be moved by the steam and to be moved by the passing of rice gruel, still more, rice gruel and steam can be distinguished securely. 
     In the rice cooker of the invention, preferably, the control means has an operation unit for instructing selection of rice cooking function, and is constituted so as to inhibit input of operation signal from the operation unit for a specific time after the lid is closed. As a result, malfunction in opening and closing of lid can be prevented securely. Preferably, an input switch of high frequency of manipulation should be disposed ahead of the top of the lid. As a result, malfunction in closing of lid can be avoided more effectively. 
     In the rice cooker of the invention, the rice gruel detecting means comprises a float and a float detecting unit, and the moving portion of the float should preferably has a slope of 5° to 15° in the case of expansion or contraction of the rice gruel generated in the inner pan. Hence the float rolls over the rice gruel. Preferably, the passage of rolling of the float is provided in a steam path of nearly tubular form in a steam tube disposed in the lid, the outline of the float is circular, grooves are provided in upper and lower sides of the steam path, the float and the lateral side of the steam path are formed so as not to contact with each other, a clearance between the steam path and the float is provided widely in the upper part of the float, blow outlets of the steam path are disposed at the lateral side and lower side, and the sectional area of the clearance of the steam path and the float is defined at about 60 to 90 mm 2  when the weight of the float is 2 to 4 g. Therefore, in a simple constitution, the float is not moved by the steam, but is moved by passing of the rice gruel, so that the rice gruel and steam can be distinguished securely. Also preventing dull action due to surface tension of the float and steam path lateral side, the float rolls easily and moves smoothly. 
     In the rice cooker of the invention, the steam tube is provided detachably in the lid, and the steam path in the float sliding portion can be cleaned easily. The float is made of a magnetic member having an elastic material such as rubber on the surface, and the impact of moving of the float is lessened, and therefore crack or cut of the float can be prevented, and the moving noise can be lowered. Moreover, a slope is provided in the bottom of the steam tube, and the lower end of the slope is provided at a higher position than the upper opening of the steam path, and therefore reflux valve of rice gruel is not necessary in the bottom of the steam tube, so that the constitution may be simplified. 
     In the rice cooker of the invention, preferably, the lid has a float detecting unit composed of a lead switch near the steam tube and at the front side of the main body, the steam path is formed so as to incline downward to the float detecting unit, a flange is provided in the rear part of the steam tube so as to be mounted on the lid only in one direction, the control means has an operation unit for instructing selection of rice cooking function, and the operation unit is constituted to inhibit input of operation signal when the steam tube is not mounted on the lid, or the lid is open. Therefore, malfunction can be prevented securely when the steam tube is not mounted or when the lid is open. 
     Preferably, the float detecting unit is designed to detect presence or absence of move of the float at a position moving about ⅓ of the moving distance of the float on the slope or in the steam path. Therefore, if the rice gruel is weak when cooking a small amount of rice, rice gruel can be detected securely. Or, by using a lead switch in the float detecting unit, and forming the lead switch in a V-form along the steam tube, the detecting precision of the float detecting unit can be enhanced. 
     In the rice cooker of the invention, the steam vent on the top of the steam tube is formed obliquely above and in the rear direction of the main body, so that the steam is exhausted to the back side of the main body. As a result, dew condensation of steam and drop of splashes on the operation unit disposed ahead of the lid can be prevented. 
     In the rice cooker of the invention, preferably, a hinge for supporting the main body and the lid by the shaft is provided in the rear part of the main body, and a steam vent is preferred to be disposed ahead of the main body on the steam tube. Therefore, drop of water drops by dew condensation in the steam tube when opening the lid to outside of the steam tube can be prevented. 
     In the rice cooker of the invention, upper frame caps for supporting the inner pan provided at three equal positions on the top of the main body, and locking rubber pieces for positioning the inner pan provided at three equal positions in the center of the inner circumference of the protective frame are alternately disposed so as to form an angle of 60°. As a result, the inner pan can be held uniformly, and set position deviation of the inner pan into the main body can be decreased. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a longitudinal sectional view of a rice cooker in a first embodiment of the invention, 
     FIG. 2 is a sectional view of steam tube of this rice cooker, 
     FIG. 3 is a sectional view showing essential parts of this steam tube, 
     FIG. 4 is a sectional view showing a steam path of this steam tube, 
     FIG. 5 is a schematic view of float detecting unit and surrounding seam tube of this rice cooker, and 
     FIG. 6 is a schematic view of the top of the lid of this rice cooker. 
     FIG. 7 is a schematic perspective view of rice gruel detecting means of a rice cooker in a second embodiment of the invention. 
     FIG. 8 is a schematic perspective view of rice gruel detecting means of a rice cooker in a third embodiment of the invention, 
     FIG. 9 is a power control diagram of this rice cooker, and 
     FIG. 10 is other power control diagram of this rice cooker. 
     FIG. 11 is a top view of appearance of essential parts near the inner pan accommodating area of a rice cooker in a fourth embodiment of the invention. 
     FIG. 12 is a longitudinal sectional view of a conventional rice cooker. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings, preferred embodiments of the invention are described in detail below. 
     (Embodiment 1) 
     A first embodiment of the invention is described by referring to FIG. 1 to FIG.  4 . As shown in these diagrams, in the first embodiment, boiling-over is prevented by a sensor in the steam tube, and the rice cooker is easier to use. That is, to keep low the height of a lid  36 , a steam tube  47  is also lower in the longitudinal direction than in the prior art, and the function for detecting rice gruel and the function for detecting opening and closing of the lid  36  are combined. 
     More specifically, the steam tube  47  incorporating a float  48  movable when opening or closing the lid  36 , and a float detecting unit  49  for detecting move and presence or absence of the float  48  are disposed ahead of the main body around the steam tube  47 , and by making use of the move of the float  48  to the hinge  38  side when the lid  38  is opened, opening or closing of the lid  36  is detected, while detaching or attaching of the steam tube  47  is detected by the presence or absence of the float  48 . 
     As shown in FIG. 2 to FIG. 4, the float  48  is, when the lid  36  is closed, disposed so as to cover the top of a blow outlet  68  of steam, and the float  48  is formed of a magnet in cylindrical or spherical form, that is, in a shape small in contact resistance. On the other hand, the steam tube  47  is provided with a steam path  70  keeping a wide clearance at the upper side of the float  48 , and the float  48  is formed so as to move in the steam path  70 . In an upper inner side  70   a  and a lower inner side  70   b  of the steam path  70 , grooves  67  for guiding the move of the float  48  are provided, and the float  48  has a convex portion  48   a  to be guided along the recessed grooves  67  provided along the enter circumference of the float  48 . 
     The rice gruel blow outlet  68  of the steam path  70  is disposed not only in the bottom but also in the lateral side, so that the float  48  is easy to roll by the steam pressure from the lateral side. The groove  67  forms a passing route for rice gruel, and also prevents impossibility of move of the float  48  due to rice gruel. 
     Concerning the constitution of the float  48 , for example, by using a magnetic material for the float  48 , a lead switch  49   a  is used in the float detecting unit  49 , or, as mentioned later, a photo sensor is used in the float detecting unit  49 , so that the presence of the float  48  may be detected by the presence or absence of its reflection. Anyway, however, the float  48  is defined by the weight of the float itself not to be moved by steam but to be moved along with rise of the rice gruel, inclination angle of the slope  47   a  of the bottom of the steam tube  47 , and the clearance between the steam path  70  and float  48 . The relation between the weight and the rice gruel was experimentally disclosed as follows: by using a columnar float (14 mm in diameter, 10 mm in width), when the sectional area of the clearance of the float  48  and steam path  70  is about  75  square millimeters (mm 2 ), and the angle of the bottom slope  47   a  is about 12°, the weight of about 2 to 4 grams (g) is suitable for adequate action to rise of rice gruel when boiling over in the rice cooking process. In this condition, it was confirmed that the operation is secure without malfunction in the range of the sectional area of the clearance of 60 to 90 mm 2  and the bottom angle of about 5 to 15°. 
     Further, in the lower part of the steam tube  47 , by forming a slope  47   b  in the upper part of the steam path  70 , the rice gruel collected in the steam tube  47  refluxes into the inner pan  32  through the steam path  70 . Therefore, reflux valve is not needed at the lower side of the steam tube  47 . Although the inner volume of the steam tube  47  is small for compact design, by detecting the move of the float  48  by the float detecting unit  49 , power supply to the heating element (heating means) is controlled depending on the detection result. In this embodiment, since it is designed to control supply of high frequency power to the bottom heating coil  33   a , the steam tube  47  of smaller space than in the prior art can be used. That is, along with the rise of the rice gruel in the steam path  70 , the rice gruel is collected in the lower part of the float  48  and the steam path  70  is clogged, and the internal pressure climbs up, the float  48  moves, and the float detecting unit  49  detects the move of the float  48 , so that the above effects are obtained. 
     At this time, the internal pressure of the rice gruel clogging the steam path  70  is about 2 to 3 cm on water column in this constitution, and there is no risk of deformation of the lid by high pressure. 
     In this embodiment, the difference between rice gruel and steam is detected by the motion of the float, but this detection may not depend on the dynamic motion, but may be realized by making use of physical difference such as viscosity of rice gruel or thermal capacity. 
     Moreover, in order to avoid breakage of the internal parts of the float  48 , steam tube  47  and steam path  70  due to sudden move of the float  48  by sudden opening or closing of the lid  36 , the surface of the float  48  is covered with buffer material  69  such as rubber or other elastic member or synthetic resin, and it is reinforced by disposing a rib at the side of the steam tube  47  near the end point of the move of the float  48 . In this constitution, breakage of steam tube  47 , steam path  70  and float  48  can be prevented, and since the float  48  is covered with an elastic member, moving noise of the float  48  may be suppressed low. 
     As shown in FIG.  5  and FIG. 6, the steam tube  47  can be detached and washed by the user same as in the prior art, but in order that the float  48  when mounting the steam tube  47  and the float detecting unit  49  may always confront, at the opposite side of the float detecting unit  49 , a flange  71  is disposed on the top of the steam tube  47  and a recess  72  corresponding to the flange  71  is disposed on the lid  36 , so that detachability of the steam tube  47  and detecting precision of rice gruel can be assured, and the front operation unit  73  can be formed widely. Moreover, since the blow outlet  68  is provided at the lowest position of the bottom, the water after washing hardly remains within the steam tube  47 , and the cleanliness can be maintained. 
     The float detecting unit  49  detects move of the float  48  at a point of short moving distance of rising of about ⅓ of the moving distance (slope) of the float  48  in the steam path.  70 , and therefore rice gruel can be detected even in the case of soft rice cooking course or soup rice cooking course by small amount and low heat. 
     As shown in FIG. 5, the lead switch  49   a  for composing the float detecting unit  49  is accommodated in a lead switch case  49   b , and it is fixed as being filled with elastic member such as silicone rubber, and is disposed near the steam tube  47 . The lead switch  49   a  is easier to detect as the magnetic force of the magnet is stronger or the distance to the magnet is shorter, but as the lead switch  49   a  is formed nearly in a V-form, the distance of the float  48  and lead switch  49   a  is shortened, and the detecting precision of the lead switch  49   a  is enhanced, and the rice gruel can be detected more securely. 
     As shown in FIG.  1  and FIG. 2, by forming the steam vent  74  backward of the main body  31  with the opening direction obliquely upward, disposing at the front side of the main body on the top of the steam tube  47 , the steam generated while cooking rice can be exhausted backward of the main body  31 . As a result, dew condensation and drop of splashes on the operation unit  73  disposed in the lid  36  can be prevented, and water drops of dew condensation in the steam tube  47  are prevented from dropping out of the steam tube  47  when opening the lid  36 . 
     Opening or closing of the lid  36  is detected as the float  48  provided inside the steam tube  47  departs from the float detecting unit  49  when the lid  36  is opened, but when closing the lid  36 , it may be also considered to close by pressing down the upper part of the lid  36 . On the other hand, in the upper part of the lid  36 , an operation board (control board)  42  is provided, and it may be likely that the lid  36  is closed while pressing an operation button by mistake. Accordingly, for a specific time after closing of the lid  36 , key input accepting on the operation board  42  is inhibited, and unintended manipulation of the user is inhibited. At this time, in order that the user can easily know the reason why key operation is not accepted, it is indicated in a display unit  75 . In the operation board  42  used as the control means, the display unit  75  is provided, and an input switch  76  is incorporated therein. 
     If the lid  36  is closed by mistake, assuming that the lid  36  is being pressed for a long time, the key of which execution is hard to understand for the user, for example, the rice cooking course selection key  76   a  is disposed away from the front central area. On the other hand, in case key operation is accepted, the cooking start key  76   b  or other key of which acceptance is relatively easy to understand for the user is disposed in the upper front part of the lid  36 , at a position easily pressed by the user when closing the lid  36 . 
     As mentioned herein, the rice gruel detector makes use of move of the float when opening or closing the lid, or due to expansion or contraction of rice gruel generated in the pan, and rice gruel can be detected in a simple constitution. Besides, a slope is provided in the bottom of the steam tube, and the float is formed of columnar or spherical ferrite disposed so as to be free to roll over the slope, and the float detecting unit is formed of a lead switch, so that the structure of the float may be suited to detection of rice gruel. 
     (Embodiment 2) 
     A second embodiment is described below. In FIG. 7, reference numeral  79  shows the inside of the steam tube  47 . A hole  80  is provided at the lower side of the steam tube  47 , and a hole  81  is formed at the upper side. The rice gruel passes through the hole  80  at the lower side, and further passes between an emitter  82  and a detector  83  of photo sensor, and goes up. At this time, the light is shielded and the rice gruel detector functions, and power supply to the inner pan  32  is stopped. By this stopping, for example, in the case of induction heating (IH), generation of rice gruel disappears soon. By the rice gruel detecting means of such constitution, boiling-over can be prevented. 
     (Embodiment 3) 
     A third embodiment is described. In this embodiment, instead of the photo sensor in embodiment  2 , a pair of electrodes are provided. In FIG. 8, when the rice gruel passes through the hole  80  at the lower side and is collected between a pair of electrodes  84 ,  84 , a current flows between the electrodes  84 ,  84 . By detecting this current, boiling-over can be prevented same as in embodiment 2. 
     Besides, for example, a PTC heater for detecting temperature change by evaporation heat is provided in a passage of rice gruel, and it may be used as rice gruel detecting means. 
     In the constitution having the rice gruel detecting means provided in the lid, for example, by disposing the rice gruel detecting means in the steam tube, mounting is easy and cleaning is easy, and clean rice gruel detecting means can be composed. Moreover, by disposing the rice gruel detecting means in the passage of rice gruel, for example, in the upper part of the inner pan  32 , easy-to-clean rice gruel detecting means is obtained. 
     As shown in FIG.  9  and FIG. 10, when rice gruel is generated, power supply to the inner pan  32  is stopped by a signal from the rice gruel detecting means. On the other hand, when generation of rice gruel is stopped, the float  48  returns to the initial position, and by detecting it, power supply to the inner pan is resumed, so that the power supply to the inner pan may be always full power. Thus, by turning on and off the power supply to the inner pan by detecting generation of rice gruel, rice and water can be sufficiently heated when cooking, so that tasty rice can be cooked. 
     (Embodiment 4) 
     The structure around the accommodating part of the inner pan  32  is described by referring to FIG.  1  and FIG.  11 . The inner pan  32  is accommodated in a protective frame  85  disposed in the main body  31 . The accommodated inner pan  32  is supported by upper frame caps  86  disposed at three equal positions at the upper end of the protective frame  85 , and positioned by pan locking rubber pieces  87  disposed at three equal positions in the center of the inner circumference of the protective frame  85 . Herein, the upper frame caps  86  and pan locking rubber pieces  87  are alternately disposed at an angle of 60°. In this constitution, the inner pan  32  is accommodated in the protective frame  85  without bias, and the distance of the inner pan  32  and bottom heating coil  33   a  is uniform in all parts, and therefore generation of local strong bubbling rice gruel in the inner pan  32  is decreased, and rise of rice gruel into the steam tube  47  is reduced. 
     The invention is not limited to those illustrated embodiments, and various changes and modifications are possible. All modifications existing within the scope or true spirit of the invention are included in the scope of the claims of the invention.