Patent Document

CROSS REFERENCE TO RELATED ART 
     This application claims the benefit of Korean Patent Application No.  2000-13183,  filed on May 9, 2000, which is hereby incorporated by reference. 
     This application also incorporates by reference co-pending application Ser. No. 09/449,156 filed on Nov. 24, 1999. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a cooking apparatus, and particularly, to a cooking apparatus having a double-layered wall structure which enables to heat a heat conductive medium filling a cavity format between the double-layered structure by an electrical heating element. 
     2. Discussion of the Related Art 
     Various types of cooking apparatus are known and used in a kitchen. Such cooking apparatus is made of one or more layers of stainless steel and has a single-layered bottom. The single-layered bottom is good for directly transmitting heat to the food contained in the utensil, but also causes burning of the food when carefully not attended to. 
     Generally, cooking pots are heated by external flames or by electrical heating devices. Such pots of the related art enable to cook food contained inside by heating the bottom surface thereof, thereby causing problems such that the cooking substances tend to scorch and stick to the bottom of the pot due to the direct heating. As a result, the genuine flavor of the cooked food is lost due to the abrupt cooling of the pot after the external heat is removed. 
     To solve the above problems, a cooking apparatus having a double-layered structure has been proposed for preventing burnt food and to improve food flavor. One of such ideas is published in Korean Utility Laid-Open Publication Nos. 85-7307 and 95-24398 which teaches that paraffin is injected between a space provided by a double-layered structure and an air-hole is established thereon. Moreover, a pot having a double-layered structure into which a working fluid is injected is illustrated in Japanese Laid-Open Publication Nos. 56-169825 and 63-48526. 
     The pots according to the related art fail to be sealed completely, contaminate the food inside due to the leakage of the heat conductive medium from the falty or leaky sealing of the double wall. 
     Accordingly, the pots according to the related arts provide poor heat efficiency, have short life-expanse due to poor mechanical strength, and fail to provide effective heat insulation. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention is directed to a cooking apparatus in the form of a container that substantially obviates one or more of the problems due to limitations and disadvantages of the related art. 
     An object of the present invention is to provide a double-layered cooking container having a secured sealing between the inner and outer shells. 
     Another object of the present invention is to provide a double-layered cooking container to improve heat efficiency by indirectly heating the heat conductive medium, thus providing long durability and even-heat distribution to the inner shell. 
     Additional features and advantages of the invention will be set forth in the description which follows and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings. 
     To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, a cooking apparatus comprises a container having an outer shell and an inner shell, wherein a cavity is provided by coupling and sealing edges of the outer and inner shells. The container comprises an electric heating element installed at a lower portion of the container between the bottom inner and outer shells, wherein the heating element is not in contact with the inner shell; and a heat conductive medium at least partially filling the cavity. The outer shell of the container defines a clamping hole for installing therein a pressure controlling member. The pressure controlling member is opened when a cavity pressure exceeds a predetermined value. 
     According to one aspect of the present invention, the pressure controlling member comprises a spring housing defining a spring device hole and a pressure controlling hole connected thereto, wherein the spring housing has a screw thread on a circumference thereof and a screw head at one end of the spring housing; a nut coupling the spring housing to the outer shell; a pressure control valve in the spring device hole to block the pressure controlling hole; a spring placed in the spring housing to bias the pressure control valve against the pressure controlling hole; and a spring suspension member having a through-hole and is being threadably coupled with the the spring housing to control the biasing force of the spring, wherein the through hole is in fluid communication with the spring device hole. 
     According to another aspect of the present invention, the pressure controlling member comprises a spring housing defining a spring device hole and a pressure controlling hole connected thereto, wherein the spring housing has a groove around the outer circumference thereof; a pressure control valve in the spring device hole to block the pressure controlling hole; a spring placed in the spring housing to bias the pressure control valve against the pressure controlling hole; and a spring suspension member having a through hole and is being coupled with the the spring housing with a step ring being placed in the groove of the spring housing. 
     In the preferred embodiment, the outer and inner shells are rolled together to provide a sealed structure. In addition, the cooking apparatus further includes a container lid covering the container and a heat insulation cover covering over the container. The container lid comprises a dome-shaped disk of tempered glass of which edge is surrounded by a guard ring. The heat insulation cover is preferably made of a stainless steel plate. 
     According to another embodiment of the present invention, the cooking container comprises an outer shell having an opening; an inner shell disposed inside the outer shell through the opening, forming a cavity between the outer and inner shells, wherein the cavity is formed substantially along the height of the inner shell and at least partially contains a heat conductive medium; a first heat conductive plate being in contact with both an inner bottom surface of the outer shell and an outer bottom surface of the inner shell to allow even distribution of heat through out the bottom surface of the inner shell; a second heat conduction plate affixed to and in contact with an outer bottom surface of the outer shell; a support cover configured to fit in surrounding relation to the second heat conduction plate; and a pressure controlling member coupled with a side of the outer shell. The pressure controlling member is similar to the ones described in connection with the first embodiment of the present invention. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
     FIG. 1 shows a partial cross-sectional view according to a first embodiment of the cooking apparatus showing a pressure controlling member; 
     FIG. 2 shows a lay-out of the present invention; 
     FIG. 3 shows a cross-sectional view of another embodiment of the pressure controlling member according to the present invention; and 
     FIG. 4 shows a cross-sectional view of a second embodiment according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. 
     FIG. 1 shows a partial cross-sectional view according to an embodiment of the present invention. FIG. 2 shows a lay-out of the present invention in FIG.  1 . The present invention prevents the food from being burnt inside a cooking container as well as from being cooled down abruptly by forming a container  1  to have a double structure providing a cavity  116  having a hollow pocket  1   a  and a heat conductive medium  2 . In the present invention, the heat conductive medium  2  is preferably silicon oil or other suitable medium known to one of ordinary skill in the art. The hollow pocket  1   a  is preferrably filled with gaseous medium, such as ambient air. 
     The container  1  of the cooking apparatus  100  according to the present invention includes an outer shell  111  and an inner shell  112  disposed adjacent the outer shell  111 . Edges of the outer and inner shells  111  and  112  are preferably rolled together to form a rolled joint  117 . As a result, the cavity  116  partially filled with the silicon oil  2  and air  1   a  is provided between the outer and inner shells  111  and  112 . The air pocket  1   a  and silicon oil  2  are sealed and are not in fluid or gaseous communication with outside unless the pressure controlling member  3  is opened. The cavity  116  is preferably filled with ambient air and silicon oil during the manufacturing process. In the preferred embodiment, the distance between the outer and inner shells  111  and  112  is approximately 15 to 25 mm, and preferably about 20 mm. Preferably, the outer and inner shells  11  and  12  are made of such materials as AISI304 stainless steel that has a thickness of about 0.6 mm. Alternatively, instead of using a single-layered stainless steel, a multiple-layered composite materials may be used. Typically, three or more layered stainless steel or combination of stainless copper and steel are preferred. 
     In the preferred embodiment of the present invention, both the outer and inner shells  111  and  112  are jointly rolled about 2 to 8 times, and preferably 3 times, to form the rolled joint  117 . The tightly rolled joint  117  prevents the air or silicon oil contained in the cavity  116  from escaping through the rolled joint  117  even when the cooking apparatus  100  is subjected to intense heat. 
     According to the preferred embodiment of the cooking apparatus  100 , the pressure controlling member  3  is provided to control the pressure in the cavity  116  formed between the outer and inner shells  111  and  112 . In particular, the pressure controlling member  3  releases the excessive pressure generated by the air  1   a  and silicon oil  2  stored in the cavity  116 . 
     Referring to FIGS. 1 and 2 and in the first embodiment of the present invention, there is provided an electrical heating element  4 , such as a resistive heating coil, for providing heat to the container  1 . The heating element  4  is preferably placed inside the cavity  116 , and more particularly, the silicon oil  2 . The heating element  4  has a pair of plugs  5  extending through the submerged in outer shell  111 . The plugs  5  are connected to an electrical heat controller to provide electricity to the heating element  4 . The heating element  4  is placed either against the upper surface of the outer shell  111  or co-planarly between the outer and inner shells  111  and  112  without touching either one of the shells. 
     Referring to FIG. 1, the pressure controlling member  3 , which is connected to the container  1  through a clamping hole l b,  includes a spring housing  6  which is afixed to the outer shell  111  of the container  1 . According to one embodiment of the present invention, the spring housing  6  has a shape of a screw or bolt which is securely afixed to the outer shell  111  using a fastening nut  7 . The spring housing  6  defines an elongated spring device hole  6   a  at one end and a pressure controlling hole  6   b  at opposite end, thus sharing the same center axis. On the outer circumference the spring housing  6  that defines the spring device hole  6   a,  there provide are threads  6   c  for receiving a spring suspension member  10 . At the other end of the spring housing  6 , a screw head  6   d  is formed to abut against the inner surface of the outer shell  111 . Preferably, a washer or packing  12  may be provided between the screw head  6   d  and the outer shell  111  to secure the sealing thereof. 
     Referring to FIG. 1, in the spring device hole  6   a,  a pressure control valve  8  made of heat-resistant rubber or other suitable material is inserted. The pressure control valve  8  preferably comprises a needle valve. A spring  9  is placed in the rear of the pressure control valve  8  and the spring suspension member  10  is coupled to the spring housing  6 . 
     The spring  9  biases the pressure control valve  8  against the pressure controlling hole  6   b  to substantially block the same. The spring suspension member  10  has inner threads matching that of the outer threads  6   c  of the spring housing  6  to fastened thereto. Thus, any excess pressure generated from the cavity  116  is released through the pressure controlling member  3  by elastic movement of the pressure control valve  8 . When sufficient pressure is created in the cavity  116 , the pressure control valve  8  is pushed back by the perssure and the pressure is relieved through the pressure controlling hole  6   b,  the spring device hole  6   a  and the orifice  10   a  defined by the spring suspension member  10 . 
     In the preferred embodiment, the lengthwise location of the spring suspension member  10  may be rotatably adjusted with respect to the spring housing  6 . The location of the spring suspension member  10  adjusts the tension in the spring  9  to control the opening and closing of the pressure control valve  8 . 
     During the manufacturing process of the cooking apparatus  100 , the silicon oil  2  may be injected into the cavity  116  before sealing the cavity  116  by rolling the inner and outer shells  112  and  111 . Alternatively, the silicon oil  2  may be introduced in the cavity  116  by injecting through the pressure controlling hole  6   b.  Furthermore, a protection cover to absorb mechanical shock as well as to improve heat insulation may be attached to the bottom of the cooking apparatus  100  for convenience. 
     The cooking apparatus  100  shown in FIG. 1 may be fitted with a heat insulating cover, such as a dome-shaped glass lid  51  shown in FIG.  4 . The lid  51  is preferably made of a tempered glass disk of which the edge is protected by a stainless steel ring. Moreover, the cooking apparatus  100  may have a heat insulation cover, similar to the stainless steel lid  41  shown in FIG.  4 . 
     FIG. 3 shows a cross-sectional view of another embodiment of a pressure controlling member  30  according to the present invention. The pressure generated from the heated silicon oil  2  in the cavity  116  is controlled by elastically suspending a pressure control valve  38 . A spring housing  36  having a spring device hole  6   a  and a pressure controlling hole  6   b  in a clamping hole  1   b  of the outer shell  111  is afixed to the outer shell  111  by welding or other suitable process. The pressure controlling member  30  may be used with the container  1  shown in FIG. 1 or that shown in FIG.  4 . The welding of the spring housing  36  to the outer shell  111  of the container  1  enhances assembly and productivity. 
     According to FIG. 3, the spring housing  36  of the pressure controlling member  30  is shaped like screw or a bolt which is securely afixed to the outer shell  111 . The spring housing  36  defines an elongated spring device hole  36   a  at one end and a pressure controlling hole  36   b  at opposite end, thus preferably sharing the same center axis. On the outer circumference of a portion of the spring housing  36  that defines the spring device hole  36   a,  there provide is a circumferencial outer groove  36   e  for receiving therein a step ring  91 . At the other end of the spring housing  36 , a screw head  36   d  is formed to be placed against the inner surface of the outer shell  111 . 
     Referring to FIG. 3, in the spring device hole  36   a,  a pressure control valve  38  made of heat-resistant rubber or other suitable materials is inserted. The pressure control valve  38  preferably comprises a needle valve. A spring  39  is placed in the rear of the pressure control valve  38  and a spring suspension member  90  is coupled to the spring housing  36 . In particular, the inner wall of the spring suspension member  90  has a matching inner groove  90   b  as that of the outer groove  36   e.  The step ring  91  is positioned between the outer groove  36   e  and the inner groove  90   b  to releasably couple the spring suspension member  90  to the spring housing  36 . The step ring  91  is made of metal or other suitable materials. 
     The spring  39  biases the pressure control valve  38  against the pressure controlling hole  36   b.  Thus, any excessive pressure generated from the cavity  116  is released through the pressure controlling member  30  by elastic movement of the pressure control valve  38 . When sufficient pressure is created in the cavity, the pressure is relieved through the pressure controlling hole  36   b,  the spring device hole  36   a  and the orifice  90   a  defined by the spring suspension member  90 . 
     When the heating element  4  of the cooking apparatus  100  shown in FIG. 1 is energized, the heating element  4  generates heat which in turn heats the silicon oil  2  stored in the cavity  116 . Due to the placement of the silicon oil  2 , the inner shell  112  of the container  1  is evenly heated, thereby providing even heat distribution to the food contained therein. As a result, the scorching of the container  1  and sticking of the food inside the container  1  is substantially minimized. Moreover, the cooking apparatus  100  according to the present invention has excellent heat retension because even if the heating element  4  is no longer energized, the hot silicon oil  2  maintains the food warmer for a longer period of time. 
     The present invention provides the pressure controlling member  3  or  30  to evenly discharge the increased inner pressure in the cavity  116 . As the inner pressure rises, the pressure control valve  8  is pushed outward to release the inner pressure. Further, when the pressure in the cavity  116  returns to a predetermined nominal value, the spring  9  biases the pressure control valve  8  to close the valve. Thus, substantially even pressure is maintained in the cavity  116  of the cooking apparatus  100 . 
     When cleaning is necessary, the double-layered cooking apparatus  100  may be simply washed similar to any other kitchen cooking apparatus. In room temperature, the pressure control valve  8  is biased to block the pressure controlling hole  6   b  to prevent any silicon oil  2  from escaping therethrough. The plug  5  portion of the heating element  4  extending through the outer shell  111  is also sealed with silicon to prevent silicon oil  2  from escaping therethrough. 
     FIG. 4 shows a cross-sectional view of a second embodiment of the cooking apparatus  200 . According to the second embodiment of the cooking apparatus  200 , the inner lid  50  is constructed with a dome-shaped disk  51  of which edge is surrounded by a safety ring  52  preferably made of stainless steel or other suitable materials. The safety ring  52  is attached to the edges of the disk  51 , thereby preventing damages to the disk  51 . However, the inner lid  50  may be used without the ring  52 . Preferably, the disk  51  is made to form a slight convexed surface with respect to the container  60  of the cookware. 
     The disk  51  of the inner lid  50  is preferrably made of tempered glass of approximately 4 mm thick. Alternatively, the disk  51  may be made of stainless steel, alumunium, aluminum alloy or other suitable materials known to one of ordinary skill in the art. 
     A handle  53  is attached to the center of the dome-shaped disk  51  by, for example, piercing the central portion of the disk  51 . Alternatively, the handle  53  may be affixed to the disk  51  by using adhesives or other fasteners. 
     The thermal insulating cover  40  is preferably made of a stainless steel plate  41  being about 0.5 to 0.7 mm thick, and preferably about 0.6 mm thick, and has a dome like figure. The insulating cover  40  and the inner lid  50  form a horizontal air cavity  44  which acts as an insulating layer to trap and hold heated air therein. As a result, once the heat source is removed from underneath the cooking apparatus  200 , the air cavity  44  and the vertical cavity  66  filled with ambient air insulate the inner shell  62  from outside and reduce heat loss, thus keeping the food contained in the inner shell  62  warmer for a longer period of time. More importantly, the structure of the present invention allows the food to be cooked even after removing heat from the cooking apparatus  200 . Alternative to a single sheet structure, the cover  40  may comprise a plurality of layers of stainless steel and/or aluminum for increased durability and preservation of heat. In the thermal insulating cover  40 , a knob  42  is attached to the center of the thermal insulating cover  40 . In the present invention, the knob  42  may include a built-in temperature gauge for measuring the inside temperture of the cookware. The temperature gauge provides the user to remove the cooking apparatus  200  from the heat source once a desired temperature has been reached. 
     The container  60  of the cooking apparatus  200  according to the present invention includes an outer shell  61  and an inner shell  62  disposed adjacent the outer shell. Edges of the outer and inner shells  61  and  62  are preferably rolled together to form a rolled joint  67 . As a result, a vertical cavity  66  partially filled with air and a heat conductive medium, such as silicon oil  68 , is provided between the outer and inner shells  61  and  62 . The cavity  66  is sealed and is not in fluid or gaseous communication with outside. The cavity  66  filled with air and silicon oil  68  is preferably filled with ambient air during the manufacturing process. In the preferred embodiment, the distance between the outer and inner shells  61  and  62  is approximately 15 to 25 mm, and preferably about 20 mm. Preferably, the outer and inner shells  61  and  62  are made of such materials as AISI304 stainless steel that has a thickness of about 0.6 mm. Alternatively, instead of using a single-layered stainless steel, a multiple-layered composite materials may be used. Typically, three or more layered stainless steel or combination of stainless copper and steel are preferred. 
     In the preferred embodiment of the present invention, both the outer and inner shells  61  and  62  are jointly rolled about 2 to 8 times, and preferably about 3 times, to form the rolled joint  67 . The tightly rolled joint  67  prevents the air or silicon oil  68  contained in the cavity  66  from escaping even when the cooking apparatus  200  is subjected to intense heat. 
     Referring to FIG. 4, there is provided a first heat conduction plate  64  placed between the outer and inner shells  61  and  62 . The first heat conduction plate  64  is preferably made of an aluminum disk, copper or other suitable materials known to one of ordinary skill in the art. The first heat conduction plate  64  is preferably flushly affixed to the bottom of the outer shell  61 . The first heat conduction plate  64  is about 1.5 to 2.5 mm thick, and is preferably about 2 mm thick. To provide speedy transmission of heat to the food contained in the cooking apparatus  200 , the first heat conduction plate  64  also abuts against the bottom of the inner shell  62 . Due to the presence of the first conduction plate  64 , there is no space or cavity  66  between the bottom of the inner shell  62  and that of the outer shell  61 . 
     In the preferred embodiment, a second heat conduction plate  65  is disposed below the bottom surface of the outer shell  61  preferably below the first heat conduction plate  64 . Similar to the first heat conduction plate  64 , the second heat conduction plate  65  is preferably made of an aluminum disk or other suitable materials known to one of ordinary skill in the art. The second heat conduction plate  65  is about 2 to 4 mm thick, and preferably about 3 mm thick. The second heat conduction plate  65  is securely affixed to the bottom of the outer shell  61  by brazing or other suitable method known to one of ordinary skill in the art. 
     The second heat conduction plate  65  is covered with a support cover  63 . The support cover  63  is attached to an outer bottom surface of the outer shell  1  fully surrounding and in contact with the second heat conduction plate  65 . The support cover  63  is preferably made of the same material as that of the container  60  of the cooking apparatus  200 . In particular, the support cover  63  is made of AISI304 stainless steel that has a thickness of about 0.5 mm. In the container  60 , the first heat conduction plate  64 , the bottom wall of the outer shell  61 , the second heat conduction plate  65  and the support cover  63  are in thermal communication with each other. 
     In the cooking apparatus  200 , the cavity  66  is partially filled with silicon oil  68  up to about 40 to 70% by volume. Preferably, the silicon oil is filled up to about 55% of the cavity  66  to accommodate for increased pressure. For example, while cooking, the pressure in the cavity  66  varies from 200 mmAG to 600 mmAG due to expansion of the silicon oil  68 . 
     According to FIG. 4, the container  60  has a pair of knobs  75  attached to opposite ends of the outer shell  61 . A pressure controlling member  3  is installed near the upper portion of the outer shell  61 . The construction and explanation of the pressure controlling member  3  have been provided above with respect to FIGS. 1 and 3 and therefore will not be repeated here. Moreover, the pressure controlling member  30  shown in FIG. 3 may be used with the container  60 . 
     The heat conducting medium or silicon oil  68  may be injected into the cavity  66  before the the outer and inner shells  61  and  62  are sealed at the joint  67 . Alternatively, silicon oil may be introduced into the cavity  66  through the pressure controlling hole of the pressure control valve  3  after the container  60  has been manufactured. 
     Once the bottom of the cooking apparatus  200  is in contact with a heat source, the content contained in the inner shell  62  is heated by the heat transmitted through the support cover  63 , second heat conduction plate  65 , outer shell  61 , first heat conduction plate  64  and finally the inner shell  12 , successively. 
     Because the heat source generally provides for uneven heat distribution to the bottom surface, the bottom of the cooking apparatus  200  is unevenly heated. However, due to the presensence of the support cover  63 , second heat conduction plate  65  and first heat conduction plate  64 , the heat from the heat source is more evenly distributed to the bottom of the inner shell  62  allowing even distribution of heat to the food contained therein. 
     The first and second conduction plates  64  and  65  also serve to heat the vertical cylindrical walls of the cooking container  60 . Although the most of the heat transmitted to the bottom of the outer shell  61  is conducted to the first heat conduction plate  64 , the rest of the heat from the first and second conduction plates  64  and  65  are transferred to the side walls of the outer and inner shells  61  and  62 , respectively. Then, the temperature of the air in the space  66  is gradually increased and the heat energy of the air is transmitted to the inner shell  62  and spread out throughout the entire wall of the inner shell  62 . Therefore, the temperature along the inner shell  62  is substantially constant at any region thereof. In other words, the temperature of the bottom of the inner shell  62  is about the same as that of the cylindrical wall. 
     The presence of silicon oil  68  and air in the cavity  66  delays heat transfer between the sides of the outer and inner shells  61  and  62  as well as provides even heat distribution as the heat conducted through the outer shell  61  of the cooking apparatus  200  primarily is not transferred to the inner shell  62  of the pot but is partially conveyed through the air. 
     The heat distributed uniformly in the inner shell  62  heats up the content in the cooking apparatus  200 . Once heated, the double-layered structure of the cooking apparatus  200  according to the present invention traps the heat, even after the heat source is removed, for a prolonged period. The heat loss through the sidewalls of the inner and outer shells  61  and  62  are slowed due to the presence of the cavity  66 . 
     The present invention provides the pressure controlling member  3  or  30  to evenly discharge the increased inner pressure in the cavity  66 . As the inner pressure rises, the pressure control valve  8  is pushed outward to release the inner pressure. Further, when the pressure in the cavity  66  returns to a predetermined nominal value, the spring  9  biases the pressure control valve  8  to close the valve. Thus, substantially even pressure is maintained in the cavity  66  of the cooking apparatus  200 . 
     As an alternative embodiment of the present inventio, the second conduction plate may have a built-in heating element embeddd in the aluminum disk. As a result, in lieu of using externally applied heat, the heating element, similar to one shown in FIG. 1, can produce heat for purpose of heating the first and second conduction plates  64  and  65 . 
     It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and equivalents.

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