INDUCTION COOKING STRUCTURE AND SYSTEM AND METHOD OF USING THE SAME

• US 20090081347A1
• Filed: 07/14/2008
• Published: 03/26/2009
• Est. Priority Date: 09/26/2007
• Status: Active Grant

• Current Assignee: Kellanova
• Original Assignee: Kellogg Company
• Inventors: GAMBINO, CHARLES
• Granted Patent: US 7,989,012 B2
• Time in Patent Office: Days
• US Class Current: 426/523
• CPC Class Codes: A21B 5/023 Hinged moulds for baking waffles
• CPC Class Codes: A47J 36/02 Selection of specific materials, e.g. heavy bottoms with copper inlay or with insulating inlay
• CPC Class Codes: A47J 37/045 with endless conveyors
• CPC Class Codes: A47J 37/0611 the food being cooked between two heating plates, e.g. waffle-irons
• CPC Class Codes: A47J 37/0676 electrically heated
• CPC Class Codes: H05B 6/1209 induction cooking plates or the like and devices to be used in combination with them
• CPC Class Codes: Y10S 99/14 Induction heating

Abstract

In summary, the invention is a method of producing an edible food product. The method includes the step of forming a vessel core with a first material having a first level of susceptibility to heating by induction. The method also includes the step of casting an apron of a second material with a second level of susceptibility to heating by induction lower than said first level around at least a first portion the vessel core in an in situ casting process to form a clad cooking vessel having a cooking surface. An uncooked food product is then disposed on the cooking surface of the clad cooking vessel and heated to produce the edible food product by subjecting the vessel core to a magnetic field.

Claims

1. A method of producing an edible food product comprising the steps of:

forming a vessel core with a first material having a first level of susceptibility to heating by induction;

casting an apron of a second material with a second level of susceptibility to heating by induction lower than the first level around at least a first portion the vessel core in an in situ casting process to form a first clad cooking vessel having a first cooking surface;

disposing an uncooked food product on the first cooking surface of the first clad cooking vessel; and

heating the uncooked food product in the first clad cooking vessel by subjecting the vessel core to a magnetic field.

2. The method as set forth in claim 1 wherein the heating step is further defined as heating the uncooked food product to cook, bake or toast the uncooked food product.

3. The method as set forth in claim 1 further comprising the step of shaping the apron with a waffle griddle pattern so that the cooked food product is in the shape of a waffle.

4. The method as set forth in claim 1 further comprising the step of shaping the apron with a flat cooking surface for receiving the uncooked food product so that the cooked food product is in the shape of a pancake.

5. The method as set forth in claim 1 wherein the disposing an uncooked food product step is further defined as disposing an uncooked batter on the first cooking surface.

6. The method as set forth in claim 1 wherein the disposing an uncooked food product step is further defined as disposing an uncooked dough on the first cooking surface.

7. The method as set forth in claim 1 further comprising the step of preheating the first cooking clad vessel by subjecting the vessel core to a magnetic field prior to the disposing an uncooked food product on the first cooking surface step.

8. The method as set forth in claim 1 further comprising the steps of:

forming a second clad cooking vessel having a second cooking surface; and

mating the second clad cooking vessel to the first clad cooking vessel after the disposing an uncooked food product step so that the second cooking surface of the second clad cooking vessel is in confronting relation with the first cooking surface of the first clad cooking vessel to substantially surround the uncooked food product.

9. The method as set forth in claim 8 wherein the forming a second clad cooking vessel step comprises the steps of:

forming a vessel core with a first material having a first level of susceptibility to heating by induction; and

casting an apron of a second material with a second level of susceptibility to heating by induction lower than the first level around at least a first portion the vessel core in an in situ casting process.

10. The method as set forth in claim 1 further including the step of placing the first clad cooking vessel in a carrier after the casting step.

11. The method as set forth in claim 1 further including the step of removing the cooked food product from the first clad cooking vessel after the heating step.

15. The method as set forth in claim 1 further comprising the step of heating the uncooked food product in the first clad cooking vessel by subjecting the first clad cooking vessel to a secondary heat source.

12. A method of forming a clad cooking vessel for cooking a food product comprising the steps of:

forming a vessel core with a first material having a first level of susceptibility to heating by induction; and

casting an apron of a second material with a second level of susceptibility to heating by induction lower than the first level around at least a first portion of the vessel core in an in situ casting process.

13. The method as set forth in claim 12 wherein the casting step is further defined as forming a multi-planar cooking surface with a plurality of lands and a plurality of grooves in the apron.

14. The method as set forth in claim 12 further comprising the step of machining a multi-planar cooking surface with a plurality of lands and a plurality of grooves in the apron after the casting step.

16. A clad cooking vessel for cooking food product comprising:

at least one vessel core formed of a first material having a first level of susceptibility to heating by induction; and

an apron of a second material with a second level of susceptibility to heating by induction lower than said first level cast around at least a first portion of said vessel core in an in situ casting process.

17. The clad cooking vessel as set forth in claim 16 wherein said vessel core is further defined as having a body consistent with the shape of the food product.

18. The clad cooking vessel as set forth in claim 17 wherein said apron includes at least one protuberance extending from said body.

19. The clad cooking vessel as set forth in claim 18 wherein said apron is cast to define a cooking surface with a plurality of lands and grooves consistent with said at least one protuberance.

20. The clad cooking vessel as set forth in claim 16 wherein said apron defines a cooking surface with a plurality of lands and grooves.

21. The clad cooking vessel as set forth in claim 16 wherein said apron defines a plurality of discrete cooking surfaces.

22. The clad cooking vessel as set forth in claim 21 wherein said apron includes a wall surrounding at least one of the discrete cooking surfaces.

23. The clad cooking vessel as set forth in claim 22 wherein said apron includes a plurality of walls, each wall surrounding at least one of said discrete cooking surfaces and separating said cooking surfaces from one another.

24. The clad cooking vessel as set forth in claim 21 wherein said at least one vessel core is disposed below all of said plurality of discrete cooking surfaces.

25. The clad cooking vessel as set forth in claim 21 wherein said at least one vessel core further comprises a plurality of cores, one core being disposed below each of said plurality of discrete cooking surfaces.

26. A production system for food products comprising:

a first endless conveyor defining a first path;

a plurality of first clad cooking vessels disposed in spaced arrangement along said first endless conveyor for movement along said first path wherein each of said plurality of first clad cooking vessels defines a first cooking surface for receiving a quantity of uncooked food product to be cooked;

a second endless conveyor defining a second path;

a plurality of second clad cooking vessels disposed in spaced arrangement along said second endless conveyor for movement along said second path wherein each of said plurality of second clad cooking vessels defines a second cooking surface for operably engaging the quantity of uncooked food product to be cooked;

at least one heating system disposed proximate to both of said first and second endless conveyors to heat said plurality of first and second clad cooking vessels; and

wherein each of said first and second paths include a first segment and a second segment, the first segments of said first and second paths overlapping to dispose said first and second cooking surfaces in confronting relation along said overlapping first segments of said first and second paths to substantially surround and evenly cook the uncooked food product.

27. The production system as set forth in claim 26 wherein said first and second conveyors are vertically stacked.

28. The production system as set forth in claim 27 wherein said at least one heating system further comprises:

a first induction coil assembly substantially surrounded by said first path to heat said plurality of first clad cooking vessels; and

a second induction coil assembly substantially surrounded by said second path to heat said plurality of second clad cooking vessels.

29. The production system as set forth in claim 26 wherein said first conveyor is disposed horizontally from said second conveyors.

30. The production system as set forth in claim 26 wherein said at least one heating system further comprises:

a first induction coil assembly;

a second induction coil assembly spaced vertically from said first induction coil to define a gap therebetween, wherein said first segments of said first and second paths overlapping so that said first and second clad cooking vessels are in confronting relation and heated within said gap.

31. The production system as set forth in claim 30 wherein said second endless conveyor includes a cam having a first portion, a vertically spaced second portion, and a crest to blend said first and second portions, said cam directing said second clad cooking vessel upward so that said first and second clad cooking vessels are in confronting relation with each other.

32. A production system for food products comprising:

a conveyor;

at least one carrier disposed on said conveyor, said carrier having a lower portion and an upper portion linked to said lower portion to move between an open position and a closed position;

at least one first clad cooking vessel disposed in said lower portion of said carrier and defining a first cooking surface for receiving a quantity of uncooked food product to be cooked;

at least one second clad cooking vessel disposed in said upper portion of said carrier and defining a second cooking surface for operably engaging the quantity of uncooked food product to be cooked while in the closed position; and

at least one induction coil assembly disposed proximate said conveyor to heat said first and second cooking vessels in said carrier.

33. The production system as set forth in claim 32 wherein first and second clad cooking vessels further comprising:

at least one vessel core formed of a first material having a first level of susceptibility to heating by induction; and

an apron of a second material with a second level of susceptibility to heating by induction lower than said first level cast around at least a first portion of said vessel core in an in situ casting process.

34. The production system as set forth in claim 32 including a plurality first clad cooking vessel and a plurality of second clad cooking vessels operably engaging the quantity of uncooked food product disposed in said plurality of first clad cooking vessels.

35. The production system as set forth in claim 32 wherein said upper portion of said carrier is hinged to said lower portion to be movable from about 0-180°

relative to said lower portion.

36. The production system as set forth in claim 32 wherein said carrier is a composite material.