Cooking System

Abstract

A smoking function in a grill-type appliance is provided, and is a cooking system. The cooking system includes: a housing having a hollow interior; a heating element configured to heat the hollow interior; a food support surface disposed within the hollow interior; and a combustible substrate module removably positioned within the housing. When positioned within the housing, the combustible substrate module is disposed in fluid communication with the hollow interior and is positioned away from the food support surface.

Description

Technical Field

[0001] Embodiments of the present disclosure relate generally to a cooking system, and more particularly, to a smoking module for imparting a smoke flavor to one or more food products being cooked in a cooking system. Background Art

[0002] Smoking can be used in culinary applications to impart a desired flavor to one or more food items. Existing systems for achieving this flavor include stand-alone smokers. However, such devices can be bulky and expensive. To smoke food using a stand-alone smoker, the user must have ample space to store and operate the smoker. Furthermore, many users may only occasionally desire to smoke food. Therefore, if a dedicated smoker is only used intermittently, owning such a device may be financially or physically impractical.

[0003] Electric countertop cooking systems are common and allow users to perform a variety of cooking operations using only a single device. Therefore, there is a need to develop a device that allows users to achieve the same smoky flavor when cooking food using a countertop cooking appliance. Summary of the Invention

[0004] According to an embodiment, a cooking system includes a housing having a hollow interior; a heating element operable to heat the hollow interior; a food support surface disposed within the hollow interior; and a combustible substrate module removably positioned within the housing. When positioned within the housing, the combustible substrate module is disposed in fluid communication with the hollow interior and is positioned away from the food support surface.

[0005] Additionally or alternatively to one or more of the features described above, in further embodiments, the housing further comprises a base and a cover in which the combustible matrix module is removably positioned.

[0006] In addition to or as an alternative to one or more of the features described above, in another embodiment, an ignition source is disposed within the housing, wherein when the combustible matrix module is positioned in the housing, the ignition source is operably connected to the ignition zone of the combustible matrix module.

[0007] Additionally or alternatively to one or more of the features described above, in further embodiments, the ignition source is separate from the heating element.

[0008] Additionally or alternatively to one or more of the features described above, in further embodiments the heating element is the ignition source.

[0009] Additionally or alternatively to one or more of the features described above, in further embodiments, the portion of the combustible substrate module is separated from the ignition source by a gap.

[0010] In addition to or as an alternative to one or more of the features described above, in another embodiment, a radiation shield is arranged between the ignition source and the combustible matrix module, and the radiation shield has an opening positioned directly adjacent to the ignition zone of the combustible matrix module.

[0011] In addition to or as an alternative to one or more of the features described above, in another embodiment, the cooking system also includes a cover movable relative to the housing, the combustible substrate module is associated with the cover, and at least one of the ignition sources is disposed within the cover.

[0012] In addition to or as an alternative to one or more of the features described above, in further embodiments, the cooking system further comprises an air movement mechanism associated with the hollow interior, and the combustible substrate module is arranged radially outward and downstream of an outlet of the air movement mechanism.

[0013] Additionally or alternatively to one or more of the features described above, in further embodiments, the combustible matrix module further comprises a body including a hollow interior having at least one compartment.

[0014] Additionally or alternatively to one or more of the features described above, in further embodiments, include at least one divider disposed within the hollow interior to define the first compartment and the second compartment.

[0015] Additionally or alternatively to one or more of the features described above, in further embodiments, the partition comprises a plurality of openings, such that the first compartment and the second compartment are arranged in fluid communication via the plurality of openings.

[0016] In addition or alternatively to one or more of the features described above, in further embodiments, the combustible matrix module further comprises a cover movable relative to the body to selectively close the hollow interior.

[0017] According to an embodiment, a combustible substrate module for an electric cooking system includes a body having at least one pilot opening and at least one outlet opening, and a hollow interior defined within the body and including at least a first compartment and a second compartment, wherein the configuration of the first compartment is selected to produce a first amount of smoke, and the configuration of the second compartment is selected to produce a second amount of smoke greater than the first amount of smoke.

[0018] Additionally or alternatively to one or more of the features described above, in further embodiments, the configuration of the first compartment is selected to generate smoke for less than or equal to about 20 minutes.

[0019] Additionally or alternatively to one or more of the features described above, in further embodiments, the configuration of the second compartment is selected to produce smoke for at least one hour.

[0020] Additionally or alternatively to one or more of the features described above, in further embodiments, the configuration of the second compartment is selected to produce smoke for at most two hours.

[0021] Additionally or alternatively to one or more of the features described above, in further embodiments, at least one dimension of the first compartment is different from at least one dimension of the second compartment.

[0022] Additionally or alternatively to one or more of the features described above, in further embodiments, the length of the first compartment is less than the length of the second compartment.

[0023] Additionally or alternatively to one or more of the features described above, in further embodiments, the height of the first compartment measured perpendicularly from the plane of the base of the body is greater than the height of the second compartment.

[0024] Additionally or alternatively to one or more of the features described above, in further embodiments, the at least one pilot opening is formed in the body adjacent the first compartment.

[0025] Additionally or alternatively to one or more of the features described above, in further embodiments, the at least one pilot opening is formed in the body at a height above the second compartment.

[0026] Additionally or alternatively to one or more of the features described above, in further embodiments, the first compartment and the second compartment are separated by a partition.

[0027] Additionally or alternatively to one or more of the features described above, in further embodiments, the partition has a plurality of openings such that the first compartment and the second compartment are arranged in fluid communication.

[0028] According to an embodiment, a cooking system includes a housing having a hollow interior, a combustible substrate module removably positioned in the housing and containing a combustible material, and an ignition source disposed within the hollow interior and operably coupled to the combustible substrate module. Operation of the ignition source is controlled in response to a state of the combustible material.

[0029] Additionally or alternatively to one or more of the features described above, in further embodiments, the ignition source is de-energized in response to determining that the combustible material within the combustible matrix module is ignited.

[0030] In addition or alternatively to one or more of the features described above, further embodiments include a sensor operable to determine when the combustible material is ignited, wherein the operation of the ignition source is controlled in response to the sensor.

[0031] Additionally or alternatively to one or more of the features described above, in further embodiments the sensor is a temperature sensor.

[0032] Additionally or alternatively to one or more of the features described above, in further embodiments, the sensor is positioned relative to the combustible substrate module to differentiate between heat generated by the ignition source and heat generated by the ignited combustible material.

[0033] Additionally or alternatively to one or more of the features described above, in further embodiments, the sensor is positioned within an interior of the combustible matrix module.

[0034] Additionally or alternatively to one or more of the features described above, in further embodiments, the ignition source is energized in response to determining that the combustible material within the combustible matrix has completely combusted.

[0035] Additionally or alternatively to one or more of the features described above, in further embodiments, the ignition source is a heating element operable to heat the hollow interior.

[0036] Additionally or alternatively to one or more of the features described above, in further embodiments, a heating element distinct from the ignition source is included, wherein operation of the heating element is controlled in response to a state of the combustible material.

[0037] Additionally or alternatively to one or more of the features described above, in further embodiments, the heating element is energized in response to determining that the combustible material within the combustible matrix module is ignited.

[0038] Additionally or alternatively to one or more of the features described above, in further embodiments, the heating element is energized in response to determining that the combustible material within the combustible matrix has completely combusted.

[0039] In addition or as an alternative to one or more of the features described above, in further embodiments, the housing further comprises a base and a cover, the heating element being arranged in the base.

[0040] Additionally or alternatively to one or more of the features described above, in further embodiments, the housing further comprises a base and a cover, the heating element being arranged within the cover.

[0041] Additionally or alternatively to one or more of the features described above, further embodiments include an air moving device that is controlled responsive to the state of the combustible material.

[0042] Additionally or alternatively to one or more of the features described above, in further embodiments, the air moving device is rotated in response to determining that the combustible material within the combustible matrix module is ignited.

[0043] According to an embodiment, a cooking system includes a housing having a hollow interior; a combustible substrate module removably positioned in the housing and containing a combustible material; and an ignition source disposed within the hollow interior and operably coupled to the combustible substrate module. An air moving device is disposed within the hollow interior. Operation of the air moving device is controlled in response to a state of the combustible material.

[0044] Additionally or alternatively to one or more of the features described above, in further embodiments, the air moving device is energized in response to determining that the combustible material within the combustible matrix module is ignited.

[0045] In addition or alternatively to one or more of the features described above, further embodiments include a sensor operable to determine when the combustible material is ignited, wherein the operation of the air moving device is controlled responsive to the sensor.

[0046] Additionally or alternatively to one or more of the features described above, in further embodiments the sensor is a temperature sensor.

[0047] Additionally or alternatively to one or more of the features described above, in further embodiments, the sensor is positioned relative to the combustible substrate module to differentiate between heat generated by the ignition source and heat generated by the ignited combustible material.

[0048] Additionally or alternatively to one or more of the features described above, in further embodiments, the sensor is positioned within an interior of the combustible matrix module.

[0049] Additionally or alternatively to one or more of the features described above, in further embodiments, operation of the air moving device is controlled to regulate a burn rate of the combustible material.

[0050] Additionally or alternatively to one or more of the features described above, in further embodiments, the rotational speed of the air moving device is controlled to regulate the burning rate of the combustible material.

[0051] Additionally or alternatively to one or more of the features described above, in further embodiments, the rotational speed of the air moving device is increased to speed up the combustion rate.

[0052] Additionally or alternatively to one or more of the features described above, in further embodiments, the rotational speed of the air moving device is reduced to slow the combustion rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The following description should not be considered limiting in any way. Referring to the accompanying drawings, similar elements are numbered the same:

[0054] Figure 1 is a perspective view of a smoking module for an electric cooking system according to an embodiment;

[0055] Figure 2 According to the embodiment Figure 1 Another perspective view of the smoke module;

[0056] Figure 3 is a perspective view of a cooking system according to an embodiment;

[0057] Figure 4 According to the embodiment Figure 3 A cross-sectional view of the cooking system; and

[0058] Figure 5 is a schematic diagram of a cooking system according to an embodiment;

[0059] Figure 6 is a perspective view of a cover of a cooking system according to an embodiment;

[0060] Figure 7 is a perspective view of a cover of a cooking system having a combustible substrate module installed therein according to an embodiment; and

[0061] Figure 8 is a schematic diagram of a control system of a cooking system according to an embodiment. DETAILED DESCRIPTION

[0062] Reference is made herein by way of example and not limitation Figures 1 to 8 A detailed description of one or more embodiments of the disclosed apparatus and methods is provided.

[0063] Now refer to Figure 1-2 , an example of a combustible matrix module 20 is shown. As shown, the combustible matrix module 20 includes a body 22 formed of a thermally conductive material, such as metal. In the non-limiting embodiment shown, the body 22 has a base 24, a first end wall 26 extending from a first end 28 of the base 24 in a first direction, a second end wall 30 extending from a second, opposite end 32 of the base 24 in the same first direction, and first and second side walls 34, 36 connected to the base 24 and extending between the first and second end walls 26, 30. In the embodiment shown, the first and second side walls 34, 36 are arranged generally parallel to each other; however, embodiments having different configurations and orientations of the walls are also within the scope of the present disclosure.

[0064] The body 22 may have a shape that is complementary to a portion of a cooking system that is configured to receive the combustible substrate module 20. In an embodiment, the combustible substrate module 20 may be positioned adjacent a generally circular component of the cooking system, which will be described in more detail below. For example, in the non-limiting embodiment shown, the first side wall 34 that is configured to face and / or contact a component of the cooking system has a generally arcuate profile. Thus, the first end wall 26 is arranged at an angle to the second end wall 30. Although the body 22 is shown as having a curvature of less than 90 degrees, embodiments in which the curvature is ninety degrees (and therefore the end walls 26, 30 are oriented generally perpendicular to each other), as well as embodiments in which the body 22 has a curvature greater than ninety degrees, are also within the scope of the present disclosure. In addition, it should be understood that embodiments of the combustible substrate module 20 in which the body 22 has another configuration are also contemplated herein.

[0065] The base 24, end walls 26, 30, and first and second side walls 34, 36 cooperate to define a hollow interior cavity 38. One or more dividers 40 may be arranged within the interior cavity 38 to divide the interior cavity 38 into a plurality of different compartments. In the non-limiting embodiment shown, a single divider 40 is arranged within the interior cavity 38 to form two compartments 42, 44; however, it should be understood that in other embodiments, two or more dividers 40 may be positioned within the interior cavity 38 to form three or more compartments. In the non-limiting embodiment shown, the divider 40 is formed from a material having one or more openings 45 therein, such as a mesh or stamped metal sheet. Thus, the compartments 42, 44 disposed on opposite sides of the divider 40 are arranged to be in fluid communication with each other via the one or more openings 45. However, embodiments in which at least one divider 40 is at least partially formed from a solid material such that adjacent compartments 42, 44 are not fluidly connected are also within the scope of the present disclosure.

[0066] In an embodiment, one of the compartments of the module, such as the first compartment 42, is configured to produce aroma smoke. As used herein, the term "aroma smoke" is intended to describe smoke that is used in conjunction with high temperature grilling to imbue the food being cooked with a smoky aroma and flavor. This aroma smoke is configured to impart flavor to the food in a manner similar to conventional charcoal grilling. Alternatively or in addition, one of the compartments of the combustible substrate module 20, such as the second compartment 44, is configured to produce low temperature slow smoke smoke. As used herein, "low temperature slow smoke smoke" is smoke that is used to cook food slowly and for a longer period of time, such as at least 30 minutes and up to about 2 hours. This low temperature slow smoke smoke is intended to achieve a rich meaty flavor, similar to food cooked using a barbecue grill.

[0067] Therefore, the configuration of the multiple compartments 42, 44 can vary based on the expected smoke generated within the compartments 42, 44. For example, one or more dimensions of the compartments 42, 44 can vary. In one embodiment, the height of the body 22, measured perpendicularly from the plane of the base 24, varies between the first compartment 42 and the second compartment 42. In the non-limiting embodiment shown, the first compartment 42, positioned adjacent to the first end wall 26, has a first height, and the second compartment 44, positioned adjacent to the second end wall 30, has a second height that is less than the first height. Thus, the height of the first end wall 26 is greater than the height of the second end wall 30, and the height of each of the first side wall 34 and the second side wall 36 varies between the first end wall 26 and the second end wall 30. In one embodiment, the height of the side walls varies so that each compartment 42, 44 has a substantially constant height along its length. Alternatively, or in addition, the length of the compartments 42, 44 can vary. In one embodiment, for example, the length of the first compartment 42, measured along the average radius of curvature, is shorter than the length of the second compartment 44. Embodiments in which the widths of the compartments 42, 44 vary are also contemplated herein.

[0068] In embodiments, the volume of the second compartment 44 is greater than the volume of the first compartment 42. For example, the volume of the second compartment 44 may be at least 30% greater than the volume of the first compartment 42, such as at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, and at least 100% greater than the volume of the first compartment 42. This larger volume is intended to store a sufficient amount of substrate to produce smoke for at least one hour, and in some embodiments, for more than one hour, such as 90 minutes, two hours, or more than two hours. However, embodiments in which the volume of the second compartment 44 is equal to or less than the volume of the first compartment 42 are also within the scope of the present disclosure. In embodiments, the volume of the first compartment 42 is approximately 30 mL, or approximately 1 / 8 cup.

[0069] The combustible matrix module 20 may include a cover 46 that can be attached to a surface of the body 22 to close access to the interior cavity 38 of the body 22. In embodiments where the upper surface 48 of the body 22 has a non-planar configuration, for example due to variations in the height of the compartments 42, 44, the cover 46 may be contoured to cover, and in some embodiments, contact, the entire upper surface 48 of the body 22. Furthermore, the cover 46 may be substantially solid such that fluid is not configured to flow from the interior cavity 38 of the body 22 through the cover 46. However, in embodiments, one or more openings 50 may be formed in the cover 46. The openings 50 may be located adjacent to only a portion of the compartments formed within the body 22 (e.g., the second compartment 44), or alternatively, adjacent to each compartment of the body 22.

[0070] The cover 46 can be in an open position relative to the body 22 in which the compartments 42, 44 are accessible or open ( Figure 2 ) and a closed position ( Figure 1 ). The cover 46 may be distinct from and separable from the body 22, or alternatively, removably connected to the body 22. Figure 2 In the non-limiting embodiment shown, the cover 46 can pivot or rotate relative to the main body 22 about a pivot axis P. However, other types or movements of the cover 46 are also within the scope of the present disclosure. In an embodiment, the cover 46, such as an end 52 of the cover 46 opposite the hinge, includes a connector 54 that is configured to cooperate with an engagement feature formed in the main body 22 to limit movement of the cover 46 relative to the main body 22 when in the closed position.

[0071] In an embodiment, the ignition zone 56 is formed at a portion of the body 22 that is specific to only one of the compartments of the body 22. Thus, the initial ignition of the contents of the combustible matrix module 20 is isolated to a single compartment of the body 22. In such an embodiment, the ignition zone 56 is not formed in the first side wall 34, the second side wall 36 at a height shared by both compartments 42, 44. Instead, Figure 1In the best illustrated non-limiting embodiment, an ignition zone 56 is formed in the first sidewall 34 adjacent to the first compartment 42 at a height higher than that of the second compartment 44. Additionally, a plurality of ignition openings 58 are formed in the ignition zone 56 of the main body 22. The ignition openings 58 may be substantially identical, or alternatively, may vary in size. Furthermore, the ignition openings may be located throughout the ignition zone 56 or may be formed only in a portion of the ignition zone 56. In one embodiment, the ignition zone 56 is formed from a mesh material attached to or integrated into the main body 22. However, in other embodiments, the ignition openings 58 are formed (e.g., stamped or punched) into the material of the first sidewall 34. The ignition openings 58 are sized and positioned within the ignition zone 56 to allow radiant heat to flow through the ignition openings 58, thereby interacting with the substrate located within the interior of the first compartment 42. Once the contents of the first compartment 42 are ignited, combustion gases are configured to flow through the divider 40 to heat and ignite the contents of the second compartment 44.

[0072] At least one other surface of the body 22, such as the opposing second sidewall 36 and / or second end wall 30, has a plurality of outlet holes 60 formed therein. The outlet holes 60 can be arranged directly adjacent to the first compartment 42 and the second compartment 44. In the non-limiting embodiment shown, the outlet holes 60 are arranged in a single row extending across the second sidewall 36 and the second end wall 30. However, any suitable configuration of the outlet holes 60 is within the scope of this disclosure. The total number of outlet holes 60 can generally be less than the total number of the ignition openings 58, and in some embodiments, the size of the outlet holes 60 is greater than the size of the ignition openings 58. The outlet holes 60 are configured to partially block the airflow through the body 22 to prevent the material in the module from burning rapidly. However, the configuration of the outlet holes 60 must be sufficient to prevent complete obstruction of the airflow, which would result in a portion of the contents of the combustible matrix module 20 not burning or not igniting.

[0073] In an embodiment, the combustible substrate module 20 is adapted for use with the cooking system 100, for example, and can be positioned on a countertop in at least one cooking mode. Figure 3 and 4 An example of a cooking system 100 is shown in greater detail in FIG. As shown, cooking system 100 includes a base 102 and a lid 104. Base 102 includes a housing 106 made of any suitable material, such as glass, aluminum, plastic, or stainless steel. A liner 108 can be disposed within a hollow interior 110 of housing 106. Liner 108 can be formed from any suitable conductive material, such as aluminum. In an embodiment, liner 108 forms an interior surface of housing 106, thereby defining hollow interior 110 of housing 106. Alternatively, liner 108 can be offset from the interior surface of housing 106. However, it should be understood that other components of cooking system 100 or its surfaces can also define hollow interior 110.

[0074] In an embodiment, a cooking container 112 can be received within the hollow interior 110 of the housing 106. While the cooking container 112 is described herein as being removable from the housing 106 of the base 102, embodiments in which the cooking container 112 is integrally formed with the housing 106 are also contemplated herein. The cooking container 112 has an interior 114 designed to receive and retain one or more consumable products, such as food products. Examples of food products suitable for use with the cooking system 100 include, but are not limited to, meat, fish, poultry, bread, rice, grains, pasta, vegetables, fruit, and dairy products. The cooking container 112 can be a pot formed from ceramic, metal, or die-cast aluminum. In an embodiment, the inner surface of the cooking container 112 includes a nano-ceramic coating, and the outer surface of the cooking container 112 includes a silicone epoxy material. However, any suitable material capable of withstanding the high temperatures required to cook food is contemplated herein. Furthermore, one or more handles (not shown) can be associated with the cooking container 112 to allow a user to easily grasp and manipulate the cooking container 112 relative to the housing 106.

[0075] One or more accessories or inserts 116 may be compatible with the cooking system 100. Examples of such accessories include, but are not limited to, a spreader, a crisping insert, a baking tray, and a sieve. In such embodiments, the inserts may be received within the hollow interior 110 of the housing 106, or alternatively, within the interior 114 of the cooking container 112.

[0076] Referring to lid 104 in more detail, it should be noted that lid 104 can be coupled to a surface of cooking vessel 112 and / or housing 106 to close access to interior 114 of cooking vessel 112. Thus, a cooking volume can be defined between interior 114 of cooking vessel 112 and the closed end of lid 104, or between a hollow interior 110 defined by housing 106 and the closed end of lid 104. In an embodiment, the diameter of lid 104 is generally complementary to the diameter of housing 106, such that lid 104 covers not only cooking vessel 112, but also an upper surface 118 of housing 106.

[0077] The lid 104 is movable relative to the base 102 between an open position and a closed position to selectively cover the hollow interior 110. For example, the lid 104 can be distinct and separate from the base 102, or the lid 104 can be movably connected to the base 102. In the non-limiting embodiment shown, the lid 104 can pivot or rotate relative to the base 102 about a pivot axis P. However, other types or movements of the lid 104 are also within the scope of the present disclosure. When the lid 104 is in the closed position, one or more fastening mechanisms (not shown) can, but need not, be used to secure the lid 104 to the base 102. Any suitable type of fastening mechanism capable of withstanding the heat associated with the cooking system 100 is contemplated as within the scope of the present disclosure.

[0078] Cooking system 100 includes at least one heating element operable to impart heat to a cooking volume during one or more operating modes of cooking system 100. In the illustrated non-limiting embodiment, heating element 120 is positioned generally at or above an upper extent 122 of cooking vessel 112, such as near the center of interior 114 of cooking vessel 112. As shown, at least one heating element 120 is mounted within lid 104, thus being completely exterior to cooking vessel 112 and vertically offset from its upper extent 122. Alternatively or additionally, heating element 124 may be disposed within housing 106, generally adjacent to bottom 126 of cooking vessel 112. However, it should be understood that embodiments in which heating elements are disposed at other locations within base 102 and / or lid 104 are also contemplated herein.

[0079] The at least one heating element 120, 124 is capable of any suitable type of heat generation. For example, heating elements 120, 124 configured to heat the cooking container 112 or one or more food items within the interior 114 of the cooking container 112 via conduction, convection, radiation, and induction are all within the scope of the present disclosure. In the illustrated non-limiting embodiment, the heating element 120 is operable to cook the food within the cooking container 112 via a non-contact cooking operation. As used herein, the term "non-contact cooking operation" includes any cooking operation in which the heating element or heat source is arranged without direct or indirect contact with the food, such as, but not limited to, convection and radiant heating. In such embodiments, the cooking system 100 further includes an air movement mechanism 128, such as a fan, which can be used to circulate air within the cooking volume. The air is heated as it flows along its circulation path, for example, by flowing over a portion of the at least one heating element 120. In the illustrated non-limiting embodiment, the air movement mechanism 128 is driven by a motor 130 having a separate cooling mechanism (not shown) coupled thereto.

[0080] In an embodiment, the heating element 124 is operable to cook food within the cooking container 112 via a contact cooking operation. As used herein, the term "contact cooking operation" includes cooking operations that transfer heat via direct or indirect contact between a heating element or heat source and the food, such as, but not limited to, conduction and induction cooking. However, it should be understood that embodiments in which the heating element 120 is operable to perform a contact cooking operation and embodiments in which the heating element 124 is operable to perform a non-contact cooking operation are also within the scope of the present disclosure.

[0081] Furthermore, in embodiments including heating element 120 and heating element 124, it should be understood that the heating elements can be operated independently or in combination to apply one or more predetermined power settings to cook the food product within the cooking container. In operation, heating elements 120, 124 can cook the food independently of the food loading. In other words, heating elements 120, 124 can cook the food independently of the amount of food within cooking container 112. Cooking operations that can be performed by cooking system 100 include, but are not limited to, pressure cooking, steam cooking, slow cooking, searing, sautéing, pan-frying, baking / roasting, dehydrating, and grilling.

[0082] The combustible matrix module 20 can be mounted within the interior of the cooking system 100 at a position within the path of a convective airflow configured to circulate through the cooking system 100 in response to operation of the air movement mechanism 128. In addition, the combustible matrix module 20 can be positioned away from a cooking surface, such as the surface of a baking sheet, accessories arranged on the baking sheet, or alternatively, the surface of the container 112. In the non-limiting embodiment shown, the combustible matrix module 20 can be positioned within the interior of the lid 104. However, it should be understood that embodiments in which the combustible matrix module 20 is mounted at another position relative to the cooking system 100 are also within the scope of the present disclosure. The total axial height of at least a portion of the combustible matrix module 20 is selected so that when the combustible matrix module 20 is mounted within the cooking system 100, the ignition zone 56 of the combustible matrix module 20 is in close proximity to or in contact with an ignition source, such as a heating element. As shown, a convection heating element 120 arranged within the lid 104 can serve as an ignition source. In such embodiments, the combustible matrix module 20 is arranged radially outward of the heating element 120. Thus, the curvature of at least first sidewall 34, including ignition zone 56, facing the ignition source, complements the curvature of heating element 120 or another component within that zone of lid 104. Also contemplated herein are embodiments in which the ignition source is separate and distinct from heating elements 120, 124 that can be used to perform cooking operations.

[0083] The radiation shield 132 is disposed between at least a portion of the combustible matrix module 20 and the ignition source. The radiation shield 132 is configured to isolate substantially all of the combustible matrix module 20 from the ignition source, except for the ignition zone 56, to prevent the contents of one or more compartments 42, 44 from being ignited simultaneously. Figure 5 and 6 , an example of a radiation shield 132 is shown in more detail. In an embodiment, the radiation shield is a generally cylindrical or dome-shaped shield surrounding the periphery of the heating element. Thus, when the combustible matrix module 20 is installed in the cover 104, the radiation shield 132 is arranged generally concentrically and between the ignition source and the first side wall 34 of the combustible matrix module 20. An opening 134 is formed in the portion of the radiation shield 132 directly adjacent to the ignition zone 56 of the combustible matrix module 20 to allow heat from the ignition source to flow through the ignition zone 56 and into the first compartment 42 of the combustible matrix module 20. In an embodiment, the radiation shield 132 further includes a member 136 protruding from one side of the cylindrical wall toward the combustible matrix module 20. As shown, the member 136 can be configured to extend above the second compartment 44 of the combustible matrix module 20 to form an additional thermal barrier between the heating element 120 and the upper surface 48 or cover 46 adjacent to the second compartment 44.

[0084] The cooking system 100 may include a temperature sensor 140 operably coupled to the controller 156. The temperature sensor 140 may be associated with the combustible substrate module 20 and may be used to detect when the substrate within the combustible substrate module 20 is burning and, therefore, producing smoke. In an embodiment, the temperature sensor 140 is arranged in contact with a portion of the combustible substrate module 20 (e.g., a sidewall thereof). However, the temperature sensor 140 may be located in any suitable location where the sensor 140 can detect substrate combustion in any compartment of the combustible substrate module 20. Furthermore, the temperature sensor 140 is positioned within the cooking system 100 so that it can distinguish between heat generated by an ignition source and heat generated by the combustion of the substrate within the combustible substrate module 20. In an embodiment, the temperature sensor 140 is a negative temperature coefficient (NTC) temperature sensor. However, any suitable type of temperature sensor 140 is within the scope of the present disclosure. Furthermore, the cooking system 100 may further include a sensor 142 operably coupled to the controller 156, such as a reed switch. In such embodiments, the sensor 142 may be used to detect the presence of the combustible substrate module 20 when installed within the interior of the cooking system 100 .

[0085] To use the combustible matrix module 20, the contents of one or more of the compartments 42, 44 of the combustible matrix module 20 are filled with a suitable material or matrix. Examples of suitable materials include, but are not limited to, wood, such as hickory, alder, and various forms of mesquite wood, including wood chips, wood chunks, pellets, sawdust, and charcoal. Once filled, the combustible matrix module 20 is installed within the cooking system 100 adjacent to the ignition source. The combustible matrix module 20 can be installed within the cooking system 100 via any suitable mechanism. For example, in an embodiment, the combustible matrix module 20 can be connected to the radiation shield 132 or another portion of the cover 104 via a snap-fit ​​connection.

[0086] To perform a cooking operation using cooking system 100, a user selects one of aroma smoke-related input 150 and low-temperature, slow-smoking-related input 152 via user interface 154 of cooking system 100. For aroma smoke applications, only first compartment 42 of combustible substrate module 20 is filled with combustible material. However, for low-temperature, slow-smoking applications, both first compartment 42 and second compartment 44 are filled with such material. These compartments 42, 44 can be filled with the same material, or alternatively, with different materials.

[0087] After a cooking operation has been selected, an ignition source for initiating combustion within the combustible substrate module 20 is energized. In embodiments where the cooking system 100 includes a dedicated pilot heater separate from the cooking heating elements 120, 124, the pilot heater will selectively activate during the preheat phase of the cooking operation in response to, for example, detecting a module within the cooking system 100 via sensor 142. Once activated, the pilot heater remains energized until the temperature sensor 140 detects that ignition of the material within the combustible substrate module 20 has occurred. Thus, in response to detecting that ignition has occurred, the controller 156 will cease providing energy to the ignition source. Furthermore, in embodiments, the pilot heater will not be energized after the preheat phase of the cooking operation, regardless of whether sensor 142 has detected ignition of the material within the combustible substrate module 20.

[0088] Alternatively, if one of the heating elements 120, 124 is configured as an ignition source, the cooking system 100 will perform a preheating operation to a temperature sufficient to initiate ignition of the material within the first compartment 42 and then cool to a user-selected target temperature. In an embodiment, the heating element is energized to preheat the interior of the cooking system 100 to at least 500°F to initiate ignition of the material within the combustible substrate module 20.

[0089] In response to the application of heat, the contents of compartment 42 will ignite and thereby generate smoke. Once the ignition source is energized, heat will penetrate the ignition source and enter the first compartment. The smoke generated by the burning material is configured to penetrate through the outlet holes 60 formed in the burning material and flow into the interior 114 of the cooking container 112 or into the cooking volume where one or more food items are located.

[0090] For aroma smoke-related operations, once the material in first compartment 42 has ignited, the material will continue to burn while the selected cooking operation is being performed. It should be understood that any of heating elements 120, 124, and / or air movement mechanism 128 may be energized during the selected cooking operation. In an embodiment, during aroma smoke-related operations, the contents of first compartment 42 will produce smoke for approximately 10 minutes, or in some embodiments, for at least 10 minutes or between 10 and 20 minutes, such as approximately 12 minutes, approximately 14 minutes, approximately 16 minutes, approximately 18 minutes, and approximately 20 minutes. The length of time that smoke is produced from the material in first compartment 42 will vary based on the selected cooking temperature and the food being cooked.

[0091] In an embodiment in which the user has selected a low-temperature, slow-smoking related cooking operation, the material in the first compartment 42 is ignited, and this ignition is transferred to the material in the second compartment 44. In an embodiment, the ignition of the material in the second compartment 44 can occur very quickly, so that the ignition of the materials in the two compartments 42, 44 can be considered to occur essentially simultaneously. However, embodiments in which the ignition of the material in the second compartment 44 is delayed relative to the ignition of the material in the first compartment 42 are also encompassed herein. In such embodiments, the material in the first compartment 42 and the material in the second compartment 44 are ignited sequentially. Once the ignition in the combustible substrate module 20 is detected, for example, by the temperature sensor 142, the operation of the air movement mechanism 128 is activated. The rotation of the air movement mechanism 128 around its axis will circulate air in and out of the cooking volume. In an embodiment, the air output from the air movement mechanism 128 is configured to flow through the combustible substrate module 20 or flow around the combustible substrate module 20. Due to this airflow, a portion of the smoke within or permeating the combustible substrate module 20 may be drawn into or entrained within the airflow configured to circulate around the exterior surface of the food product within the cooking system 100 .

[0092] In an embodiment, the air moving mechanism 128 is configured to rotate at a low speed. A controller 156 operably coupled to the air moving mechanism 128 can be configured to control the speed of the air moving mechanism 128 to adjust the combustion rate of the material within the combustible substrate module 20, for example, in response to a temperature detected by the sensor 140. For example, when the fan speed is increased, the additional oxygen provided to the interior of the combustible substrate module 20 will increase the combustion temperature, and when the fan speed is reduced or stopped, the oxygen inside the combustible substrate module 20 is reduced, thereby lowering the combustion temperature. The fan speed can be varied between two or more speeds during low temperature slow smoking operation to extend the length of time that the contents of the combustible substrate module 20 burn as long as possible while generating smoke that is hot enough to obtain the desired cooking result. In an embodiment, the temperature of the smoke generated during low temperature slow smoking operation is between 200°F and 250°F.

[0093] In operation, the temperature sensor 140 can be used to detect when the material within the combustible substrate module 20 has completely burned. For example, when the sensor 140 fails to detect heat associated with the burning of the material of the combustible substrate module 20 even at an increased fan speed, it can be determined that all of the material burning within the combustible substrate module 20 has been extinguished.

[0094] The low-temperature slow smoking operation can be combined with another cooking operation of the cooking system 100. In such embodiments, once the sensor 142 has determined that the material within the combustible substrate module 20 is completely extinguished, another cooking operation can be initiated. For example, once the cooking system 100 has detected that the material within the combustible substrate module 20 is no longer producing smoke, a convection cooking operation using the heating element 120 and the air movement mechanism 128 can be automatically initiated. This secondary cooking operation can be performed for a set amount of time, can be performed to complete cooking the food, or can be performed to allow the food to reach a desired temperature. Once the cooking operation is complete, the combustible substrate module 20 can be removed from the cooking system 100 and the burned contents of the combustible substrate module 20 can be discarded.

[0095] As shown and described herein, the cooking system 100 configured to receive the combustible substrate module 20 is configured to enhance the various flavors that can be achieved via the cooking system. Furthermore, different types of flavors can be imparted to food based on the type of smoke generator installed within the compartments 42, 44 of the combustible substrate module 20. Thus, the cooking system 100 provides an enhanced user experience.

[0096] The term "about" is intended to include the degree of error associated with the measurement of the particular quantity based on the equipment available at the time the application was filed.

[0097] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the present disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that when used in this specification, the terms "comprises and / or comprising" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0098] Although the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. Furthermore, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the basic scope of the present disclosure. Therefore, it is intended that the present disclosure not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out the present disclosure, but that the present disclosure will encompass all embodiments falling within the scope of the claims.

Claims

1. A cooking system comprising: a housing having a hollow interior; a heating element operable to heat the hollow interior; a food support surface disposed within the hollow interior; a combustible matrix module removably positionable in the housing, the combustible matrix module comprising a body including a hollow interior having a plurality of compartments defined by at least one divider; an ignition source disposed within the housing, wherein the ignition source is operably coupled to an ignition zone of the combustible matrix module when the combustible matrix module is positioned in the housing, the ignition zone being specific to one of the plurality of compartments; as well as a radiation shield disposed between the ignition source and the combustible matrix module, the radiation shield having an opening positioned directly adjacent the ignition zone of the combustible matrix module and a member projecting from a side of a cylindrical wall of the radiation shield toward the combustible matrix module; wherein the combustible matrix module is arranged in fluid communication with the hollow interior of the housing when positioned in the housing, and Wherein when the combustible substrate module is positioned in the housing, the combustible substrate module is disposed away from the food supporting surface.

2. The cooking system of claim 1 , wherein the housing further comprises a base and a cover, the combustible substrate module being removably positionable in the cover.

3. The cooking system of claim 1, wherein the ignition source is separate from the heating element.

4. The cooking system of claim 1, wherein the ignition zone of the combustible substrate module is separated from the ignition source by a gap.

5. The cooking system of claim 1 , wherein the cooking system further comprises an air movement mechanism associated with the hollow interior of the housing, and the combustible substrate module is disposed radially outward and downstream of an outlet of the air movement mechanism.

6. The cooking system according to claim 1, wherein: The at least one divider defines a first compartment and a second compartment, the at least one divider comprising a plurality of openings such that the first compartment and the second compartment are arranged in fluid communication via the plurality of openings.

7. The cooking system of claim 1, wherein the ignition source is de-energized in response to determining that the combustible material within the combustible substrate module is ignited.

8. The cooking system of claim 1, wherein the ignition source is energized in response to determining that the combustible material within the combustible substrate module has completely combusted.

9. The cooking system of claim 1 further comprising a heating element distinct from the ignition source, wherein operation of the heating element is controlled in response to a state of the combustible material within the combustible substrate module.

10. The cooking system of claim 9, wherein the heating element is energized in response to determining that the combustible material within the combustible substrate module is ignited.

11. The cooking system of claim 9, wherein the heating element is energized in response to determining that the combustible material within the combustible substrate module has completely combusted.

12. The cooking system of claim 7, further comprising an air moving device controlled in response to a condition of the combustible material.

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