Modular cooking appliance with a grease shield

Abstract

The present invention discloses a modular cooking device. The modular cooking device includes a housing for accommodating a first interchangeable cooking module and a second interchangeable cooking module. The first interchangeable cooking module houses a first oven, and the second interchangeable cooking module houses a second oven. A grease shield is located within the first oven. The second oven is different from the first oven. The modular cooking device further includes: a control panel for receiving cooking inputs; a controller for controlling the first interchangeable cooking module and the second interchangeable cooking module; and a single power plug for receiving power from a wall-mounted power outlet.

Description

Technical Field

[0001] The present invention generally relates to cooking appliances, and more particularly to a modular cooking appliance having a plurality of ovens capable of cooking various food types simultaneously. Background Art

[0002] To cook and serve a wide variety of food items such as pizzas, baked goods, breakfast sandwiches, proteins, etc., food service operators typically have to have different types of ovens at the same store location. Different operating skills are generally required to cook using each of the different types of ovens, and multiple ovens tend to occupy valuable countertop space and require multiple power plugs.

[0003] The present invention provides an improved cooking appliance that can simplify the cooking tasks of food service operators. Summary of the Invention

[0004] The object of the present invention is to provide a modular cooking device that can greatly simplify the cooking tasks of food service operators, save valuable countertop space, and reduce the number of power plugs used.

[0005] To achieve the above object, the present invention provides a modular cooking device, comprising:

[0006] A housing having a first interchangeable cooking module and a second interchangeable cooking module;

[0007] A first oven received within the first interchangeable cooking module;

[0008] A first grease shield located within the first oven;

[0009] A second oven received within the second interchangeable cooking module, wherein the second oven is different from the first oven;

[0010] A control panel on the housing for receiving cooking inputs;

[0011] A controller within the housing for controlling the first interchangeable cooking module and the second interchangeable cooking module; and

[0012] A single power plug for receiving power from a wall-mounted power outlet.

[0013] Optionally, the first grease shield includes a first wall, a second wall, and a rear wall.

[0014] Optionally, the interior angle between the first wall and the rear wall is between 90° and 105°.

[0015] Optionally, the internal angle between the second wall and the rear wall is between 90° and 105°.

[0016] Optionally, one of the first wall, the second wall, and the rear wall includes a plurality of openings for return air to pass through.

[0017] Optionally, the modular cooking device further includes a second grease shield located within the second oven.

[0018] Optionally, the second grease shield includes a first wall, a second wall, and a rear wall.

[0019] Optionally, the internal angle between the first wall and the rear wall is between 90° and 105°.

[0020] Optionally, the internal angle between the second wall and the rear wall is between 90° and 105°.

[0021] Optionally, one of the first wall, the second wall, and the rear wall includes a plurality of openings for return air to pass through.

[0022] According to one embodiment of the present invention, a modular cooking device includes a housing configured to receive a first interchangeable cooking module and a second interchangeable cooking module. The first interchangeable cooking module houses a first oven, and the second interchangeable cooking module houses a second oven. A grease shield is located within the first oven. The second oven is different from the first oven. The modular cooking device further includes: a control panel configured to receive cooking inputs; a controller configured to control the first interchangeable cooking module and the second interchangeable cooking module; and a single power plug configured to receive power from a wall-mounted power outlet.

[0023] Compared with the prior art, the beneficial effects of the modular cooking device of the present invention are as follows:

[0024] It can greatly simplify the cooking tasks of food service operators, save valuable worktop space, and reduce the number of power plugs used.

[0025] All features and advantages of the present invention will become apparent in the following detailed written description. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present invention itself, its preferred mode of use, further objects, and advantages will be best understood by reference to the following detailed description of the illustrated embodiments when read in conjunction with the accompanying drawings, in which:

[0027] Figure 1 Is an isometric view of a modular cooking appliance according to one embodiment;

[0028] Figure 1A Is an isometric view of the structure of a modular cooking appliance according to an alternative embodiment;

[0029] Figure 1B Is according to one embodiment of Figure 1A Is an isometric view of an interchangeable cooking module within a modular cooking appliance;

[0030] Figure 1C Is according to one embodiment of Figure 1B Is an isometric view of the rear wall within an interchangeable cooking module;

[0031] Figure 1D Is a top view of a grease shield to be placed within an interchangeable cooking module according to one embodiment of Figure 1B an interchangeable cooking module;

[0032] Figures 2A to 2C Is according to one embodiment of Figure 1 Is a cross-sectional view of an impact oven within a modular cooking appliance;

[0033] Figure 3 Is according to one embodiment of Figures 2A to 2C Is a schematic diagram of a heating and air flow system within an impact oven;

[0034] Figure 4 Is according to one embodiment of Figure 1 Is an isometric view of a convection oven within a modular cooking appliance;

[0035] Figure 5 Is according to one embodiment of Figure 4 Is a schematic diagram of a heating and air flow system within a convection oven; and

[0036] Figure 6A Is according to one embodiment of Figure 1 Is a front cross-sectional view of a microwave oven within a modular cooking appliance;

[0037] Figure 6B Is Figure 6A Is an enlarged isometric view of a cooking rack within a microwave oven;

[0038] Figures 6C to 6E Is according to one embodiment of Figure 6A Is a cross-sectional view of a food delivery system within a microwave oven;

[0039] Figure 7 Is a block diagram of a controller for controlling various oven modules within a modular cooking appliance according to one embodiment of Figure 1 a modular cooking appliance;

[0040] Figure 8A shows an example of a food item table within a modular cooking appliance of Figure 1 ;

[0041] Figure 8B shows an example of a maximum current draw table within a modular cooking appliance of Figure 1 ;

[0042] Figure 8C shows an example of a current draw history table within a modular cooking appliance of Figure 1 ; and

[0043] Figure 9 is a flowchart of a method for cooking a food item via a modular cooking appliance according to one embodiment of Figure 1 ; DETAILED DESCRIPTION

[0044] Ⅰ. Configuration of Modular Cooking Appliance

[0045] Referring now to the drawings and specifically to Figure 1 , an isometric view of a modular cooking appliance according to one embodiment is depicted. As shown, the modular cooking appliance 10 is defined by a housing 11 that houses a plurality of interchangeable cooking modules. For the present embodiment, the housing 11 includes interchangeable cooking modules 12a - 12c, but those skilled in the art will understand that the number of interchangeable cooking modules within the housing 11 can be more or less than three. Each of the interchangeable cooking modules 12a - 12c is configured to receive an oven. The ovens housed within the interchangeable cooking modules 12a - 12c can be the same or different from each other. For the present embodiment, the interchangeable cooking module 12a houses an impingement oven that can be used to cook pizza, the interchangeable cooking module 12b houses a convection oven that can be used to cook more delicate yeast - risen food items such as cinnamon rolls, and the interchangeable cooking module 12c houses a microwave oven that can be used to cook hot dogs.

[0046] Alternatively, the interchangeable cooking module 12a can house a first convection oven, the interchangeable cooking module 12b can house a second convection oven, and the interchangeable cooking module 12c can house an impingement oven. Basically, the modular cooking appliance 10 can accommodate any combination of ovens based on the preferences of the food service operator. Any one of the interchangeable cooking modules 12a - 12c housed within the modular cooking appliance 10 can be replaced by field service personnel without disturbing other aspects of the modular cooking appliance 10.

[0047] For this embodiment, the heights of the interchangeable cooking modules 12a - 12c are the same, such that the height of the housing 11 corresponds to the total number of interchangeable cooking modules installed. Alternatively, the heights of the interchangeable cooking modules 12a - 12c can be different from each other, depending on the type of oven housed therein. For example, a convection oven for cooking yeast - fermented products may be taller than an impact oven for cooking pizza. Thus, the height of the housing 11 will correspond to the total height of the ovens housed therein.

[0048] The interchangeable cooking modules 12a - 12c respectively include openings 16a - 16c to allow food items to be conveyed into the ovens located within the interchangeable cooking modules 12a - 12c.

[0049] The modular cooking appliance 10 includes a common control panel 17 for controlling all the various ovens and food - loading mechanisms housed within the interchangeable cooking modules 12a - 12c. Each of the food - loading mechanisms allows a food item to be loaded into the cooking chamber of a corresponding oven. After the food item has been placed on the food - loading mechanism, the operator can input operating parameters such as cooking temperature, cooking time, blower speed, etc. via the control panel 17 to control the cooking of the food item to be cooked, and the food - loading mechanism will automatically convey the food item into the oven to start cooking.

[0050] Alternatively, in the absence of using a food - loading mechanism or when there is no food - loading mechanism attached to the oven, the food item can be manually placed by the operator into the cooking chamber of the oven.

[0051] The control panel 17 is preferably implemented with a touch screen, but can also be implemented with a keyboard and a liquid - crystal display (LCD) well - known in the art.

[0052] Now referring Figure 1A , an isometric view of the structure of a modular cooking appliance 10' according to an alternative embodiment is depicted. As shown, the modular cooking appliance 10' is defined by a housing 11' that houses the interchangeable cooking modules 12a - 12c. Each of the interchangeable cooking modules 12a - 12c is adapted to receive an oven, such as a microwave oven, a convection oven, an impact oven, etc.

[0053] Each of the interchangeable cooking modules 12a - 12c is respectively associated with one of the forward slots 14a - 14c. The openings 16a - 16c allow food items to be conveyed between the ovens located within the interchangeable cooking modules 12a - 12c and their associated forward slots 14a - 14c. For example, each of the forward slots 14a - 14c may accommodate a food loading mechanism for conveying the food placed thereon to the oven housed within the adjacent interchangeable cooking module 12a - 12c via the corresponding openings 16a - 16c. Specifically, the food placed on the food loading mechanism housed in the forward slot 14a will be conveyed to the oven housed in the interchangeable cooking module 12a, the food placed on the food loading mechanism housed in the forward slot 14b will be conveyed to the oven housed in the interchangeable cooking module 12b, and the food placed on the food loading mechanism housed in the forward slot 14c will be conveyed to the oven housed in the interchangeable cooking module 12c. After the food has been cooked, the food may return through the food loading mechanism to the forward slot from which it entered the associated oven.

[0054] The modular cooking appliance 10' includes a common control panel 17' for controlling all the various ovens and food loading mechanisms respectively housed within the interchangeable cooking modules 12a - 12c and the forward slots 14a - 14c.

[0055] A. Interchangeable Cooking Modules

[0056] The basic construction of the interchangeable cooking modules 12a - 12c is substantially the same as each other. Thus, only the basic construction of the interchangeable cooking module 12a will be further described in detail.

[0057] Now referring Figure 1B , an isometric view of an interchangeable cooking module 12a according to one embodiment is illustrated. As shown, the interchangeable cooking module 12a includes a space for accommodating an oven (not shown) and two openings, such as openings 16a and 16a', located at both ends of the space for accommodating the oven. Along the longitudinal axis, the upper half of the interchangeable cooking module 12a is substantially the same as the lower half of the interchangeable cooking module 12a, such that depending on the orientation of the interchangeable cooking module 12a within the housing 11, either opening 16a or opening 16a' may be used for passing food items. During assembly, after the orientation of the interchangeable cooking module 12a within the housing 11 has been determined, one of the openings 16a and 16a' may be closed with a rear wall (see Figure 1C ).

[0058] The top and bottom of the interchangeable cooking module 12a are formed by insulating surfaces 18. The insulating surfaces 18 include a fill envelope that can be filled with a high specific heat substance. For example, after the oven has been placed within the interchangeable cooking module 12a, a liquid containing a suspended high specific heat substance (such as sand or salt suspended in silicone) can be injected into the fill envelope within the insulating surfaces 18 until the insulating surfaces 18 fully expand into the space between the insulating surfaces 18 and the oven. When the oven is heated, thermal energy is stored in the high specific heat substance.

[0059] Reference now Figure 1C , illustrating an embodiment of Figure 1B An isometric view of a rear wall within an interchangeable cooking module 12a. As shown, the rear wall includes a set of connectors 15-1 to 15-6. During assembly, the oven module to be placed within the interchangeable cooking module 12a is fully seated therein in order to achieve connection between a subset of connectors 15-1 to 15-6 and the oven module. Each oven type includes a specific set of electrical connectors that mate with corresponding ones of connectors 15-1 to 15-6 to enable the appropriate electrical and control network for the operation of the oven. For example, an impingement oven includes electrical connectors for mating with connectors 15-1 and 15-4, a convection oven includes electrical connectors for mating with connectors 15-2 and 15-5, and a microwave oven includes electrical connectors for mating with connectors 15-3 and 15-6.

[0060] Reference now Figure 1D , illustrates a top view of a grease shield according to one embodiment. As shown, the grease shield S1 includes a left wall S1a, a right wall S1b, and a rear wall S1c, which are all connected to each other to form a U-shaped shield. At least one of the left wall, the right wall, and the rear wall S1a-S1c includes a plurality of small openings for return air to pass through. The left wall S1a and the rear wall S1c of the grease shield S1 are joined at an angle θ between 90° and 105°. Similarly, the right wall S1b and the rear wall S1c of the grease shield S1 are joined at an angle θ between 90° and 105°.

[0061] Grease shield S1 can be placed on interchangeable cooking modules (such as Figure 1B The purpose of the grease shield S1 is to prevent the grease in the food from touching the wall of the oven chamber during cooking. Therefore, the grease shield S1 should be placed in the oven chamber located in the interchangeable cooking module before cooking begins. The grease shield S1 can be removed from the oven chamber at any time for cleaning.

[0062] B. Impulse Oven

[0063] Reference now Figures 2A to 2C , depicting an embodiment according toFigure 1 Cross-sectional view of the impingement oven within the interchangeable cooking module 12a of the modular cooking appliance 10. As shown, the impingement oven 20 includes a housing 21 that provides a cavity 29 and a cavity opening 28. The impingement oven 20 also includes a substantially flat food loading platform 23. The food loading platform 23 is configured to receive a cooking plate 25. Any food item intended to be cooked by the impingement oven 20 is initially placed on the cooking plate 25 or the food loading platform 23. As Figure 2C shown, when cooking a food item, the food loading platform 23 and the cooking plate 25 are located inside the cooking cavity 29.

[0064] Additionally, the housing 21 also houses a top plenum 35 and a bottom plenum 38. The top plenum 35 is connected to a top air intake plate 34. The bottom plenum 38 is connected to a bottom air intake plate 37. The top air intake plate 34, the top plenum 35, the bottom air intake plate 37, and the bottom plenum 38 are part of the heating and air flow system of the impingement oven 20 such that the hot air in the top plenum 35 and the bottom plenum 38 is in gas communication with the cavity 29 through the top air intake plate 34 and the bottom air intake plate 37, respectively. The top air intake plate 34 and the bottom air intake plate 37 include a plurality of openings for directing a hot pressurized air stream towards any food item placed on the food loading platform 23 located within the cavity 29. Those skilled in the art will appreciate that the top plenum 35 or the bottom plenum 38 can be in gas communication with the cavity 29 via various air opening configurations (such as circular openings, nozzles, tubes, rectangular openings, etc.). Additionally, air can enter the cavity 29 through only one of the top plenum 35 or the bottom plenum 38.

[0065] The impingement oven 20 is also associated with a food delivery system 22. As shown, the food delivery system 22 includes a food loading platform 23 connected to a food delivery carriage c1 via a connector 27. The food loading platform 23 can be transported into and out of the cooking cavity 29 by a belt drive mechanism that includes a belt b1, a belt drive wheel w1 driven by a belt drive motor m1, and an opposing pulley w2. The belt b1 is connected to the carriage c1 via belt locks BL1 and BL2. The carriage c1 is connected to a carriage rail s1. For this embodiment, there are four carriage rails connected to the carriage c1, namely, as Figure 2A shown, two front carriage rails s1, and two rear carriage rails (not shown) located on opposite sides of the carriage c1. The belt b1 moves between the front carriage rails s1 and the rear carriage rails. As Figure 2B shown, when the belt drive motor m1 is engaged, the belt b1 moves the carriage c1, thereby transporting the food loading platform 23 into and out of the cooking cavity 29 through the opening 28.

[0066] During the cooking process, the food loading platform 23 can move back and forth approximately 1" to promote even cooking of the food. To move the food loading platform 23 back and forth during the cooking process without allowing air to escape through the opening 28, the door d1 must be thick enough to substantially prevent air from escaping through the opening 28 at either extreme of the back-and-forth movement.

[0067] The operating parameters for the impingement oven 20 can be input via the control panel 17 (see Figure 1 ), and these operating parameters are for cooking any food item placed on the cooking plate 25 that is to be transported into the cooking chamber 29.

[0068] Now referring to Figure 3 , a schematic view of the heating and air flow system within the impingement oven 20 according to one embodiment is depicted. The air within the cooking chamber 29 is initially pumped into the heater plenum 31 via the air inlet 30. The heater plenum 31 includes a base heater 39a and a boost heater 39b. After the air has been sufficiently heated by the base heater 39a and the boost heater 39b, the hot air is then directed to the top plenum 35 via the top blower 32 and to the bottom plenum 38 via the bottom blower 33. During cooking, the base heater 39a is typically turned on, and the boost heater 39b is only activated when necessary. The pressurized hot air formed within the top plenum 35 is then directed to the chamber 29 via a plurality of openings located on the top inlet plate 34 (see Figures 2A to 2C ). Similarly, the pressurized hot air formed within the bottom plenum 38 is then directed to the chamber 29 via a plurality of nozzles located on the bottom inlet plate 37 (see Figures 2A to 2C ). Although the hot air is shown being sent to the top air plenum 35 and the bottom plenum 38 via separate blowers, those skilled in the art should understand that the hot air can be sent to the top plenum 35 and the bottom plenum 38 via a single blower.

[0069] C. Convection Oven

[0070] Now referring to Figure 4 , an isometric view of the convection oven within the slot 12b of the modular cooking appliance 10 according to one embodiment is depicted. As shown, the convection oven 40 includes a housing having a cooking chamber 49 that is defined by a top inlet plenum 41, a bottom inlet plenum 42, a rear wall 43, and two side walls 44a, 44b. Located on one or more of the side walls 44a, 44b and the rear wall 43 are return air openings, such as the opening 45a, for returning air to a blower system (not shown). Preferably, the convection oven 40 also includes a food loading mechanism similar to the Figure 1 food loading mechanism 22 shown. Figures 2A to 2C

[0071] Now refer to Figure 5 , which depicts a cross-sectional view of the heating and air flow system within a convection oven 40 according to one embodiment. As shown, the blower 51 is preferably located at the rear of the convection oven 40. Hot air from a heater (not shown) is directed by the blower 51 through a triangular air diverter 52, which divides the air leaving the blower 51 into a top air flow and a bottom air flow. The top air flow and the bottom air flow pass through a top intake plenum 41 and a bottom intake plenum 42, and enter the cooking chamber 49 through a top convection plate 45 and a bottom convection plate 46. After transferring heat from the hot air to the food placed in the cooking chamber 49, the air is drawn in through a return air path.

[0072] The operator can input commands such as cooking temperature, cooking time, fan speed, etc. via the control panel 17 (see Figure 1 ) to effect cooking control of any food item placed within the cooking chamber 49 of the convection oven 40.

[0073] D. Hot Air Oven with Built-in Magnetron

[0074] Now refer to Figure 6A , which illustrates a cross-sectional view of a hot air oven with a built-in magnetron within an interchangeable cooking module 12c of a modular cooking appliance 10 according to one embodiment. As shown, the hot air oven 60 includes a cooking chamber 69 and at least one magnetron 81 configured to generate microwave radiation for the cooking chamber 69. The hot air oven 60 may further include a second magnetron (not shown) that may be activated simultaneously with or independently of the magnetron 81. In some embodiments, the hot air oven 60 further includes a waveguide 82 configured to direct and / or distribute the microwave radiation generated by the magnetron 81 into the cooking chamber 69. Figure 1 In addition, the hot air oven 60 includes a blower 83 for providing an air flow to facilitate hot air cooking within the cooking chamber 69. In a preferred embodiment, a plurality of air guides 84a direct hot air in a horizontal direction (as shown by arrow a1) through a horizontal plenum 84b, where a portion of the air is directed through openings 84c in a jet plate 84d, while the remaining air is directed through a vertical plenum 84e and through a bottom air opening 84f located at the bottom of the cooking chamber 69. The air passing through the bottom air opening 84f moves in a horizontal direction opposite to the air passing through the horizontal plenum 84b (as shown by arrow a2) beneath a cooking rack 85 that supports food and includes a plurality of air deflectors 86 of different lengths.

[0075] An enlarged isometric view of the cooking rack 85 is shown. Figure 6B An enlarged isometric view of the cooking rack 85 is shown.

[0076] Air moves horizontally below the cooking rack 85. The angle between the air deflector 86 and the cooking rack 85 with respect to the oncoming horizontally moving air is less than 90°. The length of the air deflector 86 that is farther away from the horizontally moving air source is greater than the length of the air deflector 86 that is closest to the horizontally moving air source. The air passing through the air deflector 86 is guided upward as shown by arrow a3 and then returns to the blower 83 through the return air opening 84i.

[0077] Now refer to Figures 6C to 6E , a cross-sectional view of a food delivery and cooking uniformity mechanism for a microwave oven 60 according to an embodiment is illustrated. As shown, the platform 63 is connected to the food delivery carriage c1 via the connector 67. The platform 63 can be delivered into and out of the cooking cavity 69 by a belt drive mechanism that includes a belt b1, a belt drive pulley w1 driven by a belt drive motor m1, and an opposing pulley w2. The carriage c1 is connected to the carriage slide rail s1. For this embodiment, there are four carriage slide rails connected to the carriage c1, namely, two front carriage slide rails s1 as Figure 6B shown, and two rear carriage slide rails (not shown) located on the opposite side of the carriage c1. The belt b1 moves between the front carriage slide rail s1 and the rear carriage slide rail. As Figure 6B shown, when the belt drive motor m1 is engaged, the belt b1 moves the carriage c1, thereby delivering the platform 63 into and out of the cooking cavity 69 through the opening 68.

[0078] The food surface 64a is connected to and supported by the slide rail 65 resting on the platform 63. Food can be placed directly on the food surface 64a or, preferably, on a plate or tray (not shown), which is then placed on the food surface 64a. The food surface 64a is connected to the crank cam mechanism 62 via a rod 64b that penetrates the door 66a and the door diverter 66b.

[0079] As Figures 6D to 6EAs shown, during cooking, the food surface 64a can move back and forth within the cooking chamber 69 to promote even cooking of the food. To move the food surface 64a back and forth within the cooking chamber 69, a motor 61 and a crank-cam mechanism 62 are utilized to move a rod 64b connected to the food surface 64a. The motor 61 is located outside the oven door formed by an outer cover 66a and an inner cover 66b. The outer cover 66a and the inner cover 66b are specifically designed to prevent microwave radiation from escaping through the opening 68 during the cooking process. Two small concentric openings with a diameter of approximately 0.3 inches are provided in the outer cover 66a and the inner cover 66b to allow the rod 64b to pass through. The wavelength of the microwave is approximately 12 cm, and the diameter of each of the two small concentric openings needs to be small enough to prevent microwave radiation from escaping through the opening. During the cooking process, the crank-cam mechanism 62 converts the rotational motion from the motor 61 into a linear reciprocating motion to move the food surface 64a back and forth within the cooking chamber 69. The food surface 64a can move on top of the platform 63 via a slide rail 65.

[0080] For this embodiment, the motor 61 and the crank-cam mechanism 62 are used to convert rotational motion into linear reciprocating motion. Those skilled in the art should understand that other mechanisms can be utilized to convert rotational motion into linear reciprocating motion, or a linear reciprocating motion can be provided directly.

[0081] Operation parameters for cooking any food item placed within the cooking cavity 69 by the microwave oven 60 can be input via the control panel 17 ( Figure 1 ).

[0082] Ⅱ. Controller

[0083] The modular cooking appliance 10 can include various oven types, but it is also capable of being powered by a single-phase 50-ampere socket as the sole power source via a single power plug. Thus, the modular cooking appliance 10 can be adopted by any food service establishment without additional modification to a common single-phase 50-ampere socket.

[0084] Now referring to Figure 7 , a block diagram of a controller for controlling various oven modules within the modular cooking appliance 10 according to one embodiment is depicted. As shown, the controller 70 includes a processor 71, a multiplexer 72, a memory 73, and control modules 74a - 74c. The memory 73 includes non-erasable and electronically programmable random access memory and read-only memory. Software and data related to the operation of the modular cooking appliance 10 are stored in the memory 73. The control module 74a is associated with the interchangeable cooking module 12a (see Figure 1A)associated, control module 74b is associated with the interchangeable cooking module 12b, and control module 74c is associated with the interchangeable cooking module 12c. During operation, control modules 74a - 74c respectively monitor the real-time current consumption of the interchangeable cooking modules 12a - 12c, and distribute current to the interchangeable cooking modules 12a - 12c and the associated oven from the power supply 75 as needed.

[0085] All the ovens in the modular cooking appliance 10 that utilize hot air cooking (such as the impingement oven 20 and the convection oven 40) are provided with a base heater and at least one boost heater. For example, the impingement oven 20 includes a base heater 39a and a boost heater 39b (see Figure 3 ). All the ovens in the modular cooking appliance 10 that utilize microwave cooking (such as the microwave oven 60) are provided with at least one magnetron. For example, the microwave oven 60 includes a magnetron 61 (see Figure 6). If the microwave oven 60 is provided with a second magnetron, the second magnetron can be activated independently of the magnetron 61.

[0086] III. Adaptive Power Management

[0087] As described above, for this embodiment, the modular cooking appliance 10 is configured with an impingement oven 20, a convection oven 40, and a microwave oven 60, where all the ovens operate from a single-phase 50-ampere outlet common in commercial kitchens. However, those skilled in the art will understand that the modular cooking appliance 10 can have any number and type of ovens all powered by a single power plug. For this embodiment, the maximum current drawn by each of the impingement oven 20, the convection oven 40, and the microwave oven 60 is as follows:

[0088]

[0089] In addition, the baseline current drawn by all the auxiliary components (such as the processor 71, the multiplexer 72, the memory 73, etc.) in the modular cooking appliance 10 during operation is 5 amperes. Therefore, for a 50-ampere power supply, at any given time, a maximum of (50 - 5 =) 45 amperes of current is available for powering the ovens.

[0090] Needless to say, if more than one oven in the modular cooking appliance 10 can be used to cook food items simultaneously, there will be many benefits. However, as shown above, the maximum current drawn by the impingement oven 20 is (8 + 12 + 12 =) 32 amperes, and the maximum current drawn by the convection oven 40 is (4 + 12 + 12 =) 28 amperes. Therefore, it is not possible to use both the impingement oven 20 and the convection oven 40 to cook food items simultaneously because the total current drawn by the two ovens (and all the auxiliary components) will exceed the 50-ampere limit.

[0091] To overcome the above 50 - ampere hurdle, the modular cooking appliance 10 employs Adaptive Power Management TM (APM) technology to intelligently distribute current to each oven so that multiple ovens can be used simultaneously for cooking food items during some time periods. APM has two control modes, namely, temperature control mode and time control mode.

[0092] A. Temperature Control Mode

[0093] When cooking a food item in temperature control mode, the oven temperature is monitored and a temperature control feedback loop is utilized to control the oven temperature for cooking the food item. Specifically, when the measured oven temperature drops below the set cooking temperature, the base heater and the boost heater within the associated oven are turned on, while when the measured oven temperature is at or above the set cooking temperature, the base heater and the boost heater within the associated oven are turned off.

[0094] During the temperature control mode, the amount of time the oven is on and the associated current drawn during the cooking cycle are recorded and stored in a current draw history table (more details below) for use in the time control mode described below if necessary.

[0095] B. Time Control Mode

[0096] When cooking a food item in time control mode, the oven temperature and the time for cooking the food item are guided by information previously stored in the current draw history table (more details below). Specifically, the base heater and the boost heater within the associated oven are allocated power during each time unit, which is the power consumed by that oven when operating in temperature control mode for cooking the same food item, as recorded in the current draw history table.

[0097] IV. Control Table

[0098] The modular cooking appliance 10 executes APM during various cooking cycles using the following three control tables. The control tables can be stored in the memory 73 (see Figure 7 ) and the information in some of the control tables will be updated throughout the operation of the modular cooking appliance 10.

[0099] A. Food Item Table

[0100] Before the modular cooking appliance 10 can be deployed to cook different types of food items, information about these food items must be input and stored (i.e., pre-programmed) in a Food Entry Table (FET) within the memory 73. The FET contains a list of all food items that can be cooked via the various ovens within the modular cooking appliance 10 and their corresponding optimal cooking settings. Basically, for each food item intended to be cooked via the modular cooking appliance 10, the operator needs to input the food item name, oven type, and cooking settings (such as cooking time, blower speed, cooking temperature, etc.) associated with the food item into the FET.

[0101] Now referring to Figure 8A , an example FET according to one embodiment is depicted. In this FET example, four types of food items are listed, namely pizza, sandwich, cookie, and hot dog. Additionally, three separate cooking phases are shown, and each cooking phase contains cooking settings such as start time and stop time, cooking temperature, blower speed, and magnetron power level. Specifically, Entry One and Entry Two include the cooking settings for cooking pizza and sandwich respectively in an impingement oven (such as impingement oven 20). Entry Three includes the cooking settings for cooking cookies in a convection oven (such as convection oven 40), and Entry Four includes the cooking settings for cooking hot dogs in a microwave oven (such as microwave oven 60).

[0102] For each of Entries One through Three, when the corresponding cooking settings are deployed, the oven will participate in hot air cooking as indicated by the associated air temperature and blower speed. For Entry Four, when the cooking settings are deployed, the microwave oven will participate in microwave cooking as indicated by the non-zero magnetron settings in Phases 1 and 3.

[0103] B. Maximum Current Draw Table

[0104] Corresponding to the list of food items stored in the FET, the maximum current draw table contains the maximum current required for each of the impingement oven 20, convection oven 40, and microwave oven 60 to cook various food items.

[0105] Now referring to Figure 8B , an example maximum current draw table is depicted. As shown, the maximum current draw table includes an oven module column, a food name column, and multiple cooking phase columns. In this example, Entry One includes the maximum current drawn by the impingement oven 20 while cooking pizza for 90 seconds, which corresponds to Figure 8A Entry One in the FET of Figure 8A Entry Two in the FET ofFigure 8A Entry three of the medium FET. Entry four includes the maximum current drawn by the microwave oven 60 while cooking a hot dog for 90 seconds, which corresponds to Figure 8A Entry four of the medium FET.

[0106] When two or more ovens are called to cook a food item in temperature control mode, the information stored in the maximum current draw table will be used to help determine whether the cooking process should be started (as will be further explained in Figure 9 ).

[0107] C. Current Draw History Table

[0108] The current draw history table contains the current drawn by each of the impingement oven 20 and the convection oven 40 during each cooking cycle while participating in cooking each type of food item in temperature control mode.

[0109] Now refer to Figure 8C , which depicts an example current draw history table. As shown, the current draw history table includes an oven module column, a food name column, and a plurality of time unit columns. Each of the time units (time unit 1 to time unit 8 in this example) is the same in time length, and each time unit can be one second, two seconds, etc., depending on the required time resolution and the memory available within the modular cooking appliance 10. When each of the impingement oven 20 and the convection oven 40 participates in cooking a specific food item, the current it draws is recorded and thus stored in different time units throughout its cooking cycle.

[0110] The current draw value recorded in each time unit can be the running average of the current drawn during the most recent 10 cookings of each food item. For example, the 3.2 ampere current draw value in time unit 1 is the running average of the current drawn by the impingement oven 20 during the most recent 10 cookings of pizza in time unit 1. The operator can change the number of cookings used to calculate the running average, and depending on the required accuracy, more than 10 cookings can be used to calculate the running average.

[0111] Basically, when cooking in temperature control mode, the modular cooking appliance 10 learns how much current is recently required in each time unit to cook each type of food item type in each of the impingement oven 20 and the convection oven 40.

[0112] The current draw values expected to be recorded in each time unit can be significantly different even for the same oven, depending on the geographical location of the oven. For example, the current draw value of an oven located in Denver, Colorado is expected to be significantly higher than that of the same oven located in Dallas, Texas. Therefore, before the current draw history table can be fully deployed for regular daily operations, it must be initialized and populated with some actual historical current draw values by performing a minimum number of pre-cookings (such as 3 times) on-site.

[0113] When two or more ovens are called upon to cook a food item, the information stored in the current draw history table will be used to help determine whether the cooking process should be started (as will be further explained in Figure 9 .

[0114] Additionally, for each time unit, the start status of the associated base heater and boost heater (not shown) can also be recorded and stored in the corresponding entry of the current draw history table.

[0115] IV. Cooking Process

[0116] Now refer to Figure 9 , which depicts a flowchart of a method for cooking a food item via a modular cooking appliance 10 according to one embodiment. The ovens within the modular cooking appliance 10 depend on the user configuration, but for this embodiment, the ovens are the shock oven 20, the convection oven 40, and the microwave oven 60. After the operator has selected the food item to be cooked from the list of food items shown on the display 17 (see Figure 1 ), i.e., the food items stored in the FET of FIG. 8 (as shown in block 90), it is determined whether any oven is currently engaged in cooking a food item (as shown in block 91).

[0117] If no oven is currently engaged in cooking a food item, the temperature control mode will be used to control the oven temperature of the selected oven to cook the selected food item throughout the cooking process, as depicted in block 92. The cooking cycle will be guided by the information stored in the FET.

[0118] However, if one (or more) of the ovens is currently involved in cooking a food item, another determination is made as to whether the total current demand of the selected oven and the involved ovens (and auxiliary components) to cook the corresponding food item will exceed the 50-ampere limit at any time during their entire respective cooking cycles in the temperature control mode, as shown in block 93. This determination is made by looking up a maximum current draw table to determine whether the sum of the currents drawn by the selected oven and the involved ovens (and auxiliary components) to cook their respective food items will exceed the 50-ampere limit in any time unit for the same ovens cooking the same food type. If not, the selected oven is allowed to immediately cook the selected food, and the temperature control mode can be continuously used throughout the cooking cycle to control the oven temperatures of both ovens, as depicted in block 92.

[0119] If the total current demand of the selected oven and the involved ovens (and auxiliary components) to cook the corresponding food item exceeds the 50-ampere limit, all of the ovens will be set to use the time control mode to control the oven temperatures throughout the cooking cycle, as depicted in block 94. In other words, any oven that is currently using the temperature control mode will be switched to the time control mode to complete the cooking process.

[0120] For example, if a pizza is currently being cooked in the impingement oven 20 and the operator wants to cook cookies in the convection oven 40 at the same time, the controller 70 checks the maximum current drawn by the impingement oven 20 when cooking the pizza and the maximum current drawn by the convection oven 40 when cooking the cookies by using the maximum current draw table. In this example, when cooking the pizza, the maximum current drawn by the impingement oven 20 is 32 amperes, and when cooking the cookies, the maximum current drawn by the convection oven 40 is 28 amperes, where the total maximum current drawn is (32 + 28 =) 60 amperes, which means that the cooking control in the impingement oven 20 will be switched to the time control mode.

[0121] Next, it is determined whether the total current demand of the selected oven and the involved ovens (and auxiliary components) to cook the corresponding food item will exceed the 50-ampere limit in any time unit during their entire respective cooking processes in the time control mode, as shown in block 95. This determination is made by looking up a current draw history table to determine whether the sum of the currents drawn by the selected oven and the involved ovens (and auxiliary components) in each time unit throughout the cooking cycle does not exceed the 50-ampere limit.

[0122] If, in the time control mode, the total current demand required by the selected oven and the participating ovens (and auxiliary components) to cook the respective food items during their entire corresponding cooking processes exceeds the limit of 50 amperes in any time unit, the selected oven must wait until the total historical current drawn in each subsequent time unit is 50 amperes or less before it can start its cooking process. Otherwise, if the total current demand does not exceed the limit of 50 amperes in any time unit, the selected oven and the participating ovens all perform their respective cooking in the time control mode.

[0123] For example, Table I (a part of the current draw history table) shows that the impact oven 20 takes five time units to cook a pizza, and the currents drawn during the first to fifth time units are 20 amperes, 32 amperes, 32 amperes, 32 amperes, and 8 amperes respectively. On the other hand, the convection oven 40 takes three time units to cook cookies, and the currents drawn during the first to third time units are 28 amperes, 16 amperes, and 16 amperes respectively.

[0124]

[0125] Table Ⅰ

[0126] In this example, the convection oven 40 can start cooking cookies in time unit 5 while the pizza is being cooked in the impact oven 20. This is because if the cookies were to start cooking in any of the time units 1 - 4 instead of time unit 5, the current drawn by the two ovens and the auxiliary components would exceed the limit of 50 amperes.

[0127] V. Uniform Operating Steps for Operator

[0128] The operating procedures for all the ovens within the modular cooking appliance 10 are the same.

[0129] For this embodiment, the modular cooking appliance 10 enters the operating mode when the oven startup is completed. During this period, each of the impact oven 20, the convection oven 40, and the microwave oven 60 preheats to their preset operating temperatures. Once in the operating mode, a list of various food items for which the operating parameters have been input via the control panel 17 is displayed on the control panel 17. The operator can select the food item to be cooked from the items displayed on the control panel 17 and place the food on the food loading mechanism of the corresponding oven. Then, the food is conveyed into the heated oven cavity for cooking.

[0130] After the cooking process has been completed, the cooked food is conveyed back from the oven cavity to where the food entered the associated oven. The food loading mechanism itself is not heated and the cooking process effectively ends once the food leaves the heated oven cavity. However, since the food loading mechanism is adjacent to the heated oven cavity contained within the interchangeable cooking modules 12a - 12c, the residual heat from the heated oven cavity contained within the interchangeable cooking modules 12a - 12c is used to reduce the rate of heat loss experienced by the most recently cooked food.

[0131] Food items can be cooked simultaneously in the impingement oven 20, the convection oven 40, and the microwave oven 60 of the modular cooking appliance 10. Similar food items can be cooked sequentially in the impingement oven 20, the convection oven 40, and the microwave oven 60 of the modular cooking appliance 10. For example, pizzas can be cooked back - to - back in the impingement oven 20, while cinnamon rolls are cooked back - to - back in the convection oven 40, and breakfast sandwiches are cooked back - to - back in the microwave oven 60. When the modular cooking appliance 10 is powered by a circuit with a wattage no greater than that of a typical single - phase 50 - ampere outlet, to make the amount of thermal energy transferred to similar food items cooked sequentially in the various ovens the same for each back - to - back cooking, the volume of the cooking cavity maintained within the interchangeable cooking modules 12a - 12c is no greater than 1.5 cubic feet for the convection oven, no greater than 1.25 cubic feet for the impingement oven, and no greater than 1 cubic foot for the microwave oven.

[0132] As described above, the present invention provides a modular cooking appliance having multiple ovens.

[0133] Although the present invention has been specifically shown and described with reference to preferred embodiments, those skilled in the art will understand that various changes in form and detail may be made without departing from the spirit and scope of the invention.

Claims

1. A modular cooking device, characterized in that, Comprising: A housing having a first interchangeable cooking module and a second interchangeable cooking module; A first oven received within the first interchangeable cooking module; The first oven having a first cooking chamber; A first grease shield located within the first cooking chamber; The first grease shield configured to prevent grease from food from contacting multiple walls of the first cooking chamber; The first grease shield including a first wall, a second wall, and a rear wall, an interior angle between the first wall and the rear wall of the first grease shield being greater than 90° and less than or equal to 105°; A second oven received within the second interchangeable cooking module, wherein the second oven is different from the first oven; A control panel on the housing for receiving cooking inputs; A controller within the housing for controlling the first interchangeable cooking module and the second interchangeable cooking module; And A single power plug for receiving power from a wall-mounted power outlet.

2. The modular cooking device according to claim 1, characterized in that, An interior angle between the second wall and the rear wall of the first grease shield is greater than 90° and less than or equal to 105°.

3. The modular cooking device according to claim 1, characterized in that, One of the first wall, the second wall, and the rear wall of the first grease shield includes a plurality of openings for return air to pass through.

4. The modular cooking device according to claim 1, characterized in that, The modular cooking device further includes a second grease shield; the second oven has a second cooking chamber; the second grease shield is located within the second cooking chamber; The second grease shield configured to prevent grease from food from contacting multiple walls of the second cooking chamber; The second grease shield including a first wall, a second wall, and a rear wall, an interior angle between the first wall and the rear wall of the second grease shield being greater than 90° and less than or equal to 105°; 5. The modular cooking device according to claim 4, wherein An interior angle between the second wall and the rear wall of the second grease shield is greater than 90° and less than or equal to 105°.

6. The modular cooking device according to claim 4, characterized in that One of the first wall, the second wall, and the rear wall of the second grease shield includes a plurality of openings for return air to pass through.

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