Cooking system

Abstract

The present invention relates to a cooking system, the cooking system comprising: a housing having a hollow interior; a heating element, which can be used for heating to the hollow interior; a food support surface, the food support surface being disposed within the hollow interior; and a combustible substrate module, the combustible substrate module being removably positioned in the housing. When positioned in the housing, the combustible substrate module is disposed in fluid communication with the hollow interior, and the combustible substrate module is disposed away from the food support surface.

Description

[0001] This application is a divisional application of Chinese invention patent application No. 202110235340.2, filed on March 3, 2021, entitled "Cooking System". Technical Field

[0002] Embodiments of this disclosure generally relate to a cooking system, and more specifically, to a smoking module for transferring smoky flavors to one or more foods being cooked in the cooking system. Background Technology

[0003] Smoking in culinary applications can impart desired flavors to one or more foods. Existing systems for achieving this flavor include stand-alone smokers. However, these devices are bulky and expensive. To smoke food using a stand-alone smoker, users must have sufficient space to store and operate it. Furthermore, many users may only want to smoke food occasionally. Therefore, owning such a device may be economically or physically impractical if it is only used intermittently.

[0004] 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 countertop cooking appliances. Summary of the Invention

[0005] According to an embodiment, a 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 matrix module removably positioned within the housing. When positioned within the housing, the combustible matrix module is arranged in fluid communication with the hollow interior and is disposed remotely from the food support surface.

[0006] In addition to one or more of the features described above, or as an alternative, in another embodiment, the housing also includes a base and a cover, in which the combustible matrix module is removably positioned.

[0007] In addition to one or more of the features described above, or as an alternative, in another embodiment, an ignition source disposed within the housing is included, wherein the ignition source is operatively coupled to an ignition zone of the combustible matrix module when the combustible matrix module is positioned within the housing.

[0008] In addition to one or more of the features described above, or as an alternative, in another embodiment, the ignition source is separate from the heating element.

[0009] In addition to one or more of the features described above, or as an alternative, in another embodiment, the heating element is the ignition source.

[0010] In addition to one or more of the features described above, or as an alternative, in another embodiment, the portion of the combustible matrix module is separated from the ignition source by a certain gap.

[0011] In addition to one or more of the features described above, or as an alternative, in another embodiment, a radiation shielding element is included, disposed between the ignition source and the combustible matrix module, the radiation shielding element having an opening located directly adjacent to the ignition zone of the combustible matrix module.

[0012] In addition to or as an alternative to one or more of the features described above, in another embodiment, the cooking system further includes a lid movable relative to the housing, the combustible matrix module being associated with the lid, and at least one of the ignition sources being disposed within the lid.

[0013] In addition to one or more of the features described above, or as an alternative, in another embodiment, the cooking system further includes an air movement mechanism associated with the hollow interior, and the combustible matrix module is arranged radially outward and downstream of the outlet of the air movement mechanism.

[0014] In addition to one or more of the features described above, or as an alternative, in another embodiment, the combustible matrix module further includes a body comprising a hollow interior having at least one compartment.

[0015] In addition to one or more of the features described above, or as an alternative, in another embodiment, at least one partition is included, arranged within the hollow interior to define the first and second compartments.

[0016] In addition to one or more of the features described above, or as an alternative, in another embodiment, the partition includes a plurality of openings such that the first compartment and the second compartment are arranged in fluid communication via the plurality of openings.

[0017] In addition to one or more of the features described above, or as an alternative, in another embodiment, the combustible matrix module further includes a cover movable relative to the body to selectively close the hollow interior.

[0018] According to an embodiment, a combustible matrix module for an electric cooking system includes a body having at least one ignition 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. The first compartment is configured to generate a first amount of smoke, and the second compartment is configured to generate a second amount of smoke greater than the first amount of smoke.

[0019] In addition to one or more of the features described above, or as an alternative, in another embodiment, the configuration of the first compartment is selected to generate smoke for a duration of less than or equal to about 20 minutes.

[0020] In addition to or as an alternative to one or more of the features described above, in another embodiment, the configuration of the second compartment is selected to generate smoke continuously for at least one hour.

[0021] In addition to one or more of the features described above, or as an alternative, in another embodiment, the configuration of the second compartment is selected to generate smoke for up to two hours.

[0022] In addition to one or more of the features described above, or as an alternative, in another embodiment, at least one dimension of the first compartment is different from at least one dimension of the second compartment.

[0023] In addition to one or more of the features described above, or as an alternative, in another embodiment, the length of the first compartment is less than the length of the second compartment.

[0024] In addition to one or more of the features described above, or as an alternative, in another embodiment, 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.

[0025] In addition to one or more of the features described above, or as an alternative, in another embodiment, the at least one ignition opening is formed in the body adjacent to the first compartment.

[0026] In addition to one or more of the features described above, or as an alternative, in another embodiment, the at least one ignition opening is formed in the body at a height above the second compartment.

[0027] In addition to one or more of the features described above, or as an alternative, in another embodiment, the first compartment and the second compartment are separated by a partition.

[0028] In addition to one or more of the features described above, or as an alternative, in another embodiment, the partition has multiple openings such that the first compartment and the second compartment are arranged in fluid communication.

[0029] According to an embodiment, a cooking system includes: a housing having a hollow interior; a combustible matrix module removably positioned within the housing and containing a combustible material; and an ignition source disposed within the hollow interior and operatively coupled to the combustible matrix module. Operation of the ignition source is controlled in response to the state of the combustible material.

[0030] In addition to one or more of the features described above, or as an alternative, in another embodiment, the ignition source is de-energized in response to determining that the combustible material within the combustible matrix module has been ignited.

[0031] In addition to one or more of the features described above, or as an alternative, in another embodiment, a sensor is included that can be used to determine when the combustible material is ignited, wherein the operation of the ignition source is controlled in response to the sensor.

[0032] In addition to one or more of the features described above, or as an alternative, in another embodiment, the sensor is a temperature sensor.

[0033] In addition to one or more of the features described above, or as an alternative, in another embodiment, the sensor is positioned relative to the combustible matrix module to distinguish between heat generated by the ignition source and heat generated by the ignited combustible material.

[0034] In addition to one or more of the features described above, or as an alternative, in another embodiment, the sensor is located inside the combustible matrix module.

[0035] In addition to one or more of the features described above, or as an alternative, in another embodiment, the ignition source is energized in response to determining that the combustible material within the combustible matrix has been completely burned.

[0036] In addition to one or more of the features described above, or as an alternative, in another embodiment, the ignition source is a heating element that can be used to heat the hollow interior.

[0037] In addition to one or more of the features described above, or as an alternative, in another embodiment, a heating element different from the ignition source is included, wherein the operation of the heating element is controlled in response to the state of the combustible material.

[0038] In addition to one or more of the features described above, or as an alternative, in another embodiment, the heating element is energized in response to determining that the combustible material within the combustible matrix module has been ignited.

[0039] In addition to one or more of the features described above, or as an alternative, in another embodiment, the heating element is energized in response to determining that the combustible material within the combustible matrix has been completely burned.

[0040] In addition to one or more of the features described above, or as an alternative, in another embodiment, the housing also includes a base and a cover, with the heating element disposed within the base.

[0041] In addition to one or more of the features described above, or as an alternative, in another embodiment, the housing also includes a base and a cover, with the heating element disposed within the cover.

[0042] In addition to one or more of the features described above, or as an alternative, in another embodiment, an air movement device is included, which is controlled in response to the state of the combustible material.

[0043] In addition to one or more of the features described above, or as an alternative, in another embodiment, the air movement device is rotated in response to determining that the combustible material within the combustible matrix module has been ignited.

[0044] According to an embodiment, a cooking system includes: a housing having a hollow interior; a combustible matrix module removably positioned within the housing and containing combustible material; and an ignition source disposed within the hollow interior and operatively coupled to the combustible matrix module. An air movement device is disposed within the hollow interior. The operation of the air movement device is controlled in response to the state of the combustible material.

[0045] In addition to one or more of the features described above, or as an alternative, in another embodiment, the air movement device is energized in response to determining that the combustible material within the combustible matrix module has been ignited.

[0046] In addition to one or more of the features described above, or as an alternative, in another embodiment, a sensor is included that can be used to determine when the combustible material is ignited, wherein the operation of the air-moving device is controlled in response to the sensor.

[0047] In addition to one or more of the features described above, or as an alternative, in another embodiment, the sensor is a temperature sensor.

[0048] In addition to one or more of the features described above, or as an alternative, in another embodiment, the sensor is positioned relative to the combustible matrix module to distinguish between heat generated by the ignition source and heat generated by the ignited combustible material.

[0049] In addition to one or more of the features described above, or as an alternative, in another embodiment, the sensor is located inside the combustible matrix module.

[0050] In addition to or as an alternative to one or more of the features described above, in another embodiment, the operation of the air movement device is controlled to regulate the combustion rate of the combustible material.

[0051] In addition to one or more of the features described above, or as an alternative, in another embodiment, the rotational speed of the air-moving device is controlled to regulate the combustion rate of the combustible material.

[0052] In addition to or as an alternative to one or more of the features described above, in another embodiment, the rotational speed of the air-moving device is increased to accelerate the combustion rate.

[0053] In addition to one or more of the features described above, or as an alternative, in another embodiment, the rotational speed of the air-moving device is reduced to slow down the combustion rate. Attached Figure Description

[0054] The following description should not be considered limiting in any way. Referring to the accompanying drawings, similar elements are numbered the same:

[0055] Figure 1 This is a perspective view of a smoking module for an electric cooking system according to an embodiment;

[0056] Figure 2 According to the embodiments Figure 1 Another perspective view of the smoked module;

[0057] Figure 3 This is a perspective view of a cooking system according to an embodiment;

[0058] Figure 4 According to the embodiments Figure 3 Cross-sectional view of the cooking system; and

[0059] Figure 5 This is a schematic diagram of a cooking system according to an embodiment;

[0060] Figure 6 This is a perspective view of the lid of the cooking system according to an embodiment;

[0061] Figure 7 A perspective view of the lid of a cooking system having a combustible substrate module installed therein, according to an embodiment; and

[0062] Figure 8 This is a schematic diagram of the control system of the cooking system according to an embodiment. Detailed Implementation

[0063] This article references examples rather than limitations. Figures 1 to 8 A detailed description of one or more embodiments of the disclosed apparatus and methods is provided.

[0064] Now for reference 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 a first side wall 36 and a second side wall 38 connected to the base 24 and extending between the first end wall 26 and the second end wall 30. In the illustrated embodiment, the first side wall 34 and the second side wall 36 are arranged generally parallel to each other; however, embodiments with different configurations and orientations of the walls are also within the scope of this disclosure.

[0065] The body 22 may have a shape complementary to a portion of the cooking system configured to receive module 20. In embodiments, module 20 may be positioned adjacent to a generally circular component of the cooking system, which will be described in more detail below. For example, in the non-limiting embodiment shown, a first sidewall 34 of the component configured to face and / or contact the cooking system has a generally arcuate profile. Thus, the first endwall 26 is arranged at an angle to the second endwall 30. Although the body 22 is shown to have a curvature of less than 90 degrees, embodiments with a curvature of 90 degrees (and therefore embodiments where endwalls 26, 30 are generally perpendicular to each other), as well as embodiments where the curvature of the body 22 is greater than 90 degrees, are also within the scope of this disclosure. Furthermore, it should be understood that embodiments in which the body 22 has a module 20 in another configuration are also covered herein.

[0066] The base 24, end walls 26, 30, and side walls 34, 36 cooperate to define a hollow cavity 38. One or more partitions 40 may be arranged within the cavity 38 to divide it into multiple distinct compartments. In the illustrated non-limiting embodiment, a single partition 40 is arranged within the cavity 38 to form two compartments 42, 44; however, it should be understood that in other embodiments, two or more partitions 40 may be located within the cavity 38 to form three or more compartments. In the illustrated non-limiting embodiment, the partitions 40 are formed of a material having one or more openings 45 therein, such as a mesh or stamped sheet of metal. Thus, the compartments 42, 44 disposed on opposite sides of the partitions 40 are arranged to be in fluid communication with each other via one or more openings 45. However, embodiments in which at least one partition 40 is at least partially formed of a solid material such that adjacent compartments 42, 44 are not in fluid communication are also within the scope of this disclosure.

[0067] In an embodiment, one of the compartments of the module, such as the first compartment 42, is configured to produce smoky smoke. As used herein, the term "smoky smoke" is intended to describe smoke used in conjunction with high-temperature grilling to infuse the food being cooked with smoky aromas and flavors. This smoky smoke is configured to impart flavor to the food in a manner similar to conventional grilling. Alternatively or additionally, one of the compartments of module 20, such as the second compartment 44, is configured to produce low-temperature slow-smoky smoke. As used herein, "low-temperature slow-smoky smoke" is smoke used for slow cooking of food and for a longer duration (e.g., at least 30 minutes and up to about 2 hours). This low-temperature slow-smoky smoke is intended to achieve a rich, meaty flavor, similar to food cooked using a barbecue grill.

[0068] Therefore, the configuration of the multiple compartments 42, 44 can vary based on the smoke expected to be generated within the compartments 42, 44. For example, one or more dimensions of the compartments 42, 44 can vary. In an 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, located adjacent to the first end wall 26, has a first height, and the second compartment 44, located adjacent to the second end wall 30, has a second height less than the first height. Therefore, 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 side walls 34, 36 varies between the first end wall 26 and the second end wall 30. In an embodiment, the height of the side walls varies such that each compartment 42, 44 has a substantially constant height along its length. Alternatively or additionally, the length of the compartments 42, 44 can vary. In an 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 of varying widths of the compartments 42, 44 are also covered herein.

[0069] In an embodiment, 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% larger 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% larger. This larger volume is intended to store a sufficient amount of matrix to produce smoke lasting 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 this disclosure. In an embodiment, the volume of the first compartment 42 is about 30 mL or about 1 / 8 cup.

[0070] Module 20 may include a cover 46 that can be attached to the surface of body 22 to close an entrance to the interior cavity 38 of body 22. In embodiments where the upper surface 48 of body 22 has a non-planar configuration, for example due to variations in the height of compartments 42, 44, the profile of cover 46 may be designed to cover and, in some embodiments, contact the entire upper surface 48 of body 22. Furthermore, cover 46 may be substantially solid, such that fluid is not configured to flow from the interior cavity 38 of body 22 through cover 46. However, in embodiments, one or more openings 50 may be formed in cover 46. Openings 50 may be located adjacent to only a portion of a compartment formed within body 22 (e.g., a second compartment 44), or alternatively, adjacent to each compartment of body 22.

[0071] The cover 46 can be in an open position relative to the main body 22 in compartments 42 and 44 that are accessible or open. Figure 2 ) and the selectively covered closed position of the inner cavity 38 ( Figure 1 The cover 46 may be different from and separable from the body 22, or alternatively, movably connected to the body 22. Figure 2 In the non-limiting embodiment shown, the cover 46 may pivot or rotate relative to the body 22 about pivot P. However, other types or movements of the cover 46 are also within the scope of this disclosure. In embodiments, the cover 46, such as the end 52 of the cover 46 opposite the hinge, includes a connector 54 configured to cooperate with an engagement feature 54 formed in the body 22 to limit movement of the cover 46 relative to the body 22 when in the closed position.

[0072] In one embodiment, the ignition zone or region 56 is formed on a portion of the body 22, specific only to one of the compartments of the body 22. Therefore, the initial ignition of the contents of the module 20 is isolated to a single compartment of the body 22. In this embodiment, the ignition zone 56 is not formed in the sidewalls 34, 36 at a height shared by the two compartments 42, 44. Instead, in Figure 1In the best-illustrated, non-limiting embodiment, the ignition zone 56 is formed in the first sidewall 34 adjacent to the first compartment 42, at a height higher than the second compartment 44. Additionally, a plurality of ignition openings 58 are formed in the ignition zone 56 of the body 22. The ignition openings 58 may be substantially identical, or alternatively, their size may vary. Furthermore, ignition openings located throughout the entire ignition zone 56 may be formed only in a portion of the ignition zone 56. In one embodiment, the ignition zone 56 is formed of a mesh material attached to or integrated into the body 22. However, in other embodiments, the ignition openings 58 are formed into (e.g., stamped or perforated into) the material of the 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 matrix 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 separator 40 to heat and ignite the contents of the second compartment 44.

[0073] At least one other surface of the body 22, such as the opposing sidewall 36 and / or the second endwall 30, has a plurality of outlet holes 60 formed therein. The outlet holes 60 may 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 endwall 30. However, any suitable configuration of the outlet holes 60 is within the scope of this disclosure. The total number of outlet holes 60 may generally be less than the total number of ignition openings 58, and in some embodiments, the size of the outlet holes 60 is larger than the size of the ignition openings 58. The outlet holes 60 are configured to partially block airflow through the body 22 to prevent rapid combustion of the material within the module. However, the configuration of the outlet holes 60 must be sufficient to prevent complete blockage of airflow, which would result in a portion of the contents of the module 20 not burning or igniting.

[0074] In one embodiment, the combustible matrix module 20 is suitable for use with the electric cooking system 100, for example, it can be positioned on a countertop in at least one cooking mode. Figure 3 and 4 An example of the cooking system 100 is shown in more detail below. As shown, the cooking system 100 includes a base 102 and a cover 104. The base 102 includes a housing 106, which is made of any suitable material (e.g., glass, aluminum, plastic, or stainless steel). A liner 108 may be disposed within the hollow interior 110 of the housing 106. The liner 108 may be formed of any suitable conductive material (e.g., aluminum). In an embodiment, the liner 108 forms the inner surface of the housing 106, thereby defining the hollow interior 110 of the housing 106. Alternatively, the liner 108 may be offset from the inner surface of the housing 106. However, it should be understood that the cooking system 100 or other components of its surface may also define the hollow interior 110.

[0075] In an embodiment, the cooking container 112 may be received within the hollow interior 110 of the housing 106. While the cooking container 112 is described herein as 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 covered herein. The cooking container 112 has an interior 114 designed to receive and retain one or more consumer products therein, 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, fruits, and dairy products, etc. The cooking container 112 may be a pot formed of ceramic, metal, or die-cast aluminum material. 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 resin material. However, any suitable material capable of withstanding the high temperatures required for cooking food is covered herein. Furthermore, one or more handles (not shown) may 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.

[0076] One or more attachments or inserts 116 may be compatible with the cooking system 100. Examples of such attachments include, but are not limited to, scatterers, crisping inserts, baking pans, and sieves. In such embodiments, the insert may be received within the hollow interior 110 of the housing 106, or alternatively within the interior 114 of the cooking container 112.

[0077] Referring more closely to lid 104, it should be noted that lid 104 may be attached to the surface of cooking container 112 and / or housing 106 to close the entrance to the interior 114 of cooking container 112. Thus, the cooking volume can be defined between the interior 114 of cooking container 112 and the end of the closed lid 104, or between the hollow interior 110 defined by housing 106 and the end of the closed lid 104. In an embodiment, the diameter of lid 104 is substantially complementary to the diameter of housing 106, such that lid 104 covers not only cooking container 112 but also the upper surface 118 of housing 106.

[0078] 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 may be separate from and detachable from the base 102, or the lid 104 may be movably attached to the base 102. In the non-limiting embodiment shown, the lid 104 may pivot or rotate relative to the base 102 about a pivot axis P. However, other types of movement of the lid 104 are also within the scope of this disclosure. When the lid 104 is in the closed position, one or more fastening mechanisms (not shown) may, 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 considered within the scope of this disclosure.

[0079] The cooking system 100 includes at least one heating element operable to impart heat to the cooking volume during one or more operating modes of the cooking system 100. In the illustrated non-limiting embodiment, the heating element 120 is positioned generally at or above the upper portion 122 of the cooking container 112, for example, adjacent to the center of, for example, the interior 114 of the cooking container 112. As shown, at least one heating element 120 is mounted within the lid 104, thus entirely outside the cooking container 112, and vertically offset from its upper portion 122. Alternatively or additionally, the heating element 124 may be disposed within the housing 106, generally adjacent to the bottom 126 of the cooking container 112. However, it should be understood that embodiments in which the heating element is arranged at another location within the base 102 and / or the lid 104 are also contemplated herein.

[0080] At least one heating element 120, 124 is capable of generating heat of any suitable type. For example, heating elements 120, 124 configured to heat the cooking container 112 or one or more foods located within the interior 114 of the cooking container 112 via conduction, convection, radiation, and induction are all within the scope of this disclosure. In the non-limiting embodiment shown, the heating element 120 is operable to cook 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 not to come into direct or indirect contact with the food, such as, but not limited to, convection and radiation heating. In such embodiments, the cooking system 100 further includes an air movement mechanism 128, such as a fan, which is 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 at least one heating element 120. In the non-limiting embodiment shown, the air movement mechanism 128 is driven by a motor 130 having a separate cooling mechanism (not shown) coupled thereto.

[0081] 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 in which heat is transferred via direct or indirect contact between the heating element or heat source and the food, such as, but not limited to, conductive and inductive cooking. However, it should be understood that embodiments of the heating element 120 operable for contact cooking operations and embodiments of the heating element 124 operable for non-contact cooking operations are also within the scope of this disclosure.

[0082] Furthermore, in embodiments including heating elements 120 and 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 are capable of cooking food independently of the amount of food loaded. In other words, heating elements 120, 124 are capable of cooking food independently of the amount of food within the cooking container 112. Cooking operations that can be performed by the cooking system 100 include, but are not limited to, pressure cooking, steam cooking, slow cooking, searing, air frying, grilling, baking / roasting, dehydration, and grilling.

[0083] The combustible matrix module 20 may be mounted within the cooking system 100 at a location configured to circulate through the convective airflow path of the system 100 in response to the operation of the air movement mechanism 128. Alternatively, the combustible matrix module 20 may be positioned away from cooking surfaces, such as the surface of a baking pan, attachments arranged on the baking pan, or alternatively, the surface of the container 112. In the non-limiting embodiment shown, the module 20 may be positioned within the lid 104. However, it should be understood that embodiments in which the combustible matrix module 20 is mounted at another location relative to the cooking system 100 are also within the scope of this disclosure. The total axial height of at least a portion of the combustible matrix module 20 is selected such that, when the module 20 is mounted within the cooking system 100, the ignition zone of the module 56 is very close to or in contact with an ignition source, such as a heating element. As shown, a convective 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. Therefore, the curvature of at least the sidewall 34, including the ignition zone 56, facing the ignition source is complementary to the curvature of another component within the zone of the heating element 120 or the cover 104. This document also covers embodiments where the ignition source is separate from and distinct from the heating elements 120, 124 used to perform cooking operations.

[0084] Radiation shielding 132 is disposed between at least a portion of module 20 and the ignition source. Radiation shielding 132 is configured to isolate substantially all of module 20 from the ignition source, except for ignition zone 56, to prevent simultaneous ignition of the contents of one or more compartments 42, 44. Referring now... Figure 5 and 6An example of the radiation shield 132 is shown in more detail. In an embodiment, the radiation shield is a generally cylindrical or dome-shaped shield surrounding the outer periphery of the heating element. Thus, when the combustible matrix module 20 is mounted within the cover 104, the radiation shield 132 is arranged generally concentrically between the ignition source and the sidewall 34 of the module 20. An opening 134 is formed in the portion of the radiation shield 132 directly adjacent to the ignition zone 56 of the module 20 to allow heat from the ignition source to flow through the ignition zone 56 and into the first compartment 42 of the module 20. In an embodiment, the radiation shield 132 further includes a member 136 projecting from one side of the cylindrical wall toward the module 20. As shown, the member 136 may be configured to extend over the second compartment 44 of the 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.

[0085] The cooking system 100 may include a temperature sensor 140 operatively coupled to a controller 156. The temperature sensor 140 may be associated with a combustible matrix module 20 and may be used to detect when the matrix within the module 20 is burning and thus producing smoke. In an embodiment, the temperature sensor 140 is arranged to contact a portion of the module 20 (e.g., its sidewall). However, the temperature sensor 140 may be located at any suitable location where the sensor 140 can detect matrix combustion in any compartment of the module 20. Additionally, the temperature sensor 140 is positioned within the cooking system 100 such that it can distinguish between heat generated by an ignition source and heat generated by matrix combustion within the 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 this disclosure. Furthermore, the cooking system 100 may additionally include a sensor 142, such as a reed switch, operatively coupled to the controller 156. In such embodiments, sensor 142 can be used to detect the presence of the combustible matrix module when the combustible matrix module 20 is installed inside the cooking system 100.

[0086] To use the combustible matrix module 20, the contents of one or more of the compartments 42, 44 of 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 leguminous shrubs, including sawdust, wood chips, pellets, sawdust, and charcoal. Once filled, module 20 is installed within the cooking system 100 adjacent to an ignition source. Module 20 can be installed within the cooking system 100 via any suitable mechanism. For example, in an embodiment, module 20 can be connected to another portion of radiation shield 132 or cover 104 via a snap-fit ​​connection.

[0087] To perform cooking operations using system 100, the user selects one of the aroma-related input 150 and the low-temperature slow-smoking input 152 via the user interface 154 of cooking system 100. For aroma-related applications, only the first compartment 42 of the combustible matrix module 20 is filled with combustible material. However, for low-temperature slow-smoking applications, both the first compartment 42 and the second compartment 44 are filled with such material. These compartments 42 and 44 may be filled with the same material, or alternatively, with different materials.

[0088] After a cooking operation has been selected, the ignition source for combustion within the start module 20 is energized. In embodiments where the cooking system 100 includes a dedicated ignition heater separate from the cooking heating elements 120, 124, the ignition heater is selectively activated during the preheating phase of the cooking operation in response to, for example, detection of the module within the cooking system 100 by sensor 142. Once activated, the ignition heater is energized until temperature sensor 140 detects that the material within module 20 has ignited. Therefore, in response to the detection of ignition, controller 156 stops supplying energy to the ignition source. Furthermore, in embodiments, the ignition heater will not be energized after the preheating phase of the cooking operation, regardless of whether sensor 142 has detected ignition of the material within module 20.

[0089] 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 reach a temperature sufficient to ignite the material within the first compartment 42, and then reduce 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 ignite the material within module 20.

[0090] In response to the application of heat, the contents of compartment 42 will ignite and thus produce smoke. Once the ignition source is powered on, heat will penetrate through the ignition source and enter the first compartment. The smoke produced by the combustion material is configured to penetrate through outlet holes 60 formed in the combustion material and flow into the interior 114 of the cooking container 112 or into the cooking volume containing one or more foods.

[0091] For aroma-smoking operations, once the material in the first compartment 42 has been ignited, it will continue to burn during the selected cooking operation. It should be understood that any of the heating elements 120, 124 and / or the air movement mechanism 128 may be energized during the selected cooking operation. In embodiments, during aroma-smoking operations, the contents of the 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 duration of smoke production from the material in the first compartment 42 will vary based on the selected cooking temperature and the food being cooked.

[0092] In embodiments where the user has selected a low-temperature slow-smoking 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 these embodiments, the ignition of the material in the second compartment 44 can occur very rapidly, such that the ignition of the material in both compartments 42, 44 can be considered to occur substantially simultaneously. However, embodiments in which the ignition delay of the material in the second compartment 44 is related to the ignition of the material in the first compartment 42 are also covered herein. In such embodiments, the material in the first compartment 42 and the material in the second compartment 44 are ignited sequentially. Once ignition is detected, for example, by a temperature sensor 142, in module 20, operation of the air movement mechanism 128 is initiated. Rotation of the air movement mechanism 128 about its axis circulates air in and out of the cooking volume. In these embodiments, the air output from the air movement mechanism 128 is configured to flow through or around the combustible matrix module 20. Due to this airflow, a portion of the smoke inside or permeating out of the combustible matrix module 20 can be drawn in or entrained in the airflow configured to circulate around the outer surface of the food within the cooking system 100.

[0093] In one embodiment, the air movement mechanism 128 is configured to rotate at a low speed. A controller 156 operatively coupled to the air movement mechanism 128 may be configured to control the speed of the air movement mechanism 128 to adjust the combustion rate of the material within the module 20, for example, in response to a temperature detected by the sensor 140. For example, when the fan speed increases, the additional oxygen supplied to the interior of the module 20 increases the combustion temperature, and when the fan speed decreases or stops, the oxygen inside the module 20 decreases, thereby reducing the combustion temperature. The fan speed may vary between two or more speeds during low-temperature slow smoking operations to prolong the combustion time of the contents of the module 20 as much as possible while generating sufficient heat to achieve the desired cooking result. In one embodiment, the temperature of the smoke generated during low-temperature slow smoking operations is between 200°F and 250°F.

[0094] During operation, temperature sensor 140 can be used to detect when the material within module 20 has been completely burned. For example, if sensor 140 fails to detect heat associated with the burning of the material within module 20 even when the fan speed is increased, it can be determined that all the burning material within module 20 has been extinguished.

[0095] The low-temperature slow-smoke operation can be combined with another cooking operation of the cooking system 100. In such embodiments, another cooking operation can be initiated once the sensor 142 has determined that the material within module 20 has been completely extinguished. For example, once the cooking system 100 has detected that the material within module 20 is no longer producing smoke, a convection cooking operation using heating element 120 and air movement mechanism 128 can be automatically initiated. This secondary cooking operation can be performed for a set amount of time, to complete the cooking of the food, or to bring the food to 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 module 20 can be discarded.

[0096] As shown and described herein, the cooking system 100, configured to receive the combustible matrix module 20, is configured to enhance various flavors achievable via the cooking system. Furthermore, different types of flavors can be imparted to food based on the type of smoke generated within the compartments 42, 44 of the combustible matrix module 20. Therefore, the cooking system 100 provides an enhanced user experience.

[0097] The term “about” is intended to include the degree of error associated with measurements of a specific quantity of equipment available at the time of application submission.

[0098] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit this disclosure. As used herein, the singular forms “a,” “an,” and “described” are also intended to include the plural forms unless the context clearly indicates otherwise. It will be further understood that, when used in this specification, the term “comprises and / or comprising” specifies the presence of the stated features, integers, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0099] While this disclosure has been described with reference to one or more exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from the scope of this disclosure. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the basic scope of this disclosure. Therefore, it is intended that this disclosure be limited to the specific embodiments disclosed as the best mode for carrying out this disclosure, but rather that this disclosure will include 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, the food support surface being disposed within the hollow interior; A combustible matrix module, wherein the combustible matrix module can be removably positioned within the housing; An ignition source is disposed within the housing, wherein when the combustible matrix module is positioned within the housing, the ignition source is operatively connected to the ignition zone of the combustible matrix module; as well as A radiation shielding element is disposed between the ignition source and the combustible matrix module, the radiation shielding element having an opening located directly adjacent to the ignition zone of the combustible matrix module; When the combustible matrix module is positioned within the housing, the combustible matrix module is arranged to be in fluid communication with the hollow interior, and When the combustible matrix module is positioned within the housing, the combustible matrix module is arranged to be away from the food support surface.

2. The cooking system of claim 1, wherein the housing further comprises a base and a cover, the combustible matrix module being removably positioned within the cover.

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

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

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

6. The cooking system of claim 1, wherein the combustible matrix module further comprises a body, the body comprising a hollow interior having at least one compartment.

7. The cooking system of claim 6, further comprising at least one partition disposed within the hollow interior of the body to define a first compartment and a second compartment, the partition including a plurality of openings such that the first compartment and the second compartment are arranged in fluid communication via the plurality of openings.

8. A cooking system, comprising: A housing having a hollow interior; A combustible matrix module, which is removably positioned within the housing, and which contains combustible material; An ignition source, wherein the ignition source is disposed within the hollow interior and is operatively connected to the combustible matrix module; as well as A sensor, operable to determine when to ignite the combustible material, wherein the operation of the ignition source is controlled in response to the sensor.

9. The cooking system of claim 8, wherein the ignition source is de-energized in response to determining that the combustible material within the combustible matrix module has been ignited.

10. The cooking system of claim 8, wherein the ignition source is energized in response to determining that the combustible material within the combustible matrix module has been completely burned.

11. The cooking system of claim 8, further comprising a heating element different from the ignition source, wherein the operation of the heating element is controlled in response to the state of the combustible material.

12. The cooking system of claim 11, wherein the heating element is energized in response to determining that the combustible material within the combustible matrix module has been ignited.

13. The cooking system of claim 11, wherein the heating element is energized in response to determining that the combustible material within the combustible matrix module has been completely burned.

14. The cooking system of claim 9, further comprising an air movement device controlled in response to the state of the combustible material.

15. A cooking system, comprising: A housing having a hollow interior; A heating element, operable to heat the hollow interior; A food support surface, the food support surface being disposed within the hollow interior; A combustible matrix module, the combustible matrix module being removably positioned within the housing, the combustible matrix module further comprising a body having a hollow interior having at least one compartment; as well as At least one partition is disposed within the hollow interior of the body to define a first compartment and a second compartment, the partition including a plurality of openings such that the first compartment and the second compartment are arranged in fluid communication via the plurality of openings; When the combustible matrix module is positioned within the housing, the combustible matrix module is arranged to be in fluid communication with the hollow interior of the housing, and When the combustible matrix module is positioned within the housing, the combustible matrix module is arranged to be away from the food support surface.

16. The cooking system of claim 15, wherein the housing further comprises a base and a cover, the combustible matrix module being removably positioned within the cover.

17. The cooking system of claim 15, further comprising an ignition source disposed within the housing, wherein the ignition source is operatively connected to an ignition zone of the combustible matrix module when the combustible matrix module is positioned within the housing.

18. The cooking system of claim 17, further comprising a radiation shield disposed between the ignition source and the combustible matrix module, the radiation shield having an opening positioned directly adjacent to the ignition zone of the combustible matrix module.

19. The cooking system of claim 17, wherein the ignition source is separate from the heating element.

20. The cooking system of claim 15, wherein the cooking system further comprises an air movement mechanism associated with the hollow interior of the housing, and the combustible matrix module is arranged radially outward and downstream of the outlet of the air movement mechanism.

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