Non-stick 3D oven liner insert

Abstract

An oven liner for placement within an oven cavity during cooking. The oven liner includes non-adherent sections corresponding to the top, bottom, and / or sides of the oven cavity. The liner is made of a non-adherent material and is easily removable for cleaning. The liner sections can be attached to the oven cavity with clips. The liner sections, such as those having a bottom section corresponding to the oven bottom and at least one side section extending from the bottom section and corresponding to the oven sidewall, can be connected to each other with a material hinge.

Description

[Technical Field]

[0001] The present invention is directed to heat-resistant polymeric materials and product uses thereof, and more particularly to oven liners for placement within an oven to protect the oven cavity and otherwise improve cleaning of the oven cavity. Summary of the Invention

[0002] A general object of the present invention is to provide an improved liner insert for lining / covering oven cavity surfaces and / or heating elements. The present invention provides a rigid, easily cleanable, fast heat dissipating, microwave transparent alternative to traditional metal oven structural components. The liner insert is rigid enough to protect multiple oven components as needed. If soiled, the liner insert is designed to be removed, cleaned (rinsed and wiped), and reinstalled.

[0003] One object of the present invention is to provide improved non-stick materials and products thereof, such as oven liners, particularly for use in high-speed ovens, quick-cook ovens, and / or conventional ovens. Embodiments of the present invention provide easy placement and removal in and from the oven; cover at least one, preferably two, and more preferably multiple surfaces (such as the bottom, sides, or oven racks) within the oven; cool quickly, do not retain heat (e.g., are largely or completely metal-free), and can withstand temperatures in excess of 375°F (191°C), more preferably up to 500°F (260°C), indefinitely. In embodiments, all components, including any mounting fasteners / connectors, are made from the same material and are also metal-free.

[0004] Another general object of the present invention is to provide a non-stick, reusable oven liner that includes at least a polymeric surface. The liner layers and / or surfaces can be formed of a "non-stick" polymer, can include a non-stick additive as part of the polymer matrix, can be dipped or spray coated with a non-stick polymer, and / or can be covered with a removable non-stick polymer surface insert. A variety of polymers are available for these applications.

[0005] Exemplary non-stick surface polymeric materials according to embodiments of the present invention include melt-processible fluoropolymers such as perfluoroalkoxyalkanes (PFA), TFE / perfluoromethylvinylether copolymers (MFA), or fluorinated ethylene propylene (FEP). Additionally, blends of fluoropolymers such as MFA, PFA, FEP, ECTEF, and PTFE, as well as non-stick silicone-containing materials, can also be utilized.

[0006] Embodiments of the present invention include improved woven / polymer / non-stick laminate materials that have structural advantages and can be pressed or otherwise molded in a forming process to provide a molded oven liner. Exemplary polymers for these embodiments include engineering resins. These are typically resins blended with fluoropolymers and / or silicones. Because incorporating fluoropolymers or silicones generally precludes the structural use of engineering resins, these engineering resins are used for barrier or wear rather than structure. The composite materials of the present invention can incorporate 100% engineering resin until the woven glass substrate is fully saturated, allowing the engineering resin to solidify and create the structural component during molding. Another feature is that the present invention combines 100% engineering resin with a non-stick material such as a fluoropolymer or silicone, resulting in good bond strength.

[0007] All embodiments of the present invention may include or be formed with a composite layer including a flexible substrate impregnated with a heat-resistant polymeric material and coated with a non-stick coating, which has structural rigidity when cured. The composite can be pressed or molded into a predetermined configuration before or during curing, and retains that predetermined configuration with structural rigidity when cured. One preferred predetermined configuration is an oven liner having a bottom and vertical wings for covering the oven sidewalls, or a flat oven liner with foldable wings for placement within the oven. Surface contours within the oven can be pressed into the liner during manufacture. Further embodiments of the present invention include a back wall cover and / or a top wall cover that can be integrally attached to the bottom and / or sides or can be attached separately.

[0008] Embodiments of the invention include surface coatings, such as those applied by spray coating or dip coating, or as films or coated fabrics. In further embodiments of the invention, the surface is first dip or spray coated and then coated / laminated with, for example, a cast or laminated film or coated fabric of one or more of a silicone material and / or a fluoropolymer, such as a melt-processible fluoropolymer or a blend of PTFE and a melt-processible fluoropolymer. Spray coatings, cast films, and the like desirably interlock together during cure, thereby providing a stronger bond to the underlying cookware surface.

[0009] The present invention includes an oven liner for placement within an oven cavity during cooking, the oven liner including at least one side section corresponding to an oven sidewall.

[0010] In an embodiment of the invention, the liner further includes a bottom section corresponding to the oven bottom, with at least one side section extending from the bottom section.

[0011] An embodiment of the present invention includes a multi-layer tri-fold oven liner / cavity insert made from multiple individual laminate layers, such as coated / impregnated flexible materials, that are pressed under heat to form the final rigid laminate liner.

[0012] The present invention also includes an oven liner or insert for placement within an oven cavity during cooking. The oven liner or insert includes a bottom section corresponding to the oven bottom and at least one side section extending from the bottom section to correspond to the oven sidewall. Preferably, the liner includes two side sections, one on each side of the bottom section. The side sections are desirably connected to the bottom section by fold hinges formed by weakened portions / perforations or reduced laminate / layer thicknesses, etc. In embodiments, the reduced thickness is formed by interruptions or gaps (e.g., grooves) in various laminate layers, such as in one or more layers below a non-adhesive top layer.

[0013] In embodiments, the individual panels are held in the oven by one or more connectors. The connectors include or form grooves for receiving and securing the edges of the liner panels. The connectors can be a single longer groove or multiple clips for each edge. The connectors are also preferably made from a heat-resistant and / or non-stick material as disclosed for the liner.

[0014] The oven liners of the present invention are desirably durable over multiple heating cycles, high temperature and water resistant, easy to clean, stain resistant, and dissipate heat rapidly, while desirably having no or little effect on food cooking. The oven may include a solid bottom section, such as to prevent liquids from dripping onto the heating element, or a perforated bottom or sides to allow for better heat / air flow.

[0015] Other objects and advantages will become apparent to those skilled in the art from the following detailed description taken in conjunction with the appended claims and drawings. [Brief explanation of the drawings]

[0016] [Figure 1] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention. [Figure 2] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention. [Figure 3] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention. [Figure 4] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention. [Figure 5] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention in combination with an exemplary oven. [Figure 6] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention in combination with an exemplary oven. [Figure 7] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention in combination with an exemplary oven. [Figure 8] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention in combination with an exemplary oven. [Figure 9] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention. [Figure 10]1 illustrates an oven cavity liner insert according to one embodiment of the present invention. [Figure 11] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention. [Figure 12] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention in combination with an exemplary oven. [Figure 13] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention in combination with an exemplary oven. [Figure 14] 1 illustrates an oven cavity liner insert according to one embodiment of the present invention in combination with an exemplary oven. DETAILED DESCRIPTION OF THE INVENTION

[0017] 1-4 illustrate a multi-layer tri-fold oven liner / cavity insert 20 (hereinafter "oven liner") according to an exemplary embodiment of the present invention. The oven liner 20 provides improved cleaning and reduces potential arcing within the oven cavity of an electric oven. The liner of an embodiment of the present invention can cover or replace a metal bottom impingement plate, which has potential arcing issues, particularly during food splatter events. The oven liner or cavity insert is designed for easy installation and removal, allowing it to be quickly rinsed and wiped clean as needed, allowing for immediate return to cooking. The construction and materials used in the present invention minimize downtime and potential burn hazards compared to traditional cleaning methods.

[0018] Figure 1 shows an oven liner 20 in a folded position for use in an oven. The oven liner 20 includes a bottom portion 22 that corresponds to the oven floor and two upwardly extending side portions 24, 26 that correspond to the oven cavity side walls. Figure 2 shows the oven liner in a flat configuration before folding, such as for improved transportation and storage.

[0019] In an embodiment of the present invention, oven liner 20 includes a fold line 30 between bottom 22 and each side 24, 26. Fold line 30 may be a line of weakness in the substrate, such as a perforation, or a line of reduced thickness, such as that better shown in Figures 3 and 4.

[0020] FIG. 4 shows an exploded view of a layered structure according to one embodiment of the present invention. It shows a non-adhesive top layer 40 extending the entire length of the oven liner 20. A second, full-length support layer 42 is added below the top layer 40. The remaining layers of the laminate oven liner include five middle layers 44 and a bottom layer 46. In the illustrated embodiment, the fold line 30 is formed by separation spaces 50 between sections of the middle layers and between sections of the bottom layer. In other words, each of the middle layer 44 and bottom layer 46 is formed with three sections: section 52 (corresponding to bottom 22), section 54 (corresponding to side 24), and section 56 (corresponding to side 36). The result is a thinner laminate thickness at the fold line 30 (see FIG. 3), with the support layer 42 exposed from the bottom within space 50.

[0021] The oven liner of the present invention, and preferably each laminate layer, is high temperature (≧375°F) resistant. For each layer, a composite can be formed by impregnating and / or coating one or more selected flexible substrates with a selected polymeric material. Exemplary flexible substrates suitable for the laminate layers include woven substrates, nonwoven substrates, open mesh / lenoweave substrates, braided substrates, and / or unidirectional fabrics such as those made using fiberglass or other suitable fibrous materials, e.g., Kevlar, Nomex, carbon fiber, quartz fiber, PEEK fiber, PAEK fiber, PPS fiber, PES fiber, PPSU fiber, LCP fiber, and / or PAI fiber, or combinations of such fibers or yarns. Exemplary polymeric materials include melt-processible fluoropolymers, preferably perfluoroalkoxyalkanes (PFA), TFE / perfluoromethylvinylether copolymers (MFA), or fluorinated ethylene propylene (FEP), PTFE homopolymers or copolymers, or combinations of such fluoropolymers, and / or engineering thermoplastics and blends thereof, which desirably serve as support and structure for the composite once molded.

[0022] According to some embodiments of the present invention, the forming process begins with a substrate, such as a woven glass fiber substrate, which may include a layer of coated linear strand glass fiber. The substrate is saturation coated with a solution of dissolved or suspended polymer, such as PAI, PPS, PEEK, PPSU, PES, or a combination thereof, or other suitable plastics known for high-temperature use. Multiple passes of the coating can be used to fully saturate the fibers and build up sufficient weight for flow and forming. The polymer-coated substrate is preferably dried and prepared in a prepreg (pre-impregnated) state. For at least the outer layers, a topcoat of PTFE or other non-stick material is applied to one or both sides. A fluoropolymer coating provides release during forming and offers a high-performance release finish for use (similar to cookware coatings). The coating can be applied, for example, by a thickly coated single layer and / or by laminating multiple layers of lighter woven or linear strand glass fiber.

[0023] In embodiments, two or more substrate layers, preferably all of the substrate layers, can be impregnated. Furthermore, two or more separately impregnated substrates can be laminated together prior to topcoating. The layers can be the same substrate material or different substrate materials, e.g., a coated woven fabric can be laminated onto one or both sides of a coated nonwoven fabric. The type and number of layers can be adjusted for stiffness as needed.

[0024] By way of example, and not limitation, in the embodiment shown in FIG. 4 , the top layer 40, support layer 42, middle layer 44, and bottom layer 46 are each made of a different material. The top layer 40 is a 10-mil fluoropolymer-coated / impregnated glass fiber material. The support layer 42 is an 8-mil fluoropolymer-coated / impregnated glass fiber material. Each middle layer 44 is a 6-mil fluoropolymer-coated / impregnated glass fiber material. The bottom layer 46 is a 6-mil fluoropolymer-coated / impregnated glass fiber material. The top layer 40 and support layer 42 are separately laminated together using heat and pressure. The remaining six layers are also laminated together in separate sections 52, 54, and 56, and then the four intermediate laminates are secured in place and laminated together for the final oven liner 20. Various die-cut shapes can be added during the intermediate lamination process and / or after the final lamination process.

[0025] As will be appreciated, various sizes, shapes, and configurations are available for oven liners, individual sections or laminate layers, folds, etc., as needed. The bottom and side sections can be molded to cover the entire corresponding oven surface or only a portion thereof. An upwardly extending third, rear section can also be included. Various openings, such as for airflow or oven components (e.g., shelf brackets, lighting, heating / microwave elements, convection elements, etc.), can be die-cut into the oven liner as needed.

[0026] 5-8 illustrate an oven liner 120 according to one embodiment of the present invention. Similar to FIGS. 1-4, the oven liner 120 includes a bottom 122 and two side sections 124, 126. Fold hinges 130 are positioned along and between the bottom 122 and each of the side sections 124, 126. The bottom 122 includes a plurality of punched, perforated openings 125, such as to allow for more efficient heated airflow. Openings 127 in the hinge area 130 allow for the attachment of existing oven components.

[0027] Figure 6 shows an exemplary oven 170. Figure 7 shows an oven liner 120 installed within an oven cavity 172. Figure 8 shows an oven rack 174 positioned on the oven liner 120 within the oven cavity 172. The oven liner or cavity insert can be customized to fit any oven cavity, as well as any other mating components necessary for proper oven function.

[0028] 9-11 show a further embodiment of an oven liner 220. The oven liner 220 includes a bottom wall 222 corresponding to the oven bottom and two upwardly extending side portions 224, 226 corresponding to the oven cavity side walls. The oven liner further includes a top wall 242 and a back wall 244 corresponding to the top and back walls of the oven cavity, respectively. The top wall 242 and the back wall 244 each preferably include openings 246 corresponding to oven components to allow heated air to pass through. Folds 230 connect the bottom portion 222 to each of the side portions 224, 226.

[0029] In the illustrated embodiment, the top wall 242 and rear wall 244 are configured as separate components 240 that are attached to the side walls 224, 226 by tabs 250 of one component fitting into slits 252 of the adjacent component. As shown, the tabs 250 extend upwardly from the side walls 224, 226 and fit into slits 252 in the top wall 242. The rear wall 244 includes tabs 250 that extend laterally into the slits 252 in the side walls 224, 226. A variety of alternative connections, such as heat-resistant "tape" or fasteners, can be used to connect various numbers and configurations of liner walls.

[0030] 12-14 illustrate a further embodiment of an oven liner 320 for an oven cavity 300. The oven liner 320 as illustrated includes two upwardly extending sidewalls 324, 326 corresponding to the sidewalls 302 and 304 of the oven cavity. Each of the sidewalls 324, 326 is a separate panel that can be separately removed for cleaning, as shown partially disassembled in FIG. 13. The oven liner 320 may also include removable bottom, top, and / or back wall panels corresponding to the bottom, top, and / or back walls of the oven, as desired. These panels may be made from any of the materials and configurations (e.g., layers) described herein.

[0031] Side walls 324 and 326 are each held in place by one or more, preferably at least two, connectors 350. Connectors 350 can be any suitable component that allows panels to slide out as shown in FIG. 13 , such as a channel rail or clip with one or more grooves, preferably U-shaped grooves, for securing edges 328 of panels 324. As shown in FIGS. 12 and 13 , connectors 350 are clips that can be attached to oven wall 302 or oven wall 304, such as by drilling and tapping. FIG. 14 shows an exemplary clip connector 350 with panel grooves 352 and tapped holes 354. Alternatively, a support structure, such as a box-shaped frame enclosure, corresponding to the oven cavity can be used to attach the connectors, or the frame can have integrally formed grooves. Additionally, the top liner panel can rest on the top surface 356 of the connector, and / or the rear and / or bottom liner panel can be held in place by the rear or bottom edges of the side panels. Alternatively, the bottom panel can be inserted between the side panels to secure the bottom edges of the side panels to the oven sides. Lower connectors can also be used. These connectors can also be used to secure the side panels of other embodiments, such as the tri-fold liner of FIG. 1.

[0032] Connector 350 can be any suitable connector made from any suitable material. In a currently preferred embodiment, the connector, and any optional support frame, is an extruded glass-filled connector. The extruded material can be any heat-resistant material discussed herein, and is desirably a PTFE material, such as those disclosed above.

[0033] Therefore, the present invention provides an oven liner or cavity insert formed of a laminated composite material that can be formed by hot pressing or other stamping / pressing molding. The oven liner has a folded three-dimensional configuration to better completely cover the surface of the oven cavity. The insert is non-stick and easily removable / replaceable for easy cleaning.

[0034] The invention illustratively disclosed herein may suitably be practiced in the absence of any element, part, step, component, or ingredient not specifically disclosed herein.

[0035] In the foregoing detailed description, the invention has been described in connection with certain preferred embodiments thereof, and although numerous details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that the specific details described herein can be varied considerably without departing from the underlying principles of the invention.

Claims

1. An oven liner for placement in an oven cavity during cooking, comprising at least one side section corresponding to an oven side wall.

2. The oven liner according to claim 1, further comprising a bottom section corresponding to the bottom of an oven, wherein at least one side section extends from the bottom section.

3. The oven liner according to claim 2, further comprising a tri-fold oven liner / cavity insert.

4. The oven liner according to claim 3, further comprising two side sections located opposite each of the bottom sections.

5. The oven liner according to claim 2, wherein the at least one side section is connected to the bottom section by a fold hinge.

6. The oven liner according to claim 5, wherein the folding hinge has a reduced thickness portion.

7. The oven liner according to claim 6, wherein the reduced thickness portion comprises a space within the laminated layer below the uppermost layer.

8. The oven liner according to claim 1, further comprising a connector for securing the side section to the oven side wall, wherein the connector has or is formed a groove for receiving and securing the edge of the side section.

9. The oven liner according to claim 1, wherein the oven liner is a press-formed and / or molded laminate of a plurality of flexible substrates coated and / or impregnated with a polymer.

10. The oven liner according to claim 9, wherein at least the uppermost layer comprises a non-adhesive polymer surface.

11. An oven liner according to claim 1, comprising a flexible base material of a woven base material, a nonwoven base material, a coarse mesh / entangled weave base material, a braided base material, and / or glass fiber, Kevlar, Nomex, carbon fiber, quartz fiber, PEEK fiber, PAEK fiber, PPS fiber, PES fiber, PPSU fiber, LCP fiber, and / or PAI fiber, or a unidirectional woven fabric formed of a combination of such fibers or yarns.

12. The oven liner according to claim 1, comprising a heat-resistant polymer material, preferably a melt-processable fluoropolymer, such as a perfluoroalkoxyalkane (PFA), TFE / perfluoromethyl vinyl ether copolymer (MFA), or a homopolymer or copolymer of fluoroethylene propylene (FEP), PTFE, or a combination thereof.

13. Use of the oven liner according to any one of claims 1 to 12 in an oven.

14. The use according to claim 13, further comprising removing, cleaning, and replacing the oven liner.

15. A method comprising preparing a removable and replaceable oven liner as described in any one of claims 1 to 12, which is separate from the oven and adapted to be removablely fixed inside the oven, and removing, cleaning, and replacing the oven liner insert in the oven cavity.

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