Movable recirculation grille with plenum and diffuser

Abstract

A recirculation grill includes a cooktop supported by a stationary frame. The grill includes an intake opening defining a plurality of slats configured to receive smoke from the cooktop, a waste tray compartment coupled to a trough for receiving waste and grease and having a removal and cleaning drawer, an interior plenum configured to generate suction to draw air and smoke from the cooktop to the intake opening, a diffuser positioned over the waste compartment and extending downward and outward, a tunnel configured to receive airflow from the plenum, and a blower housing containing a blower fan configured to draw air and smoke from the cooktop through the plenum to the intake opening. The intake opening, plenum, and blower are configured to achieve 100% visible smoke capture.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 62 / 884,014, filed August 7, 2019, which is incorporated by reference in its entirety. [Technical field]

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to the field of indoor grills and cooktables, and more particularly to recirculating grills / tables.

[0003] Indoor grills for restaurants and private use are known in the art. Cooking food produces smoke. Traditionally, indoor cooking using electricity or gas as a power source has required smoke ventilation. This often means the installation of expensive, fixed and robust ventilation systems such as fume hoods. The use of fume hoods is a significant burden on heating, ventilation and air conditioning (HVAC) systems. These overhead hoods must be physically positioned directly over the cooking surface and, despite their physical location, are unable to adequately capture smoke. As a result, people in the vicinity of these systems are more likely to be exposed to odors and inhale the smoke, which also contributes to odor pollution. The need for proper ventilation further limits flexibility, innovation and design of the corresponding grill or cooking surface.

[0004] In traditional Japanese steakhouses and teppanyaki restaurants, the grills take up a significant amount of floor space. They are fixed in place to accommodate the corresponding overhead ventilation hood system. This limits the restaurant's creativity and does not allow for a variety of styles, seating arrangements, and overall designs. Furthermore, if ventilation is not perfect, customers will complain about odors that stick to their clothes and ruin their meal. These indoor grills are difficult to clean and operate because many of the structural components are fixed to meet fire and safety standards.

[0005] Indoor recirculating grills are known. These grills and cooktops are designed in a manner that does not require overhead ventilation and hood systems. However, the safety certifications required to commercially operate these grills are typically governed by UL and / or ETL standards. UL / ETL certification requires 100% smoke capture along with fire safety and electrical and mechanical shutdown, which becomes difficult to achieve as cooking units become smaller in size.

[0006] Regardless of other attempts to solve the problems associated with existing grills, none teach or suggest materials and / or methods that have the advantages and features of the present disclosure. Summary of the Invention

[0007] The present disclosure provides a cooking apparatus comprising: (a) a cooktop supported by a stationary frame; (b) an intake opening defining a plurality of slats configured to receive smoke from the cooktop; (c) a waste tray compartment coupled to a trough for receiving waste and grease and having a removal and cleaning drawer; and (d) an interior configured to generate suction to draw air and smoke from the cooktop into the intake opening. of plenum, and (e) waste tray It is located to cover the compartment, Towards the opposing plenum wall (f) a tunnel configured to receive airflow from the plenum; and (g) a blower housing containing a blower fan configured to draw air and smoke from the cooktop through the plenum to an intake opening. a waste tray compartment is located through the plenum and the diffuser forms an upper portion of the waste tray compartment. Provides air intake openings, plenums, and ventilation fan can be configured to achieve 100% visible smoke capture. The plenum forms an open space configured to expand, cool, and direct the airflow from the intake opening into the tunnel. In one example, the plenum defines a segmented sidewall with a downwardly sloping portion configured to collect grease at a bottom of the plenum. The plenum can be configured to: Cooktop The filter may be configured to have a distance of at least 18 inches from the first filter contact.

[0008] In one example, the diffuser is configured to direct the airflow in two opposing outward directions. N The inclined portion may include a central portion. Opposing The diffuser extends downward toward the plenum walls at an angle configured to direct the airflow away and downward within the plenum. In another example, the diffuser includes a vertical end connected to an opposing angled portion configured to direct the airflow downward into the lower portion of the plenum. The diffuser may be formed of a metal such as stainless steel. In yet another example, the plenum is configured to condense large grease particles within the air entering through the intake openings to fall out of the air and form along the plenum walls, with the plenum walls angled toward a grease trap located at the bottom of the grill.

[0009] The present disclosure provides a grill with curved plenum walls. The plenum is configured to form upper and lower vent sections configured to create a vacuum effect at the intake opening. The intake opening may be configured to create a surface area sufficient to capture 100% visible smoke. A waste compartment is located through the plenum and a diffuser forms an upper portion of the waste compartment. A trough is an elongated trough that extends most or all of the length of the cooktop and is located below the intake opening.

[0010] The present disclosure provides a recirculation grill further including a push air duct coupled to a push air blower and a push air opening, operable to capture visible smoke from the opposite side of the cooktop and direct it over the cooktop to the intake opening. In one example, the tunnel housing may include a wool baffle filter and a combination disposable filter having a minimum efficiency reporting value (MERV) filter and a carbon filter. The blower fan may be configured to adjust speed in response to a variable fan drive and control process, and the blower is configured to draw air and smoke through the plenum from the cooktop to the intake opening.

[0011] The present disclosure further provides a recirculation grill including a moveable platform supporting a blower housing and a tunnel, operative to slidingly engage a fixed frame supporting a cooktop, the moveable and fixed frames being a modular frame formed from modular frame segments. The grill may further include a controller coupled to the heating element, the blower fan, a plurality of airflow and temperature sensors located within the plenum and tunnel, and a safety system. The controller is configured to monitor the performance of the blower fan and any filters within the tunnel, and activate the safety system when certain wind speed or temperature thresholds are exceeded.

[0012] For purposes of summarizing the disclosure, certain aspects, advantages, and novel features of the disclosure have been described herein. It is to be understood that not all such advantages are necessarily achieved in accordance with any one embodiment of the disclosure. Thus, the disclosure may be embodied or carried out in a manner that achieves or optimizes one advantage or advantages as taught herein, without necessarily achieving other advantages as taught or suggested herein. The features of the disclosure that are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of this specification. These and other features, aspects, and advantages of the disclosure will be better understood with reference to the following drawings and detailed description. [Brief description of the drawings]

[0013] The figures accompanying the written portion of this specification illustrate embodiments of the present disclosure and methods of use, constructed and operative in accordance with the teachings of the disclosure.

[0014] [Figure 1A] FIG. 1A is a top view of the recirculation grill of the present disclosure with an outer housing. [Figure 1B] FIG. 1B is a front view of the recirculation grille of FIG. 1A. [Figure 1C] FIG. 1C is an isometric view of the recirculation grille of FIG. 1A. [Figure 1D] FIG. 1D is a side view of the recirculation grille of FIG. 1A. [Figure 2A] FIG. 2A is a top view of the recirculation grill of FIGS. 1A-1D without the outer housing, exposing the flow tunnel with the blower housing and blower fan. [Figure 2B] FIG. 2B is a front view of the exposed recirculation grille of FIG. 2A. [Figure 2C] FIG. 2C is an isometric view of the exposed recirculation grille of FIG. 2A. [Figure 2D] FIG. 2D is a side view of the exposed recirculation grille of FIG. 2A. [Diagram 3] FIG. 3 is an exploded view of the recirculation grill of the present disclosure. [Figure 4A] FIG. 4A is a top view of the recirculation grille having an elongated trough with internal components exposed and extended from the housing via a movable platform. [Figure 4B] FIG. 4B is an isometric view of the exposed recirculation grille of FIG. 4A. [Figure 5A] FIG. 5A shows the plenum of the interior portion of the recirculation grille of the present disclosure. [Figure 5B] FIG. 5B shows a diffuser according to the present disclosure. [Figure 6A] FIG. 6A is a top view of the movable platform extended for use with a recirculating grill having an outer housing. [Figure 6B]FIG. 6B is a front view of the recirculation grill of FIG. 6A with the movable platform extended. [Figure 6C] FIG. 6C is an isometric view of the recirculation grill of FIG. 6A with the moveable platform extended. [Figure 6D] FIG. 6D is a side view of the recirculation grill of FIG. 6A with the moveable platform extended. [Figure 7A] FIG. 7A is an exposed side view of the mobile platform of FIG. 6A having modular frame segments. [Figure 7B] FIG. 7B shows a connector piece of the modular frame of the moveable platform of FIG. 7A. [Figure 7C] FIG. 7C shows a modular bracket of the moveable platform of FIG. 7A. [Figure 7D] FIG. 7D is a side view of the example modular bracket of FIG. 7A. [Figure 8A] FIG. 8A shows a top view dining surface design associated with the recirculating grill of the present disclosure. [Figure 8B] FIG. 8B is an isometric view of the recirculation grille of FIG. 8A. [Figure 9A] FIG. 9A is a front view of a baffle filter for use with the recirculation grill of the present disclosure. [Figure 9B] FIG. 9B is an exploded side view showing the components of the baffle filter of FIG. 9A. [Figure 9C] FIG. 9C is an isometric view of the exploded view of FIG. 9B. [Figure 9D] FIG. 9D is a front view of a combination filter for use in the recirculation grill of the present disclosure. [Figure 9E] FIG. 9E is a side view of the combination filter of FIG. 9D. [Figure 9F] FIG. 9F is an isometric view of the combination filter of FIG. 9D. [Figure 10] FIG. 10 is a flow chart relating to a variable fan drive for use with the recirculation grill of the present disclosure. [Figure 11A] FIG. 11A is an isometric view of a recirculation grill having a baffle filter positioned at an angle within the tunnel of the recirculation grill of the present disclosure. [Figure 11B] FIG. 11B is a side view of the recirculation grille of FIG. 11A.

[0015] Various embodiments of the present disclosure are described below in conjunction with the accompanying drawings, in which like designations refer to like elements.

[0016] The present disclosure provides a recirculating grill having at least one or more of the following features: (i) a diffuser and internal plenum operable to improve airflow into the tunnel and control grease, (ii) a waste trough extending the entire length or majority of the cooking surface and located below the opening, (iii) a movable platform for improved access and maneuvering of the internal parts of the cooking unit for cleaning and repair, (iv) a variable fan drive (VFD) for improved efficiency and control of airflow through the filter, and (v) a combination filter operable to improve disposal, cleaning, and replacement of the filter. The present disclosure provides a recirculating grill / table that is movable and meets certain requirements according to UL / ETL safety standards. Compared to prior art grills, there are improvements in ease of use / maintenance, effective heating characteristics, and low levels of sound / vibration that do not spoil meals. This included a modular grill / table that can be efficiently disassembled for shipping and transportation.

[0017] The terms "grill" and "table" are used interchangeably in the industry and herein. Commercial kitchens and teppanyaki style restaurants typically feature one or more grills with a flat-top cooking surface heated by multiple electric or gas burners connected to control knobs for adjusting cooking temperatures. The grill / table includes internal components located below the cooking surface. The grill / table may include an outer housing sized and shaped to protect and conceal the internal components. If the grill / table is mobile or grounded to the restaurant seating area with nearby patrons, additional safety precautions are required.

[0018] 1A-7D, an exemplary cooking unit, or recirculation grill, or table 100 is shown. In this example, the grill 100 includes a cooktop 110 that is positioned relatively flat on an interior portion of the grill. The cooktop 110 may be made of any material sufficient to facilitate cooking and cleaning. In this example, the cooktop 110 is made as a single plate of stainless steel. The cooktop 110 may define a rectangle having a length "L" along a longer side and a width "W" along a shorter side. A user or cook / chef can access and control the food preparation at a front location along the length L. In a teppanyaki style restaurant, patrons or customers can sit on the opposite side from the front along the perimeter along the width W, while guests are exposed and view the preparation of their food up close. This is often desirable, as witnessing the cooks at work is an important part of the entertainment and appeal of the restaurant.

[0019] The recirculating grill 100 includes internal components that can support the cooktop 110 and capture smoke resulting from cooking. As shown in FIG. 1, the grill 100 is surrounded by side walls 115 and a front face cover 116 and a back wall (not shown), thereby forming an outer housing. These walls enclose the internal components for safety and aesthetic purposes, and also act as a muffler to limit, reduce, or eliminate unwanted noise. A baffle filter door 118 is located along the cover 116 and is removable to allow access to a tunnel 120 that houses one or more filters. In one example, an optional controller 122 is located along the cover 116 and can allow a user to control the heat of the cooktop 110, turn the grill 100 on and off, and provide basic diagnostic data that can be viewed on a corresponding screen. In one example, the controller 122 includes touch screen control and compatibility along with a digital display. In a further example, the controller 122 is programmable and includes artificial intelligence and smart adaptability to adjust to specific applications to enhance or improve the efficiency and performance of the grill. To this Is, tone This may include adjusting hot zones relative to physical and environmental conditions.

[0020] The internal components of the grill 100 include a tunnel 120 and a blower housing 121. The tunnel 120 functions as a filter housing that holds a filter operable to filter the smoke and airflow drawn from the cooktop 110. When food is cooked on the cooktop 110, the smoke and exhaust air is pushed by the air being pushed through the push air duct 119 and drawn in through the air intake opening 112. During use of the grill 100, the smoke / air becomes contaminated with grease and food particles and needs to be filtered before being released from the grill 100. The tunnel 120 often encloses a filter including a baffle filter and a secondary filter (see Figures 9-11). The push air duct 119 is connected to a push air blower 128, which pushes air directly out of the push air opening 129. The push blower 128 creates a low velocity air that is pushed across the cooktop towards the air intake opening 112. This creates an air curtain above the cooktop 110. An air curtain in combination with a pull blower in the blower housing 121 prevents air contamination and allows for 100% visible smoke capture.

[0021] The blower housing 121 includes a blower fan 123 that draws air from the cooktop 110. The blower must be strong enough to draw air at a sufficient velocity from the cooktop 110 through the intake openings 112, through the plenum 150, and into the tunnel 120, where it is filtered before being drawn through the blower fan 123 and exhausted from the grill 100. This air can be referred to as "recirculated air." The recirculated air is pushed out and creeps across the floor and out at the feet of the user. In one example, a louvered vent 127 is positioned toward the front of the grill 100 to direct the air downward as it escapes. In one example, the blower fan 123 includes an inlet ring that channels air into the blower for increased efficiency. The blower fan includes a rearward curved centrifugal fan that creates the airflow necessary to capture the smoke.

[0022] To heat the cooktop 110, multiple electric heating elements 126 are located directly under the cooktop 110. In this example, three heating elements 126 are provided, creating cooking or heating zones on the top of the cooktop 110. This allows the user to control cooking in different ways by creating different temperatures on the surface. For example, one zone can be used to heat rice and vegetables, while another zone can be used to cook meat and fish at a higher heat. The heating elements 126 are electrically coupled to a power source (not shown) to provide heat to the cooktop 110 and a control knob (not shown) to manually control the temperature of the cooking surface. In another example, digital and smart controls are employed. Gas can also be used as a heat source and is within the scope of this disclosure. A fire suppression nozzle 114 is located adjacent to the air intake opening 112 and is directed toward the cooktop 110. This is a safety measure that releases a fire suppression agent when triggered by a fail-safe safety mechanism. Safety compliance requires that the nozzle 114 is present and functional along with a corresponding sensor inside the grill 100. The safety sensors are configured to activate the nozzles 114 when predetermined temperature or pressure thresholds are exceeded.

[0023] Grill 100 further includes a splash guard 113 located around the perimeter of cooktop 110. The splash guard 113 is configured to reduce and prevent grease and food from dripping or being pushed off of cooktop 10. This is particularly useful in restaurants where patrons are seated close to the cooking surface.

[0024] <trough> In one example, the grill 100 includes an elongated trough or "grease" trough 125 configured to extend the length L of the cooktop 110. In one example, the cooktop 110 is 48 inches along the length L, and the trough 125 extends over most or all of the length L. The trough 125 is formed in an opening along the front surface 116. This allows a user to push waste and food through the opening and capture within the trough 125. An air intake opening 112 is located directly above the trough 125 and has openings or slats 152 along the back surface to capture smoke and exhaust from the cooking surface. Additional grease and particles in the air captured by the openings 112 can be captured in the trough 125. Waste captured in the trough 125 is pushed into a waste compartment 111, which is a drawer that can be opened from the front cover 116 of the grill 100. The waste drawer 111 collects food waste and grease pushed into the trough by a user. The trough 125 can shorten the cooking surface along the width W relative to the opening 112 so that the air curtain is sufficient to prevent contaminated air from escaping the cooking surface. The trough 125 extends along the length L to facilitate a user removing waste from the cooktop 110. The trough 125 includes a downward slope to allow waste to flow toward the waste drawer 111.

[0025] Additional internal components of the grill 100 include an electrical box 124 that can be positioned next to the blower housing 121 and houses the electronics and power connectors for most or all of the electrical portions of the grill 100. This includes the blower, heating elements, controls, and sensors. A fire suppression tank 140 carries the extinguishing agent and delivers the agent to the nozzles 114 upon initiation via a fire suppression line 141. In this example, the fire suppression tank 140 is located on the opposite side of the blower housing 121 compared to the electrical box 124. Also, a system release module 142 can be provided, which is a mechanical system that releases extinguishing agent when activated. UL / ETL compliance requires both sensor-based and mechanical safety features.

[0026] <Plenum and diffuser> With particular attention to FIGS. 5A and 5B, the present disclosure provides a method for determining whether or not a tunnel 121 is connected to an intake opening 112. A plenum 1 that defines an open space in a structure configured to encourage and promote effective airflow 50. Plenum 150 connects opening 112 to tunnel 121. This This is the first route that air will take to reach the filtration system housed in Tunnel 121. The plenum utilizes a diffuser 151 to direct air around the diffuser 151. This forces the cooking surface (Cooktop 110) to move before it comes into contact with the first filter. ) to meet the safety requirement of 18 inches from the plenum wall 153. In this example, the slits are configured to form a structure that slopes downward and outward toward the slits. The diffuser is separated by a relatively flat or horizontal central section 1501 and a Two opposing inclined portions 150 sloping downward and away from the defined plane AA 2. In one example, the ramp 1502 is in contact with the plenum wall 15 of the outer housing of the table. 3, causing airflow away from the central portion 1501. Diffused air is sent to the plenum 150 It may further include a vertical end 1503 that flows downward into the lower portion of the

[0027] In one example, the diffuser 151 is made of a metal such as stainless steel, such as 304 or 316. The various sections can be welded. In use, air enters through the intake opening 112 and hits the diffuser 151, splitting the air and moving it along the slope 1502 towards the side wall 115 in at least two different directions. The physical presence created by the diffuser 151 pushes the air towards the plenum wall 153 and down into the tunnel 121. As the air expands and cools rapidly as the volume of space in the plenum increases, larger particles fall out of the air before it is filtered. This acts as a pre-filter for smoke or gases that are recirculated through the grill 100. The diffused air will make a sharp turn around the diffuser 151, causing excess grease to fall to the bottom of the plenum 150 and drain into the grease tray 154. As the oily air passes through the plenum 150, the cool temperature of the metal causes the grease to naturally solidify on the outermost wall 153. In one example, the bottom of the plenum 150 is sloped downward along a drain 1504 in the wall 153 to allow gravity to drain grease particles into the grease tray 154 .

[0028] In this example, the shape of the plenum walls 153 is segmented, exhibiting sharp connections rather than smooth curves. While either is contemplated within the scope of this disclosure, the segmented curved design is easier to manufacture since the segments can be welded. The plenum walls 153 are configured to direct and encourage airflow and grease downwardly towards the bottom of the plenum 150.

[0029] The diffuser 151 effectively creates two vent sections, an upper plenum 155 above the diffuser 151 and a lower plenum 156 below the diffuser 151. These vent sections have a larger ratio of the opening of the section to the volume of the cube within the section. The necessary "suction" effect is achieved at the intake opening 112 to generate the necessary air velocity for 100% or close to 100% visible smoke capture. The surface area across the intake opening 112 creates the air velocity and the ratio of air to air volume. This is balanced within the shape of the plenum side walls 153 to achieve 100% visible smoke capture for a given size of grill 100. Varying the surface area of ​​the intake opening 112 allows the velocity to be manipulated and varying the shape of the plenum walls 153 allows the suction effect to be manipulated through volume change. Decreasing the volume increases the velocity. However, increasing the volume places a greater strain on the blower and filters. Therefore, the size and shape of the plenum 150 must be optimally balanced to ensure sufficient blower and smoke capture.

[0030] The positioning of the waste drawer 111 must accommodate the space requirements of the plenum 150 since the plenum encompasses the entire front of the table 100. Thus, the waste drawer 111 does not fit directly under the cooktop 110 as in existing indoor countertops. In this example, the waste drawer 111 is placed in the center of the plenum 150 and extends across the plenum 150, reaching the underside of the cooktop 110. This takes advantage of the dead space created by the diffuser 151 to minimize the effect of impeding airflow. In this example, the diffuser 151 forms the top of the drawer 111.

[0031] Platform Design The present disclosure further provides a mobile platform that operates to allow efficient and effective manipulation of the table 100 and access and cleaning of the internal components. In this example, the mobile platform includes a fixed frame 130 that forms a structure that holds the cooktop 110 and some of the internal components. The fixed frame 130 forms modular frame segments 230 that define mounting slots 231 that extend the length of the frame segments 230. In this example, each modular frame segment 230 defines a relatively square cross-section and can be cut to any desired size. In one example, the frame segments 230 are fabricated from aluminum or any material to hold the table 100 and its internal components. The fixed frame 130 includes a horizontal frame segment 130 and a vertical frame segment 133. In this example, the platform further includes wheels 117, such as caster wheels. The wheels extend down from the horizontal frame segment 130 to allow the entire table 100 to be manually maneuvered along a floor or flat surface. This allows for the desired movement of each table 100 unit to improve cleaning, design, access, etc.

[0032] The fixed frame 130 serves as a foundation frame. The movable frame 131 is connected to the fixed frame 130 and is operable to slide within the fixed frame 130. In a closed configuration, as shown in FIG. 1, the movable frame 131 is located entirely within the fixed frame 130 and is located below the cooktop 110. In an open configuration, the internal components can be pulled out from the outer housing and exposed, as shown in FIGS. 3, 4A, 4B, 6A, 6C, 6D, and 7A. In these examples, the movable frame 131 slides out to provide access to the internal components. The movable frame 131 supports ducts for the fire protection system, tunnel, and blower housing. In another example, an electrical box is also located on the movable frame 131. The movable frame 131 can be constructed of modular frame segments 230, similar to the fixed frame 130. In this example, the movable frame 131 is further connected to a sliding drawer 132 that allows the movable frame 131 to slide along guide tracks.

[0033] Each frame segment 230 may be capped at each end by a connector piece 232. In this example, the connectors 232 form four protrusions 233 that define channels 234 therebetween. The channels 234 allow the connectors 232 to attach and connect to any other modular frame segments 232 by engaging the channels 231. Thus, multiple frame structures may be formed and designed to mount and hold the table 100 and any corresponding components. This allows for increased customization and design.

[0034] In one example, the platform design consists of two parts: a mobile platform 131 and a fixed frame 130. The mobile platform 131 is attached to the fixed frame 130 by slides on both sides of the table 100 along the width W. When slidably separated, the fixed frame 130 supports the cooktop 110, the heating elements 126, the electrical box 124, the thermocouple, the junction box, and the push air assembly 128. The mobile platform 131 supports the blower 123, the tunnel assembly 120, and the fire protection system components 140, 141, and 142. In another example, the electrical box is supported by the mobile frame. With the table 100 open, there is easy access to the top of the tunnel 120, allowing access and replacement of the filters. Furthermore, maintenance is easy and accessible on the right and left sides of the mobile platform, where the electrical box 124 and the fire protection system components 140, 141, and 142 are located, respectively, and also under the cooktop 110 for the heating elements 126.

[0035] The platform design allows improved access to the internal components for cleaning, filter replacement, and maintenance. The filters must be at nearly ground level due to 710B safety regulations requiring a minimum of 18 inches and table height. Reaching this area for cleaning or replacing the filters requires crawling on the floor. Also, because electrical and fire protection require space on either side of the tunnel, it is not easy to access the tunnel behind these systems without a mobile platform as described herein. Also, the fire and electrical systems must be accessed from floor level without the mobile platform of the present disclosure. The present disclosure provides a table that can be separated into two sections that allows top access to the filters, electrical, and fire protection systems.

[0036] Isolating the electrical box with a fixed frame improves the electrical organization. With the box fixed, the technician can access most areas of the table without having to manipulate or touch the electrical box. This allows the electrical box and the connection points for other components or power sources to be fixed. The electrical box may contain two multiplexers connected via a coiled cable. The fire protection system connection has a dedicated coiled cable.

[0037] Fire piping, wiring between moving parts, and fixing / leveling need to be optimized when using a moving platform. For fire piping, the fixed frame moves further inwards to allow the fire protection pipe to extend into the plenum and reach the cooktop. Thus, the fire protection system remains on the moving platform. Wiring between moving parts uses curly cables that return to a spring-like shape when not extended. Leveling is achieved by placing the frame on leveling casters that include both legs and wheels. For fixing, the platform is attached to the frame via slides that are large enough to support the weight of the platform. This allows for the unlikely event of extra weight on the platform, such as a person leaning on the plenum.

[0038] FIG. 8 shows an example of a table 100 having an eating or dining surface 300 surrounding a cooktop 110. Because the table 100 is movable and portable, a variety of dining surface designs can be realized. In this example, the dining surface 300 is relatively square. However, other shapes are contemplated within the scope of the present disclosure, such as circular and rectangular. The dining surface 300 can be movable, allowing it to move with the table 100, or fixed, allowing the table 100 to move in and out of the surface. Additionally, it is contemplated that a variety of materials and design aesthetics can be implemented on the dining surface 300.

[0039] Filtering design using variable fan drive Previous models have a high cost of ownership due to the labor costs involved in cleaning the electrostatic precipitator (ESP) filters in the proper procedure and frequency. The cost of training employees to maintain and clean these units is relatively high. If handled improperly, the ESP is easily damaged and causes failure. The present disclosure provides a grill that uses a passive filter. In one example, the passive filter includes a MERV-style filter, such as the Merv15, a combination odor control filter (combo filter), and a wool baffle filter. The passive filter is disposable when it is fully saturated with grease and needs to be replaced. In addition, the internal parts that require cleaning are designed to be easily accessible, reducing cleaning time. The use of a passive filter can increase static pressure compared to the use of an ESP. However, the use of a variable fan drive (VFD) to control the blower speed (see flow diagram in FIG. 10) can extend the filter life. In one example, the VFD can monitor up to a 10% airflow change per UL / ETL standards (a change in airflow of more than 10% will shut the unit off). This filter placement results in 100% visual capture required to capture smoke and less than 5ppm (parts per million) of oily vapors measured at the exhaust in EPA tests. This creates opposing conditions, requiring minimum air velocity for proper filtering and higher air velocity for capture.

[0040] 9-11, the present disclosure provides a combination disposable filter 500. The combination filter works in conjunction with a wool covered baffle filter 400. A variable speed fan is used rather than a constant speed fan to extend the life of the filter. The wool baffle filter 400 includes a frame 410 that holds together a wool insert 412 and a baffle filter 414. The baffle filter 414 can be removed and washed. The wool baffle filter 400 first captures the larger grease particles that account for most of the grease that enters the system (table 100). The wool cover 412 on the filter 400 is also disposable and needs to be replaced as needed. Any grease remaining in the air then collects in the combo filter 500.

[0041] The combo filter 500 consists of a single package of two different filters 512 and 514. The first is the MERV filter 512, which collects physical airborne grease. The second is the carbon filter 514, which absorbs odor-causing particles. Due to 710B regulations, the recirculation unit must shut down if the airflow changes by more than 10%, and all filters may require detection. The variable fan drive (VFD) can increase its speed so that the airflow can be maintained even if the filter becomes saturated. Due to the nature of the MERV filter, the filtering efficiency increases when the filter becomes saturated, so there is no risk of it not being able to capture even if the fan speed increases. This allows the filter to be used for the entire life of the filter without the need to change it due to airflow conditions. To address this detection, the combo filter 500 was specially designed for user ease and to limit the amount of detection required.

[0042] Traditional systems use electrostatic precipitators, or ESPs. ESPs have cleaning and reliability issues. ESPs are high voltage components and should only be handled by professionals for safety. Also, mishandling ESPs often damages the internal plates / cells. If a cell is bent or damaged, the ESP will short out the power pack and the unit will fail. ESPs need to be cleaned frequently and are more likely to be damaged if not handled by professionals.

[0043] Another issue with filtering is the actual filter space. Filtration efficiency depends on the length of time the oily air passes through the filter. Two ways to accomplish this are to slow the air or increase the depth of the filter. To address this issue, baffle filters 400 are positioned at an angle within the tunnel 120 (see FIG. 11) to choke the airflow and increase the usable depth of the tunnel 120.

[0044] 10 is a flow diagram of a process 600 for a variable fan drive. In this example, process 600 begins in box 610 where airflow is measured by an airflow sensor. The airflow sensor generates an input signal in box 620. The input signal in box 620 is then received by a programmable logic controller (PLC) in box 630. This generates an output signal in box 630 which then moves to box 650 to adjust a variable fan drive (VFD). The VFD then adjusts the fan speed accordingly in box 660.

[0045] Odor removal and reduction is an issue to be addressed when working with recirculating grills and indoor restaurant environments. Thus, in another example, a finishing filter is provided in the airflow flow path after the air has been purified by both the baffle filter and the combination filter. This finishing filter includes a filtering material with a relatively large surface area and can capture and / or remove remaining odor particles such as fatty acids from meat. In another example, the finishing filter is specifically designed to remove odors resulting from cooking steak / beef, seafood, chicken, vegetables, rice, and cooking oils.

[0046] The present disclosure provides a recirculating grill / table that uses a trough 125 to collect grease by draining it into the interior of the grill 100. The trough 125 is located just before the intake opening 112, which increases the distance required for smoke capture. Therefore, the opening 112 covers the trough 125, eliminating this drawback and increasing the capture depth. The composition of the filter 400 / 500 can also be adjusted to optimize the airflow, balancing the air speed to volume ratio that creates the suction effect while handling the appropriate air speed for capture. The addition of a push air opening 119 and push air blower 128 on the opposite side of the cooktop 110 from the opening 112 captures additional trapped air and prevents it from escaping away from the table. This draws air in the direction of the opening 112, making it easier to capture.

[0047] Service cost reductions can also be achieved with the disclosed grill. Previous models had no indication to diagnose technical issues. For example, ESP malfunctions were mostly due to lack of cleaning. Without proper cleaning, a lot of grease / debris can build up in the ESP, leading to electrical shorts. If corrective action is not taken, the power pack will go into safety mode, causing reduced filtration efficiency and smoke capture. The disclosed grill incorporates a smart system that warns the user via the Human Machine Interface (HMI) screen with fuses, highlighted short circuit indications, and outputs instructions to address specific malfunctions.

[0048] The present disclosure provides a grill / table with standard dimensions that will fit with other units in most kitchens. In one example, the grill / table of the present disclosure fits into the standard kitchen griddle dimensions of 30 inches (height) x 50 inches (length) x 33 inches (width).

[0049] The present disclosure provides a mobile grill / table with reduced weight and size that allows the unit to be easily moved around and through doors without additional labor. The table weight is reduced by using cast aluminum heaters and eliminating the mounting plates. Furthermore, the change from mild steel to aluminum extrusions allows for significant weight reduction. Aluminum extrusions are not only advantageous for weight reduction, but also allow for a modular design. Aluminum extrusions and subsystems are removable by bolts for field replacement while not requiring specialized expertise, thus reducing service costs. Also, transportation is simplified as the frame can be partially assembled.

[0050] The present disclosure provides user-friendly features including ease of use / maintenance. Unlike limited automatic thermostats ("ATC"), the grill of the present disclosure utilizes an advanced HMI (smart) system display that provides diagnostic information to the end user. These messages can alert the user to change filters, change fuses, or watch for active shorts. Significantly reduces downtime and maintenance costs. Another benefit includes the maintenance level, such as cleaning and changing filters. As previously discussed in the cost of ownership, the use of a passive filter in the VFD eliminates the need to clean the main active filter. If the filter becomes clogged with grease, the VFD will increase the blower speed to maintain proper air speed and capture. This continues until the filter reaches the "end of life" and the HMI notifies the user to change the filter.

[0051] Additionally, the mobile platform allows the filtering, opening and fire protection systems to be located on the mobile platform, housed within a fixed frame that holds the electrical system, push air and cooktop. This allows the mobile platform to be deployed to easily access and service the filtration tunnel and other essential systems. Filter replacement is facilitated by the simple procedure of opening the tunnel door, discarding the old filter and sliding in a new one. After the safeties are properly locked and the mobile platform is returned to its original position, the unit can be powered on and operated.

[0052] An important aspect of foodservice cooking appliances is reliability and efficient heating characteristics, including heat up / reheat rates. A common criticism of electric appliances is that gas-powered units have no measurable temperature characteristics. Achieving and maintaining sufficient heat can be a big challenge as available amperage must be split between cooking and the recirculating built-in hood system. In one example, to improve heating capacity, the present disclosure provides a 50 amp tabletop unit, increasing available amperage. In one example, a clad cooktop is provided. Clad cooktops are layers of aluminum, steel, or other metals that enhance heat transfer characteristics. Aluminum has properties that enhance heat transfer and reduce heat recovery times. A cast aluminum heating assembly covers the largest area of ​​the cooktop underside creating more even heating characteristics from edge to edge.

[0053] The present disclosure provides a table that can reduce and cancel sound and vibration. In a recirculating grill, the blower generates more sound and vibration from the motor and airflow. The high pitched whistling sound is caused by air leaks / gaps in the improper manufacturing process. In one example, the exhaust exits the grill based on the concept that the larger the muffler size, the lower the pitch. High pitched sounds are harsher than lower pitches at the same decibels. To avoid using a traditional muffler, the grill is surrounded by double corrugated boards to muffle the sound generated within the grill. Also, the blower and all moving parts are secured with appropriate gaskets to minimize sound and vibration. The inside wall surface of the table effectively acts as a muffler that can affect the exhaust. Since a large amount of exhaust exits the grill under the frame in all directions, the exhaust is directed to a specific area to control turbulence and entrainment. To achieve this, a kick plate is provided around the grill to prevent air leakage and louver panels and diffusers are added to the plenum to direct the exhaust at a downward angle.

[0054] The present disclosure utilizes aspects such as a movable platform with a fixed frame, using passive filters in conjunction with a VFD to maintain the lowest possible wind speed for capture, using the outer frame itself as a muffler to address sound and space issues, providing a trough in front of the recirculation system opening, and arranging the baffle filter at an angle.

[0055] It should be noted that the steps described in the method of use may be performed in many different orders depending on the user's preferences. The use of "step of" in the claims herein should not be construed as "step for" and no desire to invoke the provisions of 35 U.S.C. 112(f) is intended. A reader of this specification should understand that other methods of use, such as, for example, a different order in the above list, the elimination or addition of certain steps, the inclusion or exclusion of certain maintenance steps, etc., will suffice under appropriate circumstances, taking into account issues such as design preferences, user preferences, marketing preferences, cost, construction requirements, available materials, advances in technology, and the like.

[0056] The embodiments of the disclosure described herein are illustrative and may be readily modified, altered, or rearranged to achieve substantially equivalent results, all of which are intended to be within the spirit and scope of the disclosure. Moreover, the purpose of the foregoing Abstract is to enable the U.S. Patent and Trademark Office and the public at large, particularly scientists, engineers, and persons of ordinary skill in the art who are not familiar with patent or legal terminology and phraseology, to readily determine the nature and substance of the technical disclosure of the present application at a glance.

Claims

1. (a) a cooktop supported by a stationary frame; (b) an intake opening defining a plurality of slats configured to receive smoke from the cooktop; (c) a waste tray compartment coupled to the trough for receiving waste and grease, the waste tray compartment having a removal and cleaning drawer; (d) an interior plenum configured to generate suction to draw air and smoke from the cooktop into the intake opening; (e) a diffuser positioned over the waste tray compartment and extending downwardly and outwardly toward an opposing plenum wall; (f) a tunnel configured to house one or more filters and to receive airflow from the plenum; (g) a blower housing containing a blower fan configured to draw air and smoke from the cooktop through the plenum to the air intake opening, A recirculation grill, the waste tray compartment being positioned through the plenum and the diffuser forming an upper portion of the waste tray compartment.

2. 10. The recirculation grill of claim 1, wherein the plenum defines an open space configured to expand, cool and direct airflow from the intake opening into the tunnel.

3. 10. The recirculation grill of claim 1, wherein the plenum defines a segmented sidewall with a downwardly sloping portion configured to collect grease at a bottom of the plenum.

4. 10. The recirculation grill of claim 1, wherein the plenum is configured so that air and smoke travel at least 18 inches through the plenum from the cooktop to the one or more filters that the air and smoke first contacts.

5. 10. The recirculation grill of claim 1, wherein the diffuser is configured to split and direct the airflow in two opposing outward directions.

6. 2. The recirculation grill of claim 1, wherein said diffuser includes a horizontal center portion located between two opposing downwardly sloping portions that extend downwardly from said center portion toward said opposing plenum walls to direct airflow away and downward within said plenum.

7. 7. The recirculation grill of claim 6, wherein the diffuser includes vertical ends connected to opposing sloped portions configured to direct airflow downward into a lower portion of the plenum.

8. 10. The recirculation grill of claim 1, wherein said diffuser is formed of metal.

9. 2. The recirculation grill of claim 1, wherein the plenum is configured to condense large grease particles within the air entering through the air intake openings and direct them down through the air along the plenum walls, the plenum walls being angled toward a grease trap located at the bottom of the recirculation grill.

10. 2. The recirculation grill of claim 1, wherein said plenum walls are curved.

11. The recirculation grill of claim 1 , wherein the plenum defines upper and lower ventilation sections configured to create a suction effect at the intake opening.

12. 10. The recirculating grill of claim 1, wherein the air intake openings receive low velocity air pushed from a push air blower that combines with a pull blower in a blower housing to form an air curtain over the cooktop to achieve 100% visible smoke capture.

13. 10. The recirculation grill of claim 1, wherein the trough is an elongated trough extending most or all of the length of the cooktop and is located below the air intake opening.

14. 10. The recirculation grill of claim 1, further comprising a push air duct coupled to a push air blower and a push air opening, operable to capture visible smoke from an opposite side of the cooktop and direct it across the cooktop to the air intake opening.

15. 10. The recirculation grill of claim 1, wherein the blower housing includes a wool baffle filter and a combination disposable filter having a minimum efficiency reporting value (MERV) filter and a carbon filter.

16. 10. The recirculation grill of claim 1, wherein the blower fan is configured to adjust speed in response to a variable fan drive and control process, the blower fan configured to draw air and smoke from the cooktop through the plenum to the intake opening.

17. 10. The recirculation grill of claim 1, further comprising a movable platform supporting the blower housing and tunnel, operable to slidingly engage a fixed frame supporting the cooktop, the movable platform and the fixed frame being a modular frame formed from modular frame segments.

18. 10. The recirculation grill of claim 1 further comprising a controller, said controller coupled to a heating element, said blower fan, a plurality of airflow and temperature sensors located within said plenum and tunnel, and a safety system.

19. 20. The recirculation grill of claim 18, wherein the controller is configured to monitor the performance of the blower fan and any filters in the tunnel and activate the safety system if certain wind speed or temperature thresholds are exceeded.

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