Cooking utensil having a graphite core
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Solution Overview
Problem
Existing cookware manufactured using solid state bonding techniques lacks improved thermal characteristics and reduced weight, as they often rely on conventional roll-bonding methods that limit material combinations and efficiency.
Innovation Solution
The development of multi-layer bonded cookware with a core layer comprising perforated graphite plates and a metal core plate, where the metal core plate is extruded through the holes of the graphite plates and metallurgically bonded to inner and outer stainless steel layers, enhancing thermal conductivity and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional roll-bonding methods are used to manufacture multi-layer cookware, then the manufacturing process is simple and well-established, but the thermal conductivity and weight reduction are limited
Solution Approach 1:
The patent employs a multi-layer composite structure combining stainless steel outer layers with a graphite core layer and aluminum intermediate layer. This composite material approach enables superior thermal conductivity through the high-performance graphite and aluminum materials while maintaining the corrosion resistance and structural integrity provided by the stainless steel layers, thereby resolving the contradiction between manufacturing simplicity and thermal performance reliability.
Solution Approach 2:
The cookware is divided into distinct functional layers: stainless steel outer layers for durability and corrosion resistance, a graphite core layer for superior thermal conductivity and weight reduction, and an aluminum intermediate layer for bonding. This segmentation allows each material to optimize its specific function, achieving enhanced thermal characteristics while maintaining ease of manufacture through modular layer assembly.
2Ease of manufacture
If conventional roll-bonding methods are used to manufacture multi-layer cookware, then the manufacturing process is well-established, but the weight is not reduced
Solution Approach 1:
The patent replaces traditional heavy metal cores with a graphite core layer combined with an aluminum intermediate layer. Graphite has a density of approximately 2.2 g/cm³ compared to steel's 7.8 g/cm³, and aluminum's 2.7 g/cm³, resulting in significant weight reduction. The composite structure maintains bonding feasibility through the aluminum layer's compatibility with both stainless steel and graphite, resolving the contradiction between established manufacturing methods and weight reduction.
Solution Approach 2:
The invention changes the material composition parameters of the core layer from traditional metals to graphite and aluminum, fundamentally altering the density and weight characteristics of the cookware while maintaining compatibility with conventional solid state bonding manufacturing processes. This parameter change achieves weight reduction without sacrificing manufacturing ease.
3Reliability
If graphite plates with holes are used in the core layer, then thermal conductivity is improved, but the bonding complexity increases
Solution Approach 1:
The aluminum intermediate layer serves as a mediator between the graphite core plates and the stainless steel outer layers. This intermediary material facilitates bonding by providing a metallurgically bondable interface, as aluminum can be bonded to both stainless steel and graphite using solid state bonding techniques. The aluminum layer compensates for the complexity introduced by the perforated graphite structure, enabling successful bonding without requiring direct bonding between incompatible materials.
Solution Approach 2:
The graphite core layer incorporates perforated plates with holes that allow the aluminum intermediate layer to extend through and bond to the stainless steel outer layers. This porous configuration of the graphite plates enhances thermal conductivity pathways while enabling the bonding structure to integrate all layers effectively. The holes in the graphite plates reduce material usage and facilitate the bonding process, resolving the contradiction between improved thermal conductivity and bonding complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration improves thermal conductivity and reduces weight by utilizing high thermal conductivity graphite and aluminum, while allowing for more efficient bonding and material combinations not possible with conventional roll-bonding, resulting in superior cooking performance.
Implementation Method 1
a metal core plate disposed between the at least two perforated graphite plates and extending through the plurality of spaced-apart holes of each of the at least two perforated graphite plates
Implementation Method 2
The at least one metal core plate may be metallurgically bonded to the inner layer and the outer layer at least through the plurality of spaced-apart holes
Implementation Method 3
the core layer may have at least two perforated graphite plates... improving thermal conductivity and reducing weight by utilizing high thermal conductivity graphite and aluminum
Data Source
AI summary
Provided is an article of cookware and a method of making the same. The cookware has a multi-layer bonded composite wall structure having an inner metal layer and an outer metal layer, and a core layer between the inner layer and the outer layer. The core layer has at least two perforated graphite plates, each plate having a plurality of spaced-apart holes formed therethrough, and at least one intermediate metal element disposed between the at least two perforated graphite plates and extending through the plurality of spaced-apart holes of each of the at least two perforated graphite plates. The at least one intermediate metal element is metallurgically bonded to the inner layer and the outer layer at least through the plurality of spaced-apart holes.