Cookware having a graphite core
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Solution Overview
Problem
There is a need for cookware that reduces weight and improves thermal characteristics using solid state bonding techniques, as existing multi-ply, bonded cookware often has low thermal conductivity and high weight due to the use of materials like stainless steel.
Innovation Solution
The development of cookware with a graphite core layer between metal layers, specifically using a solid state bonding method where the graphite core has spaced-apart holes and the metal layers have upwardly protruding dimples, allowing for metallurgical bonding and improved thermal conductivity while reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional multi-layer bonded cookware uses stainless steel outer layers bonded to aluminum or copper central layers, then thermal conductivity is improved, but weight remains high
Solution Approach 1:
The patent uses a composite structure with stainless steel outer layers, aluminum intermediate layers, and a graphite core layer. This multi-material composite approach combines the high thermal conductivity of aluminum and graphite with the durability and corrosion resistance of stainless steel, achieving improved thermal performance while reducing overall weight compared to traditional all-metal constructions.
Solution Approach 2:
The invention applies different materials to different regions of the cookware: stainless steel provides structural integrity and corrosion resistance in outer layers, aluminum provides high thermal conductivity in intermediate bonding layers, and graphite provides thermal distribution and weight reduction in the core. Each material is positioned where its specific properties are most beneficial.
2Weight of moving object
If solid state bonding technique is used to manufacture cookware, then weight is reduced and thermal characteristics are improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs preliminary surface preparation steps including abrasion and cleaning of all bonding surfaces before assembly. The multi-layer structure is pre-configured with specific materials and thicknesses, and the solid state bonding process is applied in a single consolidated step after all components are positioned, reducing overall manufacturing complexity despite the advanced bonding technique.
Solution Approach 2:
The solid state bonding process utilizes controlled changes in temperature, pressure, and time parameters to achieve metallurgical bonding between layers. By optimizing these parameters, the process achieves strong bonds while maintaining the lightweight composite structure, balancing manufacturing complexity with performance benefits.
3Temperature
If graphite core layer with holes is used between metal layers, then thermal distribution is improved, but bonding complexity increases
Solution Approach 1:
The graphite core layer incorporates a controlled porous structure with holes that enhance thermal distribution through increased surface area and potential convection pathways. The porous graphite material maintains structural integrity while improving thermal characteristics, and the holes are strategically positioned to facilitate bonding with adjacent metal layers without requiring additional complex bonding mechanisms.
Solution Approach 2:
The graphite core layer with holes acts as an intermediary between the aluminum intermediate layers, facilitating thermal energy distribution while the hole structure allows for mechanical interlocking and metallurgical bonding with the aluminum layers. This intermediary structure simplifies the overall bonding process by providing both thermal and mechanical functions in a single component.
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
The cookware achieves reduced weight and enhanced thermal performance by utilizing pyrolytic graphite for even heat distribution and metallurgical bonding of the metal layers, resulting in improved cooking efficiency and induction heating effectiveness.
Implementation Method 1
The cookware may have an inside surface defined by the at least one upper metal layer and a core layer comprising a central graphite disc having a plurality of spaced-apart holes formed in a patterned array
Implementation Method 2
a method for making the cookware using a solid state bonding technique
Data Source
AI summary
Provided is cookware made from a bonded multi-layer composite having at least one upper metal layer, a lower metal layer having a plurality of upwardly protruding, spaced-apart dimples formed thereon, and a graphite core layer disposed between the at least one upper metal layer and the lower metal layer. The graphite core layer has a plurality of spaced-apart holes extending through the graphite layer. The plurality of dimples extend through the plurality of holes, and the plurality of dimples are metallurgically bonded to the at least one upper metal layer and an outer portion of the lower metal layer is metallurgically bonded to the at least one upper metal layer. The at least one upper metal layer has a layer of stainless steel or titanium bonded to a sub-layer of aluminum. A method of making the bonded multi-layer composite cookware is also disclosed.