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 cookware made by these methods lacks optimal weight reduction and thermal performance.
Innovation Solution
The cookware is manufactured using a bonded multi-layer assembly with a perforated graphite layer positioned between metal layers, where the graphite layer has a thickness of at least 0.010 inches and a plurality of spaced-apart holes, and the metal layers are metallurgically bonded via posts extending through the holes, allowing for efficient heat distribution and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If aluminum or copper layers are bonded to stainless steel to improve thermal conductivity, then thermal conductivity is improved, but weight increases
Solution Approach 1:
The patent uses a porous graphite foam core layer instead of solid aluminum or copper layers. The porous structure reduces the density and weight of the thermal conductivity layer while maintaining heat distribution capabilities. The graphite foam provides sufficient thermal conductivity to improve upon stainless steel alone without the weight penalty of traditional aluminum or copper bonding layers.
Solution Approach 2:
The patent creates a composite structure combining stainless steel outer layers with a graphite foam core layer. This composite material approach allows the cookware to leverage the corrosion resistance of stainless steel and the thermal conductivity of graphite, achieving improved thermal performance without using heavier traditional metal bonding layers.
2Ease of manufacture
If solid state bonding techniques are used to manufacture cookware, then manufacturing complexity is reduced, but thermal characteristics and weight reduction are insufficient
Solution Approach 1:
The porous graphite foam core enables solid state bonding while providing superior thermal characteristics compared to traditional solid metal layers. The foam structure allows for effective heat distribution across the cooking surface without requiring complex multi-layer bonding processes, maintaining ease of manufacture while improving thermal performance.
Solution Approach 2:
The patent changes the physical state and structure of the thermal conductivity layer from solid metal (aluminum/copper) to porous graphite foam. This parameter change in material structure allows the material to provide sufficient thermal conductivity for cookware applications while reducing weight, all within the context of solid state bonding manufacturing processes.
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 solution results in cookware with reduced weight, improved thermal conductivity, and even heat distribution across the cooking surface, enhancing cooking performance while maintaining durability.
Implementation Method 1
a perforated graphite layer having a thickness of at least 0.010 in. (0.254 mm) and a plurality of spaced-apart holes formed therethrough... improved thermal conductivity, and even heat distribution across the cooking surface
Implementation Method 2
The second metal layer may be metallurgically bonded to the first metal layer at least via the plurality of spaced-apart posts
Data Source
AI summary
Provided is cookware made from a bonded multi-layer blank assembly. The cookware has a first metal layer, a second metal layer having a cavity with a plurality of spaced-apart posts protruding from a bottom surface of the cavity, and a perforated graphite layer having a thickness of at least 0.010 in. (0.254 mm) and a plurality of spaced-apart holes formed therethrough. The perforated graphite layer is positioned within the cavity of the second metal layer such that the plurality of spaced-apart posts extend through the plurality of spaced-apart holes. The second metal layer is metallurgically bonded to the first metal layer at least via the plurality of spaced-apart posts. A method of making the bonded multi-layer composite cookware is also disclosed.