Corrugated Base Susceptor for Even Microwave Heating
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Solution Overview
Problem
Microwave ovens tend to cook food items unevenly and fail to achieve a balanced heating and browning of the crust, particularly for bread and dough-based products like pizzas and pies.
Innovation Solution
The use of thermally insulated susceptor structures comprising multiple susceptor layers and a corrugated base, with optional polymer film and paper layers, to enhance microwave energy absorption and distribution, thereby improving heating, browning, and crisping of food items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single susceptor layer is used, then the structure is simple, but heating uniformity and browning effectiveness are insufficient
Solution Approach 1:
The susceptor structure is divided into multiple layers (first susceptor layer, second susceptor layer) positioned at different heights relative to the food item. This segmentation allows different portions of the food to receive differentiated microwave energy absorption, improving heating uniformity while maintaining structural manageability through systematic layering
Solution Approach 2:
The patent introduces a vertical dimension by positioning susceptor layers at different heights (first susceptor layer at a first height, second susceptor layer at a second height). This three-dimensional arrangement creates multiple heating zones that work together to achieve uniform heating and effective browning across the entire food surface
2Temperature
If thermal insulation base is added, then heat retention is improved, but device complexity increases
Solution Approach 1:
A thermal insulation base is introduced as an intermediary component between the susceptor layers and the heating surface. This base layer (comprising insulating material) acts as a mediator that traps and retains heat generated by the susceptor layers, preventing heat loss to the underlying surface and thereby improving overall heat retention efficiency
Solution Approach 2:
The structure combines multiple materials with complementary properties: susceptor materials for microwave absorption, insulating materials for heat retention, and support materials for structural integrity. This composite construction achieves superior thermal performance while distributing functional requirements across different material layers
3Manufacturing precision
If multiple susceptor layers with insulating base are used, then heating and browning effectiveness is enhanced, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process is segmented into distinct stages: forming the thermal insulation base, positioning the first susceptor layer, positioning the second susceptor layer, and adding the support structure. This segmentation allows each component to be manufactured and assembled independently, reducing overall manufacturing complexity while achieving the desired heating effectiveness
Solution Approach 2:
The patent establishes a vertical assembly sequence where layers are added in order of height (base first, then first susceptor layer at first height, then second susceptor layer at second height). This dimensional approach to assembly simplifies the manufacturing process by providing a clear vertical construction sequence that can be systematically followed
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 significantly enhances the heating, browning, and crisping of food items by converting microwave energy into thermal energy, maintaining heat within the food item, and allowing for effective ventilation to prevent moisture buildup, resulting in more even and effective cooking.
Implementation Method 1
Each microwave energy interactive element comprises one or more microwave energy interactive components or segments arranged in a particular configuration to absorb microwave energy, transmit microwave energy, reflect microwave energy, or direct microwave energy
Implementation Method 2
The base generally may provide thermal insulation between the microwave energy interactive element and the heating environment
Implementation Method 3
at least one aperture or cutout may extend through one or more layers of the structure to provide direct heating and/or ventilation to the bottom surface of the food item
Data Source
Figure 1~3
Figure 4~6
Figure 7~9A
AI summary
A thermally insulated susceptor structure (100) comprises a dimensionally stable base (110) having a first side and a second side opposite the first side, a first susceptor (106a) overlying the first side of the base, and a second susceptor (106b) overlying the second side of the base. The base (110) includes a plurality of flutes or corrugations.