Egg Tray Assembly with Diffuser Plate for Even Heat Distribution

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Solution Overview

Problem

Eggs are sensitive to cooking conditions in impingement and convection ovens, and existing tray assemblies fail to ensure even heat distribution, leading to inconsistent cooking results, especially when accelerated cooking technologies are used.

Innovation Solution

A tray assembly with a diffuser plate and protrusions that create recesses for eggs, allowing for even air diffusion and contact, which helps in maintaining the natural shape and consistency of eggs during cooking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If hot air is circulated around eggs in impingement or convection ovens, then cooking speed is improved, but heat distribution becomes uneven causing inconsistent cooking results

Engineering Contradiction:
Improvecooking speedVSAvoidheat distribution uniformity
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

A diffuser plate is introduced as an intermediary component between the heat source and the eggs. The diffuser plate with its array of holes distributes the hot air flow evenly across multiple eggs simultaneously, preventing direct concentrated heat exposure on individual eggs while maintaining high cooking speed through continuous air circulation.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The diffuser plate segments the continuous hot air flow into multiple discrete streams through its array of holes. This segmentation allows each egg to receive distributed, uniform heat exposure rather than concentrated direct heat, achieving even cooking across all eggs while maintaining overall cooking efficiency.

Inventive Principle:
Principle #1Segmentation

2Loss of time

If accelerated cooking technologies are used, then cooking time is reduced, but egg appearance and consistency become inconsistent

Engineering Contradiction:
Improvecooking timeVSAvoidegg appearance consistency
Core Design Contradiction:
Loss of timeVSManufacturing precision

Solution Approach 1:

The diffuser plate serves as a mediator that enables accelerated cooking by distributing heat uniformly across all eggs simultaneously. This allows the cooking process to proceed quickly while maintaining consistent appearance and texture throughout the egg batch, as each egg receives equal heat exposure.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The diffuser plate creates locally optimized heat distribution conditions for each egg by directing air flow through specifically positioned holes. This ensures that each egg receives appropriate heat exposure for consistent cooking results, while the overall system maintains accelerated cooking speeds.

Inventive Principle:
Principle #3Local quality

3Productivity

If direct hot air exposure is applied to eggs, then cooking efficiency is improved, but egg white becomes rubbery and yolk overcooks

Engineering Contradiction:
Improvecooking efficiencyVSAvoidegg texture quality
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The diffuser plate acts as an intermediary that distributes hot air flow to prevent direct concentrated exposure on individual eggs. This maintains cooking efficiency through continuous air circulation while preventing rubbery egg whites and overcooked yolks by ensuring uniform, gentle heat distribution across all eggs.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The system applies partial hot air exposure to each individual egg through the diffuser plate's distributed holes, rather than excessive direct exposure. This partial action approach maintains overall cooking efficiency while preventing localized overcooking that would degrade egg texture quality.

Inventive Principle:
Principle #16Partial or excessive action

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 tray assembly ensures consistent cooking by diffusing air evenly over the eggs, preventing overcooking and achieving a crispy exterior while maintaining a desired texture and appearance, especially beneficial for cooking egg yolks.

Implementation Method 1

A tray assembly with a diffuser plate and protrusions that create recesses for eggs, allowing for even air diffusion and contact

Methodology Applied
Scientific EffectAir diffusion: Diffusion

Implementation Method 2

Each protrusion includes a bottom wall and a contoured surface. Each recess presents a non-uniform opening in the top side defined by an arcuate lip connecting the top side with the contoured surface. The contoured surface includes a ledge portion adjacent the bottom wall.

Methodology Applied
Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11730303B2Tray assembly
Publication Date: 2023.08.22 COOKTEK INDUCTION SYST LLC
  • US11730303B2 patent drawing
  • US11730303B2 patent drawing
  • US11730303B2 patent drawing

AI summary

A tray assembly includes a tray having a top side, an underside opposite the top side, and a plurality of protrusions extending from the underside. Each protrusion defines a recess in the top side and has a bottom wall and a contoured surface connecting the bottom wall to the top side. The tray assembly also includes a diffuser in the form of a plate with a plurality of apertures therethrough. The diffuser is couplable to the tray and positionable a spaced distance above the top side of the tray.