Multi-Layer Heat Zone Pan With Cooler Sidewalls
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Solution Overview
Problem
Conventional multi-ply bonded cookware often experiences hot sidewalls that lead to difficult-to-clean burned-on grease spatter due to inadequate thermal insulation, and existing manufacturing methods result in high material costs and scrap losses.
Innovation Solution
The cookware features a central copper, aluminum, or graphite core disc bonded with stainless steel layers, utilizing a solid state bonding technique under high pressure and temperature to create a thermal insulation gap between the core and aluminum layers, reducing sidewall temperature and allowing for lighter weight and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional multi-ply bonded cookware uses a central copper or aluminum core extending through the entire sidewall, then high thermal conductivity is achieved for even heating, but the sidewalls become too hot causing burned-on grease spatter and difficult cleaning
Solution Approach 1:
The core is segmented into two distinct zones: a central high-conductivity core (copper or aluminum) for even heating, and an outer aluminum layer that is thermally insulated from the central core by an air gap. This segmentation allows the central cooking surface to remain hot for effective cooking while the sidewalls stay cooler to prevent grease spatter
Solution Approach 2:
An air gap is introduced as a thermal intermediary between the central copper/aluminum core and the outer aluminum layer. This air gap acts as a thermal barrier that blocks heat transfer to the sidewalls, thereby reducing sidewall temperature and preventing burned-on grease spatter while maintaining efficient heat distribution at the cooking surface
2Ease of manufacture
If conventional roll-bonding techniques are used to bond copper, aluminum, and stainless steel layers, then multi-layer composite cookware is manufactured, but high material costs and scrap losses occur
Solution Approach 1:
The manufacturing process transitions from conventional roll-bonding to solid state bonding, changing the bonding parameters from room temperature or low temperature rolling to high temperature and high pressure conditions. This parameter change enables direct bonding of the multi-layer composite structure, reducing material waste and improving manufacturing efficiency
Solution Approach 2:
The invention uses a multi-layer composite structure consisting of a central copper or aluminum core, an outer aluminum layer, and stainless steel bonding layers. This composite material design allows optimization of thermal conductivity in the central zone while maintaining structural integrity and reducing overall material costs through selective material placement
3Temperature
If a central copper core extends through the entire sidewall to provide high thermal conductivity, then even heating is achieved, but the cookware becomes heavier
Solution Approach 1:
High thermal conductivity is applied locally only where needed - in the central cooking surface area - rather than throughout the entire sidewall. The central copper or aluminum core provides excellent heat distribution at the cooking surface, while the sidewalls use lighter aluminum material that is thermally insulated from the central core, achieving both even heating and weight reduction
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 effectively keeps sidewalls cooler, preventing burned-on grease and reducing material waste, while enabling the use of diverse stainless steel grades and alternative materials, resulting in a more efficient and cost-effective cookware production process.
Implementation Method 1
As used herein, the term 'solid state bonding' means a method of bonding two or more stacked discs of metals or metal alloys together using high pressure and high temperature
Implementation Method 2
The aluminum core layer is spaced from the outer edge of the central copper disc by a gap so as to insulate the aluminum layer from conductive heat transfer from the copper central core disc
Data Source
AI summary
Provided is an article of cookware and a method of making same. The cookware is made from a bonded, multi-layer composite comprising a core construction having a central core disc of a high heat conductive material and an outer ring-shaped core disc surrounding and spaced from the central core disc by a gap to minimize thermal conduction from the central core disc to the outer ring-shaped core disc.