Honeycomb Mesh Screen for Uniform Microwave Oven Grilling

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Solution Overview

Problem

Microwave ovens with supplemental heating systems for grilling and broiling face issues with non-uniform spatial distribution of IR radiation, leading to inconsistent cooking results.

Innovation Solution

A metallic mesh screen with a honeycomb pattern of hexagonal apertures is placed between the IR radiation sources and the cooking cavity to uniformly distribute IR radiation and minimize microwave energy losses, using high-temperature austenitic stainless steel and a reflective layer to protect the IR sources and users.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a supplemental heating system with IR radiation source is added to microwave oven for grilling and broiling, then cooking functionality is improved, but non-uniform spatial distribution of IR radiation causes inconsistent cooking results

Engineering Contradiction:

Improvecooking functionalityVSAvoidcooking uniformity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

A metallic mesh screen is introduced as an intermediary component between the IR radiation source and the food. This screen acts as a mediator to redistribute the IR radiation spatially, converting the non-uniform radiation pattern from the source into a uniform distribution across the cooking surface, thereby achieving consistent grilling and broiling results while maintaining the supplemental heating functionality

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If metallic mesh screen is placed between IR radiation source and cooking cavity to distribute IR radiation, then cooking uniformity is improved, but microwave energy field losses increase

Engineering Contradiction:

Improvecooking uniformityVSAvoidmicrowave energy field losses

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The metallic mesh screen parameters are specifically optimized with a honeycomb pattern where the aperture dimension Ax is less than or equal to about 3 times the spacing Bx between adjacent apertures. This parameter relationship creates a frequency-selective structure that allows microwave energy to pass through with minimal reflection and absorption, reducing energy losses while still achieving uniform IR radiation distribution

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If honeycomb pattern screen with Ax <= 3Bx is used to minimize microwave energy losses, then energy efficiency is improved, but IR radiation uniformity may be compromised

Engineering Contradiction:

Improvemicrowave energy field lossesVSAvoidIR radiation uniformity

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The honeycomb pattern parameters are precisely controlled with the constraint that Ax (aperture dimension) is less than or equal to about 3 times Bx (spacing between adjacent apertures). This specific parameter relationship optimizes the balance between microwave transmission efficiency and IR radiation uniformity, ensuring that the screen allows sufficient microwave energy passage while maintaining effective IR radiation distribution for consistent cooking

Inventive Principle:

Principle #35Parameter changes

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 ensures uniform grilling and browning of food while reducing microwave energy field losses and protecting the IR sources from damage, resulting in improved cooking performance and safety.

Implementation Method 1

at least one IR radiation source for generating IR radiation that is projected into the cooking cavity

Methodology Applied

Scientific EffectIR radiation: Infrared Radiation

Implementation Method 2

minimizing microwave energy field losses

Methodology Applied

Scientific EffectMicrowave energy field: Microwave Radiation

Data Source

PatentUS11184958B2Microwave oven grilling apparatus with high efficiency honeycomb pattern screen

Publication Date: 2021.11.23 WHIRLPOOL CORP

AI summary

A microwave oven is provided including a cooking cavity for receiving food to be cooked, at least one microwave source for generating microwave energy inside the cooking cavity, and a supplemental heating system positioned to heat the food. The supplemental heating system includes at least one IR radiation source for generating IR radiation and a metallic mesh screen placed between the at least one IR radiation source and the cooking cavity for spatially distributing the IR radiation to uniformly project into the cooking cavity and minimizing microwave energy field losses. The metallic mesh screen includes a plurality of hexagonal apertures arranged in a honeycomb pattern. The distance between parallel sides of each one of the hexagonal apertures is Ax and the distance between each hexagonal aperture and each adjacent hexagonal aperture is Bx where Ax is less than or equal to about 3 times Bx.