Infrared Grill Grate Assembly Without Separate Emitter Plates
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Solution Overview
Problem
Existing infrared grilling systems face issues such as high costs due to expensive burners, flare-ups, extended preheat times, inadequate heat distribution for searing, and the need for separate emitter plates, which hinder efficient infrared cooking.
Innovation Solution
A cooking grate assembly with a lower radiating structure and food support ribs that allow hot combustion gases to flow through, reducing preheat time and increasing heat transfer, eliminating the need for separate emitter plates and minimizing flare-ups, while using lower-cost burners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional infrared emitter plates are used, then infrared cooking performance is achieved, but device complexity and cost increase due to separate emitter plates and expensive burners
Solution Approach 1:
The patent combines the emitter plate function and food support grate function into a single integrated structure. The grate assembly includes a radiating plate with openings and food support bars positioned above the openings, eliminating the need for separate emitter plates while maintaining infrared cooking performance through hot gas flow through the openings
Solution Approach 2:
The grate assembly serves multiple functions simultaneously: it supports food, radiates infrared energy, and allows hot gas flow. The radiating plate with openings enables the structure to function as both a support surface and an infrared emitter, reducing overall system complexity
2Ease of manufacture
If open grate structures are used, then cost is reduced, but flare-up problems occur due to ignition of dripping fat
Solution Approach 1:
The grate assembly has different properties in different locations: open areas for gas flow and heat radiation, and solid food support bars for structural support. The food support bars are positioned to provide support while allowing controlled gas flow through the openings below, preventing flare-ups while maintaining cooking performance
3Ease of manufacture
If conventional grate structures are used, then manufacturing is simpler, but preheat time is extended and searing performance is inadequate
Solution Approach 1:
The grate assembly utilizes gas flow dynamics by positioning openings in the radiating plate to allow hot combustion gases to flow directly through the structure and contact the food support bars. This pneumatic flow design rapidly heats the grate components, reducing preheat time while maintaining simple manufacturing
Solution Approach 2:
The grate assembly is segmented into multiple components: radiating plate with openings, food support bars, and side supports. This segmentation allows hot gases to flow through multiple pathways, rapidly heating different sections of the grate simultaneously and reducing overall preheat time
4Ease of manufacture
If lower-cost burners are used, then device cost is reduced, but thermal efficiency and infrared energy transfer are insufficient
Solution Approach 1:
The radiating plate contains multiple openings that function as a porous structure, allowing hot combustion gases to flow through while the solid portions radiate infrared energy. This design captures and directs thermal energy efficiently, improving thermal efficiency and infrared transfer even with lower-cost burners
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 grate assembly achieves faster heating, higher thermal efficiency, and increased infrared energy transfer to food, reducing preheat time by up to 32% and enhancing grill marks, while being cost-effective and resistant to flare-ups.
Implementation Method 1
hot combustion gas or other hot flue gas will flow into the rib elements
Implementation Method 2
Outdoor grilling systems which primarily utilize infrared radiant energy for cooking food items
Implementation Method 3
Outdoor grilling systems which primarily utilize infrared radiant energy for cooking food items
Data Source
AI summary
An outdoor grill assembly with a cooking grate therein. The cooking grate can be a one-piece structure but is preferably a two-piece structure wherein the upper piece comprises longitudinally extending food support ribs having hollow interiors. The ribs will be positioned over and cover open areas in the lower structure so that combustion gases flowing through the open areas of the lower structure will flow into the hollow interiors of the food support ribs.