Nonstick composite materials and molded nonstick cookware
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Solution Overview
Problem
Existing nonstick cookware, particularly for commercial use, faces issues with durability, food support, heat dissipation, cleanability, and appearance, especially in high-speed ovens, and often requires recoating or replacement.
Innovation Solution
A nonstick laminate material composed of flexible substrates coated with heat-resistant polymers, pressed under high heat and pressure to form cookware with structural rigidity, including a raised rim for support and nonstick properties, capable of withstanding high temperatures without metal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polymer coated non-metal cooking sheets are used, then metal-free heat-resistant cooking is achieved, but structural rigidity and food support are insufficient
Solution Approach 1:
The patent applies composite materials by combining multiple laminate layers with different properties. The flexible substrate provides heat resistance and flexibility, while the coated fabric layers contribute nonstick properties and structural reinforcement. This composite structure achieves both metal-free operation and sufficient structural rigidity for commercial cooking applications.
Solution Approach 2:
The patent applies local quality by differentiating the properties of different laminate layers. Each layer is optimized for specific functions: the flexible substrate handles thermal stress and provides base strength, while the coated fabric layers provide nonstick surfaces and additional structural support where needed. This localized optimization resolves the contradiction between flexibility and rigidity.
2Ease of operation
If polymer coating is applied to provide nonstick properties, then nonstick performance is improved, but coating durability and resistance to flaking deteriorate
Solution Approach 1:
The patent uses composite materials with multiple coated fabric layers, each contributing to the overall nonstick and durable performance. The combination of different coated fabrics creates a synergistic effect where the coating is distributed across multiple layers, reducing stress on any single coating and preventing flaking while maintaining nonstick properties.
Solution Approach 2:
The patent segments the nonstick function across multiple laminate layers rather than relying on a single thick coating. Each layer provides a portion of the nonstick surface area, and the segmented structure reduces the mechanical stress on any individual coating layer, thereby improving durability and preventing flaking.
3Ease of manufacture
If single-layer laminate is used, then manufacturing simplicity is maintained, but structural rigidity and durability are insufficient
Solution Approach 1:
The patent employs composite materials with multiple laminate layers that are bonded together. This composite construction provides the necessary structural rigidity and durability for commercial cookware while maintaining manufacturing simplicity through standardized lamination processes and integrated production methods.
Solution Approach 2:
The patent merges multiple functional layers into a single integrated cookware component. The flexible substrate and coated fabric layers are combined through lamination to create a unified structure that provides both structural rigidity and nonstick properties, eliminating the need for separate components and simplifying manufacturing.
4Productivity
If known cooking sheets are used, then basic cooking function is provided, but heat dissipation and operator safety are compromised
Solution Approach 1:
The patent uses composite materials with a flexible substrate that inherently provides thermal management properties. The combination of materials creates a structure that dissipates heat effectively, preventing excessive heat buildup that could harm operators while maintaining the cooking function. The composite structure allows for controlled heat transfer and distribution.
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 laminate material provides durable, nonstick, and heat-resistant cookware that maintains structural integrity, supports food items, and cools quickly, suitable for high-speed ovens, with improved ease of use and longevity.
Implementation Method 1
pressed under high heat and pressure to form cookware with structural rigidity
Implementation Method 2
heat-resistant polymers... capable of withstanding high temperatures... and cools quickly
Data Source
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AI summary
Heat resistant and/or nonstick polymer materials and composites, and cookware including a food support surface comprising an integrated or attached cooking surface formed of the materials and composites. The cookware includes a laminate material with structural rigidity, wherein the laminate material includes a flexible substrate impregnated with the heat resistant polymer material and/or coated with a nonstick coating, and pressed or molded in a shaped cookware or other nonstick items or component. Various cooking devices can be pressed from the material, as well as oven or vehicle components.