Fluoropolymer Release Sheet with Nucleation Structures for Grease Splatter

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Solution Overview

Problem

Commercially prepackaged and restaurant cooking processes face challenges with grease splatter, which leads to increased cleaning efforts, sanitation issues, and safety hazards due to the adhesion of food and juices to cooking surfaces, particularly when using low surface energy materials that can superheat and project hot grease and water.

Innovation Solution

A sheet material with a low surface energy polymer, such as fluoropolymer, and reinforcement materials like fiberglass, featuring nucleation structures at a density of at least 10 per square inch, which promotes evaporation and reduces splatter by forming small bubbles, thereby limiting superheating and adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If low surface energy materials are used to prevent sticking, then adhesion of food to cooking surface is reduced, but superheating occurs leading to grease splatter and safety hazards

Engineering Contradiction:

Improvenon-stick propertyVSAvoidgrease splatter

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent applies a porous coating layer on the cooking surface that allows controlled interaction with grease and water. The porous structure prevents superheating by providing nucleation sites for bubble formation, thereby reducing grease splatter while maintaining non-stick properties through the low surface energy material.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses a composite structure combining a low surface energy material (for non-stick property) with a porous coating layer (for splatter control). This composite approach integrates two functional layers: one that prevents adhesion and another that prevents superheating and grease projection.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If non-stick cooking surfaces are used to prevent meat from sticking, then cleaning effort is reduced, but grease splatter increases causing sanitation issues and safety hazards

Engineering Contradiction:

Improvecleaning efficiencyVSAvoidgrease splatter

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The porous coating layer provides nucleation sites that prevent superheating of grease and water, thereby reducing grease splatter. This maintains the non-stick property for easy cleaning while adding the function of splatter control through the porous structure.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent converts the potentially harmful effect of superheating and grease splatter into a beneficial controlled evaporation process. The porous structure promotes gentle bubbling and evaporation instead of violent splatter, turning a harmful phenomenon into a controlled, safe process.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Object-affected harmful factors

If standard cooking surfaces are used without non-stick properties, then grease splatter is reduced, but meat sticks to the surface requiring increased cleaning effort

Engineering Contradiction:

Improvegrease splatter controlVSAvoidcleaning effort

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The porous coating layer serves dual functions: it controls grease splatter through nucleation sites that prevent superheating, and it maintains non-stick properties that reduce cleaning effort. The porous structure allows the coating to interact beneficially with grease and water during cooking.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The composite structure combines a porous coating layer with a low surface energy material, achieving both grease splatter control and non-stick properties. This integrated solution simultaneously addresses cleaning efficiency and splatter control without compromise.

Inventive Principle:

Principle #40Composite materials

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 sheet material effectively reduces splatter and adhesion, enhancing safety and cleaning efficiency while maintaining non-stick properties, as demonstrated by its resistance to hot grease and durability in cooking environments.

Implementation Method 1

the water can be coated by the grease and can superheat. When a portion of the water flashes to steam, hot grease and water are projected from the surface as splatter

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

the sheet material can include a fluoropolymer coating disposed between the major surface of the sheet material and the reinforcement material

Methodology Applied

Scientific EffectNucleation: Nucleation

Data Source

PatentUS8673449B2Cooking release sheet materials and release surfaces

Publication Date: 2014.03.18 SAINT GOBAIN PERFORMANCE PLASTICS CORP

AI summary

A cooking release material includes a layer comprising fluoropolymer. The cooking release material has a major surface having nucleation structures in a density of at least 10 per square inch. The cooking release material can include a reinforcement material, the layer coated over the reinforcement material. The cooking release material can include a second layer forming the major surface.