Segmented Oven Air Plenums for Uniform Multi-Rack Heating
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Solution Overview
Problem
Conventional convection ovens experience uneven heating due to regions of high and low air flow, leading to inconsistent cooking results, where food items on different racks or at different heights are cooked at varying rates, resulting in food waste and increased labor and time requirements to achieve uniform cooking.
Innovation Solution
The design incorporates one or more air plenums within the oven cavity, featuring offset top and bottom air outlets and impermeable front and rear surfaces, which direct heated air uniformly into upper and lower cooking chambers, optimizing air flow distribution and reducing cooking time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a fan is used to circulate heated air in a conventional convection oven, then air movement is generated to distribute heat, but regions of high and low air flow are created resulting in uneven heating
Solution Approach 1:
The oven cavity is divided into multiple cooking chambers separated by air plenums. Each plenum acts as an independent air distribution zone with its own outlets, segmenting the air flow paths to eliminate large regions of high and low air flow. This segmentation allows more uniform heat distribution across different racks and positions.
Solution Approach 2:
Air plenums are introduced as intermediary structures between the heating elements and the food items. These plenums receive heated air from the fan and redistribute it through multiple offset outlets, acting as mediators that transform the uneven fan-generated air flow into more uniform multi-directional air flow patterns.
2Productivity
If multiple racks are placed at different heights to accommodate various foods, then cooking capacity increases, but uneven heating occurs between racks at different heights
Solution Approach 1:
The vertical space between racks is segmented into separate cooking chambers by air plenums. Each chamber is an independent air distribution zone with controlled outlets, allowing uniform heat distribution within each chamber. This enables multiple racks at different heights to be cooked uniformly despite the height differences.
Solution Approach 2:
Different regions of the oven cavity are given different air flow characteristics through locally adapted plenum designs. Each cooking chamber has outlets positioned to provide optimal air flow for that specific zone, ensuring that food items at different heights receive appropriate heating conditions for uniform cooking.
3Productivity
If food items are placed on different racks to increase cooking capacity, then productivity increases, but food waste increases due to overcooking in high heat portions
Solution Approach 1:
By segmenting the oven into multiple cooking chambers with controlled air flow, food items on different racks are protected from excessive heat exposure. Each chamber maintains appropriate heating conditions, preventing overcooking and reducing food waste while maintaining high cooking capacity through multi-rack operation.
4Manufacturing precision
If reduced cooking temperatures and blower speeds are used to overcome uneven cooking, then cooking uniformity improves, but cook times increase and labor requirements increase
Solution Approach 1:
The segmented plenum structure enables maintained high blower speeds and cooking temperatures while achieving uniform cooking. The multiple offset outlets distribute hot air evenly across all cooking chambers, allowing fast cooking without sacrificing uniformity, thus reducing both cook time and labor requirements.
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
This configuration ensures more uniform heating across the oven cavity, reducing food waste and labor by maintaining consistent cooking temperatures and times, even for items at different heights and on the same rack.
Implementation Method 1
an air blower for sending heated air to the left side air channel and the right side air channel
Implementation Method 2
an intermediate air plenum defining the bottom of an upper cooking chamber and the top of a lower cooking chamber within the oven cavity
Data Source
AI summary
A convection oven having one or more intermediate air plenums is disclosed. An intermediate air plenum placed within an oven cavity defines the bottom of an upper cooking chamber and the top of a lower cooking chamber. Each intermediate air plenum comprises a left side air inlet for receiving heated air from a left side air channel located on a left side cavity wall of the oven cavity, a right side air inlet for receiving heated air from a right side air channel located on a right side cavity wall of the oven cavity, a top plenum surface including a plurality of top air outlets configured to direct a portion of the heated air upwards, and a bottom plenum surface including a plurality of bottom air outlets configured to direct a portion of the heated air downwards. The top and bottom plenum surfaces are preferably shaped to optimize even distribution of heated air flow into the oven cavity.