A gas-fired, double-sided griddle apparatus for high-volume commercial cooking comprises double-sided griddles, each having a lower platen having a horizontal lower cooking surface and an upper platen having an upper cooking surface; a positioning mechanism for moving the upper platen of each griddle into a horizontal position in contact with the food, permitting the upper platen to press downward against the food until the cooking surface reaches a predetermined level above the cooking surface of the lower platen, stopping the downward movement at that level, and lifting the upper platen away from the food after a predetermined cooking time; a counterflow heater for heating a supply of oil to desired temperatures; and apparatus for circulating the heated oil through a serpentine path wherein the oil contacts, and transfers heat to, a first region of the lower platen and a similar path wherein the oil transfers heat to a second region of the upper platen that is positioned directly above, and parallel to, the first region while cooking food located between the two regions of the platens. A weight controlled valve in the oil circulating apparatus maintains substantially constant pressure in the oil.
This invention relates to cooking apparatus It has to do more particularly with gas-fired double-sided griddles for high-volume cooking of meat, eggs, pancakes, and other foods.
CROSS REFERENCE
The present invention is related to the subject matter disclosed in the following United States patent applications and patents, all of which are incorporated herein by reference:
U.S. Pat. Ser. No., filed May 20, 1992, pending by Paul E. George, II, Richard E. Wendorf, and Bruce E. Taber, for Weight Controlled Valve; now U.S. Patent.
U.S. Ser. No. 07/953,557, filed Sept. 29, 1992, pending by Paul E. George, II, and John S. Barnhart, for Heat Exchanger; now United States Patent
U.S. Ser. No. 07/886,509, filed May 20, 1992, pending by J. Douglas Dickson, for Positioning Mechanism; now United States Patent.
The following disclosure includes, with slight revision, the paper "A Gas-Fired, Double-Sided Griddle for High-Volume Commercial Cooking", by Paul E. George, II, John D. Dickson, and Donald E. Fritzsche; presented May 21, 1991, at the 1991 International Appliance Technical Conference held at University of Wisconsin-Madison; Madison Wisconsin, U.S.A. May 21-22, and published in the Proceedings of the 42nd Annual International Appliance Technical Conference, pp. 51-65.
BACKGROUND, FIELD, PRIOR ART
To increase the speed of cooking in high-production environments or where customer service time is crucial, food can be griddled from both sides simultaneously by placing a heated surface in contact with the top. Not only does this process decrease cooking time by a factor of two or more, it also improves quality.
A typical gas-fired double-sided griddle according to the present invention provides outstanding temperature uniformity, fast response, and high efficiency, including low idle energy consumption.
A circulating hot oil system as shown in FIG. 8 transfers heat to the cooking surfaces from a gas-fired oil heater as shown in FIG. 9, located below the griddle A simple, effective, and robust system shown in FIGS. 1-7 positions the upper platens to maintain intimate contact with the food without excessively compressing soft foods.
Heating on a hot flat surface has been one of the mainstays of food preparation for thousands of years, as evidenced by scorched rocks found in archeological digs. The process, now called griddling, cooks rapidly by effectively conducting heat from the griddle to the food. Griddling also provides a rapidly seared food surface that seals in juices. Most foods are cooked from both sides sequentially; they are flipped about half way through the cooking process. Although a variety of foods are prepared on griddles, hamburgers are the dominant product. Hamburgers are particularly adapted to preparation in this way since the natural oils melted out of the meat form an effective heat transfer medium between the meat and the griddle. Texturing or puncturing the hamburger surface increases cooking speed by providing a convective path for hot grease to reach the center of the patty.
To increase the speed of cooking in high-production environments or where customer service time is crucial, food can be griddled from both sides simultaneously by placing a heated surface in contact with the top. Not only does this process decrease cooking time by a factor of two or more, it also improves quality. Because both sides are seared simultaneously, more natural juices are retained. The operator-dependent flipping operation is eliminated, thus improving product consistency.
Electrically heated top platens have been used by two major food chains for several years. These devices were commercially successful but deficient in performance because of the high operating cost of resistance electric heating, the high installation cost to rewire for the high power draw, and overheating of those portions of the griddle not in contact with food.
SUMMARY
The gas-fired double-sided griddle of the present invention eliminates these problems and improves surface temperature uniformity while providing very fast response. A circulating hot oil system transfers heat to the cooking surfaces from a gas-fired oil heater located below the griddle. A simple, effective, and robust system positions the upper platens to maintain intimate contact with the food without excessively compressing soft foods.
Typical apparatus for cooking according to the present invention comprises double-sided griddle means having a lower platen providing a horizontal lower cooking surface and an upper platen providing an upper cooking surface; means for positioning the upper cooking surface in a predetermined sequence before, during, and after cooking; means for heating a supply of oil to temperatures within a predetermined range; and means for circulating the heated oil through a serpentine path wherein the oil contacts, and transfers heat to, a substantial first region of the lower platen and a serpentine path wherein the oil contacts, and transfers heat to, a substantial second region of the upper platen that is positioned directly above, and parallel to, the first region while cooking food located between the first and second regions of the platens.
The positioning means typically comprises means for moving the upper platen into a horizontal position in contact with the food, permitting the upper platen to press downward against the food until the cooking surface reaches a predetermined level above the cooking surface of the lower platen, stopping the downward movement at that level, and lifting the upper platen away from the food after a predetermined cooking time; and preferably comprises apparatus substantially as disclosed in FIGS. 1-7 and the associated description herein.
Preferably the heating means comprises gas burning counterflow apparatus substantially as disclosed in FIG. 9 and the associated description herein.
The oil circulating means typically comprises apparatus substantially as disclosed in FIG. 8 and the associated description herein; including a weight controlled valve substantially as disclosed in FIGS. 13-15 and the associated description herein, for maintaining substantially constant pressure in the circulating oil.
Preferably the circulating means comprises also a heat exchanger substantially as disclosed in FIGS. 16-18 and the associated description herein.
In typical apparatus according to the invention platen temperature is controlled by a solenoid valve that is either open if the platen is below a predetermined set point or closed if the platen is above the set point; a dead band of about 3.degree. to 8.degree. F. is included in the controller; when the solenoid valve opens, hot oil flows through the platen and heats the cooking surface; when the valve closes, hot oil is trapped inside the platen, and as the oil cools, the platen temperature rises until the metal and oil equilibrate.
DRAWINGS
FIGS. 1-7 are schematic sectional views of typical cooking apparatus according to the present invention. These figures show the apparatus in various stages of a typical cooking sequence.
FIG. 8 is a schematic diagram showing a typical hot oil system for a gas-fired double-sided griddle for high-volume commercial cooking in which the valve in FIGS. 13-15 is especially useful.
FIG. 9 is a schematic sectional view of a typical counterflow fluid heater incorporating preheating of the fuel-air mixture in cooking apparatus as in FIGS. 1-8.
FIG. 10 is a schematic plan view of a heating platen showing the locations of thermocouples used in testing the uniformity of temperature therein.
FIG. 11 is a graph of measured cooking surface and oil temperatures as functions of the time from starting to heat a griddle in the cooking apparatus.
FIG. 12 is a perspective view of typical cooking apparatus according to the present invention with the right upper platen in the raised position.
FIG. 13 is a partly schematic front sectional view of a typical weight controlled valve according to the present invention, showing the weight and piston in their lowest position.
FIG. 14 is a similar view of the same valve (except for an alternative, slightly modified, inlet portion at the bottom), showing the weight and piston in their highest position.
FIG. 15 is a top sectional view of the valve in FIG. 13, taken in the plane 3--3 in FIG. 13.
FIG. 16 is a schematic sectional plan view of a typical heat exchanger according to the present invention.
FIG. 17 is a schematic edge view of the same heat exchanger.
FIG. 18 is an enlarged sectional view of the portion of the heat exchanger that is encircled in FIG. 17.
FIG. 19 is a schematic cross-sectional view of two adjacent channels in a heat exchanger as in FIGS. 16-18, illustrating typical methods of two-dimensional modeling to determine substantially optimal dimensions therein.
FIG. 20 is a schematic drawing generically representing the channel in a heat exchanger as in FIGS. 16-18, and illustrating a simplified model to calculate the temperatures along the length of the channel.
FIG. 21 is a graph of temperature versus length at successive points along the inlet half of the channel and at adjacent points along the outlet half of the channel for a well-designed heat exchanger according to the present invention.
FIG. 22 is a graph similar to FIG. 21 for a heat exchanger of the same general type, poorly designed.
PREFERRED EMBODIMENTS
Circulating Oil System
A schematic diagram of the circulating oil system is shown in FIG. 8. The system comprises a pump 41, an oil heater 42, a supply manifold 46, a return manifold 48, a pressure control valve 10, six (or more) platens 43A-43F, and their associated control valves 49A-49F. The platens 43 are flat heat exchange surfaces bolted to the backs of the cooking surfaces as shown in FIGS. 17 and 18. The success of the system depends largely on a ready supply of hot oil 23 that can be immediately circulated through a platen 43 when heat is needed. Maintaining a proper differential pressure between the supply and return manifolds 46,48 and balancing the thermal inertia of the platens 43 with the amount of oil 23 introduced to the platen are also important. Surface temperature uniformity is achieved by an improved method of passing oil 23 through the platens 43.
Platen temperature is controlled by a solenoid valve 49 which is either open if the platen 43 is below set point or closed if the platen 43 is above set point. A five degree dead band is included in the controller. When the solenoid valve 49 opens, hot oil 23 flows through the platen 43 and heats the cooking surface. When the valve 49 closes, hot oil 23 is trapped inside the platen 43. As the oil cools, the platen temperature rises until the metal and oil equilibrate. The platen 43 is designed so that a full charge of oil at 450.degree. F. will not cause the platen to heat more than about 15.degree. above set point even under low-temperature conditions. For example, if the control set point is 250.degree. F., and the platen temperature drops below 247.5.degree. F., the solenoid valve 49 opens until the platen temperature rises to 252.5.degree. F. and then closes. The heat capacity of the platen 43 is over 15 times that of the oil 23, so the equilibrium temperature without heat loss is less than 256.degree. F. When cooking, the temperature overshoot is actually lowered by the heat load on the platen 43. As platen temperature is increased to 350.degree. F., the amount of overshoot drops since the oil 23 must cool less before matching the platen temperature. Heat loss from the platen is also higher so that overshoot is almost nonexistent at 350.degree. F.
The minimum mass of the platens 43 is defined by temperature overshoot; the maximum is not constrained. However, quickest response is obtained by platens with the minimum mass. Fortunately the response time of the platens is more dependent on surface contact between the oil 23 and platen 43 than on the total mass of oil in the system. One key to successful operation of the griddle is to maximize oil side heat transfer area and minimize oil inventory in the platen.
An oil temperature controller turns the burner 62 on or off to maintain the oil temperature, leaving the heater 42 between 420.degree. and 450.degree. F. Oil 23 is circulated continuously through the oil heater 42. In fact, the oil flow through the heater 42 is independent of the number of platens in service The burner 62 is turned on when the oil leaving the heater 42 drops below 420.degree. F. and off when it rises to 450.degree. F. Since the heater 42 is designed to increase oil temperature about 15.degree., all the oil 23 in the supply/return system is at least 435.degree. F. when the burner turns off. With the burner 62 off, the temperature exiting the heater 42 equals the entering temperature, and the minimum oil temperature is 420.degree. F. During idle operation (no platens calling for oil), the burner 62 runs less than five minutes every hour.
The pressure differential between the supply and return manifolds 46, 48 is maintained by a special dead-weight valve 10, shown in detail in FIGS. 13-15. A weight 22 is supported by the pressure differential between the manifolds 46, 48 and rises or falls to increase or decrease flow as needed to maintain constant differential pressure. Because the design flow through the oil heater 42 is greater than the required flow with all platens 43 on, the weight 22 "floats" whenever the pump 41 is running and a magnetic switch 31, 32 on the weight ensures that adequate oil flow is available to the heater 42 before the burner is allowed to operate. Because the pump 41 sees constant head (pressure), the flow through the oil heater 42 is constant. Frictional pressure drop introduces only minor variations in oil flow. The dead-weight valve 10 is located at the opposite end of the manifolds 46, 48 from the supply and return connection to eliminate dead spots. When configured as shown in FIG. 8, the entire supply manifold 46 is filled with hot oil 23 at all times.
The oil heater 42, shown in FIG. 9, consists of a coil of finned tubing 61 surrounding a cylindrical burner 62. The velocity in the coil 61 and the surface area of the fin 65 are balanced so that metal surface temperatures in contact with the oil 23 are limited to less than about 550.degree. F. Typically the dimensions of the components of the oil heater 42 are approximately proportional to those in FIG. 9. The fins 65 are radial, about 0.03 inch thick, and evenly spaced at about ten per inch, along the tubing 61, where the outer diameter of the tubing 61 is about one inch.
As shown in FIG. 9, the heater 42 is a two-pass, counter/crossflow design. Flue gases 63 exit over the coolest oil and surround the inlet air pipe 64, providing some air preheat. Flue gas 63 exits the rear of the griddle and can be attached to a direct vent or vented to a hood. High fin area and counterflow design allow flue gas temperatures to approach to within 100.degree. F. of the entering oil temperature.
The coil 61 is positioned inside a housing 69 to collect and direct gases in an advantageous path 72. The cylindrical burner 62 is positioned coaxially with the coil 61 near one end. The air and gas supply to the burner 62 pass along the axis of the coil 61 and are bathed by the flue products leaving the system. A baffle 71 positioned on the air and gas supply pipe 64 forces gases from the burner 62 to flow through the fins 65 of the tube 61 as indicated at 72.
The burner 62 is a fully premixed, cylindrical, conventional perforated screen burner. A small forced draft fan draws air 66 from the oil system cavity. The fan discharge 66 is located directly opposite to the gas inlet 67; therefore gas/air mixing is readily achieved. The burner entrance tube provides additional opportunity for mixing. A spark ignitor 68 introduced from the end of the heater 42 ignites the burner 62 following a 15-second prepurge. The forced draft fan operates only during the prepurge and when the burner 62 is on to minimize heat loss during the off cycle. Because excess air is controlled, heater steady state efficiency exceeds 75 percent and the overall appliance efficiency is greater than 70 percent.
Advantages of this system include its compact design, simplicity of construction, high performance due to highly enhanced surfaces and control of gas flow, and preheating of the air and gas mixture to recover heat from the flue products and improve flame stability.
Upper Platen Positioning System
The second important aspect of the gas-fired, double-sided griddle is a means of conveniently positioning an upper cooking surface in contact with the product. Testing with a variety of schemes revealed that effectively searing the top side of a hamburger requires contact between the platen 43A, 43C, or 43E and the hamburger. Further, cooking speed is greatly enhanced by direct contact. However, excessive pressure on the hamburgers increases the tendency to stick and may crush the meat to a hard, unpalatable consistency.
Product uniformity objectives were realized by a counterbalanced, parallel motion positioning system 80. The upper platen positioning system 80 is shown schematically in FIGS. 1-7. The positioning system 80 allows two distinct motions by the platens 43A,C,E; pivoting about the point 81, and an up and down vertical motion via the rear linkage bar 82, with the platens 43A,C,E parallel to the lower cooking surfaces 43B,D,F.
The upper platens 43A,C,E are supported by a pivoting cantilever 83 that allows the upper platens to be raised to 60.degree. above horizontal. Compression springs 84 inside the cantilever housing 85 counterbalance the weight of the upper platens 43A,C,E about the pivot point 81 so that a force of only about 10 pounds is required to close and latch the platens. A platen opens automatically when the latch 86 is released. The upper platens are positioned parallel to the lower platen by adjusting the latch position.
The entire cantilever 83, spring 84, and upper plate system is attached to a four-bar mechanism 82,87,88,89 at the back of the griddle that maintains the upper platens 43A,C,E parallel to the lower platens 43B,D,F. A manually or motor-actuated low-limit stop 91 adjusts the minimum gap between the upper and lower platens. The gap may be set at any position up to one inch. The low-limit stop 91 defines the final, minimum thickness of the product and is set to match the food product.
An auxiliary lifting device (manual or electrical) can raise the four-bar mechanism 82,87,88,89 to approximately 11/8" above the lower platen surface. When the auxiliary lifter is lowered, the upper platen 43A will settle onto the lower stop 91 or the food, whichever is contacted first. The upper platen 43A is not lowered onto food until after it is latched; therefore warped frozen foods cannot prevent latching.
At the end of a cooking cycle, the latch 86 is released, the platens 43A,C,E tilt upward, and the four-bar mechanism 82,87,88,89 is driven to the full up position. After loading food on the griddle, the upper platens are manually latched and then automatically lowered. If the platens contact food (e.g., a warped frozen hamburger) before they settle to the lower stop, the weight of the platens rests on the food. A compression spring 92 on the pivot support 82 counterbalances the upper platen weight so that no more than 40 pounds of force is applied to the food. Experience has shown that this weight is acceptable for a group of five or more hamburgers. Forty pounds is acceptable for a single hamburger only if the lower stop 91 limits the travel to avoid crushing the hamburger. For a warped frozen food product, the initial contact coupled with a concentration of weight causes the offending item to thaw more rapidly and relieve the interference. Of course, all of the hamburgers (or other products) are the same thickness when finished since the upper platen is constrained to move parallel to the lower platen.
FIG. 12 shows a prototype griddle with the right upper platen in its raised position. Unlike the currently available double-sided griddles, there are no knobs or cams on the upper platens; they have an aesthetically pleasing, uncluttered look. More importantly, the simple lines that result from the cantilever design improve cleanability.
Heat Exchanger
Each upper platen 43A,C,E is equipped with a removable shoe 111, shown in FIGS. 17 and 18, which is mechanically attached to the heat exchanger 110 of the upper oil transfer platen 43A,C,E. A layer of heat transfer grease improves contact between the shoe and the oil platen over their contiguous surfaces, as indicated 112 in FIG. 18. The shoe 111 may be coated with a highly durable non-stick coating, which is expected to exceed a six-month operational lifespan. Access to the mounting hardware is through the upper cantilever cover.
Griddle Performance
Griddle design and performance parameters are listed in Tables 1 and 2. Summarizing briefly, the griddle is over 70 percent efficient, uses less than 15,000 Btu/hr when idling at temperature (with upper platens lowered), and provides outstanding surface temperature uniformity and zone separation. The griddle can cook 720 quarter-pound hamburgers per hour.
Surface, Temperature, and Uniformity
FIG. 10, which is to scale, shows the positions of thermocouples welded on an upper platen during a temperature uniformity test. The platen is 28.5 inches long and 11.5 inches wide. Excluding the corners, the thermocouple temperature range (maximum minus minimum) was 5.degree. at any specific time. Incorporating the 5.degree. dead band in the controller, the temperature range during steady state operation is 10.degree..
Start-Up and Recovery
FIG. 11 shows a temperature trace for the griddle as it warms from a cold condition to 360.degree. F. Each diamond on the 300.degree. line represents a load of ten hamburgers applied to a 12-inch wide section of the griddle. Hamburgers were loaded sequentially from the left section to the right. The griddle achieved cooking temperature in 12 minutes, and 120 hamburgers were cooked in 13 minutes. A skilled operator could have done better. As expected, temperature was less uniform during cooking than during testing because frozen hamburgers were placed on the griddle. However, there is no detectable temperature drop during cooking. A 30 degree sag did occur near the 27-minute mark when a soaking wet bath towel was placed on the griddle to begin cleaning.
Zone Separation
A pancake was placed to overlap two zones during cooking. The zone on the left was set for 265.degree. F. and the zone on the right for 400.degree. F. Two points were apparent from this qualitative test: zone separation is excellent since the 400.degree. to 275.degree. F. transition was observed to take place in less than one inch, and each section of the pancake was uniformly browned, showing local qualitative uniformity that confirms the quantitative data outlined above.
Cooking Performance
The griddle has been tested on hamburgers (double-sided), pancakes (double and single-sided), bacon (double-sided), and eggs (double and single-sided). Sunny side up eggs were prepared with the upper platen latched, but not touching the eggs. The result was a firmly cooked white and a warm, but uncooked, yolk. Performance was excellent on all foods tested. Upper to lower platen parallelism is crucial for double-sided cooking uniformity.
The gas-fired double-sided griddle meets or exceeds all of the engineering objectives required for a successful commercial appliance.
TABLE 1
______________________________________
DESIGN PARAMETERS
Design Parameter Goal Status
______________________________________
Cooking surface size (in.)
281/2 .times. 36
281/2 .times. 36
Overall size Not specified
421/2 .times. 36
Weight Not specified
.about.950 lbs
Control range (F.)
100-400 100-400
Control differential
3 F. 2.5 F.
Controlled zones 6 3 upper
3 lower
Venting Not specified
Direct vent
or to hood
______________________________________
TABLE 2
______________________________________
PERFORMANCE PARAMETERS
Performance
Parameters Goal Status Comments
______________________________________
Input (Btu/hr)
<160,000 150,000
Heat-up time
<17 min. <14 min. To 400 F., all
(from cold start) platens
Efficiency 70% >70% Water boil
method, bottom
platen only
Idling energy
Not specified
<15,000 With covers
Btu/hr closed, 375 F.
set point on all
platens
Total load/hr
720 720 80% lean, 51/4
(1/4 lbm burger) diameter
Response time
Not specified
<17 sec Includes plate
cool down from
top of control
range
Zone overshoot
+15 F. <5 F. For cooking
temperature
>300 F.
Surface .+-.10 F. over
.+-.5 F. over
Shoe/platen
temperature
80% of 90% of interface is
uniformity surface surface crucial to
surface
temperature
uniformity
Sticking to upper
Not sticking
Field replace-
Non-stick
platen able non-stick
material field
shoe (6-month
tested on
estimated life)
electric
Noise level
<65 dBa <68 dBa at No sound
operator absorbing
position material in
place
Control ambient
<120 F. -120 F. Microprocessor
based controls,
single board for
all control
functions
______________________________________
Cooking performance appears to be better than in other known double-sided griddles. Surface temperature and zone separation are outstanding. The improved performance is attributable largely to the use of a hot oil system to transfer heat to the cooking surfaces and the incorporation of counterbalanced parallel motion linkages for the upper platens.
Summary
The gas-fired, double-sided griddle system includes a lower cooking surface, at least one upper cooking surface, means for positioning the upper cooking surface, a circulating oil system, and other minor components necessary for control and safety. A novel feature of the griddle is the use of hot oil to transfer heat from a gas flame to the cooking surfaces. Further, the details of the oil system and the means by which heat is transferred from the oil to the cooking surface are particularly useful in achieving good cooking performance.
The circulating hot oil system coupled with the convoluted spiral heat exchanger/platen design (FIG. 16) enables very uniform cooking surface temperature, a low mass platen (therefore quick response) and excellent separation between cooking zones on the lower surface. These features depend on having a supply of oil that is hot and available for circulation to the platen at any time.
The weight controlled valve 10 and continuously recirculating oil loop 41-49 in FIG. 8 provide a constant pressure differential between the supply and return manifolds 46,48 and insure that hot oil 23 is always available in the supply manifold 46. Thus control of cooking surface temperature is achieved by the simple expedient of turning on or off a valve 49 to allow or stop the flow of oil to the platen 43. The control valve 49 for each platen 43 is beneficially located downstream of the platen 43 where oil temperatures have been cooled and are therefore less severe on the valve 49.
Another function of the weight controlled valve 10 is to insure that there is always full oil flow through the oil heater 42. If sufficient oil flow always exists through the oil heater 42, then the temperature of the oil can be controlled by simply turning on the burner 62 in response to a low temperature. If full oil flow is not assured at all times, the burner 62 must be modulated or interlocked with oil flow to prevent overheating the oil. Further, if the burner firing rate must be keyed to the oil flow, there is an inherent time delay between the time that heat is required by one cooking surface (platen) and the time that the burner 62 and oil heater 42 can provide that heat.
With a fully recirculated system 40 such as is used on the griddle, all of the oil 23 is maintained at a minimum temperature at all times. The thermal mass of the heated oil 23 in the recirculation loop 41-49 provides the capacity to respond to heavy griddle platen. Thus, the recirculating oil loop 41-49, deadweight valve 10 and burner 62 cooperate with the requirements of the cooking surfaces to provide a benefit not obtainable with other oil system arrangements.
The use of a circulating hot oil 23 is particularly beneficial for transferring heat to the upper, movable platens 43A,C,E. Other methods that have been tried include electric resistance heaters, infrared burners facing down, and vapor energy transport (e.g., Satani et al., U.S. Pat. No. 4,955,361).
These methods and apparatus are more complex than the present circulating oil system 40. The cost of electric resistance heat energy is high. The use of infrared heaters facing downward has disadvantages: If used directly, no contact with the meat for surface searing is possible. If a heated metal platen is placed below the burners, a surface searing can be achieved, but temperature control is very difficult because portions of the surface not in contact with a food product will overheat while surfaces in contact with the food may be too cool. In either case, the efficiency is low because the burners cannot emit more than perhaps half of the higher heating value of the fuel as radiant energy.
The use of vapor energy transport is potentially comparable in performance to circulating oil; but temperature control is achieved by changing vapor pressure in the system which requires longer times to accomplish than the on/off valve control available with the circulating oil system.
The four-bar mechanism 82,87,88,89 in FIGS. 1-7 provides a simple, uncluttered arrangement for positioning the upper cooking surfaces 43A,C,E that is superior to other techniques that depend on stops that rest on the griddle. An important benefit to this arrangement is that it permits automation of the upper griddle position by use of relatively conventional hardware. Because a single lift point is sufficient, as opposed to three or four in other known equipment, and is independent of the griddle surface, a small gear motor may be used to position the stop 91 for the lower griddle position in FIG. 6 and may also be used to lift the griddle substantially above the food for non-contact cooking if desired.
The uniform surface temperature is primarily a result of the method of circulating oil 23 in the convoluted spiral pattern heat exchanger 110 of FIGS. 16-18. The convoluted heat transfer channel 112 allows platen surface temperatures of about .+-.5.degree. F. to be achieved even though the oil changes temperature by as much as 40.degree. F. as it flows through the platen.
In addition to the convoluted spiral 112, a typical design includes an engineered balance between the mass of steel in the platen 43 and the total mass of oil 23 contained within the platen. This is coupled with the use of a low temperature difference, high convection coefficient configuration for the platens. In other words, the flow passage 112 is designed to have a high oil velocity but a minimum of contained oil 23 so that when oil flow is stopped the surface temperature does not rise excessively due to the energy in the oil 23.
The high velocity permits sufficient heat transfer without requiring a high oil temperature, which also limits the maximum rise in platen temperature when oil flow is stopped. The inlet oil temperature need only be about 40.degree. F. above the platen temperature to achieve adequate heat transfer. For practical control it is convenient to have the entering oil 23 at about 420.degree. to 450.degree. F. for cooking at temperatures up to about 400.degree. F. A beneficial modification is to have the maximum oil temperature adjusted to about 45.degree. F. over the hottest platen setpoint. This is possible using a simple integrated electronic control system.
Another attribute designed into the griddle to achieve uniform surface temperature is a minimum conduction path between sections and between the edge sections and the griddle frame and splash guard. A thin griddle plate 111 minimizes crosstalk between sections; but may not even out the temperature between the channels on the platens for the same reason, a minimum conduction path. Eight channels per platen, as in FIG. 16, coupled with a 3/16" griddle plate seems to provide a good balance between these two competing requirements and provide sufficient strength as well.
As discussed above, the oil temperature is only slightly higher than the platen temperature. If one or two hamburgers are cooked on the front of a platen, the heat load in that area requires that heat be supplied to the platen. For electric or conventional gas, this can result in severe overheating of the unused portions of the griddle because heat is added to those areas even when it is not needed. Since the maximum oil temperature is about 450.degree. F., the maximum temperature to which unheated portions of the griddle can be heated is about 450.degree. F., which is not unnecessarily hazardous to personnel, food products, or surface coatings. The surface temperature uniformity design aspect also relates to this attribute.
Cooking zone separation is related to the conduction path between zones as discussed above. Zone separation is an important attribute for griddle flexibility and the level of zone separation we have achieved has been impressive to people in the food service industry.
The griddle should warm up from cold rapidly, should recognize the presence of a frozen hamburger quickly, should avoid a sag in temperature with a heavy food cooking load, and should recover from a heavy load as soon as possible without overshooting the set temperature. The circulating hot oil system of FIG. 8 is particularly good at quick recovery and minimizing sag, because we maintain a constantly circulating reserve of hot oil which can be introduced to the platen quickly. Further, the thin griddle plate permits sensing temperature only slightly below the surface so that the presence of food is detected early. Finally, the low mass of steel in the system allows the griddle to heat up from cold rapidly. It also permits a cooldown on change to a lower setpoint temperature more rapidly than with other griddles.
Because the combustion process is isolated from the heating surfaces by the hot oil, it is possible to design a high efficiency heater specifically for the oil. The heater design includes a relatively high oil velocity to minimize surface temperatures and maximize oil life, a high gas side surface area to extract energy from the combustion products and, in our design, some preheating of the incoming air to conserve energy and improve efficiency. The burner is a fully premixed power burner that is well matched to the heater coiled tubing. While we have not measured NOx from the prototype griddles, similar configurations using premixed burners and rapid flue gas temperature quench by finned tubes achieve less than 30 ppm NOx as compared to 60 to 100 for a conventional griddle.
Positioning Mechanism
To griddle hamburgers or other food from both sides simultaneously, it is desirable, though not necessary, to contact both sides of the product with a heated surface. The present invention accomplishes this while controlling the force applied to the product, as well as providing an adjustable stop to prevent crushing delicate food items.
The positioning apparatus 80 is shown schematically in FIGS. 1-7 heated upper platen 43A is suspended from a combined housing and support 94 having a pivot point 81 near the rear of the platen. The platen 43A typically may rotate about the pivot point 81 through an angle of about -60 to 80 degrees, allowing the platen to be positioned parallel to the lower griddle platen 43B for cooking and raised to nearly perpendicular to the lower griddle for loading and unloading and when not in use. The pivot is mounted on a movable assembly 82,87,88 as shown which permits the upper platen 43A to move up and down parallel to the lower platen 43B. The distance between the upper and lower platens is limited by a stop 91 which stops upper platen downward travel.
A spring 84 counterbalances the upper platen 43A so that it will remain in the up position, as in FIG. 3, until it is pulled down. The spring 84 also raises the platen 43A at the end of the cooking cycle.
The spring 84 is in compression between the left end 95 of the cantilever housing 85 and the right end 96 of the rod 97, which is connected pivotally at 98 to the vertically movable bar 82. So the spring 84 urges the cantilever housing 85 to the left and, when not prevented by the latch 86, pulls the right end 83 of the cantilever 85 to the left; and thus swings the housing 94, and everything in or attached to it, upward about the lower pivot point 81. Alternatively, the same function might be provided, but less safely, by a spring connected in tension between the upper pivot point 98 and the right end 83 of the cantilever housing 85.
Another spring 92, located at the rear of the movable assembly, counterbalances the weight of the platen and positioning assembly to control the force placed on the food product.
This positioning apparatus has several advantages. Other similar griddles use three or four positioning devices, which support the upper platen directly from the lower. These devices interfere with the cooking surface and catch grease. The present device uses a single positioning stop which is away from the cooking surface and is easily automated.
The force applied to the food product can be controlled. This permits a lighter contact with the food product, as desired. With other devices, the full weight of the upper platen rests on the food until relieved by the stops.
The mechanism is extremely robust, and due to its simplicity, inexpensive.
The absence of adjusting knobs on the upper platen improves visual appeal and eliminates cleaning difficulties.
A typical cooking cycle proceeds as follows:
With food loaded on the lower platen, the operator closes the upper platen 43A, either manually or by turning on partly or fully automated activating equipment down from the nearly vertical position of FIG. 1 to the horizontal position of FIGS. 2 and 3.
The latch bar 86 drops into place, resting on the stop 99 (as shown in FIG. 2) and thus locking the upper platen assembly 94 into the horizontal position, parallel with the lower platen 43B.
The upper platen 43A is not in contact with the food, because the supporting mechanism 94 etc. is held up at the bar (82) lifting surface 102 (Cam plate) by the raise/lower cam 100 (FIG. 3).
The cam motor 101 activates, rotating the cam 100 downward to lower the platen 43A onto the food (FIG. 4).
The uncounterbalanced net weight of the upper platen assembly 43A, 94 etc. bears on the food, maintaining intimate contact for fast cooking. As the food shrinks, the platen 43A moves downward until the limit plate 103 makes contact with the adjustable stop 91 under the four-bar linkage 82,87,88,89, as shown in FIG. 5. The stop 91 is motorized and is set by the griddle computer according to the type of food being cooked.
Cooking proceeds for a timed interval set by the electronic computer. At the end of the cycle, the cam motor 101 activates, rotating the cam 100 upward against the cam plate 102, lifting the upper platen 43A vertically away from contact with the food, as shown in FIG. 7, and the latch solenoid 104 activates, pulling the latch 86 upward away from the stop 99 and thus releasing the upper platen assembly 43A,94 and allowing it to return to its tilted position under the influence of the lifting spring 84 (FIG. 6 and FIG. 1).
Bearing on the food with the uncounterbalanced portion of the platen weight cooks food at a higher speed.
The heated platens 43A, 43B stay parallel during cooking, so that all food pieces of a particular load are cooked to a final thickness that is the same.
The limit stop 91 prevents the weight from crushing the food when cooking a single piece or any soft food, such as pancakes.
The limit stop 91 for each upper platen 43A,C,E has a simple adjustment at a single point.
The single point adjustment is easily motorized, so that food settings can be performed under computer control.
Each upper platen of a multi-zone griddle has an independent adjustment, so that different foods can be cooked simultaneously.
The lift cam 100 relieves the weight load on the adjuster, so that it can be moved easily by hand or by a small motor.
The four-bar mechanism 82,87,88,89 is compatible with wide bearing spans, a robust feature that insures that the platen does not vibrate excessively or move out of position under load.
Weight Controlled Valve
Referring now to FIGS. 13, 14, and 15, a typical pressure regulating valve 10 according to the present invention, adapted for mounting and operation in a predetermined fixed attitude, comprises a housing 11 having an inlet port 12 and an outlet port 13; and a straight elongate tube 14 so affixed to the housing as to be positioned vertically when the valve 10 is mounted in the fixed attitude for operation, and having an opening 15 at its lower end communicating with the inlet port.
A piston 16 having a solid horizontal lower end 17 extends down into the tube 14 from the open upper end 18 of the tube 14, and closely but slidably fits therein. A substantially lengthwise aperture 19 in the tube 14, extends upward from a level 20 near the lower end of the tube 14 to a level substantially below the upper end 18 of the tube. The piston 16 is slidable between a lower position, as in FIG. 13, with its lower end 17 below the lower end 20 of the aperture 19 and an upper position, as in FIG. 14, with its lower end 17 substantially above the lower end 20 of the aperture 19.
A weight 22 in, and spaced from, the housing 11, is positioned to exert a downward force on the piston 16 by virtue of the gravitational attraction of the weight 22 to the earth; such that, when fluid 23 is supplied under pressure to the inlet port 12, the fluid 23 presses upward against the lower end 17 of the piston 16, the weight 22 presses downward against the piston 16; and when the lower end 17 of the piston 16 is at a level between the ends 20, 21 of the aperture 19 the fluid 23 flows in from the inlet port 12, through the open portion of the aperture 19, into the other space in the housing 11, and out through the outlet port 13, at a substantially constant predetermined pressure that is directly proportional to the combined mass of the piston 16 and the weight 22.
The weight 22 is typically positioned to press against the upper end 24 of the piston 16, and preferably is affixed to the piston 16 as indicated at 25.
Typically the weight 22 comprises predominantly an annular bod
