Note: Descriptions are shown in the official language in which they were submitted.
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MICROWAVABLE COOKING IMPLEMENTS AND
METHODS FOR CRISPING FOOD ITEMS USING THE SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application,
Serial
No. 11/157,747, filed June 21, 2005, now pending, which is a continuation-in-
part of
application Serial No. 10/883,348, filed July 1, 2004, now U.S. Pat. No.
7,850,035
issued December 14, 2010. The contents of each of the foregoing applications
are
incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present disclosure relates to microwavable cooking implements and,
more particularly, to a microwavable cooking implement having a resilient
silicone
cooking surface that permits air circulation both above and beneath the
cooking surface
for crisping food items.
BACKGROUND
[0003] Potato chips are among the most popular snack food. Because potato
chips are typically deep fried, many seek to limit or avoid consumption of
potato chips
for health reasons.
[0004] Baked potato chips are one alternative to the traditional deep fried
potato
chips. Baking, however, typically requires the use of oil to coat the cooking
surface so
as to prevent the potato chips from sticking to the pan or other cooking
surface.
[0005] The use of microwaves to prepare potato chips has been proposed as yet
another alternative. For example, U.S. Pat. No. 5,389,768 discloses a circular
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microwavable potato chip maker that is molded of a plastic material and having
a row of
spacers defining slots between each adjacent pairs of spacers. The potato chip
are
positioned vertically in the slots in a spaced array to facilitate their
cooking in a
microwave oven.
[0006] The disadvantage of the plastic microwavable potato chip maker,
however, is that the potato chip slices must be arranged on its side and
larger or thin
slices may fold down upon itself. Moreover, there is a risk that the potato
chips may
stick to the surface of the plastic material during cooking. Additionally,
plastic materials
are prone to burning at high temperatures and which, in turn, may result in
the release
of harmful toxins.
[0007] Moreover, plastic microwavable potato chip makers may not be suited for
other types of cooked or crisped food, such as fruit or vegetable chips or
fries, as these
items typically have a size, width or dimension that is unsuitable for such a
device.
BRIEF SUMMARY
[0008] The present disclosure provides a cooking implement that may be used to
cook and crisp a variety of foods in a microwave. The cooking implement
permits
efficient heat transfer by providing a cooking surface that is made of a
silicone material.
Silicone material has superior release characteristics which prevent foods
from sticking
thereon. This is particularly advantageous for thinly-sliced food items, such
as fruit and
potato chips, which typically require delicate handling. Thus, the cooking
implements
and methods for using the cooking implements are advantageous in that its use
in
cooking or crisping food does not require the addition of oils or other
ingredients other
than the food item being crisped.
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[0009] The configuration of the cooking implement provides for a pattern of
air
circulation that allows food items of a wide range of sizes, shapes and
dimensions to
attain a desirably crispy texture when cooked. A support system is provided
such that
air circulation is provided on both sides of the cooking surface. A plurality
of holes may
be provided to further increase air circulation and thus allow for the food
thereon to be
cooked and even crisped.
[0010] The cooking implement is also configured such that multiple cooking
implements may be stacked on top of one another, thereby increasing the
quantity of
food items cooked in a single cooking cycle.
[0011] In one embodiment, the cooking implement comprises a resilient cooking
surface, a peripheral rim surrounding the resilient cooking surface, a frame
configured
couple to the peripheral rim, and a support structure. The frame imparts a
tensile
strength across the resilient cooking surface when coupled to the peripheral
rim and the
support structure is configured to support the resilient cooking surface and
allow a
circulating air space underneath the resilient cooking surface
[0012] In another embodiment, the cooking implement comprises a resilient
cooking surface, a peripheral member coupled to the resilient cooking surface;
and a
support structure configured to provide an air space beneath the resilient
cooking
surface. A tensile force is imparted across the resilient cooking surface by
stretching
the resilient cooking surface caused by either one or both of the peripheral
member
and/or the support structure.
[0013] In yet another embodiment, the cooking implement comprises a resilient
cooking surface, a periphery surrounding the resilient cooking surface, a
substantially
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rigid frame and a support structure supporting the resilient cooking surface
above the
ground and allowing a circulating air space underneath the resilient cooking
surface.
The periphery is characterized as having an outermost first dimension and the
substantially rigid frame has a second dimension that is different from the
first
dimension of the periphery. A tensile force is imparted across the resilient
cooking
surface by coupling the periphery and the substantially rigid frame.
[0014] In a further embodiment, a plurality of cooking implements may be
stacked
on top of one another by having a first perimeter defined by the support
structure less
than a second perimeter defined by an outer peripheral lip.
[0015] A method of crisping food items is further provided. The method
comprises placing a layer of a food item on top of a resilient cooking surface
of a
cooking implement and heating the cooking implement with the food items for a
predetermined time. The predetermined time may depend on any one or more of at
least the power of the microwave oven, the thickness of the food items, and
desired
amount of crispiness. The cooking implement is characterized as having a
resilent
cooking surface maintained at tension by a rigid frame coupled to a periphery
surrounding the resilient cooking surface. The cooking implement further
comprises a
support structure to elevate the resilient cooking surface at a distance above
the ground
to allow a circulating air space underneath the resilient cooking surface and
the resilient
cooking surface further comprises a plurality of holes to allow air
circulation
therethrough to further facilitate crisping of the food items placed
thereupon.
[0016] In accordance with one aspect of the method, the food items are
uncooked potato slices having a thickness of less than 5 mm.
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[0017] In accordance with a second aspect of the method, a single layer of
uncooked potato slices is placed on top of the resilient cooking surface.
[0018] In accordance with a third aspect of the method, the heating is
performed
by a microwave at 600 to 1500 watts for 10 seconds to 12 minutes.
[0019] Other objects, features and advantages of the present invention will
become apparent to those skilled in the art from the following detailed
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Illustrative embodiments of the present invention are described herein
with
reference to the accompanying drawings, in which:
[0021] FIG. 1 is a perspective view of an embodiment of the cooking implement.
[0022] FIG. 2 is an exploded perspective view of the cooking implement of FIG.
1.
[0023] FIG. 3 is a top elevational view of the cooking implement of FIG. 1
[0024] FIG. 4 is a cross-sectional view of the cooking implement along A-A of
FIG. 3.
[0025] FIG. 5 is a side elevational view of the cooking implement of FIG. 1.
[0026] FIG. 6 is a bottom view of the cooking implement of FIG. 1.
[0027] FIG. 7 shows multiple cooking implement stacked on top of one another.
[0028] Like numerals refer to like parts throughout the several views of the
drawings.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Reference is made to FIGS. 1-6 which illustrate a non-limiting
preferred
embodiment of the cooking implement 100.
[0030] The cooking implement 100 is depicted as generally comprising a
resilient cooking surface 110, a periphery 120 surrounding the resilient
cooking surface
110, and a plurality of supports 130. The periphery 120 is coupled to a frame
140. The
coupling of the periphery 120 to the frame 140 imparts a tensile force across
the
resilient cooking surface 110 such that an air space is provided underneath
when
weighted with food items.
[0031] The resilient cooking surface 110 may be made of any heat-resistant
elastomeric material which preferably is capable of withstanding temperatures
above at
least 140 C. In a particularly preferred embodiment, the resilient cooking
surface 110
consists solely of a thin silicone membrane. In a preferred embodiment, the
thickness
of the resilient cooking surface 110 is less than 5 mm and more preferably
between 0.5
mm and 2.0 mm in an unstretched state. Because the silicone membrane is
relatively
thin, it allows for efficient heat transfer. The thin silicone membrane is
stretched by
virtue of coupling the periphery to a rigid frame and/or support. In a
particularly
preferred embodiment, the stretching and thus the tensile force that is
imparted across
the thin silicone membrane is sufficient to support the weight of up to 5
kg/cm2 without
substantial deformation of the thin silicone membrane. This permits the thin
silicone to
fully support and suspend the food items and allow for efficient heat transfer
and
crisping by permitting air circulation both above and below the thin silicone
membrane.
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[0032] A plurality of holes 112 may be provided on the resilient cooking
surface
110 to further enhance the heat transfer and provide a pattern of air
circulation
therethrough. Although FIGS. 1-7 depict the plurality of holes 112 as having a
circular
shape, it is understood that the plurality of holes 112 may be of any
geometric
configuration (e.g., triangular, rectangular, etc.) or combinations thereof.
Moreover, as
more clearly depicted in FIG. 6, the plurality of holes 112 may be of varying
sizes or
diameters 112a, 112b and 112c. The size and geometric shape of the plurality
of holes
112 may be chosen based on the types of food items for which the cooking
implement
100 may be designed to cook and crisp. Larger or thicker food items may
require larger
holes, whereas smaller or thinner food items may require smaller holes.
[0033] While the resilient cooking surface 110 is depicted as having a
substantially flat surface, it may also have a non-flat surface and may
include waves or
other structural designs and/or textures on one or both sides. In particular,
with various
non-flat designs, different patterns of air circulation may be provided.
[0034] The periphery 120 surrounds the resilient cooking surface 110. In one
embodiment, the periphery 120 may be generally contiguous with the resilient
cooking
surface 110. In another embodiment, the periphery 120 may be a separate
structure
that is coupled to the resilient cooking surface 110.
[0035] The periphery 120 has either the same or a greater thickness as the
resilient cooking surface 110 when it is unstretched. In a preferred
embodiment, the
periphery 120 comprises a silicone exterior that is contiguous with the
resilient cooking
surface 110. In one embodiment, the periphery has a thickness that is
sufficient to
support the frame 140 and allow a tensile force to be imparted onto the
resilient cooking
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surface 110. In an alternative embodiment, the periphery 120 may further
comprise a
reinforcement that renders it more rigid than the resilient cooking surface.
The
reinforcement may be comprised of any material that imparts rigidity, such as
a
polyamide (e.g., Nylon or Zytel), liquid crystal resins (e.g., Zenite), or
combinations
thereof.
[0036] The periphery 120 is preferably shaped to as to couple either one or
both
of the support structure 130 or the frame 140. In the preferred embodiment
depicted in
FIGS. 1-6, the periphery 120 is defined as a area bounded by the resilient
cooking
surface 110 and a circumferential rim projecting downwardly at about a 90
degree angle
from the resilient cooking surface and terminating in a circumferential lip
125. The
frame 140 is configured to fit within the space bounded between the resilient
cooking
surface 110 and the circumferential lip 125 and to exert a outward radial
force against
the periphery 120 and therefore impart a tensile force across the resilient
cooking
surface 110.
[0037] The support structure 130 is further associated with the cooking
implement 100 so as to elevate the resilient cooking surface 110. The support
structure
130 allows a circulating air space underneath the resilient cooking surface
110. As
further depicted in FIG. 5, the support structure 130 may comprise a plurality
of legs
projecting downwardly from the resilient cooking surface 110 so as to elevate
the
resilient cooking surface 110 above the surface 50 on which it rests. In this
configuration, air is permitted to circulate both into and outside of the area
underneath
the resilient cooking surface 110. Moreover, the plurality of holes 112 permit
further air
to circulate across the resilient cooking surface 110. The circulation of air
during
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cooking is what permits the foods cooked on top of the resilient cooking
surface 110 to
achieve a crispy texture.
[0038] The support structure 130 preferably has a silicone exterior and may
further have a reinforcement as described with respect to the periphery to
impart
additional rigidity. Alternatively, the support structure 130 may be comprised
solely of
silicone having sufficient thickness to impart sufficient rigidity to support
the resiiltn
cooking surface 110 when it is weighted with up to 5 kg/c,2 of food items.
[0039] The height of the support structure 130 is such that it provides
sufficient
clearance and air space underneath the resilient cooking surface 110 when
weighted
with food items placed on top of the resilient cooking surface 110. The height
of the
support structure 130 therefore depends on the amount of tensile force exerted
onto the
resilient cooking surface 110 and may range anywhere between 5 mm to 10 cm.
The
greater the tensile force exerted onto the resilient cooking surface 110, the
lower the
height required of the support structure 130 to maintain adequate airspace
underneath
the resilient cooking surface 110.
[0040] The frame 140 may be constructed of any rigid or substantially rigid
material that is also resistant to temperature. The frame 140 is preferably
made of a
high temperature thermoplastic or a metal that is capable of resisting
temperatures of
over at least 140 C. The frame may also be made of a polypropylene material
that is
sufficient thermally resistant. The frame is configured to couple to the
periphery 120
and impart a tensile force across the resilient cooking surface 110. The frame
140 may
be the same or different shape as the periphery 120.
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[0041] In one embodiment, the frame 140 has the same shape as the periphery
120. In the embodiments depicted in FIGS. 1-6, wherein the shape is
substantially
circular, a radial tensile force may be exerted across the resilient cooking
surface 110
by coupling the periphery 120 onto the frame 140 to cause a stretching of the
resilient
cooking surface 110. For example, the frame 140 may have a dimension that is
larger
than the dimension of the periphery 120. In accordance with this embodiment,
as
shown in FIG. 2, the diameter of the frame 140 (d2) may be larger than the
diameter of
the periphery 120 (dl). Preferably, the ratio of the diameters of the
periphery to that of
the frame (dl:d2) is in the range of 0.50 to 0.99, and more preferably from
0.80 to 0.99.
The tensile force exerted on the resilient cooking surface 110 is preferably
such that it
supports a weight of up to 1 kg/cm2, and more preferably up to about 5kg/cm2
without
substantial deformation of the resilient cooking surface 110. Substantial
deformation of
the resilient cooking surface 110 is understood to mean the degree of
deformation such
that it contacts the surface upon which the support structure 130 rests.
[0042] In another embodiment, the frame 140 may have a different shape than
the periphery 120. The difference in shapes may allow for the tensile force to
be
imparted across specific dimensions. For example, in one embodiment, the frame
140
may be an oval shape or rectangular shape, whereas the periphery 120 may be of
a
circular shape, such that when the periphery 120 is stretched over the frame
140, a
tensile force is exerted in substantially in two directions.
[0043] An external circumferential lip 160 may be provided that extends
beyond the outer perimeter of the support structure 130. The external
circumferential lip
160 may be provided to allow multiple cooking implements 100 to be stacked on
top of
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one another. FIG. 7 shows a stacked assembly of four cooking implements 100a-
d,
wherein the respective support structures 130 are depicted as resting on top
of the
external circumferential lips 160 of the cooking implement 100. The external
circumferential lip 160 is more clearly depicted in FIGS. 4-5 as extending
beyond the
perimeter of the support structure 130. The support structure 130 preferably
define a
circumference that is smaller than the external circumferential lip 160 so
that the
support structure 130 may comfortable rest on top of the external
circumferential lip 160
in the stacked configuration.
[0044] In a preferred embodiment, the cooking implement 100 comprises two
main pieces - a first piece comprising the resilient cooking surface 110,
periphery 120,
support structures 130 and a second piece comprising the frame 140. The first
piece
may be completely made of silicone or may comprise additional reinforcements
or other
materials. In a particularly preferred embodiment, the entire external surface
of the first
piece comprises silicone.
[0045] In yet another embodiment, the above-described first and second pieces
may be a single integral structure.
[0046] In yet a further embodiment, each one of the resilient cooking surface
110,
periphery 120, support structures 130 and frame 140 may be separate components
which are coupled to one another by methods known in the art.
[0047] The cooking implement 100 described herein may be used to cook and
crisp a variety of different food items, such as potato chips, apple chips,
French fries,
and almost any kind of food item for which a crispy texture is desired.
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[0048] To that end, a method is provided of cooking and crisping food items.
In a
preferred embodiment, a single layer of a food items is placed on top of the
resilient
cooking surface 110 and the cooking implement with the food items are heated
for a
predetermined period of time, depending on the food items and the desired
level of
cooking and/or crisping. Surprisingly impressive results have been obtained
particularly
with respect to producing potato chips. In a preferred embodiment, uncooked
potato
slices having a thickness of less than 5 mm, and more preferably less than 2
mm, may
be placed on top of the resilient cooking surface 110 and heated in a
microwave oven at
600 to 1500 Watts for 10 seconds to 15 minutes or until the desired amount of
cooking
or crisping is attained.
[0049] It is to be understood that the detailed description and specific
examples,
while indicating preferred embodiments of the present invention, are given by
way of
illustration and not limitation. Many changes and modifications within the
scope of the
present invention may be made without departing from the spirit thereof, and
the
invention includes all such modifications.
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