Silicone Coating For Baking Surface

Abstract

A cooking utensil that includes a non-stick release agent that is mechanically secured to a substrate of the cooking utensil. The invention also pertains to a method for using the cooking utensil to heat and/or bake food products, and to a method for recoating the non-stick release agent on the substrate of the cooking utensil.

Claims

1. A cooking utensil comprising: a substrate; one or more surface structures on an outer surface of the substrate; and, a non-stick release agent mechanically connected to the one or one or more surface structures, a top surface of the non-stick release agent forming a non-stick surface on said cooking utensil.

2. A cooking utensil comprising: a substrate; and, a non-stick release agent that is mechanically connected to the substrate, the substrate and/or the non-stick release agent includes one or one or more surface structures that facilitate in mechanically connecting the non-stick release agent to the substrate, a top surface of the non-stick release agent forming a non-stick surface on said cooking utensil.

3. A method for heating or baking a food product by use of a cooking utensil comprising: providing a cooking utensil, said cooking utensil comprising: a substrate; and, a non-stick release agent that is mechanically connected to the substrate, the substrate and/or the non-stick release agent includes one or one or more surface structures that facilitate in mechanically connecting the non-stick release agent to the substrate, a top surface of the non-stick release agent forming a non-stick surface on said cooking utensil; placing the food product in contact with the non-stick surface on the cooking utensil; heating or baking the food products while the food product is in contact with the non-stick surface on the cooking utensil; and, removing the food product from contact with the non-stick surface on the cooking utensil.

4. A method for mechanically securing a non-stick release agent to a substrate of a cooking utensil, the method comprising: providing a cooking utensil that has the substrate; forming a plurality of surface structures in the substrate; and, applying the non-stick release agent to the substrate that includes the plurality of surface structures, said plurality of surface structures forming a mechanical connection with the non-stick release agent.

5. A method for mechanically securing a non-stick release agent to a substrate of a cooking utensil, the method comprising: providing a cooking utensil that has the substrate; providing a non-stick release agent, a top surface of the non-stick release agent forming a non-stick surface on said cooking utensil; mechanically connecting the non-stick release agent to the substrate, the substrate and/or the non-stick release agent includes one or one or more surface structures that facilitate in mechanically connecting the non-stick release agent to the substrate.

6. A method for re-coating a cooking utensil with a non-stick release agent, the method comprising: providing a cooking utensil having a worn and/or damaged coating of a non-stick release agent; removing the worn and/or damaged non-stick release agent from a substrate of the cooking utensil without damaging the substrate or any surface structures on the substrate; providing an unused non-stick release agent, a top surface of the non-stick release agent forming a non-stick surface on said cooking utensil; and, mechanically connecting the non-stick release agent to the substrate, the substrate and/or the non-stick release agent includes one or one or more surface structures that facilitate in mechanically connecting the non-stick release agent to the substrate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0066] Reference may now be made to the drawings which illustrate various non-limiting embodiments that the invention may take in physical form and in certain parts and arrangement of parts wherein:

[0067] FIG. 1 is an illustration of the prior art arrangement for applying a silicone layer to the surface of a substrate of a cooking utensil (which would typically be a spray resin) and an illustration of one non-limiting embodiment of the present invention that uses a plurality of surface structures to mechanically connect the silicone layer (which might typically be a liquid silicone rubber or elastomeric silicone) to the surface of a substrate of a cooking utensil and a comparison of the temperature profiles of the top surface of the silicone coating during the heating of the substrate;

[0068] FIG. 2 is an illustration showing a method of mechanically applying a plurality of surface structures to a top surface of a substrate of a cooking utensil in accordance with one non-limiting aspect of the present invention;

[0069] FIG. 3 is a cross-sectional illustration of another non-limiting configuration of a plurality of surface structures on a top surface of a substrate that extend upwardly from the top surface of the substrate and a layer of silicone coated on the surface structures in accordance with a non-limiting aspect of the present invention;

[0070] FIG. 4 is a cross-sectional illustration of another non-limiting configuration of a plurality of surface structures on a top surface of a substrate that are recessed in the top surface of the substrate and a layer of silicone coated on the surface structures in accordance with a non-limiting aspect of the present invention;

[0071] FIG. 5 is a cross-sectional illustration of another non-limiting configuration of a plurality of surface structures on a top surface of a substrate that are recessed in the top surface of the substrate and a layer of silicone coated on the surface structures in accordance with a non-limiting aspect of the present invention;

[0072] FIG. 6 is a cross-sectional illustration of another non-limiting configuration of a plurality of surface structures on a top surface of a substrate that extend upwardly from the top surface of the substrate and a layer of silicone coated on the surface structures in accordance with a non-limiting aspect of the present invention;

[0073] FIG. 7 is a cross-sectional illustration of another non-limiting configuration of a plurality of surface structures on a top surface of a substrate that extend upwardly from the top surface of the substrate and a layer of silicone coated on the surface structures in accordance with a non-limiting aspect of the present invention; and,

[0074] FIG. 8 is a cross-sectional illustration of another non-limiting configuration of a plurality of surface structures on a top surface of a substrate that are recessed in the top surface of the substrate and a layer of silicone coated on the surface structures in accordance with a non-limiting aspect of the present invention.

DETAILED DESCRIPTION OF THE NON-LIMITING EMBODIMENTS

[0075] The present invention is directed to cooking utensils having a non-stick release agent, and in particular to cooking utensils having a non-stick release agent that is mechanically connected to the surface the cooking utensil. One non-limiting non-stick release agent that can be used in the present invention is silicone. Silicone is a food safe material that forms a low-stick or non-stick surface when exposed to many different types of food products. For example, when heating or baking bakery products, the silicone surface forms nearly a non-stick surface with the bakery products. Silicone also does not degrade below temperatures of about 500-600 F., thus can be used to heat and cook many types of food products. The silicone coating can be silicone or a silicone resin or can be silicone that includes one or more additives.

[0076] Although silicone is known to form a non-stick cooking surface for cooking utensils, silicone coatings present several challenges that have inhibited wide adoption of such coatings on cooking utensils. Silicone is known to be a compound that has good insulating properties. As such, silicon coatings that are too thick can interfere with the proper baking of a food product. Silicone also has a greater heat expansion coefficient than most substrates upon which the silicone is coated thereon. As such, during repeated heating and cooling of the substrate of the cooking utensil, the smaller expansion and resulting contraction of the substrate as compared to the silicone coating causes the silicone coating to release from the surface of the substrate and further the substrate loses its non-stick surface. The loss of adhesion between the silicone coating and the substrate results in air pockets forming between the silicone coating and the substrate that interfere with the uniform heat transfer from the substrate to the silicone coating and to the food product being heated or baked on the top surface of the silicone layer. As illustrated in FIG. 1, the temperature profile on the left side illustrates the significant temperature decrease between the substrate temperature and the surface of the silicone coating where the silicone layer has separated from the substrate as illustrated in the left side illustration in FIG. 1. This of course has been the end result of the use of sprayed adhesive resin-based silicone coatings.

[0077] The surface structures in accordance with the present invention creates a mechanical connection between the substrate and the silicone coating that minimizes the temperature decrease between the temperature of the substrate and the top surface of the silicone coating. One non-limiting surface structure arrangement is illustrated in the right side illustration of FIG. 1 and the temperature profile is represented below such illustration. As is evident between the two temperature profiles set forth in FIG. 1, the mechanical connection created by the plurality of surface structures on the substrate surface minimizes the loss of temperature between the substrate and the top surface of the silicone coating.

[0078] Generally, for cooking utensils that are used to cook, bake or heat a food product, the substrate is typically formed of a high heat conducting material (e.g., metal, etc.); however, this is not required.

[0079] The shape and configuration of the surface structures are non-limiting. Likewise, the method by which the surface structures are formed on the substrate surface is non-limiting. FIG. 2 is an illustration of a non-limiting method for mechanically forming a plurality of surface structures on the top surface of a substrate in accordance with one non-limiting aspect of the present invention. Initially, a substrate (i.e., part of the cooking surface of a cooking utensil) is provided. The substrate can be successively machine-stamped, thereby providing a plurality of undercut features on the cooking surface of the substrate; however, this is not required.

[0080] Step 1 of FIG. 2 illustrates a top surface of a substrate prior to beginning the process of forming a plurality of surface structures in the substrate surface. The top surface of the substrate is illustrated as being generally flat; however, this is not required.

[0081] Step 2 of FIG. 2 illustrates the top surface of the substrate being subjected to a stamping process wherein a plurality of indents have been formed in the substrate surface.

[0082] Step 3 of FIG. 2 illustrates the top of the indents that were formed in Step 2 being further subjected to a second stamping process wherein a V-shaped groove is formed in the top of the indents.

[0083] Step 4 of FIG. 2 illustrates the top of the indents that were formed in Step 3 being further subjected to a third stamping process wherein the tops of the indents are flattened thereby forming a plurality of surface structures on the substrate surface wherein a top portion of the surface structure has a greater cross-sectional area than a portion of the surface structure that is located below the top of the surface structure. As such, an undercut is formed under the top of the surface structure that can be used to mechanically secure a layer of silicone coating that has been applied to the substrate and the surface structures on the substrate. Generally, when the silicone layer is applied to the substrate and the surface structures on the substrate, the thickness of the silicone layer that is located above the top surface of the surface structures is generally at least about 0.05 inches and typically no more than about 0.25 inches; however, this is not required. The method by which the silicone coating is applied to the substrate and the surface structures on the substrate is non-limiting. In one non-limiting application method, the silicone is spray coated on to the substrate and the surface structures on the substrate.

[0084] FIGS. 3-8 are cross-sectional illustrations of other non-limiting surface structure configurations that can be used in accordance with the present invention. The top line in each of the figures represents the top surface of the silicone coating. The bottom line in each of the figures represents the base of the substrate. The surface structures (as illustrated in FIGS. 2-8) are configured provide a sufficient mechanical connection between the substrate that the silicone coating such that the silicone coating does not release from the substrate and surface structures during the heating and cooling of the substrate.

[0085] FIGS. 3, 6 and 7 illustrate surface structures in the substrate surface that extend upwardly from the substrate surface and extend into a portion of the silicone coating. As illustrated in the figures, the surface structures do not extend fully through the silicone coating.

[0086] FIGS. 4, 5 and 8 illustrate surface structures in the substrate surface that are recessed into the top surface of the substrate.

[0087] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the constructions set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The invention has been described with reference to preferred and alternate embodiments. Modifications and alterations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the invention provided herein. This invention is intended to include all such modifications and alterations insofar as they come within the scope of the present invention. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention, which, as a matter of language, might be said to fall therebetween.