VERTICAL ELECTRIC COOKER AND SMOKER AND SMOKE BOX
20170020148 ยท 2017-01-26
Inventors
- William A. Dixon (Columbus, GA, US)
- Sleiman Assaad Adallah (Columbus, GA, US)
- Mark Stephen McQuagg (Midland, GA, US)
Cpc classification
A23B4/056
HUMAN NECESSITIES
Y02A40/90
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
A23B4/0523
HUMAN NECESSITIES
A23V2002/00
HUMAN NECESSITIES
International classification
Abstract
A vertical electric cooker and smoker having lower air intake vents and upper exhaust vents which together create a more balanced flow and distribution of smoke and reduce the operating pressure of the system to allow a much larger load of wood chips to be used without refilling. A smoke box is also provided for holding and properly combusting the larger quantity of wood chips in an oxygen deficient environment. The smoke box has a false bottom and discharges the smoke through a circuitous exhaust flow path. Also, the electric heating elements of the cooking and smoking apparatus are contained in an assembly which provides an air gap beneath the smoker box and also shields the smoker box to prevent the wood chips in the smoker box from becoming overheated.
Claims
1. An apparatus for cooking and smoking food comprising: a vertically extending cooking and smoking chamber having a left side wall, a right side wall, a back wall, a front opening, and a bottom floor; a door positionable on the front opening for closing and opening the front opening; one or more air intake vents provided in a lower portion of the cooking and smoking chamber; one or more exhaust vents provided in an upper portion of the cooking and smoking chamber; and one or more electric heating elements positioned in the lower portion of the cooking and smoking chamber, the one or more electric heating elements being spaced above the bottom floor of the cooking and smoking chamber.
2. The apparatus of claim 1 comprising two of the air intake vents and two of the exhaust vents wherein a first of the air intake vents is provide through a lower portion of the right side wall, a second of the air intake vents is provide through a lower portion of the left side wall, a first of the exhaust vents is provided through an upper portion of the right side wall, and a second of the exhaust vents is provided through an upper portion of the left side wall.
3. The apparatus of claim 2 wherein the first and the second air intake vents are located at an elevation which is at or below an elevation of the electric heating element.
4. The apparatus of claim 2 wherein: the first air intake vent comprises one or a series of openings extending horizontally across at least 30% of a horizontal width of the right side wall and the second air intake vent comprises one or a series of openings extending horizontally across at least 30% of a horizontal width of the left side wall.
5. The apparatus of claim 2 wherein the first and the second air intake vents each have an open flow area in a range of from 1.0 to 4.0 inches.sup.2 per each 2.94 ft.sup.3 of volume of the cooking and smoking chamber.
6. The apparatus of claim 5 wherein the first and the second exhaust vents each have a flow area in a range of from 4.0 to 9.0 inches.sup.2 per each 2.94 ft.sup.3 of volume of the cooking and smoking chamber.
7. The apparatus of claim 6 wherein the first and the second exhaust vents each have a louvered cover.
8. The apparatus of claim 2 wherein: the cooking and smoking chamber has an uppermost food support rack positioned therein and the first and the second exhaust vents are positioned at an elevation above an elevation of the uppermost food support rack.
9. The apparatus of claim 1 further comprising: a smoke box for generating smoke; and a smoke box placement station in the cooking and smoking chamber for placement of the smoke box at least partially over the one or more electric heating elements.
10. The apparatus of claim 9 wherein: the apparatus further comprises an element tray in which the one or more electric heating elements are positioned, the element tray being spaced above the bottom floor of the cooking and smoking chamber and the smoke box placement station comprises a cover plate on the element tray which at least partially covers the one or more electric heating elements and a plurality of spacing elements on an upper surface of the cover plate on which the smoke box is placeable to provide an air gap between a bottom of the smoke box and the cover plate.
11. The apparatus of claim 10 wherein the element tray has a reflective upper surface positioned beneath the one or more electric heating elements.
12. The apparatus of claim 10 further comprising: an air gap between the element tray and the back wall of the cooking and smoking chamber and a horizontal reflector plate extending rearwardly from the element tray toward the back wall of the cooking and smoking chamber which shields a vertical back side of the smoke box from radiant energy which is emitted from the one or more electric heating elements, reflected from the reflective upper surface of the element tray, or both.
13. The apparatus of claim 9 wherein the smoke box comprises: a container having an actual bottom and an interior and a false bottom in the interior of the container spaced above the actual bottom of the container such that a bottom air space is defined between the false bottom and the actual bottom of the container.
14. The apparatus of claim 9 wherein the smoke box comprises: an interior combustion area for combusting wood chips or other pieces in an oxygen deficient environment to produce smoke and an exhaust flow assembly which defines a circuitous exhaust flow path for the smoke wherein the smoke must flow in a first direction through an inner flow gap formed by the exhaust flow assembly and then must flow in a second direction, different from the first direction, through an outer flow gap formed by the exhaust flow assembly.
15. The apparatus of claim 14 wherein the exhaust flow assembly further comprises: a first obstructing structure in the inner flow gap which at least momentarily alters the flow path of the smoke as the smoke travels from an inlet end to an outlet end of the inner flow gap and a second obstructing structure in the outer flow gap which at least momentarily alters the flow path of the smoke as the smoke travels from an inlet end to an outlet end of the outer flow gap.
16. The apparatus of claim 15 wherein the first and the second obstructing structures each comprise an upstream rail and a parallel downstream rail, the upstream and the downstream rails each have a plurality of holes for flow of the smoke through the rails, and the holes of the downstream rail are not in alignment with the holes of the upstream rail.
17. The apparatus of claim 15 wherein the exhaust flow assembly is formed in a lid of the smoke box.
18. The apparatus of claim 15 wherein the exhaust flow assembly is formed in a vertical side wall of the smoke box.
19. The apparatus of claim 15 wherein the exhaust flow assembly is formed in a plurality of vertical side walls of the smoke box.
20. A smoke box apparatus comprising: a container having an interior combustion area for combusting wood chips or other pieces in an oxygen deficient environment to produce smoke and an exhaust flow assembly which defines a circuitous exhaust flow path for the smoke wherein the smoke must flow in a first direction through an inner flow gap formed by the exhaust flow assembly and then must flow in a second direction, different from the first direction, through an outer flow gap formed by the exhaust flow assembly.
21. The smoke box apparatus of claim 20 wherein the container has an actual bottom and a false bottom is positioned in the container at the bottom of the interior combustion area, the false bottom being spaced above the actual bottom of the container such that a bottom air space is defined between the false bottom and the actual bottom of the container.
22. The smoke box apparatus of claim 20 wherein the exhaust flow assembly further comprises: a first obstructing structure in the inner flow gap which at least momentarily alters the flow path of the smoke as the smoke travels from an inlet end to an outlet end of the inner flow gap and a second obstructing structure in the outer flow gap which at least momentarily alters the flow path of the smoke as the smoke travels from an inlet end to an outlet end of the outer flow gap.
23. The smoke box apparatus of claim 22 wherein the first and the second obstructing structures each comprise an upstream rail and a parallel downstream rail, the upstream and the downstream rails each have a plurality of holes for flow of the smoke through the rails, and the holes of the downstream rail are not in alignment with the holes of the upstream rail.
24. The smoke box apparatus of claim 22 wherein the exhaust flow assembly is formed in a lid of the container.
25. The smoke box apparatus of claim 22 wherein the exhaust flow assembly is formed in a vertical side wall of the container.
26. The smoke box apparatus of claim 22 wherein the exhaust flow assembly is formed in a plurality of vertical side walls of the container.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] An embodiment 2 of the vertical electric cooker and smoker provided by the present invention is shown in
[0035] The multiple food support racks 12 will preferably be mounted on opposing stamped side plates 15, using common formations found in indoor ovens for retaining cooking racks. However, this stamped detail 15 is preferably not integral with the side wall of the cooking and smoking chamber 8 as would be normal in an indoor oven, but is more preferably attached as a separate part as depicted for additional flexibility in the manufacturing and configuration of the inventive apparatus 2.
[0036] As shown in
[0037] Each of the side air intake vents 24 and 28 preferably comprises one opening (e.g., an elongate slot) or a series of openings 25 which (a) preferably extend(s) laterally in the side wall 30 or 32 of the vertical box 4 across at least 30% (more preferably across from about 75% to about 85%) of the width of the side wall 30 or 32 and (b) is preferably centered in the lower portion of the side wall 30 or 32. Proportionally speaking, the total flow (opening) area provided by each of the air intake vents 24 and 28 is preferably in the range of from about 1.0 to about 4.0 inches.sup.2, more preferably from about 2.0 to about 3.0 inches.sup.2, per 2.94 ft.sup.3 of volume of the cooking and smoking chamber 8. Although it is preferred that the air intake vents 24 and 28 not be adjustable, the inventive apparatus 2 can optionally include louvers, sliding covers, or other features for selectively changing the open area of the intake vents 24 and 28.
[0038] As further shown in
[0039] Each of the exhaust vents 34 and 36 preferably (a) is located from about 1.5 to about 6.5 inches from the upper end of the cooking and smoking chamber 8, (b) is located within from about 2.5 to about 4.5 inches from the back wall 38 of the cooking and smoking chamber 8, (c) has a louvered exterior cover 40 which operates to direct smoke from the forward end 94 of the lid assembly 82 of the smoke box 18 up and through a plurality of food support racks 12, and (d) provides a total effective proportional flow area, through the cover 40 if present, in the range of from about 4.0 to about 9.0 inches.sup.2, more preferably from about 6.0 to about 7.0 inches.sup.2, per 2.94 ft.sup.3 of volume of the cooking and smoking chamber 8.
[0040] The inventive placement of the lower pair of air intake vents 24 and 28 and the upper pair of exhaust vents 34 and 36 on each side of the cooking smoking chamber 8 creates a balanced flow of ventilating air through the cooking and smoking chamber 8 on both sides, thus providing a more even distribution of smoke and heat inside the chamber 8. The admission of cool, fresh outside air also reduces the production of CO.sub.2, as shown in tests of the inventive apparatus 2. In these tests, over the space of the first two hours of operation, the exhaust from the inventive cooking and smoking chamber 8 had a CO.sub.2 concentration of no more than 0.78%, normally between 0.10% and 0.15%. However, without the air intake vents 24 and 28, a CO.sub.2 concentration of up to 2.25%, normally between 1.3% and 2.1%, was produced.
[0041] Moreover, these tests further showed that the cooling air flow provided by the inventive venting arrangement unexpectedly only slightly reduced the average internal temperature in the cooking and smoking chamber 8 for the first hour of operation, after which the temperatures were comparable. Although the reason for this surprising result is not known with certainty, it is believed to be the effect of the interior of the cooking and smoking chamber 8 as a whole reaching a radiant heat equilibrium state after an hour of operation with radiant energy becoming the dominant mode of heat transfer.
[0042] The visual effect of the use of the inventive venting arrangement with a large fuel load of the type discussed below was that the wood smoke did not become overly dark or dense, but retained the light grey-blue color desired. The inventive venting arrangement also reduced the amount of condensation of smoke and water vapor on the surface of the food during cooking.
[0043] In addition, the venting arrangement reduces the operating pressure within the cooking and smoking chamber 8 and therefore, in conjunction with the larger size and inventive design and structure of the smoke box 18 (discussed below), allows a much larger load (up to as much as four cups or more) of wood chips, pellets or other pieces to be used in the smoke box 18. Heretofore, in the prior single top vented electric smoker cabinets because of the build-up of pressure and unburned, flammable hydrocarbons caused by the partial combustion of, and the production of smoke from, the wood chips, the quantity of wood chips which could be used in the cabinet was only about of a cup or less.
[0044] Also, by providing lower air intake vents 24 and 28 and upper exhaust vents 34 and 36 on both sides of the cooking and smoking chamber 8 of the inventive apparatus 2, the cooking and smoking chamber 8 is more evenly filled with smoke without any voids in the cooking and smoking zone. The inventive venting arrangement additionally assists in directing the smoke upwardly through the food support racks 12, thereby uniformly contacting and covering the food products with the desired amount of smoke.
[0045] The improved electrical heating element assembly 14 used in the inventive vertical electric cooker and smoker 2 preferably comprises: a holding tray 46 having a reflective interior bottom surface 48; one or more electric heating elements 50 positioned in the tray 46 above the reflective bottom surface 48; a rear attachment bracket 52; and a plurality of bottom legs 53. The rear bracket 52 secures the heating element assembly 14 to the back wall 38 of the cooking and smoking chamber 8 and provides an air gap between the holding tray 46, and smoke box 18, and the back wall 38 of the chamber 8. The bottom legs 53 preferably space the holding tray 46 about 2.25 inches above the bottom 16 of the cooking and smoking chamber 8. Also, a pair of spacers 54 and 57 project from the side of the holding tray 46 for spacing the holding tray 46 and smoke box 18 from the interior surface of the right side wall 32 of the vertical box 4 to provide an air gap of about 0.40 inches.
[0046] As seen in
[0047] The retaining station 55 preferably comprises: (a) a cover plate 56 which at least partially covers the electric heating element(s) 50 and acts as a bottom plate for the retaining station 55; (b) a plurality of spacers (stand-offs) 58 projecting from the upper surface of the cover plate 56 to create an air gap 60 between the surface of the cover plate 56 and the bottom surface of the smoke box 18; (c) a receiving slot structure 65, including two short vertical side walls 62 and 64, a short vertical back wall 66, and an open front end 68, for receiving and aligning the bottom of the smoke box 18 on top of the cover plate 56; and (d) a reflector plate 70 extending rearwardly from the top of the short back wall 66 of the smoke box receiving slot structure 65 for shielding the back of the smoke box 18 from radiant energy emitted or reflect by the heating element(s) 50 and/or the reflecting surface 48.
[0048] The height of the stand offs 58 is preferable at least 0.12 inches but not more than 0.25 inches above the cover plate 56. The height of the stand offs 58 is more preferably in the range of from about 0.10 inches to about 0.14 inches. By way of example, but not by way of limitation, the cover plate 56 is preferably formed of aluminized steel, low carbon steel, stainless steel, porcelain coated de-carb steel, cast iron or cast aluminum and the stand offs 58 are preferably formed of aluminized steel, low carbon steel, stainless steel, porcelain coated de-carb steel, cast iron or cast aluminum.
[0049] As an alternative to the use of the stand offs 58, washers, screw assemblies, extruded holes, square extrusions, a plurality of elongated stand offs in receiving slot structure 65 or in the bottom of the smoke box 18, for example, could instead be used to create or provide a space between the cover plate 56 and the bottom of the smoke box 18.
[0050] In the inventive vertical electric cooking and smoking apparatus 2, the cover plate 56 which acts as shield above the heating elements 50, the spacers (stand-offs) 58 which raise the bottom of the smoke box 18 off of the cover plate 56, the spacers 54 and 57 which provide an air gap between the side of the smoke box 18 and the interior side wall of the cooking and smoking chamber 8, and the rear reflector 70 which shields the back of the smoke box 18, operate together to (a) reduce the temperature and heat transfer at the bottom of the smoke box 18 sufficiently to increase the smoke time, (b) provide even heating at the bottom of the smoke box 18 so that the entire lower layer of wood chips inside the box 18 will start at the same time, and (c) eliminate hot pockets within the smoke box 18.
[0051] The embodiment 18 of the inventive smoke generating box used in the vertical electric cooking and smoking apparatus 2 is illustrated in
[0052] The rectangular box 75 will preferably be sized to contain at least four cups of wood chips or other pieces above the false bottom 80. The interior of the rectangular box 75 will preferably have (a) a longitudinal length in the range of from about 6.0 inches to about 6.25 inches, (b) a width in the range of from about 4.25 inches to about 4.40 inches, and (c) a height in the range of from about 3.0 inches to about 3.25 inches.
[0053] The lid assembly 82 of the inventive smoke generating box 18 comprises: (a) a lower lid piece 90 having a lateral row of smoke openings 92 which extend through the lower lid piece 90 adjacent to the forward end 94 of the lid assembly 82; (b) an upper lid piece 96 having a lateral row of smoke openings 98 which extend through the upper lid piece 96 adjacent to the forward end 94 of the lid assembly 82; (c) a middle lid piece 100 positioned between the upper lid piece 96 and the lower lid piece 90 and having a lateral row of smoke openings 102 which extend through the middle lid piece 100 adjacent to the rearward end 104 of the lid assembly 82; (d) a lower horizontal flow gap 106 formed between the lower and middle lid pieces 90 and 100; (e) an upper horizontal flow gap 108 formed between the middle and upper lid pieces 100 and 96; (f) a lower flow rail piece 110 extending laterally in the lower flow gap 106; and (g) an upper flow rail piece 112 extending laterally in the upper flow gap 108.
[0054] Each of the laterally extending lower and upper flow rail pieces 110 and 112 comprises a pair of parallel pass-through rails 110a and 110b and 112a and 112b which extend laterally across and block the upper and lower horizontal flow gaps 106 and 108. The upstream rail 110a, 112a of each rail piece 110, 112 has a series of smoke inlet holes 114, 116 provided therethrough. The downstream rail 110b, 112b of each rail piece 110, 112 has a series of smoke outlet holes 118, 120 provided therethrough. Preferably, the smoke outlet holes 118, 120 of each rail piece 110, 112 are not in alignment with the smoke inlet holes 114, 116 of the rail piece 110, 112. As a result, smoke flowing into an inlet hole 114, 116 cannot flow directly (i.e., in a straight line) through an outlet hole 118, 120 but instead is forced to change direction at least to some degree within the rail piece 110, 112.
[0055] The lower rail piece 110 is preferable positioned in the lower flow gap 106 at from about to about , more preferably from about to about , of the distance from the inlet end 122 to the outlet end 124 of the lower flow gap 106. Similarly, the upper rail piece 112 is preferable positioned in the upper flow gap 108 at from about to about , more preferably from about to about , of the distance from the inlet end 126 to the outlet end 128 of the upper flow gap 108.
[0056] For each of the lower, upper, and middle lid pieces 90, 96, 100, the total proportional flow area of the respective row 92, 98, or 102 of smoke openings provided therethrough will preferably be, in the range of from about 0.9 to about 2.6 inches.sup.2, more preferably from about 1.3 to about 1.6 inches.sup.2, per 80 in.sup.3 of volume of the cooking and smoke box 18.
[0057] The lower and upper flow gaps 106 and 108 formed between the lid pieces will preferably each have a height which is in the range of from about 0.10 to about 0.17 inches, more preferably from about 0.12 to about 0.15 inches.
[0058] The total proportional flow area of the smoke inlet or outlet holes 114, 116, 118, or 120 provided through each individual upstream and downstream rail 110a, 110b, 112a, or 112b of the rail pieces 110 and 112 will preferably be in the range of from about 0.25 to about 1.0 inches.sup.2, more preferably from about 0.44 to about 0.62 inches.sup.2, per 80 in.sup.3 of volume of the cooking and smoke box 18. For each of the rail pieces 110 and 112, the distance between the upstream rail 110a, 112a and the downstream rail 110b, 112b thereof will preferably be in the range of from about 0.25 to about 0.50 inches, more preferably from about 0.36 to about 0.40 inches.
[0059] In the inventive smoke box 18, the smoke generated by heating the wood pieces in the box 75 is forced to flow along a defined circuitous flow path 130 in which the smoke travels into the smoke openings 92 of the lower lid piece 90, through a first portion of the lower horizontal flow gap 106 to the lower rail piece 110, through the offset holes 110a and 110b of the lower rail piece, from the lower rail piece 110 to the smoke openings 102 of the middle lid piece 100, through a first portion of the upper horizontal flow gap 108 to the upper rail piece 112, through the offset holes 112a and 112b of the upper rail piece 112, from the upper rail piece 112 to the smoke openings 98 of the upper lid piece 96, and out of the smoke openings 98 into the cooking and smoking chamber 8 of the inventive vertical electric apparatus 2.
[0060] This circuitous path 130 acts as a flame suppression mechanism to prevent and contain any fire in the smoke box and additionally provides for cooling and mixing of the smoke produced in the inventive smoke box 18 so that the smoke exhausted from the lid outlet openings 98 has a relatively uniform temperature and smoke concentration. The length of the circuitous path 130 also allows for the smoke temperature to be hot enough to maintain suspension of the smoke particles in the atmosphere but cool enough to stay well below any ignition point when it exits from the smoke box 18.
[0061] An alternative embodiment 150 of the inventive smoke box is illustrated in
[0062] In the inventive smoke box 150, each of the one or more vertical sides having a circuitous smoke exit path 152 provided therein comprises: (a) an inner vertical wall 162 having a row of smoke openings 164 which extend across the upper end portion thereof; (b) an outer vertical wall 166 having an open upper end 168; (c) a middle vertical wall 170 positioned between the inner and outer vertical walls 162 and 166, and having a row of smoke openings 175 which extend across the bottom portion thereof; (d) an inner vertical flow gap 172 formed between the inner and middle vertical walls 162 and 170; (e) an outer vertical flow gap 174 formed between the middle and outer vertical walls 170 and 166; (f) an inner flow rail piece 176 extending horizontally in the inner flow gap 172; (g) an outer flow rail piece 178 extending horizontally in the outer vertical flow gap 174; and (h) a row of smoke exhaust openings 180 formed through the top of the lid 182 of the box along the edge of the lid 182 for placement over the open upper end 168 of the outer vertical wall 166.
[0063] Consequently, in the circuitous flow path 152 defined in the inventive smoke box 150, the smoke is forced to flow into the smoke openings 164 at the upper end of the inner vertical wall 162, downwardly through the inner flow gap 172 to the inner rail piece 176, from the inner rail piece 176 to the flow openings at the bottom of the middle vertical wall 170, upwardly through the outer vertical flow gap 174 to the outer rail piece 178, and from the outer rail piece 178 to and out of the smoke exhaust openings 180 of the lid 182. Alternatively, the smoke could exit through side exhaust openings provided at the upper end of the outer wall 166 rather than through the lid 182.
[0064] The flow opening areas of the walls and lid, the rail piece flow opening areas, and the flow gap widths for the circuitous flow path 152 of the inventive smoke box 150 will preferably be the same as those of the flow path 130 provided in the lid assembly of the inventive smoke box 18.
[0065] Thus, the present invention is well adapted to carry out the objectives and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within the invention.