Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
  • B21C23/00—Extruding metal; Impact extrusion
  • B21C23/22—Making metal-coated products; Making products from two or more metals
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47J—KITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
  • A47J36/00—Parts, details or accessories of cooking-vessels
  • A47J36/02—Selection of specific materials, e.g. heavy bottoms with copper inlay or with insulating inlay
• • A—HUMAN NECESSITIES
  • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
  • A47J—KITCHEN EQUIPMENT; COFFEE MILLS; SPICE MILLS; APPARATUS FOR MAKING BEVERAGES
  • A47J37/00—Baking; Roasting; Grilling; Frying
  • A47J37/10—Frying pans, e.g. frying pans with integrated lids or basting devices
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
  • B21K25/00—Uniting components to form integral members, e.g. turbine wheels and shafts, caulks with inserts, with or without shaping of the components
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B1/00—Layered products having a non-planar shape
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
  • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/08—Interconnection of layers by mechanical means
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
  • B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
  • B32B9/007—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile comprising carbon, e.g. graphite, composite carbon
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
  • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B9/041—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2250/00—Layers arrangement
  • B32B2250/05—5 or more layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2250/00—Layers arrangement
  • B32B2250/42—Alternating layers, e.g. ABAB(C), AABBAABB(C)
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/30—Properties of the layers or laminate having particular thermal properties
  • B32B2307/302—Conductive
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/732—Dimensional properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2439/00—Containers; Receptacles
  • B32B2439/02—Open containers

Definitions

• the present invention relates to multi-ply, bonded cookware having a central area of a cooking surface that has a higher level of thermal conductivity than a distal area of the cooking surface, as well as sidewalls of the cookware.
• a method for making the cookware using solid state bonding is also disclosed.
• Multi-layer bonded composite cookware in which various materials are joined together to combine the desired physical properties of each of the materials into a composite.
• the corrosion resistance of stainless steel is ideal for the cooking surface as well as for the exterior surface of cookware; however, the thermal conductivity of stainless steel is not relatively high.
• aluminum and/or copper offer much higher thermal conductivities and have been bonded to stainless steel to provide well- known composite cookware items such as pots, pans, and the like.
• Multi-layer bonded cookware is known in the art, as shown in a number of patents, such as, for example: United States Patent Nos. 4,246,045 and 4,167,606 to Ulara; and United States Patent Nos.
• a solid state bonding technique using high static pressure and heat applied over time to make a plurality of composite blanks of, for example, a combination of stainless steel - aluminum - stainless steel in the manufactured cookware is disclosed in United States Patent No. 9,078,539 to Groll et al.
• cookware may have a multi-layer bonded composite wall structure.
• the cookware may have an inner metal layer and an outer metal layer, and a core layer between the inner layer and the outer layer.
• the core layer may have at least two perforated graphite plates, each plate having a plurality of spaced-apart holes formed therethrough, and at least one intermediate metal element disposed between the at least two perforated graphite plates and extending through the plurality of spaced- apart holes of each of the at least two perforated graphite plates.
• the at least one intermediate metal element may be metallurgically bonded to the inner layer and the outer layer at least through the plurality of spaced-apart holes.
• cookware may have a multi-layer bonded composite wall structure.
• the cookware may have an inner metal layer and an outer metal layer; and a core layer between the inner layer and the outer layer.
• the core layer may have at least two perforated graphite plates, each plate having a plurality of spaced-apart holes formed therethrough, and at least one metal core plate disposed between the at least two perforated graphite plates and extending through the plurality of spaced-apart holes of each of the at least two perforated graphite plates.
• the at least one metal core plate may be metallurgically bonded to the inner layer and the outer layer at least through the plurality of spaced-apart holes.
• the at least one metal core plate may be an aluminum plate.
• the at least one metal core plate can be a disc having a diameter equal to or larger than the at least two perforated graphite plates.
• the at least one metal core plate may have a thickness of 0.032 in.
• At least one of the perforated graphite plates may have a thickness between 0.0010 in. and 0.0050 in.
• the inner layer may be stainless steel and have a thickness between 0.010 in. to 0.015 in.
• the outer layer may be stainless steel and have a thickness between 0.010 in. to 0.020 in.
• the inner layer and the outer layer may be
• the at least one metal core plate may be a disc having a diameter of 5 in. to 25 in.
• At least one of the perforated graphite plates may be a disc having a diameter of 2 in. to 20 in.
• At least one of the perforated graphite plates may be made from pyrolytic graphite.
• the plurality of spaced-apart holes of at least one of the perforated graphite plates may have a diameter of 0.025 in. to 0.25 in.
• the at least one metal core plate may be metallurgically bonded to the inner metal layer and the outer metal layer in an area surrounding the at least two perforated graphite plates.
• the cookware may be formed as a fry pan.
• the cookware may have a bottom portion surrounded by a sidewall, and the at least two perforated graphite plates may be located only in the bottom portion.
• the at least one metal core plate may have a pair of metal core plates disposed between the at least two perforated graphite plates.
• the at least two perforated graphite plates may have at least one perforated graphite plate disposed between the inner metal layer and the at least one metal core plate, and at least one perforated graphite plate disposed between the metal core plate and the outer metal layer.
• cookware may have an inner metal layer; an outer metal layer; and at least one perforated graphite plate having a plurality of spaced-apart holes formed therethrough disposed between the inner metal layer and the outer metal layer. At least one of the inner metal layer and the outer metal layer may extend through the plurality of spaced-apart holes of the at least one perforated graphite plate.
• the inner metal layer may be metallurgically bonded to the outer metal layer at least through the plurality of spaced-apart holes.
• At least one of the inner metal layer and the outer metal layer may be made as an aluminum plate. At least one of the inner metal layer and the outer metal layer may have a thickness of 0.032 in.
• the perforated graphite plate may have a thickness between 0.0010 in. and 0.0050 in.
• the inner layer may be stainless steel and have a thickness between 0.010 in. to 0.015 in.
• the outer layer may be stainless steel and have a thickness between 0.010 in. to 0.020 in.
• the inner layer and the outer layer may be circular with a diameter of 5 in. to 25 in.
• the at least one perforated graphite plate may be a disc having a diameter of 2 in. to 20 in.
• the at least one perforated graphite plate may be made from pyrolytic graphite.
• the plurality of spaced-apart holes of the at least one perforated graphite plate may have a diameter of 0.025 in. to 0.25 in.
• the inner metal layer may be metallurgically bonded to the outer metal layer in an area surrounding the at least one perforated graphite plate.
• the cookware may be formed as a fry pan.
• the cookware may have a bottom portion surrounded by a sidewalk and the at least one perforated graphite plate may be located only in the bottom portion.
• a method of making multi-layer bonded cookware may include providing an inner metal layer and an outer metal layer; providing a core layer between the inner layer and the outer layer to define a stacked blank assembly, the core layer comprising at least two perforated graphite plates, each plate having a plurality of spaced-apart holes formed therethrough, and at least one metal core plate disposed between the at least two perforated graphite plates; and applying heat and pressure to the stacked blank assembly such that the at least one metal core plate is extmded through the plurality of spaced-apart holes of each of the at least two perforated graphite plates and is metallurgically bonded to the inner layer and the outer layer at least through the plurality of spaced-apart holes.
• a method of making multi-layer bonded cookware may include providing an inner metal layer and an outer metal layer; providing a perforated graphite plate between the inner metal layer and the outer metal layer to define a stacked blank assembly, the perforated graphite plate having a plurality of spaced-apart holes formed therethrough; and applying heat and pressure to the stacked blank assembly such that the inner metal layer is metallurgically bonded to the outer metal layer at least through the plurality of spaced-apart holes of the perforated graphite plate.
• Fig. 1 is an exploded isometric view of a blank assembly of one embodiment or aspect of the present disclosure
• FIG. 2 is a cross-sectional view of a bonded blank assembly of Fig. 1 ;
• FIG. 3 is an enlarged view of Detail A shown in Fig. 2:
• Fig. 4 is a cross-sectional view of a formed fry pan shape made from the bonded blank assembly of Fig. 2;
• Fig. 5 is an exploded side view of a blank assembly of another embodiment or aspect of the present disclosure.
• Fig. 6 is an exploded side view of a blank assembly of another embodiment or aspect of the present disclosure.
• Fig. 7 is an exploded side view of a blank assembly of another embodiment or aspect of the present disclosure.
• substantially parallel means a relative angle as between two objects (if extended to theoretical intersection), such as elongated objects and including reference lines, that is from 0° to 5°, or from 0° to 3°, or from 0° to 2°, or from 0° to 1°, or from 0° to 0.5°, or from 0° to 0.25°, or from 0° to 0.1°, inclusive of the recited values.
• solid state bonding means a method of bonding two or more stacked plates of metals or metal alloys together using high pressure (typically over 5,000 psi) and high temperature (typically over 600 °F), wherein the high pressure is applied in a normal or axial direction, i.e., 90° relative to the plane of the stacked plates.
• metallurgical bonding or “metallurgically bonded” refers to a bond formed between similar or dissimilar materials that is free of voids or discontinuities.
• Figs. 1-3 depict various views of a blank assembly 2 used in making one presently preferred embodiment of the cookware of the present invention.
• the materials are positioned in an ordered array to create the blank assembly 2 as shown.
• the surface preparation steps may include degreasing, surface abrasion by chemical or mechanical methods, and the like.
• the blank assembly 2 comprises upper and lower plates 4 and 8 which will form the inner and outer surfaces, respectively, of the cookware after the bonding and forming steps.
• at least one of the upper and lower plates 4 and 8 is formed from metal, such as stainless steel, or titanium.
• the stainless steel may be 300 grade or 400 grade stainless steel.
• both the upper and lower plates 4 and 8 are formed from stainless steel.
• the upper and lower plates 4 and 8 may be discs about 14 inches in diameter to form a near-net size blank for making a fry pan of 10 inches in diameter.
• the upper and lower plates 4 and 8 may be discs from about 5 inches to about 20 inches in diameter. In this manner, scrap losses can be minimized.
• the size of the upper and lower plates 4 and 8 can be increased or decreased to make fry pans of larger or smaller sizes, respecti vely.
• the thickness of upper and lower plates 4 and 8 may be about 0.015 to 0.03 inches.
• the lower plate 8 of stainless steel may be made of a ferro-magnetic stainless steel, such as a 400 grade in order to make the finished cookware suitable for use on an induction cooking apparatus.
• the upper plate 4 is a food-grade stainless steel, such as an austenitic 300 grade.
• at least one of the upper and lower plates 4 and 8 may be made from food-grade metal other than stainless steel, such as titanium.
• the central core layer 6 includes at least one perforated graphite plate 10 having a plurality of spaced-apart holes 12 and at least one intermediate metal element, such as at least one metal core plate 14.
• the core layer 6 has a pair of perforated graphite plates 10, with one plate positioned on each side of a single metal core plate 14. After the solid state bonding process, the metal core plate 14 is extruded through the holes 12 of each perforated graphite plate 10 and is bonded with the upper and lower plates 4 and 8.
• the core layer 6 has a pair of perforated graphite plates 10 with two or more stacked metal core plates 14 positioned between the pair of perforated graphite plates 10.
• one perforated graphite plate 10 is directly between the upper plate 4 and the metal core plate(s) 14, and the other perforated graphite plate 10 is directly between the metal core plate(s) 14 and lower plate 8.
• the perforated graphite plate 10 is about 0.0010-0.0050 inches thick and has the plurality of spaced-apart through holes 12 formed therethrough.
• the size of the perforated graphite plate 10 is sized to be smaller than the metal core plate 14 and the upper and lower plates 4 and 8 so that an outer edge of the perforated graphite plate 10 is spaced radially inwardly from the outer edges of the metal core plate 14, and the upper and lower plates 4 and 8.
• a diameter of the perforated graphite plate 10 may be selected to correspond to a diameter of the cooking surface of the cookware 30 such that the perforated graphite plate 10 is spaced apart from the radiused portion 32 of the formed cookware 30 (Fig. 4) in the region where a flat bottom 34 transitions to a sidewall 36.
• the diameter of the perforated graphite plate may be 7 - 9 inches, for example.
• the holes 12 in the perforated graphite plate 1 0 may be about 0.025-0.25 inches in diameter.
• the holes 12 may be spaced apart from each other randomly, or in a pattern.
• the holes 12 may be arranged in a circular array.
• the density of the holes 12 i.e., number of holes 12 per unit area
• the density of the holes 12 may be uniform across the perforated graphite plate 10, or it may vary between different portions of the perforated graphite plate 10.
• the density of the holes 12 may increase or decrease in a radial direction of the perforated graphite plate 10.
• the holes 12 may be provided in one or more groupings of holes 12.
• the perforated graphite plate 10 may be made of pyrolytic graphite so as to transmit thermal energy primarily in a radial (rather than axial) direction. In this manner, the cooking surface can be heated uniformly, while avoiding hot spots.
• Graphite is preferably selected due to its high coefficient of thermal conductivity (approximately 1 ,700 W/mK versus approximately 200 W/mK for aluminum).
• the metal core plate 14 of the central core layer 6 encapsulates the perforated graphite plate 10 between the upper and lower plates 4 and 8 by being metallurgically bonded with the upper and lower plates 4 and 8 during the solid state bonding process.
• a bottom portion of the metal core plate 14 is extruded through the holes 12 of the lower perforated graphite plate 10b during the solid state bonding process and is bonded with the upper surface of the lower plate 8.
• An upper portion of the metal core plate 14 is extruded through the holes 12 of the upper perforated graphite plate 10a during the solid state bonding process and is bonded with the lower surface of the upper plate 4.
• the metal core plate 14 is larger in diameter than the perforated graphite plates 10a, 10b, the metal core plate 14 is bonded with the upper and lower plates 4 and 8 over an entire surface of the metal core plate 14 surrounding the perforated graphite plates 10a, 10b.
• the metal core plate 14 is formed from aluminum alloy, such as 1 100 grade aluminum alloy. In other examples, the metal core plate 14 is formed from pure aluminum, aluminum clad metal, copper, or any other metal capable of metallurgically bonding with the upper and lower plates 4 and 8.
• the metal core plate 14 is larger than the perforated graphite plates 10a, 10b and may be sized to correspond to the size of the upper and lower plates 4 and 8.
• the metal core plate 14 may be a disc about 14 inches in diameter to form a near-net size blank for making a fry pan of 10 inches in diameter. In other examples, the metal core plate 14 may be a disc about 2-20 inches in diameter. In this manner, scrap losses can be minimized.
• the size of the metal core plate 14 can be increased or decreased to make fry pans of larger or smaller sizes, respectively.
• the thickness of the metal core plate may be about 0.032 to 0.040 inches.
• the blank assembly 2 is formed by stacking the central core layer 6 on an upper surface of the lower plate 8.
• the central core layer 6 can be stacked on the lower plate 8 by placing the lower perforated graphite plate 10b on top of the lower plate 8, followed by the metal core plate 14 and the upper perforated graphite plate 10a.
• the upper plate 4 is then stacked on a top surface of the upper perforated graphite plate 10a.
• the upper plate 4, the central core layer 6, and the lower plate 8 are aligned such that centers of each layer share a common axis.
• the layers may be stacked such that their centers are offset from one another.
• the upper plate 4, the central core layer 6, and the lower plate 8 are substantially parallel to each other.
• the blank assembly 2, or a plurality of stacked blank assemblies 2 are then placed in a press apparatus (not shown) for application of a load or pressure in the normal direction relative to the planes of plates in the blank assemblies 2. While under a pressure of between 10,000 and 20,000 psi, heat is applied to the blank assembly or assemblies 2 between about 800°F and 1 ,400°F for a sufficient time (about 1 - 2 hours) to achieve solid state bonding (i.e., metallurgical bonding) between the plates in the blank assembly or assemblies 2.
• the material of the metal core plate 14 is softened with the increase in temperature and is extruded through the holes 12 of the perforated graphite plates 10a, 10b to be metallurgically bonded with the upper and lower plates 4 and 8.
• Good bonding between stainless steel and aluminum is obtained at a pressure of 20,000 psi at a temperature of 860°F after about one hour.
• Each blank assembly 2 is then removed from the press apparatus and allowed to cool.
• cooling may be accomplished by exposure to ambient air or by using a cooling agent, such as forced air or liquid.
• the bonded blank assembly 2 is formed in a drawing press or hydroform machine (not shown) into a desired shape, such as a fry pan shape 30 depicted in Fig. 4. It will be seen in Fig. 4 that the metal core layer 14 is extruded through the holes 12 in the perforated graphite plates 10a, 10b and is bonded to the upper and lower plates 4 and 8. The metal core layer 14 is further bonded to the upper and lower plates 4 and 8 in an area surrounding the perforated graphite plates 10a, 10b, such as in the area defining the sidewail 36 of the fry pan 30. A handle or handles (not shown) may be attached to the cookware in a known manner.
• blank assemblies 2 useful in making cookware, are shown in accordance with other preferred and non-limiting embodiments or aspects of the present disclosure.
• the components of the blank assemblies 2 shown in Figs. 5-7 are substantially similar or identical to the components of the blank assembly 2 described herein with reference to Figs. 1 -3.
• the previous discussion regarding the blank assembly 2 generally shown in Figs. 1 - 3 is applicable to the embodiments shown in Figs. 5-7, only the relative differences between the blank assembly 2 generally shown in Figs. 1 -3 and the blank assemblies shown in Figs. 5-7 are discussed hereinafter.
• the blank assembly 2 comprises upper and lower plates 4 and 8 which will form the inner and outer surfaces, respectively, of the cookware after the bonding and forming steps. Between the upper and lower plates 4 and 8 is a central core layer 6'.
• the central core layer 6' includes three perforated graphite plates 10a, 10b, and 10c, and a pair of metal core plates 14a, 14b disposed between the perforated graphite plates 10a, 10b, and 10c.
• Each of the perforated graphite plates 10a, 10b, 10c has a plurality of spaced-apart holes 12.
• the upper surface of the upper metal core plate 14a and the lower surface of the lower metal core plate 10b are extruded through the holes 12 of the first and third perforated graphite plates 10a, 10c, respectively, and are metallurgically bonded with the upper and lower plates 4 and 8, respectively.
• the lower surface of the upper metal core plate 14a and the upper surface of the lower metal core plate 14b are extruded through the holes 12 of the intermediate perforated graphite plate 10b and are metallurgically bonded with each other.
• the upper and lower metal core plates 14 are further bonded to the upper and lower plates 4 and 8 in an area surrounding the perforated graphite plates 10a, 10b, and 10c.
• the blank assembly 2 does not have a core layer, such as the core layer 6 shown in Figs. 1-3 or the core layer 6' shown in Fig. 5. Instead, the blank assembly 2 has an upper plate 4' made from a first material, such as stainless steel, and a lower plate 8' made from a second material, such as aluminum.
• the perforated graphite plate 10 having a plurality of holes 12, as described herein, is disposed between the upper and lower plates 4' and 8'. In some examples, a plurality of perforated graphite plates 10 may be stacked between the upper and lower plates 4' and 8'.
• the upper surface of the lower plate 8' is extruded through the holes 12 of the perforated graphite plate(s) 10 and is metallurgically bonded with the lower surface of the upper plate 4'.
• the upper and lower plates 4' and 8' are further metallurgically bonded with each other in an area surrounding the perforated graphite plate 10.
• the upper plate 4", the lower plate 8", and the metal core plate 14" are all made from the same material, such as aluminum.
• a pair of perforated graphite plates 10a, 10b, as described herein, are disposed between the upper plate 4", the lower plate 8", and the metal core plate 14".
• a plurality of perforated graphite plates 10a may be stacked directly on one another between the upper plate 4" and the metal core plate 14", and/or a plurality of graphite plates 10b may be stacked directly on one another between the metal core plate 14" and the lower plate 8".
• the lower surface of the upper plate 4" and/or the upper surface of the metal core plate 14" are extruded though the holes of the upper perforated graphite plate 10a and are metallurgically bonded together.
• the upper surface of the lower plate 8" and/or the lower surface of the metal core plate 14" are extruded through the holes of the lower perforated graphite plate 10b and are metallurgically bonded together.
• the upper and lower plates 4" and 8" are further metallurgically bonded with the metal core plate 14" in an area surrounding the perforated graphite plates 10a, 10b.
• solid state bonding technique of bonding pre-cut near net shape plate blanks not only reduces scrap losses heretofore encountered in the conventional roll bonding manufacture of composite cookware but also permits the use of other materials in making multiple composites which have proven difficult, impossible and/or expensive to roll-bond.
• solid state bonding permits the use of different grades of stainless steel than otherwise possible in conventional roll bonding so as to lower costs of materials.
• solid state bonding further allows encapsulating of materials, such as graphite, that cannot otherwise be bonded to stainless steel.
• the present invention may be further characterized by one or more of the fol lowing clauses:
• Cookware having a multi-layer bonded composite wall structure, the cookware comprising: an inner metal layer and an outer metal layer; and a core layer between the inner layer and the outer layer, the core layer comprising at least two perforated graphite plates, each of said at least two perforated graphite plates having a plurality of spaced-apart holes formed therethrough, and at least one metal core plate disposed between the at least two perforated graphite plates and extending through the plurality of spaced- apart holes of each of the at least two perforated graphite plates, wherein the at least one metal core plate is metallurgically bonded to the inner layer and the outer layer at least through the plurality of spaced-apart holes.
• Clause 3 The cookware of any of clauses 1 -2, wherein the at least one metal core plate has a thickness of 0.032 in.
• Clause 4 The cookware of any of clauses 1-3, wherein at least one of the perforated graphite plates has a thickness between 0.0010 in. and 0.0050 in.
• Clause 5 The cookware of any of clauses 1-4, wherein the inner layer is stainless steel and has a thickness between 0.010 in. to 0.015 in.
• Clause 6 The cookware of any of clauses 1-5, wherein the outer layer is stainless steel and has a thickness between 0.010 in. to 0.020 in.
• Clause 7 The cookware of any of clauses 1-6, wherein the inner layer and the outer layer are circular with a diameter of 5 in. to 25 in.
• Clause 8 The cookware of any of clauses 1-7, wherein the at least one metal core plate has a diameter of 5 in. to 25 in.
• Clause 9 The cookware of any of clauses 1-8, wherein at least one of the perforated graphite plates has a diameter of 2 in. to 20 in.
• Clause 10 The cookware of any of clauses 1-9, wherein at least one of the perforated graphite plates is made from pyrolytic graphite.
• Clause 1 1. The cookware of any of clauses 1-10, wherein the plurality of spaced-apart holes of at least one of the perforated graphite plates have a diameter of 0.025 in. to 0.25 in.
• Clause 12 The cookware of any of clauses 1 -1 1 , wherein the at least one metal core plate is metallurgically bonded to the inner layer and the outer layer in an area surrounding the at least two perforated graphite plates.
• Cookware having a multi-layer bonded composite wall structure, the cookware comprising: an inner metal layer; an outer metal layer; and at least one perforated graphite plate having a plurality of spaced-apart holes formed therethrough disposed between the inner metal layer and the outer metal layer, at least one of the inner metal layer and the outer metal layer extending through the plurality of spaced-apart holes of the at least one perforated graphite plate, wherein the inner metal layer is metallurgically bonded to the outer metal layer at least through the plurality of spaced-apart holes.
• Clause 16 The cookware of clause 15, wherein at least one of the inner metal layer and the outer metal layer is made as an aluminum plate.
• Clause 17 The cookware of clause 15 or clause 16, wherein at least one of the inner metal layer and the outer metal layer has a thickness of 0.032 in.
• Clause 1 8. The cookware of one of clauses 15-17, wherein the at least one perforated graphite plate has a thickness between 0.0010 in. and 0.0050 in.
• Clause 19 The cookware of one of clauses 15-18, wherein the inner layer is stainless steel and has a thickness between 0.010 in. to 0.015 in.
• Clause 20 The cookware of one of clauses 15-19, wherein the outer layer is stainless steel and has a thickness between 0.010 in. to 0.020 in.
• Clause 21 The cookware of one of clauses 15-20, wherein the inner layer and the outer layer are circular with a diameter of 5 in. to 25 in.
• Clause 22 The cookware of one of clauses 15-21 , wherein the at least one perforated graphite plate has a diameter of 2 in. to 20 in.
• Clause 23 The cookware of one of clauses 15-22, wherein the at least one perforated graphite plate is made from pyrolytic graphite.
• Clause 24 The cookware of one of clauses 15-23, wherein the plurality of spaced- apart holes of the at least one perforated graphite plate have a diameter of 0.025 in. to 0.25 in.
• Clause 25 The cookware of one of clauses 15-24, wherein the inner metal layer is metallurgically bonded to the outer metal layer in an area surrounding the at least one perforated graphite plate.
• Clause 26 The cookware of one of clauses 15-25, wherein the cookware is formed as a fry pan.
• Clause 27 The cookware of one of clauses 15-26, wherein the cookware comprises a bottom portion surrounded by a sidewall, and wherein the at least one perforated graphite plate is located only in the bottom portion.
• a method of making multi-layer bonded cookware comprising: providing an inner metal layer and an outer metal layer; providing a core layer between the inner layer and the outer layer to define a stacked blank assembly, the core layer comprising at least two perforated graphite plates, each plate having a plurality of spaced-apart holes formed therethrough, and at least one metal core plate disposed between the at least two perforated graphite plates; and applying heat and pressure to the stacked blank assembly such that the at least one metal core plate is extruded through the plurality of spaced-apart holes of each of the at least two perforated graphite plates and is metallurgically bonded to the inner layer and the outer layer at least through the plurality of spaced-apart holes.
• a method of making multi-layer bonded cookware comprising: providing an inner metal layer and an outer metal layer; providing a perforated graphite plate between the inner metal layer and the outer metal layer to define a stacked blank assembly, the perforated graphite plate having a plurality of spaced-apart holes formed therethrough; and applying heat and pressure to the stacked blank assembly such that the inner metal layer is metallurgically bonded to the outer metal layer at least through the plurality of spaced-apart holes of the perforated graphite plate.
• Clause 31 The cookware of any of clauses 1-14 and 30, wherein the at least two perforated graphite plates comprises at least one perforated graphite plate disposed between the inner metal layer and the at least one metal core plate, and at least one perforated graphite plate disposed between the metal core plate and the outer metal layer.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Ceramic Engineering (AREA)
• Food Science & Technology (AREA)
• Chemical & Material Sciences (AREA)
• Cookers (AREA)
• Frying-Pans Or Fryers (AREA)

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• 2017
  • 2017-02-15 WO PCT/US2017/017911 patent/WO2018151716A1/en unknown
  • 2017-02-15 CA CA3053508A patent/CA3053508A1/en active Pending
  • 2017-02-15 CN CN201780086569.6A patent/CN110602969A/zh active Pending
  • 2017-02-15 EP EP17896454.0A patent/EP3582664A4/de active Pending

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