The Innovation Behind the Typhur Dome Air Fryer

All Started with Cooking Science

For families or parties, when we require a substantial amount of food, the existing air fryers in the market offer us two choices.

The first option involves stacking food for cooking, but this often leads to unsatisfactory results. From the perspective of culinary science, when food is stacked or overcrowded in an air fryer, air and heat cannot circulate evenly over the surface of each item, resulting in uneven heating. This may lead to some parts becoming burnt while others remain undercooked. To achieve a perfect cooking outcome, we need more cooking space.

The second choice is to cook in two separate batches, but this process is both cumbersome and time-consuming, providing a less than ideal experience for users. We need a better solution.

This is the goal of Typhur: to design an entirely new air fryer that not only doubles the cooking area but also avoids extending the cooking time. This is made possible by Typhur's innovative optimization of airflow and heat distribution, ensuring that food can be quickly and uniformly cooked.

Challenges We Are Facing

However, during the design process, we encountered certain challenges. First, when we expanded the fryer's cooking area, the hot air couldn't uniformly reach every corner, resulting in uneven cooking. To address this challenge, we increased the surface area of the heating element and fan, broadening the heat source range, which enhanced cooking uniformity to some extent. However, we were not satisfied with just that.

Another challenge we faced was that, with increased cooking capacity, transferring more heat would inevitably extend the cooking time, which contradicted our overall goal. We attempted to increase the heating element power and fan airflow to expedite the cooking process. However, due to limitations in home power supply and the risk of excessive airflow causing food surfaces to dry out too quickly, resulting in hardened exteriors and undercooked interiors, there were restrictions regarding both power and airflow. Hence, we needed to explore alternative solutions.

Bigger and faster: Inspired by Pizza Oven

Just as we were grappling with the direction to pursue, we drew inspiration from Pizza Ovens! We noted that a circular chamber had the ability to distribute heat more evenly. As a result, we adopted its chamber design and incorporated it into our exploration of fluid dynamics.

Upon conducting a thorough analysis of fluid dynamics, we determined that a flat, curved inner chamber could effectively disperse hot air across a larger food surface area, promising more comprehensive heating in theory, and consequently enhancing cooking uniformity. Moreover, the airflow's effective velocity on the food's surface increased, leading to a significant improvement in heat transfer efficiency.

Relentlessly tested

With the theoretical analysis validated, we proceeded to create structural models and design fluid simulations. We meticulously fine-tuned the chamber's geometric dimensions, fan blade model, and the relative positions between the heating element and fan. Each adjustment necessitated remodeling and computer simulations.

Following the positive outcomes from the simulation analysis, we commenced prototype production and conducted practical food cooking tests.

Adhering to the principles of cooking science, we quantitatively analyzed cooking results:

Our assessment of uniformity involved using a color chart to count varying degrees of browning;
We recorded heating speed through temperature sensors situated within the cooking chamber;
And gauged cooking effectiveness by monitoring food moisture loss or central temperature.

After over 500 rounds of simulation analysis, prototype adjustments, and more than a thousand food cooking tests, Dome emerged as the air fryer that provides the most even cooking and the fastest cooking speed (#1 fast), presenting an outstanding choice for large-capacity cooking scenarios.

Quietness

To achieve high-capacity and high-speed cooking, we introduced a larger chamber, more powerful fan blades, and a faster flow field. However, these enhancements introduced challenges related to vibration and noise, which had a detrimental impact on the user's cooking experience. To address the noise issue, we employed a series of highly efficient engineering techniques and innovative designs.

First, we designed a direct current (DC) brushless motor that was more expensive but offered superior performance. This motor featured a more consistent air gap magnetic field, reducing torque fluctuations during rotation and effectively decreasing vibration and noise levels.
Second, we adopted a FOC(field-oriented control) algorithm with a higher computational complexity, requiring chips with enhanced processing capabilities. This application effectively suppressed speed fluctuations, further reducing noise.

In terms of production manufacturing, we subjected the power system to dynamic balancing selection, choosing only components with extremely high balance for the production of the "Dome" air fryer, ensuring the product's exceptional quality.

Through these innovations and improvements, we successfully addressed the noise issue, providing users with a quieter and more enjoyable cooking experience.

Self-Clean

After resolving challenges related to cooking capacity, speed, and noise, we turned our attention to the issue of cleaning the air fryer. We realized that the top area inside the machine was often challenging to clean thoroughly, with accumulated oil residues gradually oxidizing and releasing unpleasant odors. Furthermore, the oxidation byproducts of fatty acids in this area pose potential health risks.

To tackle the issue of oil residue buildup on the top, we initially designed the top surface to be easily cleaned. However, due to the presence of heating elements and fans, users find it difficult to thoroughly clean this area. Therefore, we began searching for a solution that wouldn't require manual cleaning.

Built to go on, and on

We learned that the chemical properties of oil residues involve decomposition at high temperatures (over 400°C), but electronic components and structural parts could not endure. When we discovered the practice of introducing catalysts to reduce the decomposition temperature in the field of oil fume purification, we began searching for the best material for this purpose. This involved conducting extensive testing of the decomposition capabilities of oil residues and comparing more than ten catalytic materials, ultimately selecting the most outstanding material for application in the Dome air fryer.

This introduced Dome as the first air fryer product to feature a self-cleaning function for oil residues. Above the chamber, we employed a porous coating material capable of adsorbing oil residue molecules and efficiently decomposing oil residues into environmentally friendly carbon dioxide and water at high temperatures. This technology not only enhances your cooking experience for better health but also contributes to maintaining the cleanliness and hygiene of the "Dome" air fryer's interior.

Engineering a better way

Overcoming a series of challenges related to uniformity, cooking speed, noise, and cleanliness, we have successfully designed Dome, an outstanding air fryer product.