OVEN APPLIANCE WITH A SINGLE HEATING ELEMENT

Description

FIELD OF THE INVENTION

The subject matter of the present disclosure relates generally to an oven appliance, such as a full-size oven appliance or range appliance, and more specifically to heating elements in an oven appliance.

BACKGROUND OF THE INVENTION

Oven appliances generally include a cabinet that defines a cooking chamber for cooking food items therein, such as by baking or broiling the food items. To heat the cooking chamber for cooking, oven appliances include one or more heating elements positioned at a top portion, a bottom portion, or both the top portion and the bottom portion of the cooking chamber. Some oven appliances also include a convection heating element and fan for convection cooking cycles in addition to a main heating element. The main heating element or elements may be used for various cycles of the oven appliance, such as a preheat cycle, a cooking cycle, or a self-cleaning cycle.

Typical oven appliances include two heating elements to perform traditional heating methods of bottom heat source baking and forced convection. Oven appliances are more costly and complex when including two or more heating elements. Accordingly, an oven appliance with a simplified and cheaper heating element system would be desirable.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, may be apparent from the description, or may be learned through practice of the invention.

In one example embodiment, an oven appliance is provided. The oven appliance includes a cabinet and a cooking chamber within the cabinet for receipt of food items for cooking. The cooking chamber is delineated by a plurality of walls including a bottom wall, a left side wall, and a right side wall. A heating chamber is defined below the cooking chamber. A heating element is positioned within the heating chamber. A fan is positioned at a back side of the heating chamber. The fan is configured to pull air through the heating chamber and into the cooking chamber. A controller is positioned within the cabinet. The controller is in operative communication with the heating element and the fan. The controller is configured to operate the heating element to heat air in the heating chamber in a first heating mode and receive an input indicative of a second heating mode. The controller is also configured to trigger the fan to pull air through the heating chamber and into the cooking chamber in response to the second heating mode and operate the heating element to heat air flowing through the heating chamber in the second heating mode.

In another example embodiment, a method of operating an oven appliance is provided. The oven appliance includes a cabinet and a cooking chamber within the cabinet for receipt of food items for cooking. The cooking chamber is delineated by a plurality of walls including a bottom wall, a left side wall, and a right side wall. A heating chamber is defined below the cooking chamber. A heating element is positioned within the heating chamber. A fan is positioned at a back side of the heating chamber. The fan is configured to pull air through the heating chamber and into the cooking chamber. A controller is positioned within the cabinet. The controller is in operative communication with the heating element and the fan. The method includes operating the heating element to heat air in the heating chamber in a first heating mode, and receiving, at the controller, an input indicative of a second heating mode. The method further includes triggering, by the controller, the fan to pull air through the heating chamber and into the cooking chamber in response to the second heating mode and operating the heating element to heat air flowing through the heating chamber in the second heating mode.

These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a front view of an example oven appliance according to one or more embodiments of the present subject matter.

FIG. 2 provides a side section view of the oven appliance of FIG. 1 in a one operating mode.

FIG. 3 provides a side section view of the oven appliance of FIG. 1 in a another operating mode.

FIG. 4 illustrates a flowchart of an example method of operating the oven appliance of FIG. 1, according to aspects of the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment may be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

As used herein, terms of approximation, such as “generally,” or “about” include values within ten percent greater or less than the stated value. In the context of an angle or direction, such terms include values within ten degrees of the stated direction. For example, “generally vertical” includes directions within ten degrees of vertical in any direction, e.g., clockwise or counter-clockwise.

FIGS. 1-3 illustrate an oven appliance 100 according to an example embodiment of the present subject matter. Oven appliance 100 includes an insulated cabinet 102 which defines a vertical direction V, a lateral direction L, and a transverse direction T. The vertical, lateral, and transverse directions V, L, and T are mutually perpendicular and form an orthogonal direction system. Cabinet 102 extends between a top portion 40 and a bottom portion 42 along the vertical direction V. Cabinet 102 extends between a left side 44 and a right side 46 along the lateral direction L and between a front portion 48 and a back portion 50 along the transverse direction T.

The present example embodiment of oven appliance 100 includes cabinet 102 with an interior cooking chamber 104 defined by a top wall 112, a floor 114, a back wall 116, and a pair of opposing side walls 118. Cooking chamber 104 is configured for the receipt of one or more food items to be cooked. Oven appliance 100 includes a door 108 pivotally mounted to cabinet 102 at the opening 106 of cabinet 102 to permit selective access to cooking chamber 104 through opening 106. A handle 110 is mounted to door 108 and assists a user with opening and closing door 108. For example, a user may pull on handle 110 to open or close door 108 and access cooking chamber 104.

Oven appliance 100 may include a seal (not shown) between door 108 and cabinet 102 that may assist with maintaining heat and cooking vapors within cooking chamber 104 when door 108 is closed as shown in FIGS. 1 and 2. Multiple parallel glass panes 122 may provide for viewing contents of cooking chamber 104 when door 108 is closed and may assist with insulating cooking chamber 104. Baking racks may generally be positioned in cooking chamber 104 for the receipt of food items or utensils containing food items. Baking racks may be slidably received onto embossed ribs or sliding rails 144 such that the racks may be conveniently moved into and out of cooking chamber 104 when door 108 is open.

One heating element may be included within cabinet 102 to provide heat to cooking chamber 104 for cooking. Such heating element may be gas or electric. For example, in the embodiment shown in FIG. 2, oven appliance 100 includes an electric resistance heating element 124 in a heating chamber 206 below floor 114 of cooking chamber 104. While provided in the present example embodiment as an electric resistance element, a person having ordinary skill in the art would understand that heating element 124 may, in other example embodiments, be a gas burner type of element. In general, heating chamber 206 may be an open space beneath floor 114 where heating element 124 may be disposed and in thermal communication with cooking chamber 104. For example, heating chamber 206 may define an inlet 210 through floor 114 for permitting airflow through heating chamber 206 and across heating element 124. In particular, inlet 210 be positioned proximate a front side 207 of heating chamber 206, or in other example embodiments inlet 210 be positioned proximate one or more of left side 44, right side 46, and front side 207. For example, inlet 210 may be positioned proximate front side 207, or positioned proximate left side 44 and right side 46 (such as two individual inlets 210 proximate the left and right side), or proximate left side 44, right side 46, and front side 207 (such as three individual inlets 210 respectively proximate to the left, right, and front side). In general, an outlet may be positioned proximate a back side 209 of heating chamber 206. In general, heating chamber 206 may include a venturi-like portion extending downwards in the vertical direction V between inlet 210 and outlet 212, e.g., heating chamber 206 may be wider near inlet 210, narrowing in the middle, and widening again leading up to outlet 212. The venturi-like portion may increase airflow velocity by compressing air flowing between inlet 210 and outlet 212.

In the illustrated example embodiment, oven appliance 100 also has a convection fan 138 positioned at back side 209 of heating chamber 206 and adjacent back wall 116 of cooking chamber 104. In general, convection fan 138 may be configured to pull air directly through heating chamber 206 and into cooking chamber 104. For example, convection fan 138 may be configured to pull air through inlet 210 of heating chamber 206, pull air across heating element 124, and force air out of outlet 212. Convection fan 138 may generally be powered by a convection fan motor 139. Further, convection fan 138 may be a variable speed fan-meaning the speed of fan 138 may be controlled or set anywhere between and including, e.g., zero and one hundred percent (0%-100%). In certain embodiments, oven appliance 100 may also include a bidirectional triode thyristor (not shown), i.e., a triode for alternating current (TRIAC), to regulate the operation of convection fan 138 such that the speed of fan 138 may be adjusted during operation of oven appliance 100. The speed of convection fan 138 may be determined by controller 140. In addition, a sensor 137 such as, e.g., a rotary encoder, a Hall effect sensor, or the like, may be included at the base of fan 138, for example, between fan 138 and motor 139 as shown in the example embodiment of FIG. 2, to sense the speed of fan 138. The speed of fan 138 may be measured in, e.g., revolutions per minute (“RPM”).

Oven appliance 100 may generally include a user interface 128 having a display 130 positioned on an interface panel 132 and having a variety of controls 134. Interface 128 allows the user to select various options for the operation of oven appliance 100 including, e.g., various cooking and cleaning cycles. Operation of oven appliance 100 may be regulated by a controller 140 that is operatively coupled to, i.e., in operative communication with, user interface 128, heating element 124, and convection fan 138, as well as other components of oven appliance 100.

For example, in response to user manipulation of the user interface 128, controller 140 may operate heating element 124. Controller 140 may receive measurements from one or more temperature sensors, such as a temperature sensor 202. Controller 140 may also provide information such as a status indicator, e.g., a temperature indication, to the user with display 130. Controller 140 may also be provided with other features as will be further described herein.

Controller 140 may include a memory and one or more processing devices such as microprocessors, CPUs, or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of oven appliance 100. The memory may represent random access memory such as DRAM or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. The memory may store information accessible by the processor(s), including instructions that may be executed by processor(s). For example, the instructions may be software or any set of instructions that when executed by the processor(s), cause the processor(s) to perform operations. For the embodiment depicted, the instructions may include a software package configured to operate the system, e.g., to execute example methods of operating the oven appliance 100. Controller 140 may also be or include the capabilities of either a proportional (P), proportional-integral (PI), or proportional-integral-derivative (PID) control for feedback-based control implemented with, e.g., temperature feedback from one or more sensors such as temperature sensors and/or probes, etc.

Controller 140 may be positioned in a variety of locations throughout oven appliance 100. In the illustrated embodiment, controller 140 is located next to user interface 128 within interface panel 132. In other embodiments, controller 140 may be located under or next to the user interface 128, otherwise within interface panel 132, or at any other appropriate location with respect to oven appliance 100. Generally, controller 140 may be positioned within cabinet 102. In the embodiment illustrated in FIG. 1, input/output (“I/O”) signals are routed between controller 140 and various operational components of oven appliance 100 such as heating element 124, convection fan 138, controls 134, display 130, alarms, and/or other components as may be provided. In one embodiment, user interface 128 may represent a general purpose I/O (“GPIO”) device or functional block.

Although shown with touch type controls 134 in FIG. 1, it should be understood that controls 134 and the configuration of oven appliance 100 shown in FIG. 1 is provided by way of example only. More specifically, user interface 128 may include various input components, such as one or more of a variety of electrical, mechanical, or electro-mechanical input devices including rotary dials, push buttons, and touch pads, e.g., such as a knob as illustrated in FIG. 2, among other possible examples and combinations. User interface 128 may include other display components, such as a digital or analog display device designed to provide operational feedback to a user. User interface 128 may be in communication with controller 140 via one or more signal lines or shared communication busses.

While oven appliance 100 is shown as a wall oven, the present invention could also be used with other cooking appliances such as, e.g., a stand-alone oven, an oven with a stove-top, or other configurations of such ovens. Numerous variations in the oven configuration are possible within the scope of the present subject matter. For example, variations in the type and/or layout of the controls 134, as mentioned above, are possible. As another example, the oven appliance 100 may include multiple doors 108 instead of or in addition to the single door 108 illustrated. Such examples include a dual cavity oven, a French door oven, and others. The examples described herein are provided by way of illustration only and without limitation.

Referring now to FIGS. 2-3, oven appliance 100 may operate selectable heating modes, such as a bake mode and a convection mode. Specifically, FIG. 2 illustrates the bake mode and FIG. 3 illustrates the convection mode, as will both be explained hereinbelow. In general, a user may interact with controls 134, or display 130, of user interface 128 to select the desired heating mode. In the present example embodiment, heating element 124 is provided as a sole heating element in oven appliance 100. In other words, heating element 124 may be the only heating element in the entire oven appliance 100, e.g., heating element 124 is the only heating element in either direct and/or indirect thermal communication with cooking chamber 104. As such, heating element 124 may be used in both heating modes described hereinbelow.

Referring specifically to FIG. 2, oven appliance 100 may operate in the bake mode. In general, the bake mode may include operating heating element 124 in order to heat the air inside cooking chamber 104. The bake mode may generally provide indirect, dry heat to cooking chamber 104. Accordingly, fan 138 may be inactive, or not spinning, and heated air inside oven appliance 100 may naturally, e.g., gradually, rise and increase cooking chamber 104 temperature. In other words, the bake mode may be a heating mode with natural convection currents.

Referring specifically to FIG. 3, oven appliance 100 may operate in the convection mode. In general, the convection mode may include operating heating element 124 and convection fan 138 in order to force heated air from heating chamber 206 into and through cooking chamber 104, as indicated by airflow indicators 1000. Accordingly, in the convection mode, convection fan 138 is active, e.g., spinning, in order to pull air through heating chamber 206 and into cooking chamber 104. In other words, the convection mode may be a heating mode with forced convection currents. The convection mode as described herein may otherwise be referred to as a true convection mode, as air indicated by airflow indicators 1000 may be pre-heated by heating element 124 before being forced into cooking chamber 104.

Turning to FIG. 4, a flowchart of an example method (e.g., method 400) of operating oven appliance 100 will be described. Although the discussion below refers to the example method 400 of operating oven appliance 100, one skilled in the art will appreciate that the example method 400 is applicable to the operation of a variety of other appliances, such as other possible variations of oven appliances. In example embodiments, the various method steps as disclosed herein may be performed (e.g., in whole or part) by controller 140, or another, separate, dedicated controller.

FIG. 4 depicts steps performed in a particular order for the purpose of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that (except as otherwise indicated) various example methods as may be disclosed herein are not mutually exclusive with each other, e.g., aspects of any one example method may be combined with aspects of any other example method, such that features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Moreover, the steps of method 400 may be modified, adapted, rearranged, omitted, interchanged, or expanded in various ways without deviating from the scope of the present disclosure.

Referring now to FIG. 4, at (410), method 400 may generally include operating a heating element in a first heating mode. For example, in the present example embodiment, oven appliance 100 may be operating heating element 124 in either the bake mode or the convection mode. Accordingly, the first heating mode may or may not include operating convection fan 138, depending on the heating mode selected as the first heating mode.

At (420), method 400 may generally include receiving an input indicative of a second heating mode. For example, the input indicative of the second heating mode may be a user interacting with controls 134, or display 130, of user interface 128, selecting a desired (second) heating mode other than the first heating mode. As such, the second heating mode may be either the bake mode or the convection mode, with respect to the second heating mode being the other option from the first heating mode, e.g., when the first heating mode is the bake mode, the second heating mode may be the convection mode.

At (430), method 400 may generally include triggering convection fan 138 in response to the second heating mode. For example, triggering convection fan 138 may generally be activating or deactivating fan motor 139 of convection fan 138. Thus, switching from the first heating mode to the second heating mode may include either activating convection fan 138 or deactivating convection fan 138, e.g., when the first heating mode is the bake mode and the second heating mode is the convection mode, triggering convection fan 138 may include activating convection fan 138.

At (440), method 400 may generally include operating the heating element in the second heating mode. For example, in the present example embodiment, oven appliance 100 may be operating heating element 124 in either the bake mode or the convection mode, depending on which mode has been selected for the second heating mode. Accordingly, the second heating mode may or may not include operating convection fan 138.

For example, in one scenario of method 400, the first heating mode may include operating heating element 124 in the bake mode. The bake mode may not include the operation of convection fan 138, and as such convection fan 138 may be inactive. The second heating mode may include operating heating element 124 in the convection mode. The convection mode may include the operation of convection fan 138, and as such convection fan 138 may be active. Accordingly, convection fan 138 may be triggered in response to the second heating mode to activate convection fan 138 in order to pull air through heating chamber 206 and into cooking chamber 104, thereby operating heating element 124 in the convection mode (the second heating mode).

In another example scenario of method 400, the first heating mode may include operating heating element 124 in the convection mode. The convection mode may include the operation of convection fan 138, and as such convection fan 138 may be active. The second heating mode may include operating heating element 124 in the bake mode. The bake mode may not include the operation of convection fan 138, and as such convection fan 138 may be inactive. Accordingly, convection fan 138 may be triggered in response to the second heating mode to deactivate convection fan 138, thereby operating heating element 124 in the bake mode (the second heating mode).

As described above, heating element 124 may be the sole heating element of oven appliance 100. In general, reducing the number of heating elements within oven appliance 100 may advantageously reduce costs and complexity of oven appliance 100. Additionally, space within cooking chamber 104 previously occupied by additional heating element(s) may become available, or usable, space within cooking chamber 104. Furthermore, as the sole heating element in oven appliance 100, heating element 124 may be used in both heating modes (baking and true convection). Accordingly, transitioning between heating modes may advantageously incur reduced thermal lag as is incurred with traditional oven appliances with multiple heating elements. As such, changing between heating modes as desired by the user may not hinder the heating process of oven appliance 100.

As may be seen from the above, provided is an oven appliance and a method of using a shared heating element for both a baking mode and a true convection mode. The common heating element is used for both the baking mode as well as the heated forced air (true convection) mode. The air passing over the heating element is circulated into the cooking chamber by a convection fan. Transition between modes may generally occur by turning the convection fan on (convection mode) or off (bake mode).

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.