COOKING APPLIANCE AND CONVECTIVE HEATING MODULE

Description

TECHNICAL FIELD

The disclosure relates to a household cooking appliance, and more specifically to a cooking appliance with a convection fan and heating assembly.

BACKGROUND

Cooking appliances such as ovens typically include a cooking chamber in which food is heated using various heat sources such as gas or electricity. Heat can be generated based on a flame, electric conduction, electric induction, microwaves, and the like. In some cases, a convection fan is used to circulate air within the cooking chamber for a more even distribution of heat.

BRIEF SUMMARY

In one aspect, the disclosure relates to a cooking appliance. The cooking appliance includes a cabinet defining a cooking chamber; an air inlet located on a wall of the cooking chamber; and a convective heating module disposed within the cabinet. The convective heating module includes a convection fan fluidly coupled to the air inlet for circulating air through the cooking chamber; a heating element positioned adjacent the convection fan; and a heat exchanger with a set of fins arranged to confront the heating element, the set of fins being movable between a first position and a second position, with the set of fins at least partially blocking radiative heat transfer from the heating element to the cooking chamber when in the second position; and a controller operably coupled to the convective heating module and having a convective cycle wherein the convection fan circulates air through the cooking chamber, and a non-convective cycle wherein the convection fan does not circulate air through the cooking chamber; wherein, during the convective cycle, the set of fins are arranged in the second position and configured to absorb thermal radiation from the heating element and to re-emit thermal energy into the cooking chamber.

In another aspect, the disclosure relates to a convective heating module for a cooking appliance having a cooking chamber. The convective heating module includes a convection fan fluidly coupled to the air inlet for circulating air through the cooking chamber; a heating element positioned adjacent the convection fan; and a heat exchanger with a set of fins arranged to confront the heating element, the set of fins being movable between a first position and a second position, with the second position inhibiting thermal radiation transfer from the heating element to the cooking chamber; wherein, during operation of the convection fan for circulating air, the set of fins are arranged to absorb incident thermal radiation from the heating element and to re-emit thermal energy into the cooking chamber.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of an exemplary cooking appliance in the form of an oven in accordance with various aspects described herein.

FIG. 2 is a schematic cross-sectional view of the oven of FIG. 1 illustrating a convective heating module in accordance with various aspects described herein.

FIG. 3 is a schematic view of an exemplary control system utilized with the convective heating module of FIG. 2 in accordance with various aspects described herein.

FIG. 4 is a schematic cross-sectional view of the convective heating module of FIG. 2 illustrating a heating element and a heat exchanger in accordance with various aspects described herein.

FIG. 5 is a schematic cross-sectional view of the heating element and heat exchanger of FIG. 4 in accordance with various aspects described herein.

DETAILED DESCRIPTION

Cooking appliances such as ovens are known to include a convection fan for circulating heated air within the cooking chamber. For example, convection ovens can include a convection fan that typically operates in a single direction to circulate air within the oven during a convection cooking cycle. Such ovens can also include one or more close-range heating elements within the cooking chamber, typically referred to as a “grill” or “broiler” assembly, which applies concentrated heat to a food item in close proximity for rapid melting, browning, searing, or the like.

In certain cases where the broiler assembly is operated simultaneously with the convection fan, e.g. broiling a first food item while baking a second food item, circulating air within the cooking chamber can have undesirable broiling outcomes for the first food item, such as inconsistent browning or melting. In addition, the intense or concentrated heat from the broiler assembly can have undesirable baking outcomes for the second food item, such as overbaking or excessive browning in certain regions.

Aspects of the disclosure provide for a cooking appliance having a convection fan simultaneously operable with a broiler assembly, and a set of fins disposed adjacent to the broiler assembly. The set of fins can be movable between multiple positions to selectively inhibit, transmit, or otherwise direct thermal radiation from the broiler assembly. The set of fins can also be configured for heat exchange within the cooking chamber, whereby thermal energy from the broiler assembly can be absorbed and re-radiated by the set of fins to reduce undesired increased-temperature zones or “hot spots” within the cooking chamber.

As used herein, the term “set” or “a set” of elements can be any non-zero number of elements, including only one. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary.

Additionally, as used herein, a “controller”, or “controller module” can include a component configured or adapted to provide instruction, control, operation, or any form of communication for operable components to affect the operation thereof. A processor or controller module can include any known processor, microcontroller, or logic device, including, but not limited to: Field Programmable Gate Arrays (FPGA), an Application Specific Integrated circuit (ASIC), a Proportional controller (P), a Proportional Integral controller (PI), a Proportional Derivative controller (PD), a Proportional Integral Derivative controller (PID controller), a hardware-accelerated logic controller (e.g. for encoding, decoding, transcoding, etc.), the like, or a combination thereof. Non-limiting examples of a controller module can be configured or adapted to run, operate, or otherwise execute program code to effect operational or functional outcomes, including carrying out various methods, functionality, processing tasks, calculations, comparisons, sensing or measuring of values, or the like, to enable or achieve the technical operations or operations described herein. The operation or functional outcomes can be based on one or more inputs, stored data values, sensed or measured values, true or false indications, or the like. While “program code” is described, non-limiting examples of operable or executable instruction sets can include routines, programs, objects, components, data structures, algorithms, etc., that have the technical effect of performing particular tasks or implement particular abstract data types. In another non-limiting example, a processor or controller module can also include a data storage component accessible by the processor, including memory, whether transient, volatile or non-transient, or non-volatile memory.

Additional non-limiting examples of the memory can include Random Access Memory (RAM), Read-Only Memory (ROM), flash memory, or one or more different types of portable electronic memory, such as discs, DVDs, CD-ROMs, flash drives, universal serial bus (USB) drives, the like, or any suitable combination of these types of memory. In one example, the program code can be stored within the memory in a machine-readable format accessible by the processor. Additionally, the memory can store various data, data types, sensed or measured data values, inputs, generated or processed data, or the like, accessible by the processor in providing instruction, control, or operation to affect a functional or operable outcome, as described herein. In another non-limiting example, a control module can include comparing a first value with a second value and operating or controlling operations of additional components based on the satisfying of that comparison. For example, when a sensed, measured, or provided value is compared with another value, including a stored or predetermined value, the satisfaction of that comparison can result in actions, functions, or operations controllable by the controller module.

As used herein, the term “fan” or “convection fan” refers to an apparatus having rotating blades or members, for example, a fan that operates to create an airflow or current of air for ventilation. Such fans can have a single rotational speed, or a variable rotational speed, e.g. “high speed,” “low speed,” “off/zero speed,” or the like.

In describing aspects illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the aspects be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose. For example, the words “connected,” “attached,” “coupled,” and “supported” and variations thereof herein are used broadly and encompass direct and indirect connections, attachments, couplings, and supports. In addition, the terms “connected,” “coupled,” etc. and variations thereof are not restricted to physical or mechanical connections, couplings, etc. as all such types of connections should be recognized as being equivalent by those skilled in the art.

Referring to FIG. 1, a perspective view of an exemplary household cooking appliance 1 is shown in the form of an oven 10 and can be used for cooking one or more food items. The oven 10 includes a chassis or cabinet 12 having a pair of spaced side walls 13, 14 joined by a top wall 15 (FIG. 2), a bottom wall 16, and a rear wall 17 to at least partially define a cooking chamber 18. Optionally, the cooking appliance 1 can include one or more hobs 19, such as a stovetop or other cooking surface in addition to the cooking chamber 18.

A closure member can be operably coupled to the cabinet 12. In the illustrated example, the closure member includes a door 20 pivotable about a hinge and selectively closing the cooking chamber 18. When the door 20 is in an opened position, a user can access the cooking chamber 18. When the door 20 in a closed position, the door 20 prevents access to the cooking chamber 18 and seals the cooking chamber 18 from the external environment. One or more sensors can optionally be provided to sense or detect a position of the door 20.

The oven 10 can also include a user interface 30 for inputting desired cooking parameters, such as a cooking temperature or time, or for selecting an automated cooking cycle. The user interface 30 can include a push button, a rotatable knob, a touch pad, a touch screen, or a voice command unit, in some non-limiting examples.

The oven 10 further includes a heating system 40 with at least one heating element for generating heat within the cooking chamber 18. For instance, the heating system 40 can include any or all of a gas heater, an electric heater, a quartz tube heater, a microwave generator, or the like, or combinations thereof. The heating system 40 can include any number of heating elements, including only one, or two or more.

Turning to FIG. 2, a schematic side view illustrates additional details of the oven 10. A lower rack 21 and an upper rack 22 are illustrated that can support food items or cookware (e.g., a pot) within the cooking chamber 18. Any number of racks can be provided, including only one, or three or more.

A convective heating module 50 can also be provided in the heating system 40. The convective heating module 50 can include a heating element 52 and a convection fan 54. The heating element 52 can be any suitable heating element, such as a quartz tube heater in a non-limiting example. The convection fan 54 can be any suitable fan for circulating air, and optionally steam when present, within the cooking chamber 18.

An energy source or power source 41 is also provided and operably coupled to the heating system 40. The power source 41 can be any suitable source of energy for generating heat, such as an electric power supply, a gas heat source, or the like.

It will be understood that the heating system 40 can also include other heating elements, including those external to the convective heating module 50. For instance, in the non-limiting example shown, a lower heating element 42 is disposed within the cabinet 12 beneath the bottom wall 16, and operably coupled to the power source 41. In such a case, heat generated by the lower heating element 42 can be conducted through the bottom wall 16 and into the cooking chamber 18. In another non-limiting example, one or more heating elements can be coupled to one or more of the walls 13, 14, 15, 16 of the cooking chamber 18. Such heating elements can be disposed within a heating element housing outside of the cooking chamber 18 in some implementations, or mounted directly to a wall within the cooking chamber 18 in some implementations. Further still, in some implementations the heating element 52 can be a sole source of heat for the cooking chamber 18 with no additional heating elements provided. In other implementations, the lower heating element 42 can be activated, whether alone or in combination with the heating element 52, for heating of the cooking chamber 18.

A controller 65 can be provided and communicatively coupled to components of the oven 10, including the heating system 40. The controller 65 can be, for example, a proportional-integral-derivative (PID) controller or any other suitable controller. The controller 65 can store data (e.g., in a memory), such as default cooking parameters, user-input cooking parameters, programs for the automated cooking cycles, or the like. The controller 65 can also send output to the user interface 30, such as for displaying a status of the oven 10 or otherwise communicating with a user.

In some implementations, a remote device such as a remote server, a database, a mobile device, a tablet, or the like can be communicatively coupled with the oven 10. In the illustrated example, the oven 10 includes a communication module 68 configured to send or receive signals from a remote device. The controller 65 can be communicatively coupled to the communication module 68, such as for implementing remote instructions for operation of the oven 10, or for transmitting data or control signals to a remote device, in non-limiting examples.

FIG. 3 is a block diagram that schematically illustrates an exemplary control system 60 of the oven 10. The control system 60 can include the controller 65. The controller 65 includes a processor 65P and a memory 65M as shown. The control system 60 can optionally include one or more sensors in signal communication with the controller 65. In the illustrated example a temperature sensor 62 and a door position sensor 64 are provided. Any number or type of sensors can be provided, such as an imaging sensor, a humidity sensor, or a light sensor, in non-limiting examples. Optionally, a door lock 66 can also be provided.

The controller 65 can be configured to activate, deactivate, or otherwise controllably operate the heating system 40, including the convective heating module 50. For instance, the controller 65 can be configured to activate or deactivate the convection fan 54, activate or deactivate the heating element 52, control a speed of the convection fan 54, control a rotation direction of the convection fan 54, control a time duration for operating the heating element 52 or the convection fan 54, in non-limiting examples. For instance, the controller 65 can include a convective cycle wherein the convection fan 54 circulates air through the cooking chamber 18. The controller 65 can also include a non-convective cycle wherein the convection fan 54 does not circulate air through the cooking chamber 18. In this manner, the controller 65 can provide instructions regarding a desired temperature of the cooking chamber 18, or the rate at which the heating system 40 heats the cooking chamber 18, or the like.

In the illustrated example, the control system 60 includes the communication module 68 configured to send or receive signals, including wired or wireless signals, from a remote device 70. Such signals can include sensor data, cooking status information, control instructions for a cooking cycle, control instructions for operating the heating system 40, or the like. The controller 65 can be coupled to the communication module 68 and controllably operate components of the oven 10 based on signals received from the communication module 68. In an alternative example, the communication module 68 can be omitted from the control system 60 such that the oven 10 can be operated solely from the user interface 30.

Referring now to FIG. 4, the convective heating module 50 is shown in further detail. The convective heating module 50 can include a housing 51 bounding an interior 53, with the heating element 52 and the convection fan 54 disposed within the interior 53. The convective heating module 50 can be mounted in any suitable location of the cooking chamber 18. As shown, the housing 51 is defined by at least a portion of the top wall 15, though this need not be the case. It is also contemplated that the convective heating module 50 can be mounted to the rear wall 17 in some implementations, or disposed within the cabinet 12 outside the cooking chamber 18 in some implementations. In this manner, the housing 51 can at least partially define the cooking chamber 18.

The housing 51 can include a set of apertures 80 fluidly coupling the interior space 53 to the cooking chamber 18. As shown, the set of apertures 80 includes an air inlet 82 in registry with the convection fan 54, and a heating inlet 84 in registry with the heating element 52. It is understood that the air inlet 82 and the heating inlet 84 can each include one or more individual apertures collectively forming the respective inlets 82, 84. In an alternative example where the convective heating module 50 is disposed within the cabinet 12 outside the cooking chamber 18, either or both of the air inlet 82 or the heating inlet 84 can be located on a wall of the cooking chamber, e.g. the top wall 15.

As shown, the heating element 52 is thermally coupled to the convection fan 54 within the interior space 53. For instance, the heating element 52 and convection fan 54 can be operated simultaneously such that the convection fan 54 circulates warmed air through the air inlet 82. In an alternative example, the housing 51 can include a dividing wall, barrier, or the like such that the convection fan 54 is at least partially thermally isolated from the heating element 52.

The convective heating module 50 can further include a heat exchanger 90 adjacent the heating element 52. The heat exchanger 90 includes a set of fins 92 arranged to confront the heating element 52 as shown. The set of fins 92 can be coupled to the housing 51 as shown.

FIG. 5 illustrates additional details of the heat exchanger 90, wherein the set of fins 92 can be movable with respect to the heating inlet 84. For instance, the set of fins can be movable between a first position 93 (shown in solid line) and a second position 95 (shown in dashed line), with the second position 95 at least partially closing the heating inlet 84. In some implementations, the set of fins 92 can be fully open in the first position 93, and can fully close the heating inlet 84 when in the second position 95. In another example, the first position 93 and the second position 95 can each define partially-open states where the set of fins 92 partially close the heating inlet 84 by differing amounts.

In the illustrated example, the set of fins 92 include louvered fins and are rotatable between the first and second positions 93, 95. It is also contemplated that the set of fins 92 can be slidable, extendable, or the like between the first and second positions 93, 95, including a combination of rotational and translational motion. It will be understood that the exact arrangement of the set of fins 92 in the first and second positions 93, 95 can differ from that shown, such as by sliding motion instead of rotation.

Regardless of the type of motion for the set of fins 92, when in the second position 95, the set of fins 92 can inhibit thermal radiation transfer from the heating element 52 to the cooking chamber 18. When in the second position 93, the set of fins 92 can absorb incident thermal radiation from the heating element 52 and re-emit thermal energy into the cooking chamber 18 by way of air encountering the set of fins 92. In this manner, the heat exchanger 90 can at partially define the heating inlet 84.

An actuator 94 can be provided and operably coupled to the set of fins 92 for movement between the first and second positions 93, 95. The actuator 94 can be any suitable actuator, including a linear actuator, a rotary actuator, a hydraulic actuator, or the like. The actuator 94 can also be communicatively coupled to the controller 65 such that the controller 65 can controllably operate the heat exchanger 90 during a cooking cycle.

In the non-limiting example shown, the set of fins 92 is coupled to a common shaft 96 that is coupled to the actuator 94. In this manner, the actuator 94 can move the set of fins 92 as a group between the first and second positions 93, 95. It is also contemplated that an individual linkage, shaft, or the like can be coupled to individual fins in the set of fins 92, providing for independent movement or individual movement of selected fins in the set of fins 92.

With general reference to FIGS. 1-5, in one example of operation, the controller 65 can controllably operate the convective heating module 50 to perform a convective cycle where the convection fan 54 is activated to circulate air as described above. The controller 65 can controllably operate the heating element 52 to generate heat, and also instruct the actuator 94 to move the set of fins 92 into the second position 95 to block radiative or direct heat from the heating element 52. Additionally, when in the second position 95, the set of fins 92 can absorb and re-emit heat from the heating element 52. Air circulating within the cooking chamber 18 can encounter the set of fins 92 and distribute the re-emitted heat within the cooking chamber 18. Such re-emission provides for a more even distribution of heat within the cooking chamber 18, which can lead to more uniform cooking outcomes or features of food items within the oven 10. In this manner, the convective heating module 50 can distribute heat more evenly, or at a more controlled rate, compared to traditional cooking appliances that can have locally-increased temperature zones or “hot spots” in regions of the cooking chamber 18.

With continued reference to FIGS. 1-5, in another example of operation, the controller 65 can controllably operate the convective heating module 50 to perform a non-convective cycle where the convection fan 54 is not activated. The controller 65 can controllably operate the heating element 52 to generate heat, and also instruct the actuator 94 to move the set of fins 92 into the first position 93. When in the first position 93, the set of fins 92 provides at least some direct radiative heat from the heating element 52 to enter the cooking chamber 18, such as for a broiling or grilling cooking cycle. In addition, it is contemplated that the set of fins 92 in the first position 93 can absorb and re-radiate thermal energy from the heating element 52 as described above, providing for improved heat distribution and rate control during non-convective cycles of operation.

To the extent not already described, the different features and structures of the various embodiments can be used in combination, or in substitution with each other as desired. That one feature is not illustrated in all of the embodiments is not meant to be construed that it cannot be so illustrated, but is done for brevity of description. Thus, the various features of the different embodiments can be mixed and matched as desired to form new embodiments, whether or not the new embodiments are expressly described. All combinations or permutations of features described herein are covered by this disclosure.

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 have 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 languages of the claims.