COOKTOP APPLIANCE BURNER ASSEMBLY

Description

FIELD OF THE INVENTION

The present subjection matter relates generally to cooktop appliances, such as cooktop appliances with gas burners for heating.

BACKGROUND OF THE INVENTION

Cooking appliances, e.g., cooktops or ranges (also known as hobs or stoves), generally include one or more heated portions for heating or cooking food items within or on a cooking utensil placed on the heated portion. For instance, burners may be included with each heated portion. The heated portions utilize one or more heating sources to output heat, which is transferred to the cooking utensil and thereby to any food item or items that are disposed on or within the cooking utensil.

Typical closed loop cooking cooktops include a control modulating a heat output to a cookware in response to temperature feedback. A control method includes flowing gas to a burner, cycling between gas flow rates resulting in a mean power level. One method of this includes adding a modulating gas valve downstream of a manually activated gas valve, where after turning the burner on, electronics may then proceed to adjust a power output downstream from the manual valve, as desired.

However, issues may arise after the burner is turned off, as air may fill the gas lines between the gas burner and the modulating gas valve. Such issues may lead to poor combustion, extinction of flames, and/or inadequate heating of cooktop components.

Some existing systems have attempted to address these issues by including multiple valves. For example, certain gas cooktop appliances include additional valves in parallel to the modulating gas valve for reducing air within the gas lines.

However, additional valves may provide additional issues, such as increased cost and complexity of the gas burner assembly, and additional potential points of failure of the gas burner assembly.

Accordingly, a gas cooktop appliance configured to reduce issues causing poor performance while also reducing cost and complexity would be useful.

BRIEF DESCRIPTION OF THE INVENTION

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

In one aspect of the present disclosure, a cooktop appliance is provided. The cooktop appliance includes a panel, a controller, and a burner assembly. The burner assembly includes a burner disposed on the panel of the cooktop appliance, and a first control valve fluidly coupled to a second control valve. The first control valve defines an inlet, a first outlet, and a second outlet, and the second control valve defines a first inlet, a second inlet, and an outlet formed within a body of the second control valve. The outlet of the second control valve is fluidly coupled with the burner to selectively direct a flow of gas thereto. The controller is configured to adjust the second control valve.

In another aspect of the present disclosure, a burner assembly is provided. The burner assembly is in operative communication with a controller of an appliance. The burner assembly includes a burner, and a first control valve fluidly coupled to a second control valve. The first control valve defines an inlet, a first outlet, and a second outlet, and the second control valve defines a first inlet, a second inlet, and an outlet formed within a body of the second control valve. The outlet of the second control valve is fluidly coupled with the burner to selectively direct a flow of gas thereto. The controller is configured to adjust the second control valve.

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 perspective view of a cooktop appliance according to one or more example embodiments of the present disclosure.

FIG. 2 provides a perspective view of a burner assembly which may be incorporated into a cooktop appliance such as the example cooktop appliance of FIG. 1, according to one or more example embodiments of the present disclosure.

FIG. 3 provides a perspective view of an example control valve of the burner assembly of FIG. 2, according to example aspects of the present disclosure.

FIG. 4 provides a first side view of the example control valve of FIG. 3.

FIG. 5 provides a second side view of the example control valve of FIG. 3.

FIG. 6 provides a third side view of the example control valve of FIG. 3.

FIG. 7 provides a section view of the example control valve of FIG. 3, along section A.

FIG. 8 provides a section view of the example control valve of FIG. 3, along section B.

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

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 can 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 can 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. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction. For example, “generally vertical” includes directions within ten degrees of vertical in any direction, e.g., clockwise, or counterclockwise.

Referring now to FIG. 1, illustrated is an example embodiments of a cooktop appliance 100 as may be employed with the present disclosure. The cooktop appliance 100 may include a panel 102 (e.g., a top panel) that extends in a lateral direction L and a transverse direction T. By way of example, panel 102 may be constructed of enameled steel, stainless steel, glass, ceramics, and/or any suitable combinations thereof.

In general, a utensil holding food and/or cooking liquids (e.g., oil, water, etc.) may be placed onto or above one or more burner assemblies 200. The gas burner assemblies 200 may be configured in various sizes so as to provide e.g., for the receipt of cooking utensils (i.e., pots, pans, etc.) of various sizes and configurations and to provide different heat inputs for such cooking utensils. Burner assembly 200 may generally include a burner 228 (FIG. 2) supported on a top surface 104 of panel 102, as discussed in greater detail below. During use, burner assemblies 200 may generally provide thermal energy to cooking utensils above panel 102.

A user interface panel 110 may be positioned on top surface 104 of cooktop appliance 100. In some example embodiments, user interface panel 110 may include user inputs, such as knob(s) 112, that may each be associated with a burner assembly, such as burner assembly 200. In general, engaging knob(s) 112 may activate burner assembly 200 and determine an amount of heat input provided by burner assembly 200 to a cooking utensil located on/above burner assembly 200. The user interface panel 110 may also be provided with one or more graphical display devices that deliver certain information to the user—e.g., whether a particular burner assembly is activated and/or the heating level at which the burner assembly is set.

Operation of the cooktop appliance 100 may be regulated by a controller 130 operably coupled to (i.e., in operative communication with) user interface 110 and/or gas burner assembly 200. For example, in response to user manipulation of the knob(s) 112 of user interface panel 110, controller 130 may operate burner 228 of burner assembly 200.

In general, controller 130 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 appliance 100. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In some embodiments, the processor may execute non-transitory programming instructions stored in memory. For example, the instructions may include a software package configured to operate appliance 100 and execute an operation routine or various methods. The memory may be a separate component from the processor or may be included onboard within the processor.

Controller 130 may be disposed in a variety of locations throughout appliance 100. In example embodiments, the controller 130 may be located under or next to the user interface panel 110. In such an embodiment, input/output (“I/O”) signals are routed between the controller 130 and various operational components of appliance 100, such as burner assembly 200, knob(s) 112, a graphical display, one or more sensors, and/or one or more alarms. In one embodiment, the user interface panel 110 may represent a general purpose I/O (“GPIO”) device or functional block.

Although shown with multiple knob(s) 112, it should be understood that knob(s) 112 and the configuration of the cooktop appliance 100 shown in FIG. 1 are provided by way of example only. More specifically, user interface panel 110 may include various input components, such as one or more of a variety of touch-type controls, electrical, mechanical, or electro-mechanical input devices including rotary dials, push buttons, and touch pads. User interface panel 110 may include other display components, such as a digital or analog display device designed to provide operational feedback to a user. User interface 110 may be in communication with the controller 130 via one or more signal lines or shared communication busses. User interface 110 may be located on a different surface of the appliance, for instance, an angled front edge or a vertical backsplash.

The cooktop appliance 100 shown in FIG. 1 illustrates one of various example embodiments of the present disclosure. Thus, although described in the context of cooktop appliance 100, the present disclosure may be used in cooktop appliances having other configurations such as varied number, size, and/or shape of the burners, e.g., a cooktop appliance with fewer burner assemblies or additional burner assemblies. Similarly, the present disclosure may be used in cooktop appliances that include an oven, i.e., range appliances.

Referring still to FIG. 1, a temperature sensor 400 may be operable to measure temperatures of separate utensils (e.g., a pot or pan, as mentioned above) on one burner 228. For example, temperature sensor 400 may be positioned over, or within, burner assembly 200, e.g., on or in the grate 302. Temperature sensor 400 may be any suitable sensor for measuring temperature, such as a resistance temperature detector, a thermocouple, an infrared temperature sensor, a bimetallic switch, etc.

As shown, burner assembly 200 may be integral to grates (e.g., grates 302), such as unitarily constructed, however, a person of ordinary skill in the art would recognize aspects of the present disclosure may be used in cooktop appliances having other configurations such as separate grate and burner assembly configurations. In general, a grate 302 may be provided extending at least partially above burner assembly 200 when the grate 302 is in a mounted position. Generally, grate 302 is configured for supporting a cooking utensil, such as a pot, pan, etc., in the mounted position. In some embodiments, one or more grates 302 may be selectively removable (e.g., to an unmounted position), such that the grate 302 can be readily lifted from the panel 102 and placed away from burner assembly 200, e.g., for cleaning of panel 102 around burner assembly 200.

In general, some example embodiments may include a griddle plate 310 disposed over panel 102. Griddle plate 310 may generally define a top cooking surface 312. In example embodiments, griddle plate 310 may be a generally planar member. In turn, top cooking surface 312 may be a substantially flat surface. Griddle plate 310 may have any suitable shape. For example, griddle plate 310 may be substantially rectangular or square, e.g., in a plane that is perpendicular to the vertical direction V. In particular, grate 302 may be positioned on the top surface 104 of panel 102 and may selectively locate and support the griddle plate 310 above burner assembly 200. For instance, in some embodiments, the grate 302 may span two burner assemblies 200, e.g., the grate 302 may consist of a single piece spanning across a first burner and a second burner, thereby defining a frame which may hold and support pots, pans, or griddle plate 310 above the burners. In additional embodiments, the griddle plate 310 may be positioned in place of grate 302 over a single burner, such as an elongated burner, e.g., as illustrated in FIG. 2.

Referring now to FIG. 2, burner assembly 200 may include a first control valve 202 and a second control valve 230 fluidly coupled and configured to selectively permit, limit, or prevent a flow of fuel (gas) to burner 228. Control valves 202, 230 may be generally provided for selectively limiting the flow of gas therethrough. Control valves 202, 230 may be mounted beneath panel 102 (e.g., to a bottom surface of panel 102). Fuel lines may also be disposed below the top panel 102. In general, the fuel lines extend between control valves 202, 230 and burner 228. Thus, the control valves 202, 230 may be sealingly coupled to the fuel lines, as will be described herein. In general, fuel may be supplied to first control valve 202 through a manifold 190, e.g., manifold 190 may supply fuel to multiple burner assemblies.

In general, first control valve 202 may be coupled to one of knob(s) 112. Thus, a user may adjust first control valves 202 with knob 112, e.g., first control valve 202 may be a manual valve, or a manually operated valve. On the other hand, second control valve 230 may be an electronically controlled valve, such as a solenoid valve. Thus, cooktop appliance may control second control valve 230, as will be described in further detail herein. In general, control valves 202, 230 may be configured for regulating fuel flow to burner 228. For example, each of first control valve 202 and second control valve 230 may block fuel flow to burner 228 of burner assembly 200 when both control valves 202, 230 are closed. Conversely, first control valve 202 may permit fuel flow through a passage 248 (FIG. 8) of second control valve 230 to burner 228 when first control valve 202 is open, e.g., passage 248 may be a through passage, as will be described in further detail herein.

In general, a user may selectively adjust first control valve 202 between the open and closed configurations (e.g., with the knob 112) in order to limit or regulate fuel flow to burner 228. When first control valve 202 is open, fuel, such as propane or natural gas, may flow to burner 228, where the fuel may be subsequently combusted. For instance, a spark igniter (not labelled) may be disposed on panel 102 and may provide a spark to ignite the fuel. As stated above, burner assembly 200 may generally include a burner 228. Burner 228 may include any suitable shape from which a flame may be emitted, such as a generally circular shape, a generally stadium geometry (e.g., as illustrated in FIG. 2), or any other suitable shape as will be recognized by those of ordinary skill in the art.

Returning again to FIG. 2, first control valve 202 may be fluidly coupled to manifold 190 or another suitable fuel source, e.g., in some embodiments the first control valve may be coupled directly to a fuel line, fluidly coupled to second control valve 230, and operatively coupled to knob 112. In particular, first control valve 202 may generally define an inlet 204 coupled to manifold 190 and two outlets coupled to fuel lines, e.g., a first outlet 206 of first control valve 202 is fluidly coupled (sealingly) to a first fuel line 210 and a second outlet 208 is fluidly coupled (sealingly) to a second fuel line 216.

Second control valve 230 may generally define a first inlet 236 (see, e.g., FIGS. 3 and 4), a second inlet 238, and an outlet 240 formed within a body 234 of second control valve 230. Second control valve 230 will be described in further detail hereinbelow. In general, first fuel line 210 may be fluidly coupled (sealingly) to first inlet 236 of second control valve 230 and second fuel line 216 may be fluidly coupled (sealingly) to second inlet 238 of second control valve 230. In other words, first fuel line 210 may extend from a first end 212 to a second end 214 (e.g., the first fuel line 210 may be bounded and defined by the ends 212, 214, and the first fuel line 210 may be positioned and configured such that fuel flows therethrough from the first end 212 to the second end 214). The first fuel line 210 may be fluidly coupled (sealingly) to first control valve 202 at the first end 212 and fluidly coupled (sealingly) to second control valve 230 at the second end 214. Similarly, the second fuel line 216 may extend from a first end 218 to a second end 220 (e.g., the second fuel line 216 may be bounded and defined by the ends 218, 220, and the second fuel line 216 may be positioned and configured such that fuel flows therethrough from the first end 218 to the second end 220). The second fuel line 216 may be fluidly coupled (sealingly) to first control valve 202 at the first end 218 and fluidly coupled (sealingly) to second control valve 230 at the second end 220.

Furthermore, outlet 240 of second control valve 230 may be fluidly coupled (sealingly) with burner 228 in order to selectively direct a flow of gas thereto. In particular, a third fuel line 222 may be fluidly coupled (sealingly) between outlet 240 of second control valve 230 and burner 228, such as third fuel line 222 may extend from a first end 224 to a second end 226 (e.g., the third fuel line 222 may be bounded and defined by the ends 224, 226, and the third fuel line 222 may be positioned and configured such that fuel flows therethrough from the first end 224 to the second end 226). The third fuel line 222 may be fluidly coupled (sealingly) to second control valve 230 at the first end 224 of the third fuel line 222 and fluidly coupled (sealingly) to burner 228 at the second end 226 of the third fuel line 222.

As may be seen in FIGS. 7 and 8, which will be described in detail further below, each of first inlet 236, second inlet 238, and outlet 240 may include a shoulder 242, 244, 246, respectively. In particular, shoulder 242, 244, 246 may be configured to receive respective fuel lines 210, 216, 222 forming the sealing engagement between the fuel line and the second control valve 230.

In general, FIGS. 3 through 8 illustrate an example embodiment of second control valve 230, according to example aspects of the present disclosure. As stated above, second control valve 230 may be an electronically controlled valve. Accordingly, second control valve 230 may include an actuator 232 configured to selectively permit, restrict, or prevent the flow of gas through second inlet 238 of second control valve 230, e.g., controller 130 may be operable to adjust second control valve 230 via controlling actuator 232.

Turning now to FIG. 3, illustrated is a perspective view of second control valve 230. In general, second control valve 230 may include actuator 232 coupled to body 234 of second control valve 230. In general, body 234 of second control valve 230 defines a first side 237, a second side 239, a third side 241, and an actuator side (whereupon actuator 232 is mounted). In particular, second control valve 230 may include first inlet 236 on first side 237, second inlet 238 on second side 239, and outlet 240 on third side 241.

Turning to FIGS. 4 through 6, illustrated are side views of second control valve 230, e.g., first side 237 (FIG. 4), second side 239 (FIG. 5), and third side 241 (FIG. 6). In general, first inlet 236 of second control valve 230 and outlet 240 of second control valve 230 form a through passage 248 (FIG. 8) through body 234. As illustrated in FIG. 5, second inlet 238 on second side 239 of second control valve 230 may be perpendicular to first inlet 236 and outlet 240 of second control valve 230, however, second inlet 238 may be in any suitable orientation such that second inlet 238 is fluidly coupled with through passage 248 within body 234, as will be described below.

Turning now to FIGS. 7 and 8, provided are section views of second control valve 230. In particular, FIG. 7 provides a section view from FIG. 3 along section A, and FIG. 8 provides a section view from FIG. 3 along section B. In general, as may be seen in FIG. 7, second inlet 238 may extend within body 234 to an actuation chamber 250 defined within body 234. In general, actuator 232 may extend within actuation chamber 250 to restrict or prevent the flow of gas, or may retract from actuation chamber 250 to permit the flow of gas. In general, second inlet 238 of second control valve 230 may be normally closed, e.g., actuator 232 may be normally extended within actuation chamber 250, restricting/preventing the flow of gas.

As such, when actuator 232 is retracted, gas may flow through second inlet 238, through actuation chamber 250, and through opening 252 into the through passage 248, as may be seen in FIG. 8. In other words, second inlet 238 of second control valve 230 may be fluidly coupled to through passage 248 between first inlet 236 and outlet 240 within body 234 of second control valve 230, whereby, when actuator 232 is retracted, gas from first inlet 236 and gas from second inlet 238 may mix/sum within through passage 248 and flow from outlet 240 to burner 228. Accordingly, adjusting second control valve 230 may include controller 130 configured to open second inlet 238 of second control valve 230, thereby selectively mixing fuel (gas) from second outlet 208 of first control valve 202 with fuel from first outlet 206 of first control valve 202 within body 234 of second control valve 230.

As noted above, controller 130 is operably coupled (e.g., electrically coupled via one or more wires or communication busses) to one or more components corresponding to burner assembly 200. Specifically, as previously stated, controller 130 may be operatively coupled to second control valve 230. In general, the heat output at burner 228 may generally correspond to an amount of gas flowed to that burner. The control valves 202, 230 may be positioned (e.g., such that an opening for gas is expanded or contracted) according to the directed heat outputs. In other words, the opening for gas through the first control valve 202 may increase or decrease based on a position of the knob 112, e.g., a rotational position of the knob 112, while the opening for gas through second control valve 230 may increase or decrease based the position of the actuator 232, which may be automatically adjusted, e.g., by controller 130, based on a set temperature. For example, during a closed-loop cooking operation, the adjustments to second control valve 230 may be automated such that the user would not need to manually adjust knob 112 during the closed-loop cooking operation. In particular, manual control of knob 112, e.g., first control valve 202, may be static, thereby defining a baseline, or minimum, fuel flow during the closed-loop operation. The adjustment of the electronic control valve, second control valve 230, may control how much additional fuel is provided to the burner(s) above the baseline/in addition to the minimum, e.g., fuel may be summed within second control valve 230 from both of first inlet 236 and second inlet 238. Thus, during the closed-loop operation, the fuel flowed to the burner may vary from “low” where the fuel flows only through first inlet 236 to “high” (or “hi”) where the fuel flows through both first inlet 236 and second inlet 238 with the second control valve 230 fully open. Further, intermediate levels of fuel may be used during the closed-loop operation via varying flow rates through second control valve 230 based on the position of second control valve 230, e.g., varying flow rates through second inlet 238. The closed loop cooking operation is described in further detail below.

In certain embodiments, controller 130 may pulse burner 228 between a fixed “low” and a discrete “high” flow of gas at a predetermined duty cycle. In general, the predetermined duty cycle may include a ratio of a first portion of a period of time to the period of time. For example, the first portion of the period of time may be a single amount of time over which the second control valve 230 is activated, e.g., supplying additional fuel, or may be a total of multiple amounts of time over which the second control valve 230 is activated. The second portion of time may be a single amount of time over which the second control valve 230 is deactivated, e.g., closed. The first portion and a second portion may add up to the total period of time. The total period of time may be the period of the duty cycle. For example, the period may be one minute, thus, a seventy five percent (75%) duty cycle may include the ratio of the first portion of the period of time to the period of time being about forty five seconds out of the sixty second period (e.g., one minute). The foregoing values are provided by way of example only and without any limitation of the present disclosure, e.g., the period may be any suitable value in seconds, minutes, and/or hours, and the duty cycle percentage may vary as well. For example, a specific set temperature may be set via other inputs on user interface panel 110, aside from knob 112. As such, controller 130 may determine a measured temperature is below the set temperature and thus may pulse burner 228, e.g., raising the measured temperature. Thus, the predetermined duty cycle (e.g., the percentage of time for the first portion and the second portion) may be adjusted by controller 130 in order to achieve the set temperature.

As may be seen from the above, an electronically controlled cooktop is configured such that a supplemental (second) fuel channel is not exposed to atmospheric air via using a unitary control valve that sums the flow of two inlet channels internally. Thus, air entrapment within the supplemental fuel lines may be prevented or reduced, thereby preventing or reducing poor performance caused by entrapped air. As such, a control valve that sums the flow of two inlet channels internally may be advantageous to increase efficiency and user satisfaction.

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 languages of the claims.