Oven Appliance with a Single Heating Element

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.

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.

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.

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.

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.

illustrate an oven applianceaccording to an example embodiment of the present subject matter. Oven applianceincludes an insulated cabinetwhich 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. Cabinetextends between a top portionand a bottom portionalong the vertical direction V. Cabinetextends between a left sideand a right sidealong the lateral direction L and between a front portionand a back portionalong the transverse direction T.

The present example embodiment of oven applianceincludes cabinetwith an interior cooking chamberdefined by a top wall, a floor, a back wall, and a pair of opposing side walls. Cooking chamberis configured for the receipt of one or more food items to be cooked. Oven applianceincludes a doorpivotally mounted to cabinetat the openingof cabinetto permit selective access to cooking chamberthrough opening. A handleis mounted to doorand assists a user with opening and closing door. For example, a user may pull on handleto open or close doorand access cooking chamber.

Oven appliancemay include a seal (not shown) between doorand cabinetthat may assist with maintaining heat and cooking vapors within cooking chamberwhen dooris closed as shown in. Multiple parallel glass panesmay provide for viewing contents of cooking chamberwhen dooris closed and may assist with insulating cooking chamber. Baking racks may generally be positioned in cooking chamberfor the receipt of food items or utensils containing food items. Baking racks may be slidably received onto embossed ribs or sliding railssuch that the racks may be conveniently moved into and out of cooking chamberwhen dooris open.

One heating element may be included within cabinetto provide heat to cooking chamberfor cooking. Such heating element may be gas or electric. For example, in the embodiment shown in, oven applianceincludes an electric resistance heating elementin a heating chamberbelow floorof cooking chamber. While provided in the present example embodiment as an electric resistance element, a person having ordinary skill in the art would understand that heating elementmay, in other example embodiments, be a gas burner type of element. In general, heating chambermay be an open space beneath floorwhere heating elementmay be disposed and in thermal communication with cooking chamber. For example, heating chambermay define an inletthrough floorfor permitting airflow through heating chamberand across heating element. In particular, inletbe positioned proximate a front sideof heating chamber, or in other example embodiments inletbe positioned proximate one or more of left side, right side, and front side. For example, inletmay be positioned proximate front side, or positioned proximate left sideand right side(such as two individual inletsproximate the left and right side), or proximate left side, right side, and front side(such as three individual inletsrespectively proximate to the left, right, and front side). In general, an outlet may be positioned proximate a back sideof heating chamber. In general, heating chambermay include a venturi-like portion extending downwards in the vertical direction V between inletand outlet, e.g., heating chambermay be wider near inlet, narrowing in the middle, and widening again leading up to outlet. The venturi-like portion may increase airflow velocity by compressing air flowing between inletand outlet.

In the illustrated example embodiment, oven appliancealso has a convection fanpositioned at back sideof heating chamberand adjacent back wallof cooking chamber. In general, convection fanmay be configured to pull air directly through heating chamberand into cooking chamber. For example, convection fanmay be configured to pull air through inletof heating chamber, pull air across heating element, and force air out of outlet. Convection fanmay generally be powered by a convection fan motor. Further, convection fanmay be a variable speed fan-meaning the speed of fanmay be controlled or set anywhere between and including, e.g., zero and one hundred percent (0%-100%). In certain embodiments, oven appliancemay also include a bidirectional triode thyristor (not shown), i.e., a triode for alternating current (TRIAC), to regulate the operation of convection fansuch that the speed of fanmay be adjusted during operation of oven appliance. The speed of convection fanmay be determined by controller. In addition, a sensorsuch as, e.g., a rotary encoder, a Hall effect sensor, or the like, may be included at the base of fan, for example, between fanand motoras shown in the example embodiment of, to sense the speed of fan. The speed of fanmay be measured in, e.g., revolutions per minute (“RPM”).

Oven appliancemay generally include a user interfacehaving a displaypositioned on an interface paneland having a variety of controls. Interfaceallows the user to select various options for the operation of oven applianceincluding, e.g., various cooking and cleaning cycles. Operation of oven appliancemay be regulated by a controllerthat is operatively coupled to, i.e., in operative communication with, user interface, heating element, and convection fan, as well as other components of oven appliance.

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

Controllermay 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. 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. Controllermay 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.

Controllermay be positioned in a variety of locations throughout oven appliance. In the illustrated embodiment, controlleris located next to user interfacewithin interface panel. In other embodiments, controllermay be located under or next to the user interface, otherwise within interface panel, or at any other appropriate location with respect to oven appliance. Generally, controllermay be positioned within cabinet. In the embodiment illustrated in, input/output (“I/O”) signals are routed between controllerand various operational components of oven appliancesuch as heating element, convection fan, controls, display, alarms, and/or other components as may be provided. In one embodiment, user interfacemay represent a general purpose I/O (“GPIO”) device or functional block.

Although shown with touch type controlsin, it should be understood that controlsand the configuration of oven applianceshown inis provided by way of example only. More specifically, user interfacemay 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, among other possible examples and combinations. User interfacemay include other display components, such as a digital or analog display device designed to provide operational feedback to a user. User interfacemay be in communication with controllervia one or more signal lines or shared communication busses.

While oven applianceis 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, as mentioned above, are possible. As another example, the oven appliancemay include multiple doorsinstead of or in addition to the single doorillustrated. 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, oven appliancemay operate selectable heating modes, such as a bake mode and a convection mode. Specifically,illustrates the bake mode andillustrates the convection mode, as will both be explained hereinbelow. In general, a user may interact with controls, or display, of user interfaceto select the desired heating mode. In the present example embodiment, heating elementis provided as a sole heating element in oven appliance. In other words, heating elementmay be the only heating element in the entire oven appliance, e.g., heating elementis the only heating element in either direct and/or indirect thermal communication with cooking chamber. As such, heating elementmay be used in both heating modes described hereinbelow.

Referring specifically to, oven appliancemay operate in the bake mode. In general, the bake mode may include operating heating elementin order to heat the air inside cooking chamber. The bake mode may generally provide indirect, dry heat to cooking chamber. Accordingly, fanmay be inactive, or not spinning, and heated air inside oven appliancemay naturally, e.g., gradually, rise and increase cooking chambertemperature. In other words, the bake mode may be a heating mode with natural convection currents.

Referring specifically to, oven appliancemay operate in the convection mode. In general, the convection mode may include operating heating elementand convection fanin order to force heated air from heating chamberinto and through cooking chamber, as indicated by airflow indicators. Accordingly, in the convection mode, convection fanis active, e.g., spinning, in order to pull air through heating chamberand into cooking chamber. 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 indicatorsmay be pre-heated by heating elementbefore being forced into cooking chamber.

Turning to, a flowchart of an example method (e.g., method) of operating oven appliancewill be described. Although the discussion below refers to the example methodof operating oven appliance, one skilled in the art will appreciate that the example methodis 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, or another, separate, dedicated controller.

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 methodmay be modified, adapted, rearranged, omitted, interchanged, or expanded in various ways without deviating from the scope of the present disclosure.

Referring now to, at (), methodmay generally include operating a heating element in a first heating mode. For example, in the present example embodiment, oven appliancemay be operating heating elementin either the bake mode or the convection mode. Accordingly, the first heating mode may or may not include operating convection fan, depending on the heating mode selected as the first heating mode.

At (), methodmay 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, or display, of user interface, 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 (), methodmay generally include triggering convection fanin response to the second heating mode. For example, triggering convection fanmay generally be activating or deactivating fan motorof convection fan. Thus, switching from the first heating mode to the second heating mode may include either activating convection fanor deactivating convection fan, e.g., when the first heating mode is the bake mode and the second heating mode is the convection mode, triggering convection fanmay include activating convection fan.

At (), methodmay generally include operating the heating element in the second heating mode. For example, in the present example embodiment, oven appliancemay be operating heating elementin 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.

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

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

As described above, heating elementmay be the sole heating element of oven appliance. In general, reducing the number of heating elements within oven appliancemay advantageously reduce costs and complexity of oven appliance. Additionally, space within cooking chamberpreviously occupied by additional heating element(s) may become available, or usable, space within cooking chamber. Furthermore, as the sole heating element in oven appliance, heating elementmay 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.

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.