Cooking Appliance and Convective Heating Module

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

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.

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.

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, a perspective view of an exemplary household cooking applianceis shown in the form of an ovenand can be used for cooking one or more food items. The ovenincludes a chassis or cabinethaving a pair of spaced side walls,joined by a top wall(), a bottom wall, and a rear wallto at least partially define a cooking chamber. Optionally, the cooking appliancecan include one or more hobs, such as a stovetop or other cooking surface in addition to the cooking chamber.

A closure member can be operably coupled to the cabinet. In the illustrated example, the closure member includes a doorpivotable about a hinge and selectively closing the cooking chamber. When the dooris in an opened position, a user can access the cooking chamber. When the doorin a closed position, the doorprevents access to the cooking chamberand seals the cooking chamberfrom the external environment. One or more sensors can optionally be provided to sense or detect a position of the door.

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

The ovenfurther includes a heating systemwith at least one heating element for generating heat within the cooking chamber. For instance, the heating systemcan 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 systemcan include any number of heating elements, including only one, or two or more.

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

A convective heating modulecan also be provided in the heating system. The convective heating modulecan include a heating elementand a convection fan. The heating elementcan be any suitable heating element, such as a quartz tube heater in a non-limiting example. The convection fancan be any suitable fan for circulating air, and optionally steam when present, within the cooking chamber.

An energy source or power sourceis also provided and operably coupled to the heating system. The power sourcecan 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 systemcan also include other heating elements, including those external to the convective heating module. For instance, in the non-limiting example shown, a lower heating elementis disposed within the cabinetbeneath the bottom wall, and operably coupled to the power source. In such a case, heat generated by the lower heating elementcan be conducted through the bottom walland into the cooking chamber. In another non-limiting example, one or more heating elements can be coupled to one or more of the walls,,,of the cooking chamber. Such heating elements can be disposed within a heating element housing outside of the cooking chamberin some implementations, or mounted directly to a wall within the cooking chamberin some implementations. Further still, in some implementations the heating elementcan be a sole source of heat for the cooking chamberwith no additional heating elements provided. In other implementations, the lower heating elementcan be activated, whether alone or in combination with the heating element, for heating of the cooking chamber.

A controllercan be provided and communicatively coupled to components of the oven, including the heating system. The controllercan be, for example, a proportional-integral-derivative (PID) controller or any other suitable controller. The controllercan 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 controllercan also send output to the user interface, such as for displaying a status of the ovenor 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. In the illustrated example, the ovenincludes a communication moduleconfigured to send or receive signals from a remote device. The controllercan be communicatively coupled to the communication module, such as for implementing remote instructions for operation of the oven, or for transmitting data or control signals to a remote device, in non-limiting examples.

is a block diagram that schematically illustrates an exemplary control systemof the oven. The control systemcan include the controller. The controllerincludes a processorP and a memoryM as shown. The control systemcan optionally include one or more sensors in signal communication with the controller. In the illustrated example a temperature sensorand a door position sensorare 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 lockcan also be provided.

The controllercan be configured to activate, deactivate, or otherwise controllably operate the heating system, including the convective heating module. For instance, the controllercan be configured to activate or deactivate the convection fan, activate or deactivate the heating element, control a speed of the convection fan, control a rotation direction of the convection fan, control a time duration for operating the heating elementor the convection fan, in non-limiting examples. For instance, the controllercan include a convective cycle wherein the convection fancirculates air through the cooking chamber. The controllercan also include a non-convective cycle wherein the convection fandoes not circulate air through the cooking chamber. In this manner, the controllercan provide instructions regarding a desired temperature of the cooking chamber, or the rate at which the heating systemheats the cooking chamber, or the like.

In the illustrated example, the control systemincludes the communication moduleconfigured to send or receive signals, including wired or wireless signals, from a remote device. Such signals can include sensor data, cooking status information, control instructions for a cooking cycle, control instructions for operating the heating system, or the like. The controllercan be coupled to the communication moduleand controllably operate components of the ovenbased on signals received from the communication module. In an alternative example, the communication modulecan be omitted from the control systemsuch that the ovencan be operated solely from the user interface.

Referring now to, the convective heating moduleis shown in further detail. The convective heating modulecan include a housingbounding an interior, with the heating elementand the convection fandisposed within the interior. The convective heating modulecan be mounted in any suitable location of the cooking chamber. As shown, the housingis defined by at least a portion of the top wall, though this need not be the case. It is also contemplated that the convective heating modulecan be mounted to the rear wallin some implementations, or disposed within the cabinetoutside the cooking chamberin some implementations. In this manner, the housingcan at least partially define the cooking chamber.

The housingcan include a set of aperturesfluidly coupling the interior spaceto the cooking chamber. As shown, the set of aperturesincludes an air inletin registry with the convection fan, and a heating inletin registry with the heating element. It is understood that the air inletand the heating inletcan each include one or more individual apertures collectively forming the respective inlets,. In an alternative example where the convective heating moduleis disposed within the cabinetoutside the cooking chamber, either or both of the air inletor the heating inletcan be located on a wall of the cooking chamber, e.g. the top wall.

As shown, the heating elementis thermally coupled to the convection fanwithin the interior space. For instance, the heating elementand convection fancan be operated simultaneously such that the convection fancirculates warmed air through the air inlet. In an alternative example, the housingcan include a dividing wall, barrier, or the like such that the convection fanis at least partially thermally isolated from the heating element.

The convective heating modulecan further include a heat exchangeradjacent the heating element. The heat exchangerincludes a set of finsarranged to confront the heating elementas shown. The set of finscan be coupled to the housingas shown.

illustrates additional details of the heat exchanger, wherein the set of finscan be movable with respect to the heating inlet. For instance, the set of fins can be movable between a first position(shown in solid line) and a second position(shown in dashed line), with the second positionat least partially closing the heating inlet. In some implementations, the set of finscan be fully open in the first position, and can fully close the heating inletwhen in the second position. In another example, the first positionand the second positioncan each define partially-open states where the set of finspartially close the heating inletby differing amounts.

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

Regardless of the type of motion for the set of fins, when in the second position, the set of finscan inhibit thermal radiation transfer from the heating elementto the cooking chamber. When in the second position, the set of finscan absorb incident thermal radiation from the heating elementand re-emit thermal energy into the cooking chamberby way of air encountering the set of fins. In this manner, the heat exchangercan at partially define the heating inlet.

An actuatorcan be provided and operably coupled to the set of finsfor movement between the first and second positions,. The actuatorcan be any suitable actuator, including a linear actuator, a rotary actuator, a hydraulic actuator, or the like. The actuatorcan also be communicatively coupled to the controllersuch that the controllercan controllably operate the heat exchangerduring a cooking cycle.

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

With general reference to, in one example of operation, the controllercan controllably operate the convective heating moduleto perform a convective cycle where the convection fanis activated to circulate air as described above. The controllercan controllably operate the heating elementto generate heat, and also instruct the actuatorto move the set of finsinto the second positionto block radiative or direct heat from the heating element. Additionally, when in the second position, the set of finscan absorb and re-emit heat from the heating element. Air circulating within the cooking chambercan encounter the set of finsand distribute the re-emitted heat within the cooking chamber. Such re-emission provides for a more even distribution of heat within the cooking chamber, which can lead to more uniform cooking outcomes or features of food items within the oven. In this manner, the convective heating modulecan 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.

With continued reference to, in another example of operation, the controllercan controllably operate the convective heating moduleto perform a non-convective cycle where the convection fanis not activated. The controllercan controllably operate the heating elementto generate heat, and also instruct the actuatorto move the set of finsinto the first position. When in the first position, the set of finsprovides at least some direct radiative heat from the heating elementto enter the cooking chamber, such as for a broiling or grilling cooking cycle. In addition, it is contemplated that the set of finsin the first positioncan absorb and re-radiate thermal energy from the heating elementas 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.