Toaster

Abstract

The present invention relates to a toaster comprising: a housing; the pair of opposite food protection pieces is located in the shell and defines a baking cavity used for containing food to be baked; a pair of heating elements located within the housing, each heating element located on a respective side of the pair of food shields; and a top cover forming an upper surface of the housing, the upper surface providing a curved portion having a first surface portion and a second surface portion, the first surface portion and the second surface portion being positioned to provide a slot between the first surface portion and the second surface portion, the top cover has a curved portion having a slot for delivering the food product to the cavity, where the curved portion has a vertical direction of extension and a horizontal direction of extension so as to converge downward to the baking cavity, where the top cover has a coating that is of a non-missed color, and where the emissivity of the non-missed color of the top cover coating is at least 0.75 to achieve a uniform heat distribution.

Description

[0001] This application is a divisional application of the invention application with the application date of June 28, 2019, application number 201980043034.X, and name “TOASTER”. Technical Field

[0002] The present invention relates to a toaster.

[0003] The invention has been primarily developed for use as a bread toaster and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use. Background Art

[0004] During the assembly of a conventional toaster, many design features can be utilized to ensure that the various components of the toaster are securely assembled and meet safety requirements. Such design features may be practical from an assembly perspective, but may not be sufficient to reduce or prevent undesirable airflow through the toasting zone (i.e., the area where the food is cooked). The presence of airflow through the toasting zone affects toasting performance by altering heat transfer to the food, which may result in uneven or inadequate toasting of the food.

[0005] Design features in conventional toasters may also affect the ability of the toaster to distribute heat from the heating element to the food sufficiently and evenly.Such design features are also prone to retaining crumbs in the food, which is undesirable for aesthetic and hygienic reasons.

[0006] Toasters are also required to meet stringent safety standards. The design features of conventional toasters may not be sufficient to meet such safety standards while also maintaining the structural integrity and toasting performance of the toaster.

[0007] Toasters are also designed to quickly and efficiently brown bread to the user's desired level.

[0008] However, known toasting systems may not be able to efficiently and accurately cook all types of bread to the same desired level for a user because the requirements for toasting different types of bread may vary due to the physical properties of the bread.

[0009] Further, known toasting systems may not be able to effectively detect and counteract operation of the toaster in which bread is not properly placed within the slot of the toaster or is not actually placed within the slot at all.

[0010] Furthermore, known toasting systems may not be able to effectively and accurately detect when a slice of bread is toasted to the user's desired level due to holes or seeds in the bread interfering with the toasting feedback signal. Summary of the Invention

[0011] It is an object of the present invention to overcome or substantially ameliorate at least one of the above disadvantages.

[0012] The present invention discloses a toaster comprising:

[0013] case;

[0014] a pair of opposed food guards positioned within the housing and defining a baking cavity for receiving food to be baked;

[0015] a pair of heating elements positioned within the housing, each heating element positioned on a respective side of the pair of food guards, wherein each food guard is spaced apart from a corresponding heating element by a gap; and

[0016] Each food guard includes an upwardly extending portion extending upwardly to a portion extending laterally therefrom so as to extend over a corresponding heating element, the laterally extending portion of each food guard projecting away from the opposing food guard.

[0017] The toaster preferably further comprises a top cover forming an upper surface of the toaster and comprising a pair of slots adapted to receive the food to be toasted, the top cover comprising portions each having a horizontal extension direction and a vertical extension direction converging toward the slots.

[0018] The cover preferably has a non-stick coating and / or a ceramic coating.

[0019] The coating is preferably a dark, non-tarnish color.

[0020] Preferably, the dark, non-tarnished color of the coating has an emissivity of about 0.75 to achieve uniform heat distribution.

[0021] The cap coating preferably has a surface texture to provide an emissivity of about 0.75 to achieve uniform heat distribution.

[0022] Each food guard preferably has a ceramic coating adapted to evenly distribute heat from the heating element into the toasting zone.

[0023] The food guard coating is preferably a dark, non-tarnish color.

[0024] Preferably, the dark, non-tarnished color of the food guard coating has an emissivity of about 0.75 to achieve uniform heat distribution.

[0025] The food guard coating preferably has a surface texture to provide an emissivity of about 0.75 for uniform heat distribution.

[0026] The laterally extending portion of each food guard is preferably curved so as to extend over the corresponding heating element.

[0027] Preferably, a gap is formed between the top cover and an upper portion of each food guard.

[0028] The width of the gap is preferably less than 3.5 mm.

[0029] The housing preferably includes an outer wall and an inner wall, and the toaster further includes a sensor mounted to the inner wall, the inner wall including an opening to allow the sensor to detect the food in the toasting cavity.

[0030] The toaster preferably further includes a pair of heating element supports mounted at the upper portion of the housing and supported at the lower portion of the housing, each heating element support including a downwardly facing portion adapted to engage and support a corresponding heating element.

[0031] Each food guard is preferably formed from a fine gauge wire mesh having mesh gaps of less than 5.3 mm.

[0032] The toaster preferably further comprises a pair of end panels, each positioned adjacent a respective end of the food guard, the end panels having a ceramic coating adapted to evenly distribute heat from the heating element into the toasting cavity.

[0033] Each end panel preferably has a non-stick coating and / or a ceramic coating.

[0034] The coating is preferably a dark, non-tarnish color.

[0035] Preferably, the dark, non-tarnished color of the coating has an emissivity of about 0.75 to achieve uniform heat distribution.

[0036] The end plate coating preferably has a surface texture to provide an emissivity of about 0.75 to achieve uniform heat distribution.

[0037] Each end panel preferably includes a pair of guide slots, and each food guard includes an upper guide pin to be mounted in the corresponding guide slot.

[0038] The guide slot is preferably located above the baking cavity so as to restrict air flow travelling across the food product.

[0039] The food guards preferably each include a lower portion providing a pivot point, and the food guards are pivotable about their pivot points between an open position and a closed position.

[0040] The food guard is preferably displaceable in a horizontal direction between an open position and a closed position.

[0041] The toaster of claim 1 , wherein the housing includes an inner wall surrounding the toasting cavity, the inner wall including an upper portion angled downwardly toward the slot.

[0042] The present invention further discloses a toaster comprising:

[0043] case;

[0044] a pair of opposed food guards positioned within the housing and defining a baking cavity for receiving food to be baked;

[0045] a pair of opposing heating elements positioned within the housing, each heating element positioned on a respective side of the pair of food guards, wherein each heating element is spaced apart from a corresponding food guard by a gap; and

[0046] a pair of spaced-apart end panels, the food guard extending between the pair of spaced-apart end panels;

[0047] wherein the heating element is supported adjacent an upper portion of the cavity so as to extend downwardly.

[0048] Each end panel preferably has a non-stick coating and / or a ceramic coating.

[0049] The coating is preferably a dark, non-tarnish color.

[0050] Preferably, the dark, non-tarnished color of the coating has an emissivity of about 0.75 to achieve uniform heat distribution.

[0051] The end plate coating preferably has a surface texture to provide an emissivity of about 0.75 to achieve uniform heat distribution.

[0052] Each food guard preferably has a ceramic coating adapted to evenly distribute heat from the heating element into the toasting zone.

[0053] The food guard coating is preferably a dark, non-tarnish color.

[0054] Preferably, the dark, non-tarnished color of the food guard coating has an emissivity of about 0.75 to achieve uniform heat distribution.

[0055] The food guard coating preferably has a surface texture to provide an emissivity of about 0.75 for uniform heat distribution.

[0056] The toaster preferably further comprises a top cover forming an upper surface of the toaster and comprising a pair of slots adapted to receive the food to be toasted, the top cover comprising portions each having a horizontal extension direction and a vertical extension direction converging toward the slots.

[0057] The cover preferably has a non-stick coating and / or a ceramic coating.

[0058] The coating is preferably a dark, non-tarnish color.

[0059] Preferably, the dark, non-tarnished color of the coating has an emissivity of about 0.75 to achieve uniform heat distribution.

[0060] The cap coating preferably has a surface texture to provide an emissivity of about 0.75 to achieve uniform heat distribution.

[0061] Each end panel preferably includes a pair of guide slots, and each food guard includes an upper guide pin to be mounted in the corresponding guide slot.

[0062] The toaster preferably further includes a crumb tray removably engageable with the base member of the housing, the crumb tray including a raised portion to engage a recessed portion of the base member to properly orient the crumb tray relative to the base member.

[0063] The crumb tray preferably further comprises an upper surface and a lower surface, the upper surface having a portion angled relative to the upper surface to reflect heat from the heating element into the toasting cavity.

[0064] The base member preferably includes an actuation member, and wherein engagement of the crumb tray with the base member causes the actuation member to make electrical contact with a switch in the base member, and disengagement of the crumb tray from the base member causes the base member to break electrical contact with the switch.

[0065] Each food guard is preferably spaced apart from the corresponding heating element by a gap; and each food guard has an upwardly extending portion and a portion extending laterally from the upwardly extending portion so as to extend over the corresponding heating element, the laterally extending portion of each food guard protruding away from the opposing food guard.

[0066] The laterally extending portion of each food guard is preferably curved so as to extend over the corresponding heating element.

[0067] The housing preferably includes an outer wall and an inner wall, and the toaster further includes a sensor mounted to the inner wall, the inner wall including an opening to allow the sensor to detect the food in the toasting cavity.

[0068] The toaster preferably further includes a pair of heating element supports mounted at the upper portion of the housing and supported at the lower portion of the housing, each heating element support including a downwardly facing portion adapted to engage and support a corresponding heating element.

[0069] Each food guard is preferably formed from a fine gauge wire mesh having mesh gaps of less than 5.3 mm.

[0070] The present invention further discloses a toaster comprising:

[0071] case;

[0072] a pair of opposing food guards positioned within the housing and defining a toasting area for receiving food to be toasted; and

[0073] A pair of heating elements are positioned within the housing, each heating element being positioned on a respective side of the pair of food guards, wherein each food guard is spaced apart from a corresponding heating element by a gap and each food guard is arranged to extend over the corresponding heating element.

[0074] The present invention further discloses a toaster comprising:

[0075] a housing having an outer wall and an inner wall;

[0076] a baking area, the baking area being located in the housing and being used to receive food to be baked;

[0077] a pair of heating elements, each heating element located on a respective side of the toasting zone; and

[0078] a sensor mounted to the inner wall, the inner wall including an opening to allow the sensor to detect the food in the toasting zone, the inner wall further including a pair of reflector tabs on opposite sides of the opening, wherein the reflector tabs are arranged at a certain angle to reflect heat generated by the heating element into the toasting zone.

[0079] The present invention further discloses a toaster comprising:

[0080] case;

[0081] a baking area, the baking area being located in the housing and being used to receive food to be baked;

[0082] a pair of heating elements positioned within the housing, each heating element positioned on a respective side of the toasting zone; and

[0083] A pair of heating element supports are mounted at the upper portion of the housing and supported at the lower portion of the housing, each heating element support including a downwardly facing portion adapted to engage and support a corresponding heating element.

[0084] The present invention further discloses a toaster comprising:

[0085] case;

[0086] a pair of opposing food guards positioned within the housing and defining a toasting area for receiving food to be toasted; and

[0087] A pair of heating elements are positioned within the housing, each heating element being positioned on a respective side of the pair of food guards, wherein each food guard is formed from a fine gauge wire mesh having a mesh gap of less than 5.3 mm.

[0088] The present invention further discloses a toaster comprising:

[0089] case;

[0090] a pair of opposed food guards positioned within the housing and defining a toasting area for receiving food to be toasted;

[0091] a pair of heating elements positioned within the housing, each heating element positioned on a respective side of the pair of food guards; and

[0092] A pair of end panels, each positioned adjacent a respective end of the food guard, the end panels having a ceramic coating adapted to evenly distribute heat from the heating element into the toasting zone.

[0093] The present disclosure also provides an improved toaster and toaster operation, and in particular, provides an improved toasting system for determining the type of bread being toasted to change toasting parameters, provides an improved toasting system for detecting when bread is not within a toasting slot being heated, or provides an improved toasting system for determining the positioning of bread before / while toasting the bread.

[0094] According to one embodiment, a toaster is provided, comprising at least one optical sensor, at least one toasting slot, at least one heating element for emitting heat in the toasting slot, and a processor, wherein the optical sensor is arranged to: emit an optical signal into the toasting slot; sense a reflected optical signal, which is reflected off a food item when the food item is placed in the toasting slot, and transmit the reflected optical signal to the processor, wherein the processor is arranged to: determine an active shadow profile based on the reflected optical signal of the food item, compare the active shadow profile with at least one stored shadow profile associated with at least one food item type to determine whether the active shadow profile and the stored shadow profile are within a defined threshold, and whereby the processor determines that the active shadow profile and the stored shadow profile are within a defined threshold of each other, and controls the heating profile of the heating element based on the food item type.

[0095] Preferably, the processor is further arranged to compare a first shadow value in the active shadow profile at a defined point in time with a second shadow value in the stored shadow profile at the same defined point in time to determine whether the first shadow value and the second shadow value are within a defined threshold.

[0096] Preferably, the processor is further arranged to adjust one or both of a time for toasting the food item and power applied to the heating element based on the processor determining that the active shadow profile and the stored shadow profile are within a defined threshold of each other.

[0097] According to another embodiment, a method of controlling a toaster is provided, the method comprising the steps of transmitting an optical signal into a toasting slot of the toaster; sensing a reflected optical signal that reflects off the food item when the food item is placed in the toasting slot, and determining an active shadow profile based on the reflected optical signal of the food item, comparing the active shadow profile with at least one stored shadow profile associated with at least one food item type to determine whether the active shadow profile and the stored shadow profile are within a defined threshold, and upon determining that the active shadow profile and the stored shadow profile are within the defined threshold, controlling a heating profile of the heating element based on the food item type.

[0098] Preferably, the method further comprises the step of comparing a first shadow value in an active shadow profile at a defined time point with a second shadow value in a stored shadow profile at the same defined time point to determine whether the first shadow value and the second shadow value are within a defined threshold.

[0099] Preferably, the method further comprises the step of adjusting one or both of a time to toast the food item and power applied to the heating element based on determining that the active shadow profile and the stored shadow profile are within a defined threshold of each other.

[0100] According to another embodiment, a toaster is provided, comprising at least one optical sensor, at least one toasting slot, at least one toasting tray for inserting food items into the toasting slot, and a processor, wherein the optical sensor is arranged to: emit an optical signal into the toasting slot; sense a reflected optical signal associated with the food item when the toasting tray moves the food item within the toasting slot, and transmit the reflected optical signal to the processor, wherein the processor is arranged to: determine an optical profile of the food item based on the reflected optical signal along an area of the food item when the food item is inserted, determine an optimal sensing position of an area along the food item corresponding to an optimal sensing area based on the determined optical profile, and move the toasting tray to a toasting position corresponding to the determined optimal sensing position.

[0101] Preferably, the toaster has a tray motor arranged to control movement of the toasting tray, wherein the processor is further arranged to determine the tray position of the toasting tray based on operation of the tray motor as the toasting tray moves within the toasting slot, wherein the processor is further arranged to control movement of the toasting tray to the tray position corresponding to the toasting position after determining the optimal sensed position.

[0102] Preferably, the optical signal sensed by the optical sensor is a light signal generated by the optical sensor that is reflected off the food item.

[0103] Preferably, the processor determines the optimal sensing position by comparing the optical profile with a stored profile associated with at least one optimal sensing region.

[0104] According to another embodiment, a method of controlling a toaster is provided, the method comprising the steps of: emitting an optical signal into a toasting slot of the toaster; sensing a reflected optical signal associated with the food item when a toasting tray of the toaster moves the food item within the toasting slot, determining an optical profile of the food item based on the reflected optical signal along an area of the food item when the food item is inserted, determining an optimal sensing position along an area of the food item corresponding to an optimal sensing area based on the determined optical profile, and moving the toasting tray to a toasting position corresponding to the determined optimal sensing position.

[0105] Preferably, the method further comprises the steps of determining a tray position of the toasting tray based on operation of a tray motor when the toasting tray moves in the toasting slot, and controlling movement of the toasting tray to a tray position corresponding to the toasting position after determining the optimal sensing position.

[0106] Preferably, the method further comprises the step of comparing the optical profile with a stored profile associated with at least one optimal sensing area.

[0107] According to another embodiment, a toaster is provided, comprising at least one optical sensor, at least one toasting slot for receiving a food item, and a processor, wherein the optical sensor is arranged to: emit an optical signal into the toasting slot; sense a reflected optical signal associated with the toasting slot, and transmit the reflected optical signal to the processor, wherein the processor is arranged to: determine whether a food item has been inserted into the toasting slot based on the reflected optical signal.

[0108] Preferably, upon determining that the food item has not been inserted into the toasting slot, the processor is further arranged to perform one or more defined tasks, the one or more defined tasks comprising: turning off one or more heating elements associated with the toasting slot; raising a toasting tray of the toasting slot; outputting an alarm signal; and turning off a user control of the toaster.

[0109] According to another embodiment, a method of controlling a toaster is provided, the method comprising the steps of transmitting an optical signal into a toasting slot of the toaster; sensing a reflected optical signal associated with the toasting slot, and determining whether a food item has been inserted into the toasting slot based on the reflected optical signal.

[0110] Preferably, upon determining that the food item has not been inserted into the toasting slot, the method further comprises the steps of: performing one or more defined tasks, the one or more defined tasks comprising: shutting down one or more heating elements associated with the toasting slot; raising a toasting tray of the toasting slot; outputting an alarm signal; and shutting down a user control of the toaster.

[0111] Other embodiments are also disclosed. BRIEF DESCRIPTION OF THE DRAWINGS

[0112] Preferred forms of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0113] Figure 1 is a schematic cross-sectional isometric view of a toaster;

[0114] Figure 2 yes Figure 1 Additional schematic cross-sectional isometric views of a toaster;

[0115] Figure 3 yes Figure 1 Schematic cross-sectional isometric view of a toaster;

[0116] Figure 4 yes Figure 1 Additional schematic cross-sectional isometric views of a toaster;

[0117] Figure 5 yes Figure 1 an enlarged schematic cross-sectional isometric view of a toaster;

[0118] Figure 6 yes Figure 1 An enlarged schematic cross-sectional top view of a toaster;

[0119] Figure 6A yes Figure 1 An enlarged schematic cross-sectional top view of a toaster in an alternative configuration;

[0120] Figure 7 yes Figure 1 Additional schematic cross-sectional isometric views of a toaster;

[0121] Figure 7A yes Figure 1 Additional schematic cross-sectional isometric views of a toaster in an alternative configuration;

[0122] Figure 8 yes Figure 1 An enlarged schematic isometric view of a heating element and a heating element support of a toaster;

[0123] Figure 9 yes Figure 8 Another enlarged schematic isometric view of the heating element and heating element support;

[0124] Figure 10 yes Figure 8 A schematic isometric view of a heating element support;

[0125] Figure 11 yes Figure 1 a schematic isometric view of an inner chassis assembly of a toaster;

[0126] Figure 12 yes Figure 11 Additional schematic isometric views of the inner chassis assembly;

[0127] Figure 12A yes Figure 11 Additional schematic isometric views of the inner chassis assembly of FIG. 1 in an alternative configuration;

[0128] Figure 13 yes Figure 1 An enlarged schematic isometric view of the silicone curtain and outer chassis reflector of a toaster;

[0129] Figure 14 yes Figure 1 Additional schematic cross-sectional isometric views of a toaster;

[0130] Figure 15 yes Figure 1 Additional schematic cross-sectional isometric views of a toaster;

[0131] Figure 16 yes Figure 1 a schematic isometric view of an upper portion of a toaster;

[0132] Figure 17 yes Figure 1 Another schematic isometric view of an upper portion of a toaster;

[0133] Figure 18 yes Figure 1 An enlarged schematic isometric view of a toaster;

[0134] Figure 19 、 Figure 19A 、 Figure 19B yes Figure 1 an enlarged schematic view of a toaster;

[0135] Figure 20 yes Figure 1 A schematic isometric view of a food guard for a toaster;

[0136] Figure 21 yes Figure 1 A schematic front view of a food guard of a toaster;

[0137] Figure 22 yes Figure 1 an enlarged schematic front view of a toaster;

[0138] Figure 23 yes Figure 1 an additional enlarged schematic isometric view of a toaster;

[0139] Figure 24 yes Figure 1 A schematic side view of a toaster;

[0140] Figure 25 yes Figure 1 an additional enlarged schematic isometric view of a toaster;

[0141] Figure 26 is a schematic front view of a food product;

[0142] Figure 27 yes Figure 1 a schematic isometric view of an inner chassis assembly of a toaster;

[0143] Figure 28 yes Figure 1 an enlarged schematic isometric view of a food tray assembly of a toaster;

[0144] Figure 29 yes Figure 28 an additional enlarged schematic isometric view of a food tray assembly;

[0145] Figure 30 yes Figure 28 an additional enlarged schematic isometric view of a food tray assembly;

[0146] Figure 31 yes Figure 1 Additional schematic cross-sectional isometric views of a toaster;

[0147] Figure 32 yes Figure 1 an enlarged schematic isometric view of a food guard spring of a toaster;

[0148] Figure 33 yes Figure 32 an additional enlarged schematic isometric view of a food guard spring;

[0149] Figure 34 yes Figure 1 Additional schematic cross-sectional isometric views of a toaster;

[0150] Figure 35 yes Figure 1 an enlarged schematic isometric view of a base member of a toaster;

[0151] Figure 36 yes Figure 1 Another enlarged schematic side view of a toaster;

[0152] Figure 37 yes Figure 1 Another enlarged schematic side view of a toaster;

[0153] Figure 38 yes Figure 1 an enlarged schematic top view of an actuating member of a toaster;

[0154] Figure 39 yes Figure 38Another enlarged schematic top view of the actuating member;

[0155] Figure 40 yes Figure 1 A schematic isometric view of a crumb tray of a toaster;

[0156] Figure 41 yes Figure 1 Additional schematic isometric views of a crumb tray of a toaster;

[0157] Figure 42 yes Figure 1 A schematic isometric view of the underside of a toaster;

[0158] Figure 43 yes Figure 1 Additional schematic isometric view of the underside of a toaster;

[0159] Figure 44 yes Figure 1 A schematic front view of a heating element of a toaster;

[0160] Figure 45 yes Figure 1 a schematic front view of an additional heating element of a toaster;

[0161] Figure 46 yes Figure 1 an enlarged schematic isometric view of a heating element of a toaster;

[0162] Figure 47 yes Figure 1 an additional enlarged schematic isometric view of a heating element of a toaster;

[0163] Figure 48 yes Figure 1 an additional enlarged schematic isometric view of a heating element of a toaster;

[0164] Figure 49 yes Figure 1 an additional enlarged schematic isometric view of a heating element of a toaster;

[0165] Figure 50 yes Figure 1 Schematic isometric view of a toaster and food warmer;

[0166] Figure 51 yes Figure 1 an enlarged schematic front view of a toaster;

[0167] Figure 52 yes Figure 1 Schematic isometric view of the wire compartment of a toaster;

[0168] Figure 53 yes Figure 1 Another enlarged schematic front view of a toaster;

[0169] Figure 54 yes Figure 1 Additional schematic isometric views of the wire compartment of a toaster;

[0170] Figure 55 yes Figure 1 a schematic isometric view of a sensor subassembly of a toaster;

[0171] Figure 55A yes Figure 55 Schematic isometric views of alternative configurations of sensor subassemblies;

[0172] Figure 56 yes Figure 1 Additional schematic isometric views of a toaster;

[0173] Figure 56A yes Figure 1 Additional schematic isometric views of a toaster in an alternative configuration;

[0174] Figure 57 yes Figure 1 Schematic isometric view of a toaster;

[0175] Figure 58 yes Figure 1 an additional enlarged schematic isometric view of a toaster;

[0176] Figure 59 yes Figure 1 Another enlarged schematic front view of a toaster;

[0177] Figures 60 to 62 Various toasters according to other embodiments of the present disclosure are shown;

[0178] Figure 63 shows a circuit block diagram according to an embodiment of the present disclosure;

[0179] Figure 64 shows a cross-sectional view of a toaster according to an embodiment of the present disclosure;

[0180] Figure 65 shows shading variation curves of different food item types according to an embodiment of the present disclosure;

[0181] Figure 66 shows a process flow chart according to an embodiment of the present disclosure;

[0182] Figure 67 shows a cross-sectional view of a toaster according to an embodiment of the present disclosure;

[0183] Figures 68 to 71 shows a toaster tray lifting mechanism according to an embodiment of the present disclosure;

[0184] Figure 72 shows a process flow chart according to an embodiment of the present disclosure;

[0185] Figure 73 shows a cross-sectional view of a toaster according to an embodiment of the present disclosure; and

[0186] Figure 74 A process flow diagram according to an embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0187] In the attached figure Figures 1 to 59 , a toaster 10 is schematically depicted. The toaster 10 includes a housing 12 having an upper portion 14 and a lower portion (i.e., a base) 16. The toaster 10 further includes a top cover 18 located on the upper portion 14 of the housing 12 and a removable crumb tray 20 located on the lower portion 16 of the housing 12. The top cover 18 includes a pair of slots 19 through which the food to be toasted is inserted. The housing 12 includes an interior 22 that houses a plurality of components for receiving and toasting food. For the purposes of this specification, it will be understood that a wide variety of food items can be cooked in a toaster. Such food items include sliced bread, bagels, crumpets, and desserts, as well as frozen versions of such food items. Throughout this specification, unless otherwise specified, the term "food item" will be used to refer to all of these food items.

[0188] The toaster 10 also includes two pairs of food guards positioned within the interior 22 of the housing 12. Each pair of food guards includes a first food guard 24a and an opposing second food guard 24b. The space between the pair of first and second food guards 24a, 24b defines two toasting zones (cavities) 25a and 25b, within which food resides during operation of the toaster 10. It should be understood that the width of each toasting zone 25a, 25b can range from 20 to 25 mm to accommodate the width of the food. The width of each toasting zone 25a, 25b also defines the distance that each of the corresponding food guards 24a, 24b can be displaced or pivoted between its open and closed positions, as will be described in further detail below. Located between each pair of food guards 24a, 24b and adjacent to the lower portion 16 of the housing 12 is a corresponding food tray 26a, 26b. Food is inserted into the toaster 10 through one of the slots 19 in the top cover 18 and rests on a corresponding food holder 26a, 26b, whereby the associated first and second food guards 24a, 24b hold (and / or align) the food in place. Each of the food holders 26a, 26b is movable from a first position adjacent the upper portion 14 of the housing 12 to receive the food and from a second position adjacent the lower portion 16 of the housing 12 to toast the food. The first position of each of the food holders 26a and 26b corresponds to the open position of the corresponding food guard 24a and 24b, and conversely, the second position of each of the food holders 26a and 26b corresponds to the closed position of the corresponding food guard 24a and 24b. The movement of each of the food holders 26a, 26b between the first and second positions can be manually actuated (e.g., by a user pushing down or pulling up a lever in the toaster 10), or automatically actuated (e.g., by detecting the presence of food and activating an associated motor-driven lift function, as described in further detail below). It is contemplated that the movement of each of the food holders 26a, 26b can also be automatically actuated by a user actuating an electronic / electrical button on the toaster 10. It will be appreciated that the associated motor-driven lift function also allows the food holders 26a, 26b to rest in any position between the first and second positions. The toaster 10 further includes a heating element assembly 28 adjacent to each of the food guards 24a, 24b. Thus, in the embodiment shown, the toaster 10 includes four heating element assemblies 28. The toaster 10 also includes a light emitting diode (LED) assembly 30 located within the interior 22 of the housing 12 adjacent to the upper portion 14.

[0189] The structure and function of each individual component of toaster 10 will now be described in further detail below.

[0190] Top cover

[0191] like Figures 3 to 5 As best shown in FIG, the top cover 18 forms the upper surface of the toaster 10 and is adapted to receive food to be toasted through the pair of slots 19. The pair of slots 19 have a generally rectangular cross-sectional shape with slightly rounded / curved corners. Figure 5 , top cover 18 includes a male feature 32 located at a lower periphery of top cover 18. Male feature 32 faces generally downward and is adapted to sealingly engage a corresponding female feature 34 (e.g., a slot) located at an upper periphery of housing 12. The corresponding arrangement of male and female features 32, 34 allows top cover 18, and specifically slot 19, to be securely aligned and attached to housing 12 during assembly without requiring additional securing tabs as are required during assembly of conventional toasters. The engagement of male and female features 32, 34 also forms a seal to reduce the presence of an exposed opening between top cover 18 and housing 12, thereby preventing undesirable airflow into interior 22 of housing 12 while food is being toasted. The corresponding arrangement of male and female features 32, 34 can also reduce the number of surfaces in toaster 10 that are susceptible to collecting debris from food.

[0192] like Figure 4 and 5 As best shown in FIG, the top cover 18 has an upper surface 36 including a curved portion 38 that curves inwardly and downwardly toward each of the slots 19. The curved portions 38 each have a horizontal extension and a vertical extension that converge toward the slot. Figure 19 and 19A The curved portion 38 is formed as a compound curve whose boundaries are defined by a height H ranging from about 10 mm to 20 mm and a width W ranging from about 30 mm to 45 mm. In a preferred form, the height H is about 15.2 mm and the width W is 37.5 mm, so as to define a compound curve having a radius of curvature R of about 24.5 mm. Figure 4 and 5The arrangement of the curved portion 38 can at least reduce or eliminate horizontal portions on the upper surface 36 of the top cover 18, thereby preventing food debris from collecting on the top cover 18. The curved portion 38 guides the debris through the slots 19 to fall or roll into the toasting zones 25a, 25b and onto the crumb tray 20. In a preferred form, the upper surface 36 of the top cover 18 (including the curved portion 38) has a non-stick and / or ceramic coating to prevent debris from resting and adhering to the upper surface 36 of the top cover 18. The non-stick and / or ceramic coating is preferably a dark (e.g., black) non-tarnishing color to reduce the appearance of defects on the top cover 18. It should be understood that the dark color (e.g., black) of the non-stick coating has an appropriate emissivity range to achieve uniform heat distribution. In a preferred form, the non-stick and / or ceramic coating is a dark color with an emissivity of less than approximately 0.75. The surface texture of the coating can also be fine-tuned based on the shade of the dark coating to ensure that the emissivity does not drop below 0.75.

[0193] refer to Figure 5 The top cover 18 also has a lower surface 40 that includes an angled portion 42 to reflect light that shines upward from the LED assembly 30 (e.g., in direction 43) and exits the toaster 10 through a gap or vent 44 between the top cover 18 and the housing 12. It is contemplated that the angle of the angled portion 42 relative to the upper surface 36 of the top cover 18 is between about 30 and 70 degrees. In a preferred form, the angle is about 50 degrees.

[0194] case

[0195] like Figure 6 and 7As best shown in FIG, housing 12 forms the main body of toaster 12 and includes an outer wall 46 forming the outer chassis of housing 12 and an inner chassis assembly 47 having an inner wall 48 surrounding toasting zones 25a, 25b. Inner wall 48 includes an opening 50 to allow sensor 52 to detect food. As will be discussed in further detail below, sensor 52 is configured to detect physical properties of the food surface to determine the optimal toasting zone. When the optimal toasting zone is found, sensor 52 sends a signal to an associated processor, which enables an associated motor to adjust the height of food trays 26a, 26b accordingly. Each sensor 52 is also configured to detect the presence or absence of food in toasting zones 25a, 25b. If no food is detected, sensor 52 sends a signal to an associated processor, which enables an associated motor to return the associated food tray 26a, 26b to its first position. A pair of reflector tabs 54 are located on either side of each opening 50 and are adapted to reflect heat from the heating element assembly 28 back into the baking areas 25a, 25b. The arrangement of the reflector tabs 54 can at least reduce the heat lost through the openings 50, which otherwise may cause uneven baking of the food. It is envisioned that the reflected heat can be adjusted by changing the length or angle of the tabs 54 or by introducing perforations into the tabs 54. In a preferred form, the angle of the tabs 54 relative to the surface of the inner wall 48 is between about 5 degrees and 45 degrees. It is also envisioned that the maximum length of the tabs 54 can be the width of the corresponding opening 50.

[0196] In such Figure 6A and 7A In the alternative embodiment shown, the reflector tabs 54 are removed.

[0197] like Figure 8 and 9As best shown in FIG, each heating element assembly 28 of toaster 10 is mounted in housing 12 via a heating element bracket 56 located in inner chassis assembly 47 and adjacent to upper portion 14 of housing 12. Each heating element bracket 56 includes a downward-facing portion 57 adapted to hold and support a heating element assembly 28. As described above, it should be understood that toaster 10 includes a pair of heating element assemblies 28 located on either side of each toasting zone 25a and 25b, resulting in a total of four heating element assemblies 28 in toaster 10. The heating element brackets 56 include tabs 58 that engage corresponding holes in inner chassis assembly 47, thereby facilitating assembly of inner chassis assembly 47 and increasing its structural integrity. The arrangement of heating element brackets 56 can at least eliminate the need for a bottom plate to secure heating element assembly 28 in inner chassis assembly 47, as in conventional toasters, thereby reducing upward-facing surfaces from the bottom of inner chassis assembly 47 that could be susceptible to debris collection.

[0198] like Figure 10 and 11 As best shown in FIG, the two component card brackets 56 located in the center of the toaster 10 include a pair of cutouts 60. The cutouts 60 on the two component card brackets 56 have an overlapping configuration so that the thermal mass of the toaster 10 can be reduced. Those skilled in the art will understand that thermal mass affects the overall toasting time, and thus, the higher the thermal mass, the slower the toasting time.

[0199] It will be appreciated that the guide slots 66a, 66b in the inner chassis assembly 47 are required for the food holders 26a, 26b to move between the first and second positions. Figure 12 and 13 As best shown in FIG, the toaster 10 includes an outer chassis reflector 62 to which is attached a silicone curtain 64. The silicone curtain 64 is adapted to provide a seal for airflow passing through the guide slots 66a, 66b. Thus, the arrangement of the silicone curtain 64 can reduce the amount of undesirable airflow through the toasting areas 25a, 25b. Figure 13 As best shown in FIG, the outer chassis reflector 62 and attached silicone curtain 64 are offset from the bake areas 25a, 25b by a distance 68 so as to reduce heat transfer to the silicone curtain 64.

[0200] In such Figure 12A In the alternative embodiment shown, the inner wall 48 of the inner chassis assembly 47 includes a dog-bone structure 69 to which the sensor 52 may be mounted.

[0201] like Figure 14As best shown in FIG, the inner wall 48 of the inner chassis assembly 47 includes an angled portion 70 that encourages debris to fall or roll onto the crumb tray 20. The arrangement of the angled portion 70 can at least reduce the number of horizontal surfaces in the inner chassis assembly 47 where debris may be susceptible to collection. It should be understood that the angle of the angled portion 70 relative to the major surface of the inner wall 48 can at least provide sufficient inclination for the top of the debris to fall or roll onto the crumb tray 20. In a preferred form, the angle of the angled portion 70 ranges from about 1.0 degrees to 89.0 degrees.

[0202] Those skilled in the art will appreciate that conventional toaster chassis end panels are typically made of steel (e.g., stainless steel, galvanized, or aluminum), which is good at reflecting heat. High heat reflected from conventional toaster chassis end panels may cause uneven toasting of food. If too much heat is reflected onto the food, the periphery of the food (which tends to be slightly dry) will toast faster than the inner areas of the food, resulting in uneven toasting. Figure 15 As best shown in FIG, the inner wall 48 of the inner chassis assembly 47 includes a pair of end panels 72 adjacent to respective ends of the food guards 24a, 24b. The pair of end panels 72 secure the heating element holder 56 in place within the inner chassis assembly 47, such that the heating element holder 56 is located in the upper portion of the end panels 72. The tabs 58 of the heating element holder 56 engage corresponding holes in the respective end panels 72. In a preferred form, each of the end panels 72 has a ceramic coating to reduce heat reflected onto the surrounding food. An example of a suitable ceramic coating includes Cerasol, which has high temperature resistance, a food-grade rating, and a suitable range of colors. The ceramic coating is preferably a dark color (e.g., black) with a suitable emissivity range for uniform heat radiation. Therefore, it should be understood that the ceramic coating on each of the end panels 72 can at least provide a uniform heating environment (i.e., by evenly distributing heat) to at least maintain an appropriate level of heating performance for the toaster 10. In a preferred form, the non-stick and / or ceramic coating is a dark color with an emissivity of less than approximately 0.75. The surface texture of the coating may also be fine-tuned for darker coating shades to ensure that the emissivity does not drop below 0.75.

[0203] Food guards

[0204] Figure 16 The pair of food guards are shown in an open position with sufficient clearance between each of the opposing food guards 24a and 24b to receive food items. Figure 17The pair of food guards are shown in a closed position whereby each of the opposing food guards 24a and 24b moves in an inward direction toward each other along respective opposing guide slots 74a and 74b. Figure 18 As best shown in FIG. 1 , food guards 24a and 24b have respective upper portions 75a and 75b supported by respective upper guard pins 76a and 76b. For example, referring to FIG. Figure 19 and 20 Each food guard 24a and 24b also includes a respective upwardly extending portion 75c and 75d, whereby the respective upper portions 75a and 75b each extend laterally therefrom so as to extend above the corresponding heating element assembly 28. In the depicted embodiment, guide slots 74a and 74b are horizontally oriented on each end panel 72 and are adapted to retain and guide respective upper guard pins 76a and 76b. It is contemplated that guide slots 74a and 74b may alternatively have a slightly curved / arcuate orientation to accommodate movement of food guards 24a and 24b in the lower pivot mode, as described in further detail below. Movement of upper guard pins 76a and 76b in respective directions 77a and 77b facilitates movement of food guards 24a and 24b between the open and closed positions.

[0205] Figure 19 The directions of movement 78a and 78b of the respective food guards 24a and 24b between the open and closed positions are shown. Figure 19 Also shown are upper portions 75a and 75b of respective food guards 24a and 24b arranged to bend over the top of heating element assembly 28 to limit access of a user's fingers to heating element assembly 28. It should be appreciated that in the closed position, a gap 80 between upper portions 75a and 75b of respective food guards 24a and 24b and lower surface 40 of top cover 18 is within safety limits according to safety compliance requirements. In a preferred form, the width of gap 80 is no greater than approximately 3.5 mm. In the closed position, food guards 24a and 24b also horizontally overlap top cover 18. Figure 19 Also shown is a test probe 82 (which simulates access to hazardous components, such as heating element assembly 28, by a child over 36 months and under 14 years of age), the end diameter of which is larger than gap 80. It should be understood that the size of gap 80 is maintained at least by the arrangement (e.g., length and orientation) of horizontally oriented guide slots 74a and 74b that guide movement of respective upper guide pins 76a and 76b. It should also be understood that each of food guards 24a and 24b is spaced apart from heating element assembly 28 to form a gap or void 81, thereby reducing the likelihood of a user's fingers contacting heating element assembly 28.

[0206] Figure 20 and 21 The food guards 24a, 24b are shown individually. It should be understood that the food guards 24a, 24b are formed from a fine-gauge wire mesh having a mesh gap 84 (e.g., the space between horizontally oriented wires or vertically oriented wires) of no more than approximately 12.1 mm to prevent access by a user's fingers. In a preferred form, the space between the horizontally oriented wires or vertically oriented wires is no more than approximately 5.3 mm. It should be understood that the end diameter of the test probe 82 described above is larger than the mesh gap 84. It should be understood that the fine-gauge wire forming the mesh of the food guards 24a, 24b has sufficient rigidity to resist deformation when force is applied to the food guards 24a, 24b, such as by a user's finger. It should also be understood that using fine-gauge wire to form the food guards 24a, 24b can at least distribute the thermal mass of the food guards 24a, 24b and allow heat to be evenly distributed to the food.

[0207] like Figure 22 and 23 As best shown in FIG, it will be appreciated that opposing guide slots 74a and 74b are located above respective toasting zones 25a and 25b to restrict the amount of airflow that travels through food product 86. As discussed above, airflow through toasting zones 24a and 25b is undesirable because it affects toasting performance by altering heat transfer to food product 86, which may result in uneven or inadequate toasting.

[0208] Figure 24An embodiment is shown in which food guards 24a and 24b are configured to move in one of two modes: a lower pivot mode 88 or a horizontal shift mode 90. Movement of food guards 24a and 24b is caused by manual or automatic actuation of food holders 26a and 26b between a first position and a second position. The mechanism that allows movement of food guards 24a and 24b will be explained in further detail below (see the 'Food Guard Springs and Earth Spring' section). In both modes 88 and 90, food guards 24a and 24b are adapted to center food 86 in a vertical orientation within toasting zones 25a and 25b. In the lower pivot mode 88, the upper portions 75a and 75b of the respective opposing food guards 24a and 24b move toward and away from each other in respective pivot directions 92a and 92b, whereby the pivot points of the food guards 24a and 24b are located at the respective lower guard pins 94a and 94b. It should be understood, therefore, that in this lower pivot mode 88, the food guards 24a and 24b pivot between an open position and a closed position, whereby in the closed position, the food guards 24a and 24b contact an upper region of the food product 86 such that the food product 86 is held and / or aligned in the center of the toasting area 25a. In the horizontal shift mode 90, the food guards 24a and 24b move toward and away from each other in respective horizontal directions 96a and 96b. Thus, in this horizontal displacement mode 90, food guards 24a and 24b are horizontally displaced between an open position and a closed position, whereby in the closed position, a vertical surface of each food guard 24a and 24b contacts food product 86 and food product 86 is centered in a vertical orientation within toasting area 25b. In this horizontal displacement mode 90, the vertical surface of each food guard 24a and 24b is also substantially parallel to the vertical surface of inner wall 48. In this horizontal displacement mode 90, food guards 24a and 24b have respective lower portions 98a and 98b supported by respective lower guard pins 94a and 94b. In this horizontal displacement mode 90, lower guard pins 94a and 94b are positioned within respective horizontal guide slots 99a and 99b in each end panel 72.

[0209] like Figure 25As best shown in FIG, two component card brackets 56 at the center of the inner chassis assembly 47 form a divider 100 between the toasting zones 25a and 25b. Thus, the divider 100 acts as a barrier to reduce or prevent airflow from traveling between the toasting zones 25a and 25b, thereby limiting the amount of airflow through the toasting zones 25a and 25b. In embodiments where only one of the toasting zones 25a or 25b is used (e.g., toasting a single slice of bread at a time), the divider 100 can at least maintain an appropriate level of toasting by reducing or preventing airflow from traveling through the food product 86, which would otherwise result in uneven toasting, undertoasting, or overtoasting. See FIG. Figure 19B The curved portion 38 of the upper surface 36 of the top cover 18 is formed as a compound curve whose boundaries are defined by a height H1 ranging from 5 mm to 15 mm and a width W1 ranging from 7 mm to 18 mm. In a preferred form, the height H1 is approximately 9.9 mm and the width W1 is approximately 12.9 mm, so as to define a compound curve with a radius of curvature R1 ranging from approximately 20 mm to 35 mm. In a preferred form, the height H2 from the uppermost area of the curved portion 38 to the upper surface 36 of the top cover is approximately 5 mm.

[0210] In a preferred form, food guards 24a and 24b have a ceramic coating to reduce the amount of heat reflected onto food 86 and to reduce the amount of shadows or grill marks 102 on food 86 (e.g., as shown in FIG. Figure 26 ). Examples of suitable ceramic coatings include Cerasol, which has high temperature resistance, a food grade rating, and a suitable range of colors. It will be appreciated that the ceramic coating on food guards 24a and 24b can also be used to disperse heat reflected onto food 86 to provide uniform toasting. The ceramic coating is preferably a dark color (e.g., black) that has a suitable range of emissivity to achieve uniform heat radiation. Thus, it will be appreciated that the ceramic coating on food guards 24a and 24b can at least provide a uniform heating environment (i.e., by evenly distributing heat) to at least maintain an appropriate level of heating performance for toaster 10. In a preferred form, the non-stick and / or ceramic coating is a dark color with an emissivity of less than about 0.75. The surface texture of the coating can also be fine-tuned based on the shade of the dark coating to ensure that the emissivity does not drop below 0.75.

[0211] Food rack

[0212] Figures 27 to 30The interaction between the inner chassis assembly 47 and the food tray assembly 106 of the toaster 10 is shown. The inner chassis assembly 47 is located in the interior 22 of the housing 12 and includes an inner wall 48 having an end panel 72 as described above. Vertically oriented guide slots 66a, 66b are located on the end panel 72. The food tray assembly 106 includes a pair of food trays 26a and 26b for supporting food 86 in the respective toasting zones 25a and 25b. The food tray assembly 106 further includes a food tray bracket 107 to hold the food trays 26a and 26b in place.

[0213] like Figure 28 As best shown in FIG, the food holders 26a, 26b include respective support portions 108a, 108b and respective arm portions 110a, 110b. Each support portion 108a, 108b has a generally zigzag profile extending in a first direction 109 defined by a first axis 112a, 112b, and the respective arm portion 110a, 110b has a generally linear profile extending in a second direction 111 along a second axis 114a, 114b, the second axis being perpendicular to the respective first axis 112a, 112b. It should be understood that in the depicted embodiment, the zigzag profile of each support portion 108a, 108b extends in a third direction 113 along a third axis 115a, 115b.

[0214] exist Figure 27 and 28 , the food holders 26a, 26b are in their assembled orientation, whereby the support portions 108a, 108b are oriented in a vertical direction to facilitate insertion of the food holders 26a, 26b into their respective vertically oriented guide slots 66a, 66b on the end panel 72 during assembly. The food holders 26a, 26b are inserted into the respective guide slots 66a, 66b along direction 117. In this assembled orientation, the arm portions 110a, 110b are oppositely oriented in a horizontal direction and disengaged from the respective retaining members 120a, 120b on the food holder support 107. Figure 29107. The food holders 26a, 26b are in their operative orientation, whereby the food holders 26a, 26b are rotated from their assembled orientation in a clockwise direction 118 (or an opposite counterclockwise direction, not shown) about the first axes 112a, 112b such that the support portions 108a, 108b are oriented in a horizontal orientation. The food holders 26a, 26b are rotated in direction 118 until the arm portions 110a, 110b are oriented in a vertical orientation so as to align with the corresponding vertically oriented retaining members 120a, 120b on the plate 107. The food holders 26a, 26b are then moved further in direction 117 toward the end panel 72 until the corresponding arm portions 110a, 110b engage the corresponding retaining members 120a, 120b. After the arm portions 110a, 110b are engaged with the respective retaining members 120a, 120b, the food trays 26a, 26b are secured to the food tray bracket 107 in the operative orientation. It will be appreciated that the arrangement of the food tray assembly 106, and specifically the rotation of the food trays 26a and 26b between the assembly orientation and the operative orientation, can at least reduce or avoid the need for additional holes in the interior chassis assembly 47 for assembling the toaster 10, thereby reducing or avoiding airflow through the toasting areas 25a, 25b.

[0215] In other embodiments (not shown), it is contemplated that the generally linear profiles of the arm portions 110a, 110b of the respective food holders 26a, 26b may alternatively extend in direction 113 along the third axis 115a, 115b. Thus, in such an arrangement, the zigzag profiles of the support portions 108a, 108b and the linear profiles of the respective arm portions 111a, 110b are parallel and coplanar. In such an arrangement, the retaining members 120a, 120b are horizontally oriented to align with the respective arm portions 110a, 110b. Alternatively, the diameters of the arm portions 110a, 110b may be greater than the diameters of the respective support portions 108a, 108b to secure the food holders 26a, 26b to the food holder support 107 (e.g., by means of tolerance clips disposed on the food holder support 107, etc.). It is also contemplated that the generally linear profiles of the arm portions 110a, 110b may alternatively extend in any direction other than the second direction 111 or the third direction 113, and the respective retaining members 120a, 120b be reconfigured accordingly to facilitate engagement of the arm portions 110a, 1110b.

[0216] Figure 30The alignment and attachment of plate 122 to food carrier bracket 107 is shown after assembly of food carriers 26a and 26b. It should be understood that plate 122 further secures food carriers 26a and 26b to food carrier bracket 107. Motor arm retaining feature 123 on food carrier bracket 107 is adapted to receive the arm of an associated motor that drives movement of food carriers 26a and 26b.

[0217] Return to Figure 27 , it will be appreciated that food carrier support 107 is movable in a vertical direction along guide rails 124a and 124b to enable food carriers 26a, 26b to be moved from a first position adjacent upper portion 14 of housing 12 (corresponding to upper portion 125a of inner chassis assembly 47) to accommodate food, and from a second position adjacent lower portion 16 of housing 12 (corresponding to lower portion 125b of inner chassis assembly 47) to toast food. As discussed above, movement of food carrier support 107 (and associated food carriers 26a, 26b) between the first and second positions can be manually actuated (e.g., by a user pushing a lever downward) or automatically actuated (e.g., by detecting the presence of food and / or by actuating an electronic / electrical button, thereby activating an associated motor-driven lift function).

[0218] Food guard spring and ground spring

[0219] like Figures 31 to 33 As best shown in FIG, toaster 10 includes a pair of food guard springs 126a and 126b coupled to upper guard pins 76a, 76b supporting food guards 24a, 24b. Food guard springs 126a, 126b include respective tapered rings 128a, 128b for coupling to respective upper guard pins 76a, 76b. Food guard springs 126a, 126b are also coupled to inner chassis assembly 47 via retaining tabs 130. Thus, food guards 24a, 24b are provided with a fixed ground connection through the connection from food guards 24a, 24b to upper guard pins 76a, 76b to food guard springs 126a, 126b, and through the connection to inner chassis assembly 47.

[0220] It should be understood that the food guard springs 126a, 126b facilitate movement of the food guards 24a, 24b between the open and closed positions. The food guard springs 126a, 126b are biased in the open position (wherein there is sufficient clearance or space between each of the opposing food guards 24a and 24b to receive food). Upon manual or automatic actuation of the food holders 26a, 26b from the first position (adjacent the upper portion 14 of the housing 12) and the second position (adjacent the lower portion 16 of the housing 12), the food holders 26a, 26b contact the respective cross portions 127a, 127b of the respective food guard springs 126a, 126b to force the cross portions 127a, 127b downward, thereby pulling the upper guard pins 76a, 76b toward each other along the respective guide slots 74a, 74b. This results in corresponding movement of the food guards 24a, 24b toward each other into the closed position, and the toasting operation begins. Once the toasting operation is complete, the food guard springs 126a, 126b return to their open position to allow removal of the food item.

[0221] Crumb tray

[0222] like Figure 34 As best shown in FIG, a removable crumb tray 20 located at the lower portion 16 of the housing 12 includes an upper surface 131 that faces the toasting zones 25a, 25b. The upper surface 131 includes an angled portion 132 to reflect heat from the heating element assembly 28 into the toasting zones 25a and 25b (e.g., in directions 134 and 136). In a preferred form, the upper surface 131 of the crumb tray 20 (including the angled portion 132) is formed of a reflective material. The arrangement of the angled portion 132 as part of the crumb tray 20 can at least reduce or avoid the need for a separate reflective panel at the bottom of the toaster. In conventional toasters, these separate reflective panels are generally horizontally oriented and therefore tend to collect and retain debris, thereby reducing reflective ability as debris accumulates and covers the surface of the reflective panel. The arrangement of the angled portion 132 as part of the removable crumb tray 20 can at least provide an efficient way to remove collected crumbs from the toaster 10 while maintaining the ability to reflect heat back into the toasting zones 25a and 25b.

[0223] In a preferred form, the upper surface 131 of the removable crumb tray 20 has a ceramic coating to reduce the amount of heat reflected onto the periphery of the food 86. An example of a suitable ceramic coating includes Cerasol, which has high temperature resistance, a food grade rating, and a suitable range of colors. The ceramic coating is preferably a dark color (e.g., black) with a suitable emissivity range for uniform heat radiation. Therefore, it should be understood that the ceramic coating on the upper surface 131 can at least provide a uniform heating environment (i.e., by evenly distributing heat) to at least maintain an appropriate level of heating performance of the toaster 10.

[0224] like Figure 35 As best shown in FIG, the toaster 10 includes a base member 138 disposed at the lower (i.e., base) portion 16 of the housing 12. The base member 138 is adapted to support the toaster 10 (e.g., on a kitchen countertop). The toaster 10 further includes an intermediate member 140 positioned within the interior 22 of the housing 12, the intermediate member being positioned between the base member 138 and the inner chassis assembly 47. The intermediate member 140 includes a plurality of protrusions 142. The removable crumb tray 20 engages the base member 138 and the intermediate member 140 via interlocking profiles that, in combination with the protrusions 142, create a tortuous flow path 144 to reduce the amount of airflow that travels through the toaster 10 and into the toasting zones 25a, 25b. It should be appreciated that the engagement of the removable crumb tray 20 and the base member 138 also provides a seal between the removable crumb tray 20 and the inner chassis assembly 47 to reduce the amount of airflow traveling into the toasting zones 25a, 25b.

[0225] Figure 36 and 38 The removable crumb tray 20 is shown engaged with the base member 138, and Figure 37 and 39 The removable crumb tray 20 is shown disengaged from the base member 138. Figure 38 As best shown in FIG, when the removable crumb tray 20 is inserted in direction 146 and engaged with the base member 138, the removable crumb tray 20 abuts an actuating member 148 in the base member 138 to push the actuating member 148 in direction 150. This movement causes the actuating member 148 to move in direction 154 into electrical contact with a switch member 152 in the base member 138. The switch member 152 is electrically associated with the heating element assembly 28 of the toaster 10. Thus, the electrical contact between the actuating member 148 and the switch member 152 allows the heating element assembly 28 to be energized. Figure 39As best shown in FIG, when the removable crumb tray 20 is removed and disengaged from the base member 138 in direction 156, the actuating member 148 (which is biased in direction 158) moves into the gap 160 vacated by the crumb tray 20. The movement of the actuating member 148 in direction 158 removes the actuating member 148 from electrical contact with the switch member 152, thereby de-energizing the heating element assembly 28. The arrangement and function of the actuating member 148 and the switch member 152 can at least ensure that the heating element assembly 28 is de-energized when the crumb tray 20 is removed from the base member 138, so that the heating element assembly 28 can be at least electrically safe to the touch if or when the heating element assembly 28 is exposed to a user.

[0226] It is contemplated that the base member 138 may also include protrusions (not shown) to limit the movement of the removable crumb tray 20 if the removable crumb tray 20 is inserted at an angle other than in the direction 146. This arrangement may at least prevent the actuation member 148 from making electrical contact with the switch member 152 if the removable crumb tray 20 is inserted at an incorrect angle or orientation, thereby preventing the heating element assembly 28 from being exposed to the user.

[0227] Figures 40 to 43 The crumb tray 20 is shown as an exterior view of the removable crumb tray, which includes a recessed portion 162 to allow a user to grasp the crumb tray 20 and pull it away from the base member 138 to remove the crumb tray 20 from the base member 138. The crumb tray 20 further includes an upper surface 131 for collecting crumbs from the food 86 and an angled portion 132 for reflecting heat back into the toasting zones 25a and 25b, as described above. The crumb tray also includes a lower surface 164 opposite the upper surface 131. Figure 41 and 43 As best shown in FIG, the lower surface 164 of the crumb tray 20 includes a raised portion 166 having a protrusion 168, and the base member 138 includes a corresponding recess 170 adapted to receive the protrusion 168. The arrangement of the raised portion 166, the protrusion 168, and the corresponding recess 170 can at least ensure that the crumb tray 20 is in the correct orientation when inserted into the base member 138. Combined with the arrangement and function of the actuation member 148 and the switch member 152 as described above, this arrangement can at least prevent the heating element assembly 28 from being energized if the crumb tray 20 is incorrectly inserted.

[0228] Heating element assembly

[0229] Figure 44An embodiment of a heating element assembly 28 is shown, comprising a first heating element portion 172 and a second heating element portion 174. In a preferred embodiment, each of the first and second heating element portions 172, 174 is formed from mica. The heating element assembly 28 further comprises a central cross section 176 extending along a longitudinal axis 178 between the first and second heating element portions 172, 174. The first and second heating element portions 172, 174 each comprise a series of transverse element lines 180. In this embodiment, the series of transverse element lines 180 are oriented at a series of angles in the general direction of the transverse axis 182. This arrangement of the central cross section 176 and the angled transverse element lines 180 creates a concentration of element lines at the center of the heating element assembly 28, thereby creating an area with greater heat output at the center of the heating element assembly 28. Since food tends to have higher moisture levels in the center than at the periphery, it is understood that the periphery of the food tends to cook faster because less time is required to heat and evaporate moisture at the periphery than in the center. It will therefore be appreciated that the above-described arrangement of central cross section 176 and angled transverse element lines 180 can at least allow heat from heating element assembly 28 to be concentrated in a central region of a food product. It is contemplated that central cross section 176 and transverse element lines 180 can be positioned at any desired location on heating element assembly 28, depending on the type of food product, to accordingly concentrate the heat output from heating element assembly 28.

[0230] Figure 45 Another embodiment of a heating element assembly 28 is shown, comprising a series of transverse element wires 184 having a generally curved configuration. In this embodiment, the series of transverse element wires 184 are held in the curved configuration by a pair of spaced-apart, longitudinally extending support brackets 186. This arrangement of curved transverse element wires 184 can at least allow heat from the heating element assembly 28 to be concentrated in the central region of the food product. Additionally, depending on the type of food product, the transverse element wires 184 can be positioned at any desired location on the heating element assembly 28 to accordingly concentrate the heat output from the heating element assembly 28.

[0231] In such Figures 46 to 49 In the illustrated embodiment, the heating element assembly 28 also includes a pair of openings 188 that are generally aligned with the openings 50 in the inner wall 48, which allow the sensor 52 to detect the food product. It is contemplated that the heating element assembly 28 may alternatively include a single opening or more than two openings. Figure 46As shown, there is a possibility that the pair of element wires 190 may be twisted and offset toward the opening 188, so that the signal from the sensor 52 may be interrupted. This may affect the performance of the sensor 52. Figure 47 As shown, a pair of main brackets 192 located at the periphery of the pair of openings 188 can be introduced to position and guide the element line 190 away from the openings 188. Figure 48 and 49 As best shown in FIG, a pair of secondary brackets 194 can be used to secure the pair of primary brackets 192 to the heating element 28. Each of the secondary brackets 194 includes a plurality of tabs 196 that extend through the associated opening 188 and fold over the opposing surface heating element 28 to secure the associated primary bracket 192 to the heating element 28.

[0232] Bun Warmer

[0233] like Figure 50 As best shown in FIG, the toaster 10 has an associated food warmer 200 that is adapted to rest on the upper surface 36 of the top cover 18. The food warmer 200 includes a flat portion 202 for receiving food to be heated (e.g., bread, bagels, buns, and desserts such as muffins and croissants) and a pair of upwardly extending portions 204 for holding the food in place. The food warmer 200 also includes a pair of handles 206 that are insulated to allow a user to safely operate the food warmer 200. It should be understood that the food warmer 200 is formed from a fine-gauge wire mesh. It should also be understood that using a fine-gauge wire to form the food warmer 200 can at least disperse the thermal mass of the food warmer 200 and allow heat to be evenly distributed to the food.

[0234] Line compartment

[0235] Figure 51 An interior cavity 208 is shown that is part of the interior 22 of the housing 12 and is adapted to receive a cord compartment 210. It should be understood that the cord compartment 210 is adapted to receive a power cord 212 (e.g., a power cord 212) of the toaster 10 to be connected to the main power switch. Figure 53 28 ). The interior of the wire compartment 210 that houses the wires 212 needs to be maintained within a specific temperature range to comply with safety requirements for power cords. Therefore, the wire compartment in conventional toasters is typically located very close to the toaster chassis where there is a lot of radiant heat from the heating element. It is contemplated that a heat reflector panel 214 can be introduced at a location between the wire compartment 210 and the inner chassis assembly 47 to reflect heat from the heating element assembly 28 away from the wire compartment 210 (e.g., at a location such as Figure 51The arrangement of the heat reflector panels 214 may thus at least ensure that the interior of the wire compartment 210 can be maintained within a safe temperature range.

[0236] It should be understood that the cord compartment 210 is a vertically extending compartment that utilizes the limited space available within the interior 22 of the housing 12 to store the power cord 212. Figure 53 As best shown in FIG, base member 138 also includes a cavity 218 that is connected to cord compartment 210 and through which extends power cord 212. Cavity 218 is adapted to allow a user to push and pull power cord 212 into and out of toaster 10 (e.g., to modify the extended length of power cord 212) without having to pick up toaster 10.

[0237] like Figure 54 As best shown in FIG. 2 , it will be appreciated that a printed circuit board (PCB) 220 supporting the electronic components of the toaster 10 is mounted in close association with the wire compartment 210 to take advantage of the limited space available within the interior 22 of the housing 12. It will also be appreciated that by mounting the PCB 220 in close association with the wire compartment 210, the wire compartment 210 can act as a heat sink to draw heat away from the PCB 220, thereby providing protection for the PCB 220 from dissipating heat from the heating element 28.

[0238] Sensor subassembly

[0239] Figure 55 A sensor subassembly 230 is shown that includes a pair of sensors 52 for detecting food products. The sensor subassembly 230 is mounted to the inner wall 48 of the inner chassis assembly 47 and includes a sensor subassembly bracket 232 and sensor subassembly components 234, 236, 238, 240, 242, 244, 246, and 248 mounted to the sensor subassembly bracket 232. It is contemplated that the simple construction and assembly of the sensor subassembly bracket 232 and components 234, 236, 238, 240, 242, 244, 246, and 248 can at least allow for mass production of the sensor subassembly 230.

[0240] Figure 55A An alternative arrangement is shown in which a first sensor subassembly 230a is mounted to the first inner wall 48a and a second sensor subassembly 230b is mounted to the second inner wall 48b. The first sensor subassembly 230a includes a sensor subassembly bracket 232 and a sensor subassembly component 234, while the second sensor subassembly 230b includes one or more of the sensor subassembly components 236, 238, 240, 242, 244, 246, and 248 described above.

[0241] like Figure 56As shown, toaster 10 includes a high-voltage cable 260 and a low-voltage cable 262 electrically connected to the electrical components of PCT 220. Those skilled in the art will appreciate that, for safety reasons, high-voltage and low-voltage cables should generally not be located in the same area within a toaster. Furthermore, the presence of high-voltage cables near sensors can cause signal noise from the high-voltage cables to interfere with sensor data. Sensor subassembly bracket 232 includes routing portions 264 and 266 to space high-voltage cable 260 away from low-voltage cable 262. This can at least reduce or eliminate the possibility of signal noise from high-voltage cable 260 interfering with sensor data.

[0242] Figure 56A An alternative embodiment is shown having the interior wall 48 configuration described above including a dog-bone structure 49 with the sensor subassembly bracket 232 and sensor subassembly 234 mounted thereon.

[0243] LED assembly

[0244] Figure 57 An exploded view of the LED assembly 30 is shown, the assembly including first and second LED brackets 270, 272 and a set of LEDs 274. The first and second LED brackets 270, 272 are mounted to the housing 12 and are adapted to hold the set of LEDs 274 in place. It should be understood that the first and second LED brackets 270, 272 include support features 276 that contact the housing 12 and allow potential loads to be distributed across the first and second LED brackets 270, 272. The arrangement of the LED assembly 30 can also enhance the structural integrity of at least the upper portion 14 of the housing 12 by providing additional structural support to the housing 12.

[0245] like Figure 58 As best shown in FIG, the LED assembly 30 includes a heat shield 278 positioned between the LED assembly 30 and the heating element assembly 28. The heat shield 278 is formed of an insulating or reflective material and is adapted to reflect radiant heat from the heating element assembly 28 away from the LED assembly 30. Thus, the heat shield 278 can at least ensure that the electronics of the LED assembly 30 are maintained within a safe temperature range. It should be understood that the support features 276 of the first and second LED brackets 270, 272 can similarly be formed of an insulating or reflective material and also adapted to reflect radiant heat from the heating element assembly 28 away from the LED assembly 30.

[0246] As discussed above, the gap or vent 44 located at the upper portion 14 between the top cover 18 of the housing 12 and the housing 12 allows light emitted from the LED assembly 30 to shine out of the housing 12. Figure 59 , the LED assembly 30 is located directly in the air flow path 280 of the toaster 10. The air flow path 280 travels from a second gap or vent 282 located at the lower portion 16 of the housing 12, through the interior cavity 208, and exits through the gap or vent 44. It should be understood that the configuration of the LED assembly 30 (e.g., the openings 284 in the first and second LED brackets 270, 272) can allow at least sufficient clearance to maintain the air flow path 280 in and out of the toaster 10.

[0247] exist Figures 60 to 74 , another embodiment of a toaster 1001 is schematically depicted. It should be understood that the components and functions of toaster 1001 operate in a similar manner to the components and functions of toaster 10 described above. The components and functions of toaster 10 and toaster 1001 may also be interchanged, depending on specific requirements. The electrical functions of toaster 1001 will now be described.

[0248] Figure 60 A cross-sectional view of a toaster 1001 is shown having a first toasting slot 1003A and a second toasting slot 1003B. The toasting slots are arranged to receive food items for toasting. The food items are placed on toasting trays (1005A and 1005B), which are shown in a lowered position and lowered into the toasting slots. An optical sensor 1007, positioned on an optical plate 1009, is positioned to transmit an optical signal into the toasting slots through a side hole 1011 in the front wall of the toasting slots and detect (i.e., sense) a reflected optical signal that is reflected from the food item when placed in the toasting slots or reflects off the facing wall of the toasting slots. It should be understood that more than one sensor may be present in more than one toasting slot of the toaster.

[0249] Located within the toasting slots are heating elements 1013. For example, there may be two opposing heating elements in the first slot 1003A and two opposing heating elements in the second slot 1003B. However, it should be understood that one or more heating elements may be present in one or more slots of the toaster.

[0250] Figure 61 Shown without outer covering Figure 60 On one end of the toaster is located a control board 1015 which contains a processor (or controller) for controlling various operations of the toaster.

[0251] Figure 62 Two different embodiments of toasters (1001A and 1001B) are shown, each having one or two user interfaces 1017 connected to a processor for controlling the operation of the toaster. The first toaster 1001A has two toasting slots, while the second toaster 1001B has four toasting slots. The user interface can be used to set a "shade" of desired toasting level between light and dark. Further, the user interface can set the type of food item to be toasted, such as snacks, crumpets, or any other type of food item, including the type of bread, such as sourdough bread, fruit bread, etc.

[0252] Figure 63 A circuit block diagram according to an embodiment of the present disclosure is shown.

[0253] A controller 2001, in the form of a microprocessor or microcontroller, is connected to a power supply system 2003, which regulates the mains electricity to which the toaster is connected. Power for the elements 1013 is fed from a controller board (not shown), which supplies power for switching the element power feeds. The power supply 2003 provides power to the optical sensor 1007, as well as the user interface 1017 and the carriage motor 2007. The controller communicates with each of the user interface 1017, the heating element 1013, the sensor 1007, the carriage motor 2007, and the carriage position sensor 2009 to send control signals and receive feedback signals.

[0254] The controller may operate using algorithms stored in internal memory, or may access algorithms from external memory. Alternatively, the controller may operate based on hardwired instructions, such as using an FPGA (Field Programmable Gate Array).

[0255] Figure 64 A cross-sectional view of a toaster according to an embodiment of the present disclosure is shown.

[0256] A food item 3001 has been placed in the first toasting slot 1003A. The optical sensor 1007 transmits 3003 an optical signal into the toasting slot. This optical signal is then reflected 3004 off the food item back to the sensor 1007. The sensor 1007 transmits the reflected optical signal to the processor 2001 (see Figure 2), wherein the processor determines the type of food item being toasted. In this example, when the heating element is active, the processor determines an active shadow profile based on the reflected optical signal for the food item, though it should be understood that the active shadow profile can also be obtained before and / or after the heating element is active, i.e., when the heating element is inactive. The processor then compares the active shadow profile determined based on the reflected optical signal with at least one stored shadow profile. Each stored shadow profile can be associated with a food item type, such as a food item type or a bread type, e.g., sourdough bread, fruit bread, white bread, whole grain bread, brown bread, crumpets, etc. The processor 2001 can then determine whether the active shadow profile and the stored shadow profile are within a defined threshold of each other to obtain a match. If a match is obtained, the processor 2001 can then control the heating profile of the heating element 1013 based on the food item type that has been detected due to the active shadow profile.

[0257] Figure 65 Shown are shading variation curves for different food item types according to an embodiment of the present disclosure.

[0258] exist Figure 65 In curve 1, the curve of the shadow change (ie, the reflected optical signal) with respect to time is shown for a standard reference food item type (such as white bread) when the heating element 1013 has been turned on. Figure 65 In Curve 2, the shadow change (i.e., the reflected optical signal) versus time curve is shown for different food item types (e.g., fruit bread) when the heating element 1013 is turned on. It can be seen that different shadow change values are apparent when comparing time point A of Curve 1 with time point A of Curve 2.

[0259] like Figure 65 As seen, the processor 2001 can compare a first shadow value of a first food item type in an active shadow profile at a defined time point (e.g., time point A) with a second shadow value of a second food item type in a stored shadow profile at the same defined time point (time point A) to determine whether the first shadow value and the second shadow value are within a defined threshold, indicating that the first food item type and the second food item type are the same food item type. For example, if the values at the defined time point are within a defined percentage threshold or a defined value, the processor 2001 determines that the food item type being toasted is the food item type associated with the stored shadow profile.

[0260] When the processor 2001 determines that the active shadow profile and the stored shadow profile are within a defined threshold of each other, the processor may adjust one or both of the time to toast the food item and the power applied to the heating element 1013 to better toast the food item.

[0261] Figure 66 A process flow diagram according to an embodiment of the present disclosure is shown.

[0262] The process begins, and at step S4001, the process transmits an optical signal into a toasting slot of a toaster. At step S4003, when a food item is placed in the toasting slot, the process senses the reflected optical signal reflected off the food item. In this example, at step S4005, when the toaster's heating element is active, the process determines an active shadow profile based on the reflected optical signal from the food item. Alternatively, the heating element can be inactive when this step is performed. At step S4007, the process compares the active shadow profile with at least one stored shadow profile associated with at least one food item type to determine whether the active shadow profile and the stored shadow profile are within a defined threshold of each other. At step S4009, the process determines whether the active shadow profile and the stored shadow profile are within a defined threshold of each other. If so, at step S4011, the process controls the heating profile of the heating element 1013 based on the food item type, or if not, returns to step S4001.

[0263] Further, the process may compare a first shadow value in the active shadow profile at a defined point in time with a second shadow value in a stored shadow profile at the same defined point in time to determine whether the first shadow value and the second shadow value are within a defined threshold.

[0264] Further, the process may adjust one or both of the time to toast the food product and the power applied to the heating element based on determining that the active shadow profile and the stored shadow profile are within a defined threshold of each other.

[0265] So, for example, by sensing the rate of change of the shadow on the bread surface, the system can detect types of bread with high moisture content and adjust the heating conditions / toasting settings accordingly. This detection method can also be used to identify unique bread types, such as bread with high sugar content (raisins), where toasting has a faster rate of change.

[0266] The following describes embodiments of a toaster and associated toaster control method for detecting optimal positioning of a toasted food item in a toasting slot of a toaster.

[0267] Figure 67 A cross-sectional view of a toaster according to an embodiment of the present disclosure is shown.

[0268] The food item 3001 has been placed in the first toasting slot 1003A on the toasting tray 1005A. Figure 67The movement of food item 3001 as it is lowered into first toasting slot 1003A is indicated. The food item is automatically lowered using a toaster lift bracket mechanism, which is described in more detail below. Optical sensor 1007 transmits an optical signal 3003 into the toasting slot against the food item. This optical signal is then reflected off the food item and back to sensor 1007. Sensor 1007 transmits the reflected optical signal to processor 2001.

[0269] The processor 2001 then determines an optical profile of the food item based on the reflected optical signal along an area of the food item as the food item 3001 moves within the slot. For example, the processor can determine the optical profile as the lift carriage mechanism lowers the food item into the slot, or as the lift carriage mechanism raises the food item from the bottom of the slot or at any other desired location.

[0270] The processor 2001 then determines an optimal sensing position along an area of the food item corresponding to the optimal sensing region based on the determined optical profile. For example, the optical profile may indicate the location of holes in the bread due to an increase or decrease in reflectivity of the optical signal, or the location of seeds in the bread. When monitoring the toasting of bread, these areas would not be optimal for guiding the optical signal. The optimal sensing position would be the sensing position that generally identifies the surface of the bread to be optimally toasted. Therefore, the processor controls the toasting tray to move it to the toasting position corresponding to the determined optimal sensing position.

[0271] Alternatively, the processor may determine the optimal sensing position by comparing the optical profile to stored profiles associated with at least one optimal sensing area of the food item.

[0272] Figures 68 to 71 A toaster tray lifting mechanism according to an embodiment of the present disclosure is shown.

[0273] like Figure 68 As shown, the toaster tray lift mechanism has a motor 2007 (e.g., a stepper motor) controlled by a processor 2001, which feeds back its position to the processor 2001. The motor positioning can be synchronized with the toasting trays (1005A, 1005B) when they are in the raised position and when the toasting trays are in the lowered position.

[0274] Attached to the motor 2007 is a flexure arm 6003 which moves in an arc (see Figure 68The spindle 6005 at the end of the arm is located in the slot 6007 of the bracket member 6009, which is connected to the top and bottom positioning of the toasting brackets (1005A, 1005B). When the motor 2007 is turned, the curved arm 6003 rotates and causes the spindle 6005 to move in an arc and slide along the slot 6007 in the direction of arrow B, thereby forcing the bracket member 6009 to slide downward in the direction of arrow C along the guide posts (6011A and 6011B).

[0275] Figure 69 The toasting trays (1005A and 1005B) are shown in a lowered position.

[0276] Figure 70 The toasting trays (1005A and 1005B) are shown in FIG. Figure 6A . Also shown are micro switches (7001, 7003) that provide feedback to the controller 2001 of the upper and lower limits based on motor rotation to stop the motor 2007 from rotating to a point where damage would occur. The micro switches can also identify a third position between the upper and lower positions.

[0277] Figure 71 Shows that Figure 70 The images correspond to the lowered positioning of the toasting trays (1005A and 1005B).

[0278] Therefore, the carriage motor 2007 is arranged to control the movement of the toasting tray under the operation of the processor 2001. When the toasting tray moves in the toasting slot, the processor 2001 can determine the tray positioning of the toasting tray based on the operation of the carriage motor, for example, by receiving feedback about the rotational positioning of the stepper motor from the stepper motor. Alternative types of motors can also be used to provide positioning feedback. Other motors can include DC motors, synchronous motors, etc. The processor 2001 can then control the movement of the toasting tray to the tray positioning corresponding to the toasting positioning after determining the optimal sensing position as discussed above.

[0279] It will be appreciated that other positioning feedback devices may be used to provide an indication of the positioning of the toasting tray. For example, the feedback device may include, for example, an optical device, a Hall effect sensor, a magnetic device, and a transducer.

[0280] Figure 72 A process flow diagram according to an embodiment of the present disclosure is shown.

[0281] The process begins, and at step S8001, the process transmits an optical signal into a toasting slot of a toaster. At step S8003, when the toasting tray of the toaster inserts a food item into the toasting slot, the process senses the reflected optical signal associated with the food item. At step S8005, the process determines an optical profile of the food item based on the reflected optical signal along the area of the food item as the food item is inserted. At step S8007, the process determines an optimal sensing position along the area of the food item corresponding to the optimal sensing area based on the determined optical profile. At step S8009, the process moves the toasting tray to a toasting position corresponding to the determined optimal sensing position.

[0282] Further, the process may determine a tray position of the toasting tray based on operation of the tray motor as the toasting tray moves within the toasting slot, and control movement of the toasting tray to a tray position corresponding to the toasting position after determining the optimal sensed position.

[0283] Further, the process may compare the optical profile to a stored profile associated with at least one optimal sensing region.

[0284] Described below are embodiments of a toaster and associated toaster control method for detecting whether a food item to be toasted has been properly placed in a toasting slot of a toaster or in a correct toasting slot of a toaster, and controlling one or more heater elements in the toaster based on the detected food item.

[0285] Figure 73 A cross-sectional view of a toaster according to an embodiment of the present disclosure is shown.

[0286] The food item 3001 has been placed in the toasting slot 1003B on the toasting tray 1005B. The optical sensor 1007 emits an optical signal and senses the reflected signal from the rear wall of the toasting slot 1003A. The reflected signal is transmitted back to the processor 2001.

[0287] The processor 2001 determines whether the food item 3001 has been inserted into the toasting slot 1003A based on the reflected optical signal. In this particular example, the food item 3001 has been placed in the incorrect slot 1003B. The reflected signal from the food item is significantly different from the reflected signal from the back of the slot.

[0288] It should be understood that slot 1003B may also have an optical sensor that can detect that a food item has been placed in the slot 1003B associated with the optical sensor. Subsequently, if the user activates one or more heating elements of a different slot 1003A, the processor can determine this and perform corrective action or output an appropriate signal.

[0289] It will be appreciated that the system would also work in a toaster having a single slot, where an optical signal is used to determine whether a food item has been correctly placed in the slot.

[0290] When the processor 2001 has determined that a food item 3001 has not been inserted into an operating toasting slot, the processor performs one or more defined tasks, which may include, for example, turning off one or more heating elements associated with the toasting slot, raising the toasting tray of the toasting slot, outputting an alarm signal and turning off user controls of the toaster.

[0291] Although this example is described with reference to a toaster having a motorized toasting tray, it should be understood that this example can be applied to a toaster having a manually operated toasting tray.

[0292] Figure 74 A process flow diagram according to an embodiment of the present disclosure is shown.

[0293] The process begins, and at step S1001, the process transmits an optical signal into the toasting slot of the toaster. At step S1003, the process senses the reflected optical signal associated with the toasting slot. At step S1005, the process determines whether the food item 3001 has been inserted into the toasting slot based on the reflected optical signal. At step S1007, the process provides an output based on the determination in step S1005.

[0294] For example, the process can perform one or more defined tasks upon determining that a food item 3001 has not been inserted into a toasting slot, the one or more defined tasks including, for example, turning off one or more heating elements 1013 associated with the toasting slot, raising the toasting tray of the toasting slot, outputting an alarm signal, and turning off a user control of the toaster. Any suitable indication can be provided on the user interface of the toaster.

[0295] Although the invention has been described with reference to a preferred embodiment, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims

1. A toaster, comprising: case; a pair of opposed food guards positioned within the housing and defining a baking cavity for receiving food to be baked; a pair of heating elements positioned within the housing, each heating element positioned on a respective side of the pair of food guards; as well as a top cover forming an upper surface of the housing, the upper surface providing a curved portion having a first surface portion and a second surface portion, the first surface portion and the second surface portion being positioned to provide a slot therebetween for delivering the food product to the cavity, The curved portion has a vertical extension direction and a horizontal extension direction so as to converge downward to the baking cavity. The top cover has a coating having a non-tarnished color, and the non-tarnished color of the top cover coating has an emissivity of at least 0.75 to achieve uniform heat distribution.

2. The toaster according to claim 1, wherein: The curved portion directs crumbs through the slot into the cavity and directly onto the crumb tray of the toaster.

3. The toaster according to claim 2, wherein: The bent portion is formed as a compound curve whose boundary is defined by a height ranging between 10 mm and 20 mm and a width ranging between 30 mm and 45 mm.

4. The toaster according to claim 3, wherein: The height is 15.2 mm and the width is 37.5 mm so as to define a compound curve with a radius of curvature of 24.5 mm.

5. The toaster according to claim 1, wherein The coating of the top cover is non-stick and / or ceramic.

6. The toaster according to claim 5, wherein: The coating of the top cover is black.

7. The toaster according to claim 1, wherein: The top cover coating has a surface texture to provide an emissivity of 0.75 for uniform heat distribution.

8. The toaster according to claim 1, wherein: Each food guard is spaced apart from the corresponding heating element by a gap; and each food guard has an upwardly extending portion and a portion extending laterally from the upwardly extending portion so as to extend over the corresponding heating element, the laterally extending portion of each food guard protruding away from the opposing food guard.

9. The toaster according to claim 1, wherein: The toaster further includes a pair of heating element supports mounted at an upper portion of the housing, each heating element support including a downwardly facing portion adapted to engage and support a corresponding heating element.

10. The toaster according to claim 1, wherein Each food guard is formed of a wire mesh having a mesh gap of less than 5.3 mm.

11. The toaster according to claim 1, wherein: Each food guard has a ceramic coating adapted to evenly distribute heat from the heating element into the baking cavity.

12. The toaster according to claim 11, wherein The food guard coating is a dark, non-tarnish color.

13. The toaster according to claim 12, wherein: The dark, non-tarnished color of the food guard coating has an emissivity of about 0.75 to achieve uniform heat distribution.

14. The toaster according to claim 11, wherein The coating of the food guard has a surface texture to provide an emissivity of about 0.75 for uniform heat distribution.

15. The toaster according to claim 1, wherein The toaster further includes a pair of end panels, each positioned adjacent a respective end of the food guard, the end panels having a ceramic coating adapted to evenly distribute heat from the heating element into a toasting zone.

16. The toaster according to claim 15, wherein The coating of the end panels is a non-tarnishing color.

17. The toaster according to claim 16, wherein: The non-tarnished color has an emissivity of about 0.75 to achieve uniform heat distribution.

18. The toaster according to claim 15, wherein: The coating of the end panels has a surface texture to provide an emissivity of 0.75 for uniform heat distribution.

19. The toaster according to claim 1, wherein The housing includes an inner wall surrounding the baking cavity, the inner wall including an upper portion angled downwardly toward the slot.

20. A toaster comprising: case; a pair of opposed food guards positioned within the housing and defining a baking cavity for receiving food to be baked; a pair of heating elements positioned within the housing, each heating element positioned on a respective side of the pair of food guards; and A top cover is located at an upper portion of the housing and includes a pair of slots, wherein the upper surface further includes a curved portion that curves inwardly and downwardly toward each slot.

21. The toaster of claim 20, wherein: Each curved portion has a vertical extension direction and a horizontal extension direction so as to converge downward to the baking cavity.

22. The toaster of claim 20, wherein: The curved portion directs crumbs through the slot into the cavity and directly onto the crumb tray of the toaster.

23. A toaster, comprising: case; a pair of opposed food guards positioned within the housing and defining a baking cavity for receiving food to be baked; a pair of heating elements positioned within the housing, each heating element positioned on a respective side of the pair of food guards; and a top cover positioned at an upper portion of the housing and including a pair of slots, wherein the top cover includes male features at a lower periphery of the top cover that face generally downward and are adapted to sealingly engage corresponding female features at an upper periphery of the housing.

24. A toaster, comprising: a housing having an outer wall and an inner wall; a baking area, the baking area being located in the housing and being used to receive food to be baked; a pair of heating elements, each heating element located on a respective side of the toasting zone; and a sensor mounted to the inner wall, the inner wall including an opening to allow the sensor to detect food in the toasting zone, the inner wall further including a pair of reflector tabs on opposite sides of the opening, wherein the reflector tabs are arranged at a certain angle to reflect heat generated by the heating element into the toasting zone.

25. A toaster, comprising: case; a baking area, the baking area being located in the housing and being used to receive food to be baked; a pair of heating elements positioned within the housing, each heating element positioned on a respective side of the toasting zone; and A pair of heating element supports are mounted at the upper portion of the housing and supported at the lower portion of the housing, each heating element support including a downwardly facing portion adapted to engage and support a corresponding heating element.

Images