Gas ignition system for a gas cooking appliance

Abstract

A gas ignition system for a gas cooking appliance is provided. The gas ignition system includes an ignition component configured to provide a feedback signal indicative of a temperature of the ignition component. The gas ignition system further includes a gas valve configured to provide gas to the ignition component based at least in part on an enable signal and one or more redundancy signals. The gas ignition system further includes an ignition controller operably coupled to the ignition component and the gas valve. The ignition controller includes an enable circuit configured to provide the enable signal based at least in part on the feedback signal. The ignition controller further includes one or more redundancy circuits configured to provide one or more redundancy signals based at least in part on the feedback signal.

Description

FIELD

[0001] Example aspects of the present disclosure relate generally to gas cooking appliances such as gas ovens, and more particularly, to gas control systems for gas cooking appliances.BACKGROUND

[0002] Gas cooking appliances generally include one or more gas heating elements configured to provide heat to cook food items. Cooking appliances, such as ovens, include heating elements positioned within a cooking chamber of the gas cooking appliance. Further, cooking appliances, such as cooktops, may include heating elements positioned atop the cooking appliance. Cooking appliances that include both an oven and a cooktop are commonly referred to as “ranges.”SUMMARY

[0003] Aspects and advantages of embodiments of the present disclosure will be set forth in part in the following description, or can be learned from the description, or can be learned through practice of the embodiments.

[0004] One example aspect of the present disclosure is directed to a gas ignition system for a gas cooking appliance. The gas ignition system includes an ignition component configured to provide a feedback signal indicative of a temperature of the ignition component. The gas ignition system further includes a gas valve configured to provide gas to the ignition component based at least in part on an enable signal and one or more redundancy signals. The gas ignition system further includes an ignition controller operably coupled to the ignition component and the gas valve. The ignition controller includes an enable circuit configured to provide the enable signal based at least in part on the feedback signal. The ignition controller further includes one or more redundancy circuits configured to provide one or more redundancy signals based at least in part on the feedback signal.

[0005] Another example aspect of the present disclosure is directed to a method for providing gas to an ignition component of a gas cooking appliance. The method includes receiving, from the ignition component, a feedback signal indicative of a temperature of the ignition component. The method further includes determining, by an enable circuit of an ignition controller, an enable signal based at least in part on the feedback signal. The method further includes determining, by one or more redundancy circuits of the ignition controller, one or more redundancy signals based at least in part on the feedback signal. The method further includes providing gas to the ignition component based at least in part on the enable signal and the one or more redundancy signals.

[0006] Another example aspect of the present disclosure is directed to a gas cooking appliance. The gas cooking appliance includes one or more ignition components configured to provide one or more feedback signals indicative of a temperature of the one or more ignition components. The gas cooking appliance further includes one or more gas valves configured to provide gas to the one or more ignition components based at least in part on an enable signal and one or more redundancy signals. The gas cooking appliance further includes an ignition controller operably coupled to the one or more ignition components and the one or more gas valves. The ignition controller includes an enable circuit configured to provide the enable signal based at least in part on a feedback signal of the one or more feedback signals. The ignition controller further includes one or more redundancy circuits configured to provide the one or more redundancy signals based at least in part on the feedback signal of the one or more feedback signals.

[0007] These and other features, aspects and advantages of various embodiments will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the description, serve to explain the related principles.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Detailed discussion of embodiments directed to one of ordinary skill in the art are set forth in the specification, which makes reference to the appended figures, in which:

[0009] FIG. 1 illustrates a front perspective view of a gas cooking appliance according to example embodiments of the present subject matter;

[0010] FIG. 2 illustrates a side cross-sectional view of the example gas cooking appliance of FIG. 1 according to example embodiments of the present subject matter;

[0011] FIG. 3 depicts an example circuit schematic of a gas ignition system according to example embodiments of the present disclosure;

[0012] FIG. 4 depicts an example circuit schematic of an ignition controller according to example embodiments of the present disclosure; and

[0013] FIG. 5 provides a flowchart of an example method for providing gas to an ignition component of a gas cooking appliance according to example embodiments of the present disclosure.

[0014] Repeat use of reference characters in the present specification and drawings is intended to represent the same and / or analogous features or elements of the present invention.DETAILED DESCRIPTION

[0015] Reference now will be made in detail to embodiments, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the embodiments, not limitation of the present disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments without departing from the scope or spirit of the present disclosure. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that aspects of the present disclosure cover such modifications and variations.

[0016] Gas cooking appliances may generally include one or more gas heating elements configured to provide heat to cook food items. The heating element may include an ignition component configured to ignite gas supplied, for example, by a gas valve. If the gas is provided and the ignition component fails to ignite, a potentially hazardous situation is created as the gas may continue to be provided. Ensuring that an ignition component will ignite (e.g., provide proof that an ignition component is capable of igniting gas) before allowing gas flow to the heating element may be important in ensuring the safety of a user. As such, electrical controls for gas cooking appliances (e.g., gas ovens) may fall under UL 60730 Class C. This may require a second level failure mode and effects analysis (FMEA) or two independent failures and for the system to still fail safe.

[0017] Some gas cooking appliances use direct spark ignition and flame monitoring, however these systems may be expensive, increasing the cost of manufacturing the appliance. Alternatively, negative temperature coefficient (NTC) ignitors may be used. With this type of ignitor, a bi-metal solution may allow gas flow after a certain current level is reached. For example, the increase in current as the ignitor heats up energizes the bi-metal switch and, in turn, opens a valve to allow the flow of gas. However, these heating systems may be expensive and may not fit in smaller gas cooking appliances as the components of the system take up a large amount of space.

[0018] Accordingly, the present disclosure includes a hardware solution for providing proof that an ignition component, such as a hot surface igniter (HSI), is capable of igniting gas in a gas fueled cooking system with a smaller footprint using electronic control. An ignition controller, such as an integrated circuit (IC) chip, is configured to control gas flow to an ignition component based at least in part on a feedback signal indicative of a temperature of the ignition component. The ignition controller includes three independent electrical pathways, each configured to receive the feedback signal. Accordingly, a gas valve is electronically controlled to provide gas to the ignition component based at least in part on signals provided by the three independent pathways of the controller.

[0019] Example aspects of the present disclosure provide many technical effects and benefits. For example, the three independent pathways of the controller may provide needed redundancy for electronic control of the gas cooking appliances (e.g., gas ovens). In addition, the use of a controller, such as an IC chip, instead of discreet components greatly reduces costs and board space while maintaining functionality. Further, the gas control system provided herein provides for a smaller footprint due to, for example, the HSI ignition component and electronically controlled gas valve.

[0020] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (e.g., “A or B” is intended to mean “A or B or both”). The term “at least one of” in the context of, e.g., “at least one of A, B, and C” refers to only A, only B, only C, or any combination of A, B, and C. In addition, here and throughout the specification and claims, range limitations may be combined and / or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

[0021] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and / or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.

[0022] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0023] The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attaching, as well as indirect coupling, fixing, or attaching through one or more intermediate components or features, unless otherwise specified herein.

[0024] Except as explicitly indicated otherwise, recitation of a singular processing element (e.g., “a controller,” “a processor,” “a microprocessor,” etc.) is understood to include more than one processing element. In other words, “a processing element” is generally understood as “one or more processing element.” Furthermore, barring a specific statement to the contrary, any steps or functions recited as being performed by “the processing element” or “said processing element” are generally understood to be capable of being performed by “any one of the one or more processing elements.” Thus, a first step or function performed by “the processing element” may be performed by “any one of the one or more processing elements,” and a second step or function performed by “the processing element” may be performed by “any one of the one or more processing elements and not necessarily by the same one of the one or more processing elements by which the first step or function is performed.” Moreover, it is understood that recitation of “the processing element” or “said processing element” performing a plurality of steps or functions does not require that at least one discrete processing element be capable of performing each one of the plurality of steps or functions.

[0025] Referring now to the figures, example aspects of the present disclosure will be discussed in greater detail.

[0026] FIGS. 1 and 2 provide perspective views of a gas cooking system according to example embodiments of the present disclosure. Specifically, FIG. 1 provides a front, perspective view of gas cooking appliance 100 as may be employed with the present subject matter, while FIG. 2 provides a side cross-sectional view of gas cooking appliance 100 of FIG. 1. As shown in FIGS. 1 and 2, gas cooking appliance 100 of the present disclosure may be a range appliance, including both and oven and a cooktop. However, it should be appreciated that gas cooking appliance 100 is provided by way of example only, and aspects of the present subject matter may be used in any suitable gas cooking appliance, such as a gas oven, a gas cooktop, or a gas range appliance. Thus, the example embodiment shown in FIGS. 1 and 2 are not intended to limit the present subject matter to any particular cooking configuration or arrangement. Indeed, aspects of the present subject matter may be applied to gas heating elements of any suitable appliance.

[0027] Gas cooking appliance 100 generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined. As illustrated, gas cooking appliance 100 includes an insulated cabinet 102. Cabinet 102 of gas cooking appliance 100 extends between a top 104 and a bottom 106 along the vertical direction V, between a first side 108 (left side when viewed from front) and a second side 110 (right side when viewed from front) along the lateral direction L, and between a front 112 and a rear 114 along the transverse direction T.

[0028] Within cabinet 102 is a cooking chamber 120 which is configured for the receipt of one or more food items to be cooked. Gas cooking appliance 100 is depicted in FIGS. 1 and 2 as a single oven range appliance with a single cooking chamber 120. However, those of ordinary skill in the art will understand that this is done by way of example only and gas cooking appliance 100 may include any number of cooking chambers 120. For example, gas cooking appliance 100 may be a double oven range appliance which includes two cooking chambers 120. Gas cooking appliance 100 includes a door 124 rotatably attached to cabinet 102 in order to permit selective access to cooking chamber 120. Handle 126 is mounted to door 124 to assist a user with opening and closing door 124 in order to access cooking chamber 120. For example, a user can pull on handle 126 mounted to door 124 to open or close door 124 and access cooking chamber 120. One or more transparent viewing windows 128 (FIG. 1) may be defined within door 124 to provide for viewing the contents of cooking chamber 120 when door 124 is closed and also assist with insulating cooking chamber 120.

[0029] As shown in FIG. 2, cooking chamber 120 is defined by a plurality of chamber walls 130. Specifically, cooking chamber 120 may be defined by a top wall, a rear wall, a bottom wall, and two side walls 130. These chamber walls 130 may be joined together to define an opening through which a user may selectively access cooking chamber 120 by opening door 124. In order to insulate cooking chamber 120, gas cooking appliance 100 includes an insulating gap defined between the chamber walls 130 and cabinet 102. According to an example embodiment, the insulation gap is filled with an insulating material 132, such as insulating foam or fiberglass, for insulating cooking chamber 120.

[0030] Gas cooking appliance 100 may also include a cooktop 140. Cooktop 140 is positioned at or adjacent top 104 of cabinet 102 such that it is positioned above cooking chamber 120. As shown in FIG. 1, cooktop 140 includes a top panel 142 positioned proximate top 104 of cabinet 102. By way of example, top panel 142 may be constructed of glass, ceramics, enameled steel, and combinations thereof. One or more grates 144 are supported on a top surface of top panel 142 for supporting cooking utensils, such as pots or pans, during a cooking process.

[0031] Gas cooking appliance 100 further includes one or more gas heating elements 150 for selectively heating cooking utensils positioned on grates 144 or food items positioned within cooking chamber 120. For example, referring to FIG. 1, heating elements 150 may be gas burners 150. Specifically, a plurality of gas burners 150 are mounted within or on top of top panel 142 underneath grates 144 that supports cooking utensils over the gas burners 150 while gas burners 150 provide thermal energy to cooking utensils positioned thereon, e.g., to heat food and / or cooking liquids (e.g., oil, water, etc.). Gas burners 150 can be configured in various sizes so as to provide e.g., for the receipt of cooking utensils (i.e., pots, pans, etc.) of various sizes and configurations and to provide different heat inputs for such cooking utensils. In some embodiments, gas cooking appliance 100 may have other cooktop configurations or burner elements.

[0032] In addition, gas heating elements 150 may be positioned within or may otherwise be in thermal communication with cooking chamber 120 for regulating the temperature within cooking chamber 120. Specifically, an upper gas heating element 154 (also referred to as a broil heating element or gas burner) may be positioned in cabinet 102, e.g., at a top portion of cooking chamber 120, and a lower gas heating element 156 (also referred to as a bake heating element or gas burner) may be positioned at a bottom portion of cooking chamber 120. Upper gas heating element 154 and lower gas heating element 156 may be used independently or simultaneously to heat cooking chamber 120, perform a baking or broil operation, perform a cleaning cycle, etc. The size and heat output of gas heating elements 154, 156 can be selected based on, e.g., the size of gas cooking appliance 100 or the desired heat output. Gas cooking appliance 100 may include any other suitable number, type, and configuration of heating elements within cabinet 102 and / or on cooktop 140. For example, gas cooking appliance 100 may further include electric heating elements, induction heating elements, or any other suitable heat generating device.

[0033] As shown in FIG. 1, a control panel assembly 160 is located within convenient reach of a user of the gas cooking appliance 100. For this example embodiment, control panel assembly 160 is positioned at a top 104 and front 112 of cabinet 102, e.g., above door 124 along the vertical direction V and forward of cooktop 140 along the transverse direction T. Control panel assembly 160 includes one or more user input devices (e.g., knobs 162, buttons 172). In some embodiments, knobs 162 may each be associated with a heating element 150 on cooktop 140. In addition, buttons 172 may be associated with heating elements 150 positioned within cooking chamber 120. For example, buttons 172 may allow the user to set cooking modes that automatically control heating elements 150 positioned within cooking chamber 120. In this manner, user input devices (e.g., knobs 162, buttons 172) may allow the user to activate each heating element 150 and determine the amount of heat input provided by each heating element 150 for cooking food items within cooking chamber 120 or on cooktop 140. Although shown with knobs 162 and buttons 172, it should be understood that user input devices and the configuration of gas cooking appliance 100 shown in FIG. 1 is provided by way of example only. More specifically, control panel assembly 160 may include various input components, such as one or more of a variety of touch-type controls, electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. Control panel assembly 160 may also be provided with one or more graphical display devices or display components, such as a digital or analog display device designed to provide operational feedback or other information to the user such as e.g., whether a particular heating element 150 is activated and / or the rate at which the heating element 150 is set. Indeed, according to the illustrated embodiment, control panel assembly 160 includes a display assembly 164, such as a liquid crystal display with an interactive display and interface.

[0034] Generally, gas cooking appliance 100 may include a control system 166 in operative communication with control panel assembly 160. Control panel assembly 160 of gas cooking appliance 100 may be in communication with control system 166 via, for example, one or more signal lines or shared communication busses, and signals generated in control system 166 operate gas cooking appliance 100 in response to user input via user input devices, e.g., control knobs 162, buttons 172, and / or display assembly 164. Input / Output ("I / O") signals may be routed between control system 166 and various operational components of gas cooking appliance 100 such that operation of gas cooking appliance 100 can be regulated by control system 166. In addition, control system 166 may also be in communication with one or more sensors, such as temperature sensor 168, which may be used to measure temperature inside cooking chamber 120 and provide such measurements to the control system 166. Although temperature sensor 168 is illustrated at a top and rear of cooking chamber 120, it should be appreciated that other sensor types, positions, and configurations may be used according to alternative embodiments.

[0035] Control system 166 includes a “processing device” or “controller” and may be embodied as described herein. Control system 166 may include a memory and one or more microprocessors, microcontrollers, application-specific integrated circuits (ASICS), CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of gas cooking appliance 100, and control system 166 is not restricted necessarily to a single element. The memory may represent random access memory such as DRAM, or read only memory such as ROM, electrically erasable, programmable read only memory (EEPROM), or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, control system 166 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and / or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.

[0036] Although aspects of the present subject matter are described herein in the context of a single oven appliance, it should be appreciated that gas cooking appliance 100 is provided by way of example only. Other oven or range appliances having different configurations, different appearances, and / or different features may also be utilized with the present subject matter, e.g., double ovens, connected oven / cooktop units, etc. Moreover, aspects of the present subject matter are equally applicable to standalone cooktops (e.g., without cooking chambers) or other cooking appliances.

[0037] Referring now specifically to FIG. 2, a schematic view of upper gas heating element 154 and lower gas heating element 156 within a cooking chamber 120 and a gas ignition system 300 will be described. In general, fuel supply system 180 is configured for selectively supplying gaseous fuel such as propane, natural gas, liquefied petroleum (LP), butane, or any other suitable fuel to heating elements 150. Fuel supply system 180 may include a pressurized gaseous fuel source (not shown), such as a natural gas supply line, a propane tank, etc. In this manner, a flow of supply fuel, such as gaseous fuel (e.g., natural gas or propane), is flowable from the fuel supply system 180 to heating elements 150. Fuel supply system 180 may further include a control valve or fuel regulating device operably coupling a gaseous fuel source to heating elements 150. In some embodiments, the fuel regulating device of fuel supply system 180 may be a gas valve, such as gas valve 192.

[0038] Specifically, the fuel regulating device may be a three-way, solenoid-controlled valve or bimetal valve for selectively directing a metered amount of fuel to upper gas heating element 154 and lower gas heating element 156. More specifically, according to an example embodiment, a user input device of control panel assembly 160, such as a button 172 (FIG. 1), may be operably coupled to fuel supply system 180 for regulating the flow of supply fuel. In this regard, a user may press a button 172 (FIG. 1) to set a cooking mode, automatically adjusting the flow of supply fuel from the gaseous fuel source to both upper gas heating element 154 and lower gas heating element 156.

[0039] Referring still to FIG. 2, gas cooking appliance 100 further includes gas ignition system 300. Gas ignition system 300 includes one or more ignition components 190 and is configured to provide proof that the one or more ignition components 190 are capable of igniting gaseous fuel. Ignition components 190 are operably coupled to each gas heating element 150 for igniting the flow of fuel as it passes into gas heating element 150. Specifically, according to the illustrated embodiment, the ignition component 190 may be defined as a hot surface igniter (HSI), e.g., such as a silicon carbide, silicon nitride, or any other suitable hot surface igniter for use with a gas heating element. In some embodiments, ignition component 190 may be a positive temperature coefficient (PTC) hot surface igniter (HSI). For example, as the temperature of the HSI rises, the resistance rises. As shown, an ignition component 190 may positioned proximate a rear of each of upper gas heating element 154 and lower gas heating element 156, (e.g., at the entrance where the flow of fuel was provided into the respective heating elements 154, 156).

[0040] Gas ignition system 300 further includes one or more gas valves 192 configured to provide gas to the one or more ignition components 190. As shown, gas valves 192 are electrically controlled gas valves that may be opened or closed by ignition controller 400. Accordingly, gas valve 192 may be fluidly coupled to a fuel supply line to receive gas from fuel supply system 180 (e.g., gas source of gas distribution system 180). Although gas valve 192 is illustrated as being a dedicated valve separate from fuel supply system 180, it should be appreciated that according to alternative embodiments, a single gas valve 192 may be used to control the flows of fuel to each gas heating element 150. However, as shown, each gas valve 192 may correspond to an ignition component 190. For example, gas cooking appliance 100 may include one or more ignition components 190 and one or more gas valves 192 corresponding to the one or more ignition components 190.

[0041] As explained briefly above, gas ignition system 300 is configured to provide proof that an ignition component is capable of igniting gas. As such, gas ignition system 300 (e.g., through gas valves 192) control the flow of fuel to ignition components 190. For example, the flow of fuel may typically ignite when ignition component 190 (e.g., HSI) reaches an ignition temperature (e.g., predetermined threshold temperature) which indicates a sufficient temperature of the HSI for igniting the flow of fuel. In order to prevent the flow of fuel into gas heating elements 150 prior to ignition component 190 reaching the ignition temperature, gas valve 192 is configured to provide gas (e.g., fuel) to the ignition component 190 based at least in part on an enable signal and one or more redundancy signals provided by ignition controller 400.

[0042] As such, gas ignition system 300 further includes ignition controller 400. As shown in FIG. 2, ignition controller 400 is operably coupled to ignition components 190 and gas valves 192. Ignition controller400 includes a plurality of internal, independent electrical pathways configured to receive a feedback signal indicative of a temperature of the ignition component 190 (e.g., HSI). Ignition controller 400 is further configured to electrically control gas valve 192 based at least in part on the feedback signal.

[0043] In some embodiments, ignition controller 400 may be a sub-system of control system 166 such that ignition controller 400 is operatively coupled to control system 166. Accordingly, ignition controller 400 may be positioned in control panel assembly 160 (FIG. 1). As such, ignition components 190 may be activated and deactivated by control system 166 to facilitate the igniting and extinguishing processes, respectively, of a gas burner 150. Specifically, for example, control system 166 may regulate a position of an igniter relay (not shown) which may be closed to energize ignition component 190, thereby causing ignition component 190 to heat up and ignite the flow of fuel. By contrast, control system 166 may open the igniter relay to permit ignition component 190 cool below temperature at which the flow of fuel may be stopped (e.g., by gas valve 19) and the flame may be extinguished.

[0044] In some embodiments, gas valve 192 may be a safety valve that is operably coupled to a fuel supply line between fuel supply system 180 and each ignition component 190. Gas valve 192 may remain in the closed position until ignition component 190 reaches or exceeds the ignition temperature for combustion. Once ignition component 190 has reached the ignition temperature, corresponding gas valve 192 may be opened by ignition controller 400 to permit the flow of fuel from the fuel supply system 180. When ignition component 190 drops below the ignition temperature after a heating cycle, gas valve 192 may be closed again to prevent the flow of fuel.

[0045] In some embodiments, gas valve 192 may be operably coupled to ignition component 190 in a manner suitable for providing a feedback signal indicating as to the temperature or the state of operation of ignition component 190. Accordingly, ignition controller 400 may receive the feedback signal from ignition component 190 via gas valve 192.

[0046] FIG. 3 provides a circuit schematic of an example gas ignition system 300 according to example embodiments of the present disclosure. Gas ignition system 300 is configured to provide proof that an ignition component 190 is capable of igniting gaseous fuel in a gas fueled cooking system, such as gas cooking appliance 100 as shown in FIGS. 1 and 2. While gas ignition system 300 is described with reference to gas cooking appliance 100, those of ordinary skill in the art will understand that gas ignition system 300 may be used in any suitable appliance or system.

[0047] As shown in FIG. 3, one or more ignition components 190 are configured to provide one or more feedback signals 302 indicative of a temperature of the ignition component 190. Specifically, ignition component 190 may be defined as a hot surface igniter (HSI) 190. As shown, HSI 190 may be represented as variable resistors.

[0048] HSI 190 may be activated and deactivated by the opening and closing of a position on an igniter relay 194 which may be closed to energize HSI 190, thereby causing HSI 190 to heat up in order to ignite the flow of fuel. Igniter relay 194 may be a part of a machine control of a gas cooking appliance. In some embodiments, ignitor relay 194 may be controlled by control system 166 as shown in FIGS. 1 and 2. In some embodiments, igniter relay 194 may activate (e.g., apply power to) an HSI 190 of when a user selects a cycle.

[0049] As shown in FIG. 3, gas ignition system 300 may further include one or more shunt sensors 310 (e.g., shunt resistors) corresponding to the one or more HSIs 190. Shunt sensors 310 are configured such to provide feedback signals 302 to the ignition controller 400. In some embodiments, ignition component 190 may be a positive temperature coefficient (PTC) HSI 190 operable to ignite gas at an ignition temperature. As shown in FIG. 3, the PTC HSI 190 may be represented as a variable resistor. Specifically, the resistance of the PTC HSI 190 increases as the temperature of the PTC HSI 190 increases. Accordingly, the measured voltage of the shunt sensor 310 may change when the HSI 190 changes. As such, feedback signal 302 provided from shunt sensor 310 is indicative of a temperature of the positive temperature coefficient (PTC) of the ignition component 190. For example, when the electrical voltage measured from the shunt sensor 310 (e.g., shunt resistor) rises above a threshold, feedback signal 302 indicates that the ignition component 190 is at or above a suitable ignition temperature and gas may be provided. Accordingly, the measured voltage from the shunt may be used to prove that the ignition component 190 (e.g., HSI) is capable of ignition.

[0050] The one or more feedback signals 302 are provided to the ignition controller 400 of gas ignition system 300. As shown, ignition controller 400 is operably coupled to the one or more ignition components 190 and the one or more corresponding gas valves 192. As previously shown in FIG. 2, gas valve 192 is configured to provide gas to ignition component 190 based at least in part on an enable signal 420 and one or more redundancy signals 422 (e.g., provided by ignition controller 400). For example, based at least in part on the feedback signal 302, ignition controller 400 is configured to open gas valve 192, providing gas to the ignition component 190.

[0051] In some embodiments, ignition controller 400 may receive power signal 412 from power supply 410 (e.g., offline switch-mode power supply). Power supply 410 may further provide neutral signal 414 to ignition controller 400. As shown in FIG. 3, neutral signal 414 may be provided from ignition relay 194. In some embodiments, power supply 410 is configured to supply power to ignition controller 400 when there is an active call for heat.

[0052] In some embodiments, gas ignition system 300 may include input connector 408 electrically coupled to ignition relay 194 and HSIs 190. As shown in FIG. 3, a call for heat signal 304 may be provided to ignition controller 400 from ignition relay 194 (e.g., via input connector 408). The call for heat signal may be represented by voltage signals from ignition relay 194. Call for heat signal 304 may be used to indicate that a gas valve 192 corresponds to the ignition component 190 that provides feedback signal 302. Specifically, call for heat signal 304 may be defined as an active voltage to both HSI 190 as well as the ignition controller 400. For example, one or more HSIs 190 may be activated to heat a cavity of a gas cooking appliance to a desired temperature during a cooking cycle selected by a user. Accordingly, power may be cycled to the one or more HSIs 190 for the cavity to remain at the desired temperature. In some embodiments, gas ignition system 300 may not be configured to hold in memory the current cycle selected by a user and may only be powered on when there is an active call for heat. Accordingly, ignition controller 400 may provide proof that the one or more HSIs 190 (e.g., ignition components 190) are capable of igniting a gaseous fuel multiple times each cooking cycle. As such, gas ignition system 300 may include a stand alone system (e.g., ignition system 350) configured to confirm that one or more ignition components 190 (e.g., one or more HSIs 190) are electrically capable of igniting gaseous fuel such that gas valves 192 corresponding to the ignition components may be controlled electronically.

[0053] In some embodiments, ignition controller 400 may provide an enable signal 420 as a pulse width modulated (PWM) signal to switching device 360 (e.g., MOSFET). Further, ignition controller 400 may provide one or more redundancy signals 422, such as two redundancy signals 422, to switching devices 362, 364 (e.g., transistors, BJT transistors). Based on the one or more redundancy signals 422, a signal is provided to gas valve 192 (e.g., solenoid switch of gas valve 192). When the enable signal 420 is provided to gas valve 192, a switching device such as a solenoid switch corresponding to gas valve 192 is opened and gas is provided to the corresponding ignition component 190.

[0054] For example, if redundancy signals 422 are provided to switching devices 362, 364, enable signal 420 may be provided to switching device 360, allowing VCC to be applied to a solenoid switch corresponding to gas valve 192. If redundancy signals 422 are not applied to switching device 362 or switching device 364, enable signal 420 will not be received at switching device 360 and gas valve 192 will not be opened. In some embodiments, gas ignition system 300 may include output connector 191. As shown in FIG. 3, output connector 191 may provide VCC to a gas valve 192 based at least in part on redundancy signals 422 and enable signal 420.

[0055] As shown in FIG. 3, gas ignition system 300 may include two ignition components 190 and two corresponding gas valves 192. However, gas control system may provide proof that any number of ignition components 190 are capable of igniting a gas supplied from any number of corresponding gas valves 192 without deviating from the scope of the present disclosure.

[0056] Referring now to FIG. 4, a block diagram depicting internal logic of an example ignition controller 400 is provided. Ignition controller 400 includes three independent electrical pathways for providing proof that an ignition component is capable of igniting gas in a gas cooking system, such as gas cooking system 300 shown in FIGS. 2 and 3.

[0057] Ignition controller 400 includes three independent electrical pathways (e.g., enable circuit 430, first redundancy circuit 432, and second redundancy circuit 434) configured to receive feedback signal 302. Ignition controller 400 may be defined as an Integrated Circuit (IC) controller, such as a CMIC. As such, enable circuit 430, first redundancy circuit 432, and second redundancy circuit 434 may be defined as internal circuits positioned within a controller package 405 of ignition controller 400.

[0058] Enable circuit 430 and redundancy circuits 432, 434 are configured to provide output signals 420, 422 based at least in part on feedback signal 302. Specifically, each circuit 430, 432, 434 may provide output signals 420, 422 based at least in part on a comparison of feedback signal 302 to a threshold indicative of an ignition temperature of the ignition component. As shown, enable circuit 430 and redundancy circuits 432, 434 may include comparator component 438 (e.g., comparator). Comparator component 438 may compare feedback signal 302 to a threshold indicative of an ignition temperature of the ignition component.

[0059] For example, an ignition component (e.g., HSI) providing feedback signal 302 may have an ignition temperature corresponding to an RMS voltage. When the RMS voltage of feedback signal 302 is greater than the threshold, comparator components 438 may provide an output signal indicating that the HSI is at or above the ignition temperature.

[0060] As shown in FIG, 4 enable circuit and redundancy circuits 432, 434 may each further include delay component 440. Delay component 440 is configured such that enable circuit 430 and redundancy circuits 432, 434 may provide output signals 420, 422 when feedback signal 302 is greater than the ignition temperature threshold for an ignition time period. For example, an ignition time period may correspond to an amount of time an ignition component is at an ignition temperature before the ignition component will ignite a gas supply. Accordingly, delay component 440 of enable circuit 430 and redundancy circuits 432, 434 is configured to provide proof that an ignition component is capable of igniting gas by determining that the ignition component (e.g., HSI) is capable of igniting the gas based at least in part on feedback signal 302.

[0061] In some embodiments, enable circuit 430 and redundancy circuits 432, 434 further receive a call for heat signal 304. As previously described, ignition controller 400 may be configured to receive input from a plurality of ignition components corresponding to a plurality of gas valves. Accordingly, call for heat signal 304 indicates that the ignition component providing feedback signal 302 corresponds to the gas valve that will be opened. For example, delay component 440 may be further configured to output a signal based at least in part on a signal received from comparator component 438 and call for heat signal 304.

[0062] While redundancy circuits 432, 434 are configured to provide redundancy signals 422 from the delay component 440, enable circuit 430 may include additional circuitry configured to provide enable signal 420 as a pulse width modulated (PWM) signal. For example, enable circuit 430 may include boost and hold circuitry 444, 446 to provide enable signal 420 as a PWM signal. In some embodiments, enable circuit 430 may have additional output logic components 448 configured to further process PWM enable signal 420.

[0063] FIG. 5 provides a flowchart of an example method 500 for providing gas to an ignition component of a gas cooking appliance according to example embodiments of the present disclosure. While method 500 is described with reference to gas cooking appliance 100, gas ignition system 300, and ignition controller 400, those of ordinary skill in the art will understand that method 500 may be implemented in any suitable gas cooking system.

[0064] At 505, method 500 includes receiving, from the ignition component, a feedback signal indicative of a temperature of the ignition component. For example, ignition controller 400 may receive feedback signal 302 from ignition component 190.

[0065] At 510, method 500 includes determining, by an enable circuit of an ignition controller, an enable signal based at least in part on the feedback signal. For example, enable circuit 430 of ignition controller 400 may determine an enable signal 420 based at least in part on feedback signal 302.

[0066] At 515, method 500 includes determining, by one or more redundancy circuits of the ignition controller, one or more redundancy signals based at least in part on the feedback signal. For example, redundancy circuits 432, 434 of ignition controller 400 may determine redundancy signals 422 based at least in part on feedback signal 302. In some embodiments, the one or more redundancy signals 422 include a first redundancy signal 422 provided by first redundancy circuit 432 and a second redundancy signal 422 provided by second redundancy circuit 434.

[0067] At 520, method 500 includes providing gas to the ignition component based at least in part on the enable signal and the one or more redundancy signals. For example, gas valve 192 may provide gas to corresponding ignition component 190 based at least in part on enable signal 420 and the one or more redundancy signals 422.

[0068] In some embodiments, the enable signal 420 and the one or more redundancy signals 422 are determined based at least in part on a comparison of the feedback signal 302 to a threshold indicative of an ignition temperature of the ignition component. For example, comparator components 438 of enable circuit 430 and redundancy circuits 432, 434 may compare feedback signal 302 to a threshold value indicative of an ignition temperature of ignition component 190 (e.g., HSI).

[0069] In some embodiments, the enable signal 420 and the one or more redundancy signals 422 are provided when the feedback signal is greater than the threshold for an ignition time period. For example, delay component 440 of enable circuit 430 and redundancy circuits 432, 434 may provide an output signal when a signal has been received from comparator components 438 for an ignition time period, providing proof that ignition component 190 (e.g., HSI) is capable of igniting gas.

[0070] In some embodiments, the enable signal 420 and the one or more redundancy signals 422 are provided based at least in part on a call for heat signal 304, the call for heat signal 304 indicating that the gas valve 192 corresponds to the ignition component 190.

[0071] In some embodiments, the enable signal 420 is a pulse width modulated (PWM) signal 420. For example, enable circuit 430 of ignition controller 400 may include boost and hold circuitry 444, 446. Boost and hold circuitry 444, 446 may provide enable signal 420 as a PWM signal based on output from delay component 440.

[0072] One example aspect of the present disclosure is directed to a gas ignition system for a gas cooking appliance. The gas ignition system includes an ignition component configured to provide a feedback signal indicative of a temperature of the ignition component. The gas ignition system further includes a gas valve configured to provide gas to the ignition component based at least in part on an enable signal and one or more redundancy signals. The gas ignition system further includes an ignition controller operably coupled to the ignition component and the gas valve. The ignition controller includes an enable circuit configured to provide the enable signal based at least in part on the feedback signal. The ignition controller further includes one or more redundancy circuits configured to provide one or more redundancy signals based at least in part on the feedback signal.

[0073] In some examples, the one or more redundancy circuits include a first redundancy circuit configured to provide a first redundancy signal based at least in part on the feedback signal, and a second redundancy circuit configured to provide a second redundancy signal based at least in part on the feedback signal.

[0074] In some examples, the enable circuit, the first redundancy circuit, and the second redundancy circuit are independent electrical pathways of the ignition controller.

[0075] In some examples, the enable signal and the one or more redundancy signals are provided based at least in part on a comparison of the feedback signal to a threshold indicative of an ignition temperature of the ignition component.

[0076] In some examples, the enable signal and the one or more redundancy signals are provided when the feedback signal is greater than the threshold for an ignition time period.

[0077] In some examples, the enable signal is a pulse width modulated (PWM) signal.

[0078] In some examples, the enable signal and the one or more redundancy signals are provided based at least in part on a call for heat signal, the call for heat signal indicating that the gas valve corresponds to the ignition component.

[0079] In some examples, the ignition component includes a positive temperature coefficient (PTC) HSI operable to ignite the gas at an ignition temperature. The feedback signal is indicative of a temperature of the positive temperature coefficient (PTC) HSI.

[0080] In some examples, the enable circuit and the one or more redundancy circuits are positioned within a controller package of the ignition controller.

[0081] Another example aspect of the present disclosure is directed to a method for providing gas to an ignition component of a gas cooking appliance. The method includes receiving, from the ignition component, a feedback signal indicative of a temperature of the ignition component. The method further includes determining, by an enable circuit of an ignition controller, an enable signal based at least in part on the feedback signal. The method further includes determining, by one or more redundancy circuits of the ignition controller, one or more redundancy signals based at least in part on the feedback signal. The method further includes providing gas to the ignition component based at least in part on the enable signal and the one or more redundancy signals.

[0082] In some examples, the one or more redundancy signals include a first redundancy signal provided by a first redundancy circuit, the first redundancy signal being based at least in part on the feedback signal, and a second redundancy signal provided by a second redundancy circuit, the second redundancy signal being based at least in part on the feedback signal.

[0083] In some examples, the enable circuit, the first redundancy circuit, and the second redundancy circuit are independent electrical pathways of the ignition controller.

[0084] In some examples, the enable signal and the one or more redundancy signals are determined based at least in part on a comparison of the feedback signal to a threshold indicative of an ignition temperature of the ignition component.

[0085] In some examples, the enable signal and the one or more redundancy signals are provided when the feedback signal is greater than the threshold for an ignition time period.

[0086] In some examples, the enable signal and the one or more redundancy signals are provided based at least in part on a call for heat signal, the call for heat signal indicating that a gas valve providing the gas to the ignition component corresponds to the ignition component.

[0087] In some examples, the enable circuit and the one or more redundancy circuits are positioned within a controller package of the ignition controller.

[0088] In some examples, the enable signal is a pulse width modulated (PWM) signal.

[0089] Another example aspect of the present disclosure is directed to a gas cooking appliance. The gas cooking appliance includes one or more ignition components configured to provide one or more feedback signals indicative of a temperature of the one or more ignition components. The gas cooking appliance further includes one or more gas valves configured to provide gas to the one or more ignition components based at least in part on an enable signal and one or more redundancy signals. The gas cooking appliance further includes an ignition controller operably coupled to the one or more ignition components and the one or more gas valves. The ignition controller includes an enable circuit configured to provide the enable signal based at least in part on a feedback signal of the one or more feedback signals. The ignition controller further includes one or more redundancy circuits configured to provide the one or more redundancy signals based at least in part on the feedback signal of the one or more feedback signals.

[0090] In some examples, the enable signal and the one or more redundancy signals are provided based at least in part on a call for heat signal, the call for heat signal indicating that a gas valve of the one or more gas valves corresponds to an ignition component of the one or more ignition components that provided the feedback signal.

[0091] In some examples, the one or more redundancy circuits include a first redundancy circuit configured to provide a first redundancy signal based at least in part on the feedback signal, and a second redundancy circuit configured to provide a second redundancy signal based at least in part on the feedback signal.

[0092] Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the present disclosure, any feature of a drawing can be referenced and / or claimed in combination with any feature of any other drawing.

[0093] While the present subject matter has been described in detail with respect to specific example embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing can readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and / or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.

Claims

1. A gas ignition system for a gas cooking appliance, comprising: an ignition component configured to provide a feedback signal indicative of a temperature of the ignition component;a gas valve configured to provide gas to the ignition component based at least in part on an enable signal and one or more redundancy signals; andan ignition controller operably coupled to the ignition component and the gas valve, the ignition controller comprising: an enable circuit configured to provide the enable signal based at least in part on the feedback signal; andone or more redundancy circuits configured to provide one or more redundancy signals based at least in part on the feedback signal.

2. The gas ignition system of claim 1, wherein the one or more redundancy circuits comprises: a first redundancy circuit configured to provide a first redundancy signal based at least in part on the feedback signal; anda second redundancy circuit configured to provide a second redundancy signal based at least in part on the feedback signal.

3. The gas ignition system of claim 2, wherein the enable circuit, the first redundancy circuit, and the second redundancy circuit are independent electrical pathways of the ignition controller.

4. The gas ignition system of claim 1, wherein the enable signal and the one or more redundancy signals are provided based at least in part on a comparison of the feedback signal to a threshold indicative of an ignition temperature of the ignition component.

5. The gas ignition system of claim 4, wherein the enable signal and the one or more redundancy signals are provided when the feedback signal is greater than the threshold for an ignition time period.

6. The gas ignition system of claim 1, wherein the enable signal is a pulse width modulated (PWM) signal.

7. The gas ignition system of claim 1, wherein the enable signal and the one or more redundancy signals are provided based at least in part on a call for heat signal, the call for heat signal indicating that the gas valve corresponds to the ignition component.

8. The gas ignition system of claim 1, wherein the ignition component comprises: a positive temperature coefficient (PTC) HSI operable to ignite the gas at an ignition temperature,wherein the feedback signal is indicative of a temperature of the positive temperature coefficient (PTC) HSI.

9. The gas ignition system of claim 1, wherein the enable circuit and the one or more redundancy circuits are positioned within a controller package of the ignition controller.

10. A method for providing gas to an ignition component of a gas cooking appliance, comprising: receiving, from the ignition component, a feedback signal indicative of a temperature of the ignition component;determining, by an enable circuit of an ignition controller, an enable signal based at least in part on the feedback signal;determining, by one or more redundancy circuits of the ignition controller, one or more redundancy signals based at least in part on the feedback signal; andproviding gas to the ignition component based at least in part on the enable signal and the one or more redundancy signals.

11. The method of claim 10, wherein the one or more redundancy signals comprises: a first redundancy signal provided by a first redundancy circuit, the first redundancy signal being based at least in part on the feedback signal; anda second redundancy signal provided by a second redundancy circuit, the second redundancy signal being based at least in part on the feedback signal.

12. The method of claim 11, wherein the enable circuit, the first redundancy circuit, and the second redundancy circuit are independent electrical pathways of the ignition controller.

13. The method of claim 10, wherein the enable signal and the one or more redundancy signals are determined based at least in part on a comparison of the feedback signal to a threshold indicative of an ignition temperature of the ignition component.

14. The method of claim 13, wherein the enable signal and the one or more redundancy signals are provided when the feedback signal is greater than the threshold for an ignition time period.

15. The method of claim 10, wherein the enable signal and the one or more redundancy signals are provided based at least in part on a call for heat signal, the call for heat signal indicating that a gas valve providing the gas to the ignition component corresponds to the ignition component.

16. The method of claim 10, wherein the enable circuit and the one or more redundancy circuits are positioned within a controller package of the ignition controller.

17. The method of claim 10, wherein the enable signal is a pulse width modulated (PWM) signal.

18. A gas cooking appliance, comprising: one or more ignition components configured to provide one or more feedback signals indicative of a temperature of the one or more ignition components;one or more gas valves configured to provide gas to the one or more ignition components based at least in part on an enable signal and one or more redundancy signals; andan ignition controller operably coupled to the one or more ignition components and the one or more gas valves, the ignition controller comprising: an enable circuit configured to provide the enable signal based at least in part on a feedback signal of the one or more feedback signals; andone or more redundancy circuits configured to provide the one or more redundancy signals based at least in part on the feedback signal of the one or more feedback signals.

19. The gas cooking appliance of claim 18, wherein the enable signal and the one or more redundancy signals are provided based at least in part on a call for heat signal, the call for heat signal indicating that a gas valve of the one or more gas valves corresponds to an ignition component of the one or more ignition components that provided the feedback signal.

20. The gas cooking appliance of claim 18, wherein the one or more redundancy circuits comprises: a first redundancy circuit configured to provide a first redundancy signal based at least in part on the feedback signal; anda second redundancy circuit configured to provide a second redundancy signal based at least in part on the feedback signal.

Images