Convection heating assembly for an oven appliance

Abstract

An oven appliance includes a cabinet defining a cooking chamber, a door rotatably mounted to the cabinet to provide selective access to the cooking chamber, and a convection heating assembly operably coupled to the cooking chamber. The convection heating assembly includes a convection fan mounted in the cabinet for circulating a flow of air in the cooking chamber and a baffle plate at least partially surrounding the convection fan for directing the flow of air.

Description

FIELD OF THE INVENTION

[0001] The present subject matter relates generally to oven appliances, and more particularly, to convection heating systems for oven appliances.BACKGROUND OF THE INVENTION

[0002] Conventional residential and commercial oven appliances generally include a cabinet that includes a cooking chamber for receipt of food items for cooking. Multiple heating elements are positioned within the cooking chamber to provide heat to food items located therein. The heating elements can include, for example, radiant heating elements, such as a bake heating assembly positioned at a bottom of the cooking chamber and / or a separate broiler heating assembly positioned at a top of the cooking chamber.

[0003] Oven appliances also commonly include a centrifugal convection fan to circulate air within the cooking chamber to facilitate quicker and more even cooking processes. However, conventional convection fans produce an uneven airflow pattern due to rotation of the fan blade. To overcome these uneven airflow patterns and associated cooking problems, certain conventional oven appliances include a reversing motor that is used to change the fan rotation direction. Notably, this solution adds cost and complexity to the system.

[0004] Accordingly, an oven appliance with an improved convection heating assembly is desirable. More specifically, a convection heating assembly that effectively facilitates convection cooking with minimal costs and complexity would be particularly beneficial. BRIEF DESCRIPTION OF THE INVENTION

[0005] Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

[0006] In one exemplary embodiment, an oven appliance defining a vertical direction, a lateral direction, and a transverse direction is provided, including a cabinet defining a cooking chamber, a door rotatably mounted to the cabinet to provide selective access to the cooking chamber, and a convection heating assembly operably coupled to the cooking chamber. The convection heating assembly includes a convection fan mounted in the cabinet for circulating a flow of air in the cooking chamber and a baffle plate at least partially surrounding the convection fan for directing the flow of air.

[0007] In another exemplary embodiment, a convection heating assembly operably coupled to a cooking chamber of an oven appliance is provided, including a convection fan mounted in a cabinet for circulating a flow of air in the cooking chamber and a baffle plate at least partially surrounding the convection fan for directing the flow of air.

[0008] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

[0010] FIG. 1 provides a front perspective view of an oven appliance according to an example embodiment of the present subject matter.

[0011] FIG. 2 provides a front perspective view of the example oven appliance of FIG. 1 with a door in the open position according to an example embodiment of the present subject matter.

[0012] FIG. 3 provides a side, schematic view of the example oven appliance of FIG. 1 according to an example embodiment of the present subject matter.

[0013] FIG. 4 provides a front, schematic view of a convection heating assembly when a convection fan rotates in a clockwise direction according to an example embodiment of the present subject matter.

[0014] FIG. 5 provides a front, schematic view of a convection heating assembly when a convection fan rotates in a counterclockwise direction according to another example embodiment of the present subject matter.

[0015] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0016] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0017] 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 (i.e., “A or B” is intended to mean “A or B or both”). 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.

[0018] 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.

[0019] 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.

[0020] As explained herein, aspects of the present subject matter are generally directed to an improved convection heating configuration that utilizes a cavity-mounted fan that is designed to exhaust air upward for uniform airflow distribution associated with single-direction fan rotation, achieved through a strategic air baffling arrangement. This baffle structure may include walls obstructing the lower half of the fan blade's perimeter, along with an upward extension on a side determined by the fan's rotation direction. The placement of the extension may vary, e.g., extending from the centerline to the top of the fan blade based on specific configurations (for a clockwise rotating fan, the extension is on the right side, and conversely for a counterclockwise rotation, it is on the left side). Overall, this design aims to enhance airflow efficiency within enclosed spaces.

[0021] FIG. 1 provides a front, perspective view of an oven appliance 100 as may be employed with the present subject matter. Oven 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, oven appliance 100 includes an insulated cabinet 102. Cabinet 102 of oven 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 (FIG. 3) along the transverse direction T.

[0022] Within cabinet 102 is a single cooking chamber 120 which is configured for the receipt of one or more food items to be cooked. However, it should be appreciated that oven appliance 100 is provided by way of example only, and aspects of the present subject matter may be used in any suitable cooking appliance, such as a double oven range appliance. Thus, the example embodiment shown in FIG. 1 is not intended to limit the present subject matter to any particular cooking chamber configuration or arrangement. Indeed, aspects of the present subject matter may be applied to any suitable cooktop appliance.

[0023] Referring now also to FIGS. 2 and 3, oven 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. As an 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.

[0024] 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 sidewalls 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, oven appliance 100 includes an insulating gap defined between the chamber walls 130 and cabinet 102. According to an exemplary embodiment, the insulation gap is filled with an insulating material 132, such as insulating foam or fiberglass, for insulating cooking chamber 120.

[0025] Oven appliance 100 also includes a cooktop 140. Cooktop 140 is positioned at or adjacent top 104 of cabinet 102 such that it is positioned above cooking chamber 120. Specifically, 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. For example, according to the illustrated embodiment, cooktop includes a ceramic glass panel 144 having a plurality of cooking zones.

[0026] Oven appliance 100 may further include one or more heating elements (identified generally by reference numeral 150) for selectively heating cooking utensils positioned on glass panel 144 or food items positioned within cooking chamber 120. For example, referring to FIG. 1, heating elements 150 may be electric burners 150. Specifically, a plurality of electric burners 150 are mounted within or on top of top panel 142 underneath a glass panel 144 that supports cooking utensils over the electric burners 150 while electric burners 150 provide thermal energy to cooking utensils positioned thereon, e.g., to heat food and / or cooking liquids (e.g., oil, water, etc.). Electric 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. According to alternative embodiments, oven appliance 100 may have other cooktop configurations or burner elements.

[0027] In addition, 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 the, e.g., the size of oven appliance 100 or the desired heat output. Oven appliance 100 may include any other suitable number, type, and configuration of heating elements 150 within cabinet 102 and / or on cooktop 140. For example, oven appliance 100 may further include electric heating elements, induction heating elements, or any other suitable heat generating device.

[0028] Although aspects of the present subject matter are described herein in the context of a single oven appliance, it should be appreciated that oven 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, standalone cooktops, etc.

[0029] As illustrated, oven appliance 100 may generally include a user interface panel 160 that is located within convenient reach of a user of the oven appliance 100. For example, according to the illustrated embodiment, user interface panel 160 is mounted at a front 112 and top 104 corner of cabinet 102, e.g., directly above door 124. Although user interface panel 160 is illustrated as being mounted at a top, front of cabinet 102, it should be appreciated that aspects of the present subject matter may be applicable to other mounting locations of control panels, e.g., such as front mount control panels, rear mount panels, etc. In addition, it should be appreciated that the present subject matter is not limited oven applications but could instead be applied to any other suitable appliance.

[0030] For this example embodiment, user interface panel 160 includes control inputs 162 that are each associated with one of heating elements 150. In this manner, control inputs 162 allow the user to activate each heating element 150 and determine the amount of heat input provided by each heating element 150 to a cooking food items within cooking chamber 120 or on cooktop 140. Although control inputs 162 are illustrated as touch-sensitive or contact inputs, it should be understood that control inputs 162 and the configuration of oven appliance 100 shown in FIG. 1 is provided by way of example only. More specifically, user interface panel 160 may include various input components, such as one or more of a variety control knobs, electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. User interface panel 160 may also be provided with one or more graphical display devices or display components 164, 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.

[0031] User interface panel 160 may be in direct operative communication with a controller 166 of oven appliance 100, such that user inputs via user interface panel 160 may be directly used to regulate operation of various components of oven appliance 100. User interface panel 160 of oven appliance 100 may be in communication with controller 166 via, for example, one or more signal lines or shared communication busses, and signals generated in controller 166 operate oven appliance 100 in response to user input via user input devices 162. Input / Output ("I / O") signals may be routed between controller 166 and various operational components of oven appliance 100 such that operation of oven appliance 100 can be regulated by controller 166.

[0032] Controller 166 is a “processing device” or “controller” and may be embodied as described herein. Controller 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 oven appliance 100, and controller 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, controller 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.

[0033] In addition, controller 166 may also be communication with one or more sensors, such as temperature sensor 168 (FIG. 3), which may be used to measure temperature inside cooking chamber 120 and provide such measurements to the controller 166. As used herein, “temperature sensor” or the equivalent is intended to refer to any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, temperature sensor 168 may each be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, a semiconductor-based integrated circuit temperature sensor, etc. In addition, temperature sensor 168 may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and / or indicative of the temperature being measured. Although exemplary positioning of temperature sensors is described herein, it should be appreciated that oven appliance 100 may include any other suitable number, type, and position of temperature and / or other sensors according to alternative embodiments.

[0034] In some embodiments, oven appliance 100 includes a convection heating assembly 200 that operates in conjunction with chamber heating elements (e.g., heating elements 154, 156) to facilitate convection cooking within cooking chamber 120. In this regard, convection heating assembly 200 may operate to circulate a flow of heated air (e.g., identified in FIGS. 4 and 5 by reference numeral 202) within cooking chamber 120 to facilitate more even heating and shorter cooking cycle times. Although an example convection heating assembly 200 is described below, it should be appreciated that variations and modifications may be made while remaining within the scope of the present subject matter.

[0035] As best shown in FIGS. 3 through 5, convection heating assembly 200 includes a convection fan enclosure 210 positioned proximate a rear of cooking chamber 120. In this regard, convection fan enclosure 210 is defined at least partially by a front wall 212 and a rear wall 214 spaced apart along the transverse direction T. Front wall 212 may defines one or more apertures 216 that permit the flow of heated air 202 to pass into and out of convection fan enclosure 210. According to alternative example embodiments, convection fan enclosure 210 may include alternative airflow paths, ducts, or other flow regulating devices for directing the flow of heated air 202 within convection fan enclosure 210 and throughout cooking chamber 120.

[0036] As illustrated, convection heating assembly 200 further includes a convection fan 220 mounted in cabinet 102 (e.g., within convection fan enclosure 210) for circulating the flow of heated air 202 in cooking chamber 120. Specifically, convection fan 220 is illustrated as a centrifugal fan, though other suitable fan types and configurations are possible and within the scope of the present subject matter. A drive motor 222 may be mounted to cabinet 102 and may be mechanically coupled to convection fan 220 for selectively rotating convection fan 220. Drive motor 222 may be a single direction motor configured to rotate convection fan 220 in a single direction (e.g., clockwise as shown in FIG. 4 or counterclockwise as shown in FIG. 5). Notably, as explained above, using a single direction drive motor 222 and rotating convection fan 220 in a single direction may minimize costs and system complexity.

[0037] As explained briefly above, conventional convection fans produce an uneven airflow pattern due to rotation of the fan blade and require the use of a reversible drive motor to achieve uniform airflow. By contrast, convection heating assembly 200 may include a baffle plate 230 that at least partially surrounds convection fan 220 for achieving uniform airflow with minimal costs and simplified motor design and operation. In this regard, baffle plate 230 may be positioned entirely within convection fan enclosure 210 around convection fan 220 for directing or otherwise manipulating the flow of heated air 202 as needed to achieve uniform cooking and fast cook times within cooking chamber 120. Although an example construction of baffle plate 230 is described herein, it should be appreciated that variations and modifications may be made while remaining within the scope of the present subject matter.

[0038] As best illustrated in FIGS. 3 through 5, baffle plate 230 is positioned within convection fan enclosure 210 and extends between front wall 212 and rear wall 214 along the transverse direction T. According to alternative embodiments, baffle plate 230 may extend across only a portion of the depth of convection fan enclosure 210. In this manner, baffle plate 230 may capture and redirect the flow of heated air 202 that is ejected along a radial direction R or a centrifugal direction from convection fan 220. For example, baffle plate 230 may be arcuate and wrap around at least a portion of a perimeter 232 of convection fan 220. The geometry of baffle plate 230 may vary depending on the construction and direction of rotation of drive motor 222, the flow dynamics and construction of convection fan 220, the shape of convection fan enclosure 210, or other parameters of oven appliance 100. For example, baffle plate 230 may wrap around at least one-third of perimeter 232, around at least one-half of perimeter 232, or around at least three-fourths of perimeter 232 of convection fan 220.

[0039] For example, baffle plate 230 may enclose at least a lower third of convection fan 220, at least a lower half of convection fan 220, or at least a lower three-fourths of convection fan 220 along the vertical direction V. In addition, it should be appreciated that baffle plate 230 may be positioned within close proximity to convection fan 220 at the enclosed areas, e.g., within 50 millimeters, within 25 millimeters, within 15 millimeters, or closer. The profile of baffle plate 230 may also be designed for optimized flow based on the geometry and operation of convection fan 220.

[0040] Referring now specifically to the example embodiments of FIGS. 4 and 5, baffle plate 230 may be formed from a plurality of linear segment 240 that are joined for directing the flow of heated air 202. For example, baffle plate 230 may be U-shaped and define an open top portion 242, e.g., that is designed for uniformly ejecting the collected and redirected flow of heated air 202 from convection fan enclosure 210 into and throughout cooking chamber 120. According to example embodiments, top portion 242 may be tapered such that it becomes wider or narrower where the flow of heated air 202 is ejected from convection heating assembly 200.

[0041] According to example embodiments, baffle plate 230 may extend from a first end 244 to a second end 246, wherein first end 244 extends higher than second end 246 along the vertical direction V. For example, the higher end of first end 244 and second end 246 may be dependent on the rotational direction of drive motor 222. In this regard, second end 246 may be higher than first end 244 when drive motor 222 is configured to rotate in a clockwise direction (e.g., as shown in FIG. 4) and the first end 244 may be higher than second end 246 when drive motor 222 is configured to rotate in a counterclockwise direction (e.g., as shown in FIG. 5). In addition, baffle plate 230 may extend at least partially above convection fan 220 along the vertical direction V, either at first end 244, second end 246, or both.

[0042] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. An oven appliance defining a vertical direction, a lateral direction, and a transverse direction, the oven appliance comprising: a cabinet defining a cooking chamber;a door rotatably mounted to the cabinet to provide selective access to the cooking chamber; and a convection heating assembly operably coupled to the cooking chamber, the convection heating assembly comprising: a convection fan mounted in the cabinet for circulating a flow of air in the cooking chamber; anda baffle plate at least partially surrounding the convection fan for directing the flow of air.

2. The oven appliance of claim 1, wherein the convection heating assembly further comprises: a convection fan enclosure positioned proximate a rear of the cooking chamber, the convection fan enclosure being defined at least partially by a front wall and a rear wall spaced apart along the transverse direction.

3. The oven appliance of claim 2, wherein the baffle plate is positioned within the convection fan enclosure and extends between the front wall and the rear wall along the transverse direction.

4. The oven appliance of claim 1, wherein the baffle plate is arcuate and wraps around at least a portion of a perimeter of the convection fan.

5. The oven appliance of claim 4, wherein the baffle plate wraps around at least half of the perimeter of the convection fan.

6. The oven appliance of claim 4, wherein the baffle plate is U-shaped and defines an open top portion.

7. The oven appliance of claim 1, wherein the baffle plate is formed from a plurality of linear segments.

8. The oven appliance of claim 1, wherein the baffle plate encloses at least a lower third of the convection fan along the vertical direction.

9. The oven appliance of claim 1, wherein the baffle plate encloses at least a lower half of the convection fan along the vertical direction.

10. The oven appliance of claim 1, wherein the baffle plate extends from a first end to a second end, the first end extending higher than the second end along the vertical direction.

11. The oven appliance of claim 1, wherein the baffle plate extends at least partially above the convection fan along the vertical direction.

12. The oven appliance of claim 1, wherein the convection fan is a centrifugal fan.

13. A convection heating assembly operably coupled to a cooking chamber of an oven appliance, the convection heating assembly comprising: a convection fan mounted in a cabinet for circulating a flow of air in the cooking chamber; anda baffle plate at least partially surrounding the convection fan for directing the flow of air.

14. The convection heating assembly of claim 13, wherein the convection heating assembly further comprises: a convection fan enclosure positioned proximate a rear of the cooking chamber, the convection fan enclosure being defined at least partially by a front wall and a rear wall spaced apart along a transverse direction, wherein the baffle plate is positioned within the convection fan enclosure and extends between the front wall and the rear wall along the transverse direction.

15. The convection heating assembly of claim 13, wherein the baffle plate is arcuate and wraps around at least a portion of a perimeter of the convection fan.

16. The convection heating assembly of claim 15, wherein the baffle plate wraps around at least half of the perimeter of the convection fan.

17. The convection heating assembly of claim 13, wherein the baffle plate is formed from a plurality of linear segments.

18. The convection heating assembly of claim 13, wherein the baffle plate extends from a first end to a second end, the first end extending higher than the second end along a vertical direction.

19. The convection heating assembly of claim 13, wherein the baffle plate extends at least partially above the convection fan along a vertical direction.

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