BUILT-IN RANGE FOR RECREATIONAL VEHICLES

Abstract

A vent cover system covers a gap between an appliance and a back wall. The vent cover system includes a gap plate securable across the countertop opening against the back wall, and a vent plate securable across the countertop opening and engaging the gap plate. A position of the vent plate is adjustable relative to the gap plate. The gap plate and the vent plate cover the gap between the appliance and the back wall. A cooktop for an appliance mounted in a countertop of a recreational vehicle includes the vent cover system.

Description

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

(NOT APPLICABLE)

BACKGROUND

The invention relates to a built-in range for recreational vehicles (RVs) and, more particularly, to a built-in range incorporating design elements that facilitate installation, reduce installation time, improve appearance and stability, and improve performance and functionality.

Oven ranges for recreational vehicles have added design challenges due to their use and functionality in a mobile environment. Typically, oven ranges are compact due to space limitations while requiring full range functionality along with a streamlined and desirable appearance. Installation of the oven range into a recreational vehicle can also be challenging as it is a large appliance that can be difficult to move and properly fit into the RV countertop. The oven range is also installed into an environment subject to vibration, which can also make it challenging to install the oven range in a secure and safe way that results in a clean and appealing appearance.

It is common in this field to make a U-shaped cutout in the RV countertop to install the range as a single unit or assembly that already includes a vent at the back. The size of the range units, however, is typically not equivalent to the full countertop surface, which means that the range units require the small portion of the countertop at the back of the range to avoid an unsightly gap and so that the unit is not oddly recessed into the cabinets or counter. This often results in a notable amount of time spent in measuring the countertop and oven range, precisely cutting the countertop, and installing the oven range into the countertop.

Existing ranges also have performance shortcomings due to poor air circulation and limited oven space.

Improvements can further be made in cooktops and cooking grates for more secure connections and better air circulation.

SUMMARY

According to the described embodiments, a chef range/appliance includes an oven and a cooktop with a plurality of burners. Among other features, the chef range of the described embodiments incorporates an adjustable depth vent cover that facilitates installation of the appliance and enables installation without unsightly gaps between the appliance, the countertop, and the back wall. The adjustable depth vent cover of the described embodiments allows for the manufacturers to make a straight and complete cutout in the countertop, which reduces waste in countertop materials and makes for easier installation of the range. The adjustable depth vent cover of the described embodiments also reduces installation time needed for the oven range into the countertop by eliminating a measuring and cutting step of the countertop. The adjustable vent cover to be installed at the gap in the back of the cutout also allows for installation of the range in various sizes of countertops.

A recessed burner and cavity increases usable oven space, and diffuser plates and a bottom plate with air intake slots help to more evenly distribute heat within the oven for better controlled cooking. The bottom burner also interacts with features in the oven door for air intake for combustion and heat circulation. The bottom burner assembly is coupled with the ventilation door, and a ventilation pathway is defined beneath and behind the appliance for increased ventilation to prevent overheating of the internal components of the oven range and to reduce the temperature of the exterior surfaces on and around the oven range.

In some embodiments, the cooktop range is recessed or sunken in so that the burners do not protrude above the countertop or top of the console. Low-profile grates are positioned on top of the burners and include outer edges shaped for added strength and tapered legs for better hold and stability. Interior portions of the grates have a raised thinner profile to facilitate airflow.

In an exemplary embodiment, a vent cover system for an appliance mountable in a countertop opening for covering a gap between the appliance and a back wall includes a gap plate securable across the countertop opening against the back wall, and a vent plate securable across the countertop opening and engaging the gap plate. A position of the vent plate is adjustable relative to the gap plate, and the gap plate and the vent plate cover the gap between the appliance and the back wall.

The vent cover system may also include connecting blocks securable in the countertop opening adjacent the back wall, where the gap plate is secured to the connecting blocks. The gap plate may include alignment tabs that are positioned for alignment with corresponding alignment markings on the appliance. The gap plate may include a slot in a side surface, where the vent plate may have a pillar extending through a side wall, and the pillar may be engaged in the slot. The vent plate may be securable to the appliance via connectors positioned through the vent plate. The vent cover system may also include a gas pressure checking point disposed under the vent plate. The appliance may include cooking grates, and a height of the vent plate may be flush with or lower than a top surface of the cooking grates.

In another exemplary embodiment, a cooktop for an appliance mounted in a countertop of a recreational vehicle includes a top tray including a plurality of burners, a plurality of control knobs respectively cooperable with the plurality of burners that selectively connect a heat source to the plurality of burners, and a cooking grate positioned on the top tray over the plurality of burners. The top tray includes a recessed area, and the plurality of burners are disposed in the recessed area and are sized such that a top of the plurality of burners is flush with or below the countertop. The cooktop also includes the vent cover system of the described embodiments.

A front grate bar and side grate bars of the cooking grate may be L-shaped. A rear grate bar of the cooking grate may be thinner than the front grate bar and may define an airflow passage.

The cooking grate may include feet that directly engage the top tray, and the feet may include tapered legs.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects and advantages will be described in detail with reference to the accompanying drawings, in which:

FIG. 1 shows the chef range installed in an RV countertop;

FIG. 2 shows a straight cut out in the RV countertop;

FIG. 3 shows an exemplary placement of the adjustable depth vent cover;

FIGS. 4 and 5 show the chef range installed in an RV countertop;

FIGS. 6A-6F and 7A-7C show details of the adjustable depth vent cover;

FIG. 8 shows a hidden gas pressure checking port accessible via the vent cover;

FIG. 9 shows cooking grates above or flush with the vent cover;

FIGS. 10A-10G show details of a bottom burner assembly and cavity;

FIGS. 11A-11G show features relating to the oven interaction with the oven door;

FIGS. 12A-12E show details of exemplary cooking grates;

FIG. 13 shows an alternative cooking grate design;

FIG. 14 shows an alignment and installation design for the bottom cosmetic panel;

FIGS. 15A-15C show a cooktop burner design with a straight venturi tube inlet;

FIGS. 16 and 17 show a flush door installation; and

FIGS. 18 and 19 show details of exemplary cooking grate feet.

DETAILED DESCRIPTION

FIGS. 1 and 4 show an exemplary appliance or chef range 10 installed in a countertop 12 of a recreational vehicle (RV). As noted previously, with prior designs, installers typically make a U-shaped cutout in the RV countertop to install the appliance as a single unit or assembly that already includes a vent at the back. The size of the range units are typically not equivalent to the full countertop surface, which means that they still need the small portion of countertop at the back of the range to avoid an unsightly gap at the back of the unit and so that the unit is not oddly recessed into the cabinets or counter.

FIG. 2 shows an improvement according to the described embodiments where the manufacturer/installer can make a straight and complete cutout in the countertop 12, thereby reducing waste in countertop materials and making for easier installation of the appliance. FIGS. 3 and 5 show a vent cover system 14 defining an adjustable depth vent cover installed at the gap in the back of the cutout. The vent cover system 14 allows for installation of the chef range 10 in various sizes of countertops.

FIGS. 6 and 7 show details of the vent cover system 14 and installation methodology. A straight cutout is made in the countertop 12 as shown in FIGS. 2 and 7. The vent cover system 14 includes a gap plate 16 that is securable across the countertop opening against a back wall, and a vent plate 18 that is securable across the countertop opening and engaging the gap plate 16. As shown, the vent plate 18 includes a plurality of openings or slots therein to exhaust heat from the appliance and facilitate vented airflow from the back of the appliance 10 through the vent plate 18. The slots of the vent plate 18 may also prevent food particles or other debris from falling into the countertop opening behind the chef range 10.

Connecting blocks 20 are securable in the countertop opening adjacent the back wall. The gap plate 16 is secured to the connecting blocks 20. In some embodiments, the gap plate 16 is provided with alignment tabs 22 that are positioned for alignment with corresponding alignment markings 24 on the appliance 10. The appliance 10 may also be secured to the blocks 20 via suitable connectors.

The vent plate 18 may be provided with a plastic pillar 25 extending through a sidewall 26. The plastic pillar 25 engages a slot 28 in a side surface of the gap plate 16. With continued reference to FIG. 7, with the pillar 25 inserted into the slot 28, the vent plate 18 can be slid backward over the gap plate 16 until the vent plate 18 sets flush against the countertop 12. The vent plate 18 is subsequently securable to the appliance 10 via connectors positioned through the vent plate 18. The vent plate 18 may be provided detached from or only partially fastened to the rear of the appliance 10 prior to installation of the appliance.

FIG. 6 shows another depth-adjustable component for accommodating the depth of a countertop overhang. In this aspect, the chef range 10 includes a cooktop 30 including a top tray 32 with a plurality of burners 34 and a plurality of control knobs 36 respectively cooperable with the plurality of burners 34 that selectively connect a heat source to the plurality of burners 34. The heat source may be propane or some other combustible gas, or the heat source may be electrical. A cooking grate 38 is positioned on the top tray 32 over the plurality of burners 34.

The control knobs 36 are secured on the outside of a cooktop faceplate 40. As shown in FIG. 6, the cooktop faceplate 40 may be provided with a recessed section 42 to accommodate a countertop overhang. FIG. 6 also shows a variation without a countertop overhang where the recessed section 42 may be left open or may be provided with a plastic insert or the like to fill the space.

In an exemplary application, with a one inch countertop overhang, the depth adjustable features of the described embodiments can accommodate a countertop depth range between 23-24.5 inches. With a zero inch countertop overhang, the installation can accommodate a countertop depth range of 22-23.5 inches. By controlling the countertop overhang depth and adjusting the vent cover system, the installation utilizing a straight cut out in the countertop can accommodate a countertop depth range from 22-24.5 inches, which encompasses most RV designs.

With reference to FIG. 8, the vent cover system 14 may incorporate a hidden gas pressure checking point 44 disposed under the vent plate 18. The gas pressure checking point 44 may be connected to a gas inlet conduit 46.

As shown in FIG. 9, in some embodiments, a height of the vent plate 18 is flush with or lower than a top surface of the cooking grates 38. This feature effectively extends the cooktop area, enabling pots to be offset to accommodate larger and multiple pots at one time. Smaller burners may be positioned at the back of the appliance to minimize overlap.

FIGS. 10A-10G show components of an exemplary oven 50 forming part of the chef range appliance 10 according to the described embodiments. The oven 50 includes an oven compartment 52 and a burner 54 positioned adjacent a bottom of the oven compartment 52. A heat diffuser 56 in the form of a heat diffuser plate is positioned above the burner 54, and air intake openings 58 are provided through the oven compartment 52 and positioned below the burner 54. At least some of the air intake openings 58 are disposed in a bottom of the oven compartment 52.

The heat diffuser 56 may be supported on a diffuser rack 60 positioned in the oven compartment 52. In some embodiments, the diffuser rack 60 defines spaces between the heat diffuser 56 and sidewalls of the oven compartment 52, thereby providing direct heat airflow from the burner 54 into the oven compartment 52.

As seen in FIG. 5, the chef range appliance 10 includes side edges 82, 84 of the upper tray 32 of the cooktop that overlap the left and right edges of the countertop 12. In an exemplary embodiment, the side edges 82, 84 each overlap with the countertop 12 by 16 mm (for example), which means that the upper tray 32 of the cooktop is 32 mm wider than the cut out of the countertop. The overlap of the cooktop over the countertop causes the chef range appliance 10 to be supported by the countertop 12. Fasteners (not shown) are preferably installed four at the front of the oven compartment and two at the rear of the oven so that the chef range appliance may withstand vibration when the RV is in use. Other fastener arrangements may be used.

With reference to FIGS. 10A-10G, the oven compartment 52 may be spaced from a floor from which the oven is spaced by feet 62 secured to an underside of the oven compartment 52, plus a gap 64 between the feet 62 and the floor, plus an indentation 66 in the bottom wall of the oven compartment 52. The gap between the feet 62 and the floor is possible by overlapping side edges of the cooktop tray 32 that are wider than the cut out, so that the appliance 10 may hang and be suspended by the countertop. Additionally, fasteners (not shown) may be used to further secure the appliance 10 to the countertop to withstand vibrations as the vehicle is in motion. In an exemplary construction, the gap 64 is 3 mm, the feet 62 are 8 mm, and the indentation 66 is 3 mm, resulting in a 14 mm gap between the bottom wall of the oven compartment and the floor or cabinet wood bottom. The feet 62, the gap 64 and the indentation 66 define an air insulation gap 68 through which air flows and exhausts via the vent cover system 14. The feet 62 ensure that even if the countertop cut out is not sized correctly, then there will still be a gap between the bottom of the oven compartment 52 and the combustible wood surface of the counter space. The feet 62 also prevent scratching and damage to the bottom of the oven compartment 52 if placed on another ground surface prior to installation.

With reference to FIGS. 11A-11G, the cooktop 30 is supported above the oven compartment 52. The cooktop control knobs 36 are positioned between the oven compartment 52 and the upper tray 32 of the cooktop. Slots 70 for air intake may be provided above the cooktop control knobs 36. A heat shield 72 may be positioned between the oven compartment 52 and the cooktop 30. As shown, the heat shield 72 defines an exhaust path for radiant heating to the vent cover system 14. That is, radiant heating flows backward due to the heat shield 72 rather than getting stuck under the control panel bottom. A larger height cooktop area facilitates hot air flow toward the back of the appliance and emission out from the vent cover system 14 with sufficient vent slots along its length. Moreover, the cooktop 30 is provided with larger distances from the heated top tray 32 to the knobs 36 to prevent the knobs 36 from heating up during use.

With continued reference to FIGS. 11A-11G, a door 74 is cooperable with the oven compartment 52 to provide access to the oven compartment 52. Air intake openings 76 may be disposed in the door 74. Additionally, the door 74 may include a plurality of side heating ventilation slots 78. In some embodiments, no slots are provided in a top portion of the door 74 to prevent hot air flow from directly blowing onto the bottom of the cooktop control panel. Multiple layer glass provides for heat insulation between the hot interior of the oven compartment 52 and the exterior of the door 74.

The recessed burner 54 within the oven compartment 52 increases usable oven space, and the heat diffuser plate 56 and air intake openings 58 help to more evenly distribute the heat within the oven for more controlled cooking. The bottom burner 54 also interacts with the ventilation slots 78 in the oven door 74 for air intake for combustion and heat circulation. The bottom burner 54 is coupled with the ventilation door and a ventilation pathway beneath and behind the appliance for increased ventilation to prevent overheating.

FIGS. 12A-12E show details of the cooking grate 38 that is positioned on the top tray 32 over the burners 34. As shown, the top tray 32 includes a recessed area 32a, where the burners 34 are disposed in the recessed area 32a. In some embodiments, the burners 34 are sized such that a top of the burners is flush with or below the countertop 12. The cooking grate 38 may be a low profile grate to minimize a height above the countertop 12.

A front grate bar 38a and the side grate bars 38b may be L-shaped to provide better strength performance and to avoid deformation across the middle for larger grates. A rear grate bar 38c may be thinner than the front grate bar 38a and may define an air flow passage for improved combustion.

Feet 80 of the grate 38 directly engage the top tray 32. In some embodiments, the feet 80 include tapered legs for better hold and stability. More specifically, with continued reference to FIGS. 12A-12E, the pit shape of the feet 80 help to limit the vibration at X and Y axes while the vehicle is in motion. As seen in FIGS. 18 and 19, feet 80 may include a brass or metallic pin portion 86 that nests into a rubber pad 88. The rubber pad 88 resists vibration and has a high temperature tolerance to avoid deformation while the chef range appliance 10 is in use. The pin portion 86 may include a knurled pin 90 with teeth 90a at an upper end of the pin portion for resisting vibration and preventing movement within the rubber pad 88 while the vehicle where the chef range appliance is installed is in motion. The pin portion 86 may include a straight cylindrical portion 90b of the knurled pin that extends to a lower end of the pin portion and is received by a tapered or narrower portion of the rubber pad 88 for anchoring the feet 80 in the top tray 32. The top tray 32 may include elliptical holes 92 to assist in receiving and retaining the rubber pad 88 of the feet 80.

The rubber pad 88 may include an external notch or taper 94 at an intermediate location of the rubber pad for encompassing the circumferential edge of the corresponding elliptical hole 92 to prevent accidental release or displacement of the rubber pad. In an exemplary embodiment, the notch or taper 94 in the exterior of the rubber pad 88 may be 7.9 mm in diameter (for example) approximate to the diameter of the elliptical hole 92 in the top tray 32, and the adjacent diameter of the rubber pad 88 may be 11.8 mm in diameter (for example). In some embodiments, the upper end of the knurled pin 90 including teeth 90a may be larger in diameter than the lower end with the straight cylindrical portion 90b, in which case the rubber pad 88 includes a correspondingly sized diameter opening. In an exemplary embodiment, the straight cylindrical portion 90b of the knurled pin has a 15-20 mm height for preventing movement or accidental displacement of the foot 80 from the top tray 32 and has a 4.1 mm diameter (for example) that fits within a 3.5 mm diameter (for example) hole in the rubber pad 88 to prevent removal from the rubber pad.

FIG. 13 shows a variation of the cooking grate 38′ that includes a solid plate portion. The solid plate portion permits the user to set an object on the grate without concern that the object would fall through the grate openings.

FIG. 14 shows a process for alignment and installation of the bottom cosmetic panel without tools. As shown, a cosmetic panel is placed on the front of the cabinet and slid upward until the tabs are successfully inserted into the oven side brackets. A chamfering feature on a rubber cover helps to guide the tabs into the oven panel. Once fully inserted, the rubber cover serves to pre-hold the panel, enabling the user to have both hands free to secure the cosmetic panel with suitable connectors. The bracket may include a shoulder that serves as a stop member to limit the depth of insertion.

FIGS. 15A-15C show yet another feature of the design incorporating a cooktop burner with a straight venturi tube inlet. The configuration reduces the distances between burners and expands the user's ability to use multiple pot sizes at the same time.

FIGS. 16 and 17 show flush built-in installation for the oven door. The console's special side design and a hidden convex door frame design allow the oven door panel to be almost flush with the cabinet front. Traditional RV ranges have a thick door with handle extending outward. The chef range flush door of the described embodiments increases space in the RV kitchen.

In some embodiments, the control knobs are sunken into the cabinet area and do not protrude out as much as conventional designs. The control knobs are behind the handle, preventing accidental bumping and turning on the knob. The countertop encapsulated into the console sides allows for the door area to protrude less into the main kitchen area. Moreover, the console side design allows up to one inch of countertop height to be encapsulated into the console to have a desirable integrated appearance.

The chef range appliance of the described embodiments incorporates design features that facilitate installation while improving functionality and appearance.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A vent cover system for an appliance mountable in a countertop opening for covering a gap between the appliance and a back wall, the vent cover system comprising: a gap plate securable across the countertop opening against the back wall; anda vent plate securable across the countertop opening and engaging the gap plate, wherein a position of the vent plate is adjustable relative to the gap plate, the gap plate and the vent plate covering the gap between the appliance and the back wall.

2. A vent cover system according to claim 1, further comprising connecting blocks securable in the countertop opening adjacent the back wall, wherein the gap plate is secured to the connecting blocks.

3. A vent cover system according to claim 1, wherein the gap plate comprises alignment tabs that are positioned for alignment with corresponding alignment markings on the appliance.

4. A vent cover system according to claim 1, wherein the gap plate comprises a slot in a side surface, wherein the vent plate comprises a pillar extending through a side wall, and wherein the pillar is engaged in the slot.

5. A vent cover system according to claim 1, wherein the vent plate is securable to the appliance via connectors positioned through the vent plate.

6. A vent cover system according to claim 1, further comprising a gas pressure checking point disposed under the vent plate.

7. A vent cover system according to claim 1, wherein the appliance includes cooking grates, and wherein a height of the vent plate is flush with or lower than a top surface of the cooking grates.

8. A cooktop for an appliance mounted in a countertop of a recreational vehicle, the cooktop comprising: a top tray including a plurality of burners;a plurality of control knobs respectively cooperable with the plurality of burners that selectively connect a heat source to the plurality of burners;a cooking grate positioned on the top tray over the plurality of burners,wherein the top tray includes a recessed area, and wherein the plurality of burners are disposed in the recessed area and are sized such that a top of the plurality of burners is flush with or below the countertop; anda vent cover system positioned in a countertop opening in the countertop for covering a gap between the cooktop and a back wall, the vent cover system including a gap plate securable across the countertop opening against the back wall, and a vent plate securable across the countertop opening and engaging the gap plate, wherein a position of the vent plate is adjustable relative to the gap plate, the gap plate and the vent plate covering the gap between the cooktop and the back wall.

9. A cooktop according to claim 8, wherein a front grate bar and side grate bars of the cooking grate are L-shaped.

10. A cooktop according to claim 9, wherein a rear grate bar of the cooking grate is thinner than the front grate bar and defines an airflow passage.

11. A cooktop according to claim 8, wherein the cooking grate comprises feet that directly engage the top tray, and wherein the feet include tapered legs.

12. A cooktop according to claim 8, further comprising connecting blocks securable in the countertop opening adjacent the back wall, wherein the gap plate is secured to the connecting blocks.

13. A cooktop according to claim 8, wherein the gap plate comprises alignment tabs that are positioned for alignment with corresponding alignment markings on the cooktop.

14. A cooktop according to claim 8, wherein the gap plate comprises a slot in a side surface, wherein the vent plate comprises a pillar extending through a side wall, and wherein the pillar is engaged in the slot.

15. A cooktop according to claim 8, wherein the vent plate is securable to the cooktop via connectors positioned through the vent plate.

16. A cooktop according to claim 8, further comprising a gas pressure checking point disposed under the vent plate.

17. A cooktop according to claim 8, wherein the cooktop includes cooking grates, and wherein a height of the vent plate is flush with or lower than a top surface of the cooking grates.