1. Field of the Invention
The present application generally relates to control knobs for cooking appliances. More specifically, the present application relates to control knobs for cooking appliances that are adaptable to multiple valve stem orientations.
2. Description of the Related Art
Cooking appliances, such as, for example, barbecues, ranges, ovens, cook tops, burners, and grills, typically have one or more control knobs that connect with a control valve that is positioned within the cooking appliance. When the valve stem is positioned within the opening in the core, rotation of the control knob rotates the valve stem to open and/or close the valve. Thus, the control knob allows a user to regulate fuel delivery for the cooking appliance by manipulating the connected gas control valve. The control valve typically includes a valve stem that has a rounded portion and a flat portion or another suitable keying configuration.
A typical control knob includes a core that is integrally formed with an outer housing of the control knob. The core can include an axial opening that has a rounded portion and a flat portion to receive and cooperate with the valve stem. The orientation of the flat portion of the opening relative to the outer surface of the control knob can be different for different gas control valves used on a single cooking appliance when the valve is in an “off” position. Because control knobs typically have gripping portions and other indicators that are positioned in a particular orientation when in use on a cooking appliance, the control knobs preferably are properly matched with the control valves such that the knobs all have the same orientation in an “off” position.
Control knobs having integrally formed metal cores can be difficult to manufacture and a plurality of such knobs with cores of differing orientations need to be manufactured. For example, some control knobs are manufactured with an integrally formed solid metal core and the opening, having the desired orientation relative to the outer housing, is machined out of the core. Forming and machining the control knobs in this manner is difficult, time consuming, and expensive. Other control knobs are cast or formed with the opening in the desired orientation relative to the control knob housing. However, a different mold or process is needed to form each desired orientation of the control knob, which also adds significant costs. Still other control knobs have a generally larger integrally formed core with a generally larger opening to receive a core insert that comprises an opening that has a rounded portion and a flat portion to receive and cooperate with the valve stem. The core insert can be inserted into the core opening in a desired orientation but typically is formed of a plastic material that can deform over time. While the insert arrangement allows for a standard control knob housing and can provide an opening having the desired orientation, the manufacturing and assembly costs and challenges associated with this type of control knob are also high.
The invention disclosed herein includes the realization that control knobs for cooking appliances can be improved and production cost reduced by having a control knob assembly comprising a knob housing, a gripping portion, and a control valve interface portion, wherein the control valve interface portion is positionable in any one of a plurality of positions relative to the knob housing, and wherein the control valve interface portion is configured to be coupled to the gripping portion. It is further recognized that cooking appliances having an overlapping control knob and bezel assembly can provide increased protection of the control knob for, and can lend enhanced appearance to, the cooking appliance.
In one embodiment, a control knob comprises a knob housing having an outer surface, an inner surface, and one or more side portions. The one or more side portions define one or more openings between the outer surface and the inner surface of the knob housing. One or more gripping portions have one or more gripping surfaces and one or more connectors. The gripping portions are configured to be coupled with the outer surface of the knob housing at the one or more side portions. The one or more connectors are configured to be positioned within the one or more openings defined in the side portions of the knob housing. A control valve interface portion comprises a core forming an elongated opening for receiving at least a portion of a control valve stem. The control valve interface portion is configured to be coupled with the inner surface of the knob housing in more than one orientation and with the one or more connectors of the one or more gripping portions.
In another embodiment, a control knob comprises a knob housing having a first surface and a second surface. A gripping portion is configured to be coupled with the first surface of the knob housing. A control valve interface portion comprises a core forming an elongated opening for receiving at least a portion of a control valve stem. The elongated opening is defined by one or more inner surfaces of the central core. At least a portion of one inner surface is generally flat. The control valve interface portion is configured to be coupled with the knob housing in any one of a plurality of positions. The orientation of the core relative to the knob housing in a first position is different than the orientation of the core relative to the knob housing in a second position. The control valve interface portion is configured to be coupled with the gripping portion in any one of the plurality of positions.
In another embodiment, a cooking appliance comprises a fuel source, a cooking apparatus, a control valve having a control valve stem, the control valve positioned between the fuel source and the cooking apparatus, and one or more control knobs. The one or more control knobs comprise a knob housing. One or more gripping portions are coupled with the knob housing. A control valve interface portion is coupled with the knob housing. The control valve interface portion comprises a core forming an elongated opening. The core is coupled with at least a portion of the control valve stem. At least one of the one or more gripping portions is coupled directly to the control valve interface portion.
These and other features, aspects and advantages of the present invention will be better understood with reference to preferred embodiments, which are illustrated in the accompanying drawings. The illustrated embodiments are merely exemplary and are not intended to limit the scope of the present invention.
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In other embodiments, the outer surface 150 of the knob housing 112 can have other suitable configurations. For example, in some embodiments, the base portion 154 of the knob housing 112 has a generally oblong shaped base portion having flat and/or curved portions. In some embodiments, the raised central portion 156 can have other suitable shapes, such as, for example, a generally rectangular shape, a generally circular shape, a generally diamond shape, a generally hourglass shape. In some embodiments, the outer surface 150 of the knob housing 112 comprises one or more flat surfaces between the base portion 154 and the raised central portion 156. In still other embodiments, the knob housing 112 tapers uniformly from the base portion 154 to the raised central portion 156. In some embodiments, one or more side portions 160, 162, 164, 166 between the base portion 154 and the raised central portion 156 are not tapered.
In the illustrated embodiment, the inner surface 152 of the knob housing 112 defines a cavity generally corresponding to the shape of the outer surface 154 of the knob housing 112. Accordingly, in some embodiments, the knob housing 112 has a generally hollow shape. In one arrangement, the knob housing is generally solid without much, if any, cavity.
The knob housing 112 preferably is configured to be coupled with one or more gripping portions 114, 116. In some embodiments, one or more openings 170, 172, 174, 176 are defined in the knob housing 112. As shown in
The knob housing 112 preferably is configured to be coupled with a control valve interface portion 118. As shown in
In one embodiment, the knob housing 112 comprises metal. In some embodiments, the knob housing 112 is cast and/or machined. In other embodiments, the knob housing 112 can comprise plastic, stone, composite, or other suitable materials or combinations of materials. In some embodiments, the knob housing 112 can be molded, shaped and/or otherwise formed.
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In some embodiments, other suitable connectors can be used to couple the gripping portion 114, 116 with the knob housing 112 and the control valve interface portion 118. For example, a latch connector, a clip connector, a wrap-around connector, a button connector, and/or a pin connector can be used in some embodiments. Moreover, fasteners of any suitable configurations can be used to couple the gripping portion 114, 116 with the knob housing 112.
The gripping portions 114, 116 preferably comprise a plastic material, a composite material, or another suitable material. In some embodiments, the gripping portions 114, 116 can be molded, shaped, cast, machined, and/or otherwise formed.
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In some embodiments, the locators are arranged such that the control valve interface portion 118 can be coupled with the knob housing 112 in any one of a plurality of configurations. For example, as shown in
In some embodiments, the base plate 250 defines a plurality of openings. As shown in
In some embodiments, the base plate 250 comprises one or more openings 290, 292, 294, 296 that are larger than the openings 270, 272, 274, 276, 278, 280, 282, 284 for receiving and coupling with the pegs 204, 206, 208, 210. The larger openings 290, 292, 294, 296 preferably are provided to limit the amount of material required to form the base plate 250. In other embodiments, larger openings are not provided.
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In some embodiments, the orientation of the central core 252 relative to the knob housing 112 determines the relative positioning of the control knob 110 on the cooking appliance 100A, 100B. For example, the orientation of control valves and valve stems can vary for different cooking appliances. In some embodiments, the control valve interface portion 118 comprising the central core 252 configured to interface with the valve stem 128, can be positioned in a desired orientation relative to the knob housing 112, such that the control knob 110 is positioned in a desired orientation relative to the cooking appliance 100A, 100B. Having the ability to configure the orientation of the central core 252 relative to the knob housing 112 during the assembly process reduces the complexity and expense associated with manufacturing specialized control knobs.
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In one embodiment, the control valve interface portion 118 comprises metal. In some embodiments, the control valve interface portion 118 is cast and/or machined. In other embodiments, the knob housing 112 can comprise plastic, stone, composite, or other suitable materials or combinations of materials. In some embodiments, the knob housing 112 can be molded, shaped and/or otherwise formed.
In one embodiment, the bezel 136 comprises a base portion 330, an outer rim portion 332, and an inner generally cylindrical flange portion 334. The base portion 330 preferably is configured to be coupled with the cooking appliance 100A, 100B. In one embodiment, at least a portion of the bezel 136 is configured to receive a fastening element, such as, for example, a screw, to couple the bezel 136 with the cooking appliance 100A, 100B.
In some embodiments, the base portion 330 of the bezel 136 defines a plurality of openings, with at least one of the openings, for example, a central opening 336, being sized and configured to receive and/or be coupled with at least a portion of the control valve 120. In some embodiments, other openings are relatively larger than, and/or relatively smaller than, the central opening 336 and are configured to limit the amount of material required to form the base portion 330 of the bezel 136.
The outer rim portion 332 and the inner generally cylindrical flange portion 334 preferably define a space 338 therebetween for receiving at least a portion of the peripheral flange 254 extending from the control knob 110. In one embodiment, the surface 340 of the outer rim portion 332 near the control knob 110 is curved. The extension of the peripheral flange 254 between the outer rim 332 and the cylindrical flange 334 of the bezel 136 provide increased protection for the cooking apparatus 100A, 100B and helps to protect the control knob assembly 110 and cooking appliance from foreign objects and/or spills that could damage or affect the connection between the control knob 110 and the control valve 120.
The bezel 136 also contains an indicator system 400. The indicator system 400 preferably comprises a light source/holder assembly 402 and a light pipe 404. In one embodiment, the light source is an LED. In another embodiment, the light source is a neon light. The light source/holder assembly 402 provides an electrical connection between any suitable light source and the electrical system of the appliance. When the light source is turned on, the light from the light source is transmitted through the light pipe 404 and is visible to users of the appliances. For instance, the light source can be used to indicate that a burner has been turned on. The light pipe 404 preferably has an upper surface 406 that is curved. The curved upper surface 406 helps to direct spills away from the light pipe 404 and the use of the light pipe 404, which protrudes from the bezel 136, helps to eliminate a location in which liquids can pool.
In one embodiment, the bezel 136 comprises metal. In some embodiments, the bezel 136 is cast and/or machined. In other embodiments, the bezel 136 can comprise plastic, stone, composite, or other suitable materials or combinations of materials. In some embodiments, the bezel 136 can be molded, shaped and/or otherwise formed.
Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In particular, the skilled artisan will appreciate, in view of the present disclosure, that certain advantages, features and aspects of the embodiments described herein may be realized in a variety of other applications, many of which have been noted above. The skilled artisan can readily adapt the principles and advantages described herein to a variety of other applications. Additionally, it is contemplated that various aspects and features of the invention described can be practiced separately, combined together, or substituted for one another, and that a variety of combination and subcombinations of the features and aspects can be made and still fall within the scope of the invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.
This application is based on and claims priority to U.S. Provisional Patent Application No. 60/679,684 (filed May 10, 2005), the entire contents of which is hereby expressly incorporated by reference herein and made a part of this specification.
Number | Date | Country | |
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60679684 | May 2005 | US |