DETECTING IMPROPER POSITIONING OF A REMOVABLE BOTTOM PANEL OF AN OVEN APPLIANCE

FIELD

The present subject matter relates generally to oven appliances, and more particularly to systems and methods for detecting a position of a bottom panel assembly for an oven appliance.

BACKGROUND

Generally, oven appliances include one or more heat sources that provide different styles of heating to a cooking chamber. One or more heat sources may be provided beneath the cooking chamber, e.g., along the vertical direction, to provide heat upward through a bottom panel of the cooking chamber. The bottom panel may thus be positioned between a heat source and a food or cooked item within the cooking chamber. During use, the bottom panel may protect the heat source from damage due to grease or food particles from cooked items within the cooking chamber. Additionally, or alternatively, the bottom panel may collect much or all of the produced contaminants from the food items. Accordingly, the bottom panel may become dirty or damaged from food particles, grease, or certain elements bonding with the bottom panel.

The bottom panel of the oven appliance may be removable, for instance, to allow for easier cleaning of the bottom panel. However, in some instances, after the removal of the bottom panel, a user of the oven appliance may improperly reposition the bottom panel during reinstallation. Improper positioning of the bottom panel within the oven appliance can negatively impact the performance of the oven appliance. For instance, improper positioning of the bottom panel can cause uneven or inconsistent heating of the cooking chamber.

Accordingly, systems and methods for detecting the positioning of a bottom panel for a cooking chamber of an oven appliance would be beneficial. More particularly, detecting improper positioning of the bottom panel (e.g., without the use of a dedicated position sensor) would be particularly useful.

BRIEF DESCRIPTION OF THE INVENTION

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

In one exemplary embodiment, a method of operating an oven appliance is provided. The method may include a step of measuring, with a temperature sensor, a first temperature of a cooking chamber during a cook cycle, The first temperature may be measured at a first predetermined time. The method may further include a step of measuring, with the temperature sensor, a second temperature of the cooking chamber during the cook cycle. The second temperature is measured at a second predetermined time. The method may also include a step of calculating, based on the first temperature and the second temperature, a heating rate. The method may further include a step of determining, based on the heating rate, a position of a bottom panel assembly.

In another exemplary embodiment, an oven appliance is provided. The oven appliance may include a temperature sensor positioned within a cooking chamber of the oven appliance. The oven appliance may also include a bottom panel assembly removably provided within the cooking chamber. The oven appliance may further include a controller. The controller operable for measuring, with the temperature sensor, a first temperature of the cooking chamber during a cook cycle, wherein the first temperature is measured at a first predetermined time; measuring, with the temperature sensor, a second temperature of the cooking chamber during a cook cycle, wherein the second temperature is measured at a second predetermined time; calculating, based on the first temperature and the second temperature, a heating rate; and determining, based on the heating rate, a position of a bottom panel assembly.

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

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.

FIG. 1 provides a front view of an oven appliance according to one or more exemplary embodiments of the present subject matter.

FIG. 2 provides a side view of the exemplary oven appliance of FIG. 1.

FIG. 3 provides a top perspective view of an interior cooking chamber of the exemplary oven appliance of FIG. 1.

FIG. 4 provides a perspective view of a bottom panel assembly according to one or more exemplary embodiments of the present subject matter.

FIG. 5 provides an exploded perspective view of the exemplary bottom panel assembly of FIG. 4.

FIG. 6 provides a rear perspective view of the exemplary bottom panel assembly of FIG. 4.

FIG. 7 provides a side cut-away view of the exemplary bottom panel assembly of FIG. 4.

FIG. 8 provides an enlarged side cut-away view of the exemplary bottom panel assembly of FIG. 7.

FIG. 9 provides a bottom perspective view of a retention clip according to one or more exemplary embodiments of the present subject matter.

FIG. 10 provides a flow diagram of an algorithm that may be used to detect a position of a bottom panel assembly of an oven appliance according to one or more exemplary embodiments of the present subject matter.

FIG. 11 provides a graph of one or more temperature data sets of a cooking chamber of an oven appliance according to one or more exemplary embodiments of the present subject matter.

FIG. 12 provides a flow chart of an exemplary method of operating an oven appliance according to one or more exemplary embodiments of the present subject matter.

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

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.

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”).

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 or systems. For example, the approximating language may refer to being within a ten 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.

Referring to FIGS. 1 and 2, an exemplary embodiment of an oven appliance 100 is provided according to one or more exemplary embodiments of the present subject matter. In particular, FIG. 1 provides a front view of the oven appliance 100. FIG. 2 provides a cross-sectional view of the oven appliance 100 taken along the 2-2 axis shown in FIG. 1. In some embodiments, the oven appliance 100 may include a cabinet or housing 101 with a cooking chamber 116 positioned therein.

In some embodiments, the cabinet 101 may extend between a first side 140 and a second side 141 along a lateral direction L, see, for example, FIG. 1. Further, the cabinet 101 may also extend between a front 142 and a back 143 along a transverse direction T, see, for example, FIG. 2. The cabinet 101 may further extend between a top 144 and a bottom 145 along a vertical direction V. The transverse direction T may be substantially perpendicular to the lateral direction L and the vertical directions V. Thus, the vertical direction V, the lateral direction L, and the transverse direction T may be orthogonally oriented such that the vertical direction V, the lateral direction L, and the transverse direction T may form an orthogonal directional system.

Moreover, the cooking chamber 116 may include a plurality of walls including bottom wall 119 (described in more detail below), back wall 120, and top wall 121, first sidewall 1181 and second sidewall 1182 that define cooking chamber 116. Bottom wall 119 and top wall 121 may be spaced apart along the vertical direction V. Back wall 120 may extend between the first sidewall 1181 and the second sidewall 1182 along the lateral direction L and also extends between top wall 121 and bottom wall 119 along the vertical direction V.

The first sidewall 1181 and the second sidewall 1182 may each include supports 122, see, for example, FIG. 2, for supporting oven racks 132, see, for example, FIG. 2, that may be selectively positioned within cooking chamber 116. Oven racks 132 may include any suitable number of racks. For example, as illustrated in FIG. 2, the oven racks 132 may include a top rack 136 and a bottom rack 138. The top rack 136 is positioned above bottom rack 138 along the vertical direction V. Additional supports 122 may be provided at or near a bottom of cooking chamber 116 to support bottom wall 119, which will be described in further detail below.

In some embodiments, the oven appliance 100 may also include a door 104 with handle 106 that provides for opening and closing access to a cooking chamber 116. A user of the oven appliance 100 may place a variety of different items to be cooked in cooking chamber 116 onto the oven racks 132. Further, in some embodiments, one or more heating elements, for instance, heating elements 117, may be positioned at the top or the bottom of cooking chamber 116 to provide heat for cooking and cleaning. Such heating element(s) may be, for example, gas heating elements, electric heating elements, microwave heating elements, or a combination thereof. Other heating elements (not shown) could be located at other locations as well. The oven appliance 100 may also include a window 110 on the door 104 that may allow a user to view the cooking chamber 116 during the cooking process, for example, the window 110 may allow a user to view food items within the cooking chamber 116 during the cooking process.

Referring to FIG. 1, the oven appliance 100 may include a user interface panel 102 having a display 103 positioned on top panel 114 with a variety of controls 112. In certain embodiments, the user interface panel 102 may allow the user to select various options for the operation of the oven appliance 100 including, for example, a temperature, a time, or various cooking and cleaning cycles of the oven appliance 100. Operation of the oven appliance 100 may be regulated by a controller 160, see, for example, FIG. 2, that is operatively coupled, for example, in communication with, user interface panel 102, heating element(s), and other components of oven appliance 100 as will be further described.

For example, in response to user manipulation of the user interface panel 102, the controller 160 may operate one or more heating elements, such as heating elements 117. In some embodiments, the controller 160 may be operable for receiving temperature measurements from a temperature sensor 113, see, for example, FIG. 2, that may be placed in cooking chamber 116 and providing a temperature indication of the temperature measurements to the user with display 103. By way of example, the controller 160 may include a memory and one or more processing devices such as microprocessors, 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. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one exemplary 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.

The controller 160 may be positioned in a variety of locations throughout the oven appliance 100. For instance, in some embodiments, the controller 160 may be located under or next to the user interface panel 102 or otherwise within top panel 114. In an exemplary embodiment, input/output (“I/O”) signals may be routed between the controller 160 and various operational components of oven appliance 100 such as the heating elements 117, the controls 112, the display 103, sensor(s) such as the temperature sensor 113, alarms, or other components as may be provided. In one exemplary embodiment, the user interface panel 102 may represent a general purpose VO (“GPIO”) device or functional block.

Although shown with touch type controls 112, it should be understood that controls 112 and the configuration of the oven appliance 100 shown in FIG. 1 is provided by way of example only. More specifically, user interface panel 102 may include various input components, such as one or more of a variety of electrical, mechanical, or electro-mechanical input devices including rotary dials, push buttons, and touch pads. The user interface panel 102 may include other display components, such as a digital or analog display device designed to provide operational feedback to a user. The user interface panel 102 may be in communication with the controller 160 via one or more signal lines or shared communication busses. Also, the oven appliance 100 is shown as a wall oven but the present invention could also be used with other appliances such as e.g., a stand-alone oven, a range, and other configurations as well.

FIGS. 3 through 9 illustrate a removable bottom panel assembly 170 according to exemplary embodiments of the present disclosure. In some embodiments, the bottom wall 119 may be formed, at least in part, as a removable bottom panel assembly 170. In detail, the removable bottom panel assembly 170 may form at least a portion of the bottom wall 119 of cooking chamber 116, and may be removable from cabinet 101, for example, for cleaning, replacement, etc. According to at least some embodiments, the removable bottom panel assembly 170 may be removed without the use of any tools, for example, screwdrivers, drills, clips, etc. In this regard, the removable bottom panel assembly 170 may easily be inserted and removed from cabinet 101.

In some embodiments, the removable bottom panel assembly 170 may include a panel 172. The panel 172 may be formed from a first material, for instance, a material that may be the same as the plurality of walls forming the cooking chamber 116. For example, in at least one embodiment of the present subject matter, the panel 172 may be formed from a metal. Additionally, or alternatively, in some embodiments, the panel 172 may be coated with a predetermined enamel, such as a waterproof coating. In this regard, the predetermined enamel may allow the panel 172 to be easily cleaned, for example, in a dishwasher appliance. In some embodiments, the enamel coating may be a non-stick enamel coating which may further increase the cleanability of removable bottom panel assembly 170.

In some embodiments, the panel 172 may include a depression 173. For instance, a central portion of panel 172 may be concave along the vertical direction V, for example, downward along the vertical direction V, to form depression 173 therein. In some embodiments, the depression 173 may advantageously increase a volumetric size of cooking chamber 116. Additionally, or alternatively, the depression 173 may store a liquid, for instance, water, therein during a cooking operation in order to produce steam or a steam effect within cooking chamber 116. The steam effect may be utilized in a cooking operation or a cleaning operation. In addition, the depression 173 may have any suitable shape. For example, in some embodiments, see FIG. 3, the depression 173 may be rectangular in shape, for example, along the lateral direction L and the transverse direction T. In at least another example, the depression 173 may include one or more notches formed therein, for example, along the transverse direction T. Thus, depression 173 may have any suitable shape formed into panel 172.

In some embodiments, the panel 172 may define a front end 174 and a rear end 176 opposite the front end 174 along the transverse direction T, see, for example, FIG. 6. For instance, when removable bottom panel assembly 170 is in an installed position within cooking chamber 116, front end 174 may be proximate door 104 while rear end 176 may be proximate back wall 120. Panel 172 may further define a first side 177 and a second side 178 opposite first side 177 along the lateral direction L, see, for example, FIG. 6. In some embodiments, when removable bottom panel assembly 170 is in the installed position, first side 177 may be proximate the first sidewall 1181 while second side 178 may proximate the opposing second sidewall 1182. Accordingly, panel 170 (e.g., defining bottom wall 119) may cover one or more heating elements 117 (e.g., provided at a bottom of cabinet 101) along the vertical direction V when removable bottom panel assembly 170 is in the installed position.

Panel 172 may include an aperture 180 defined therethrough (e.g., along the vertical direction V). In some embodiments, the aperture 180 may allow fluid communication between heating element 117 (e.g., a heating element chamber) and cooking chamber 116. In detail, heat (or heated air) produced by heating element 117 may flow through aperture 180 into cooking chamber 116 to cook or heat items provided within cooking chamber 116. Aperture 180 may define a lateral axis 182 (e.g., along the lateral direction L) and a transverse axis 184 (e.g., along the transverse direction T). In at least some embodiments, lateral axis 182 is longer than transverse axis 184. Aperture 180 may be located proximate front end 174 of panel 172. Additionally, or alternatively, aperture 180 may be provided adjacent to depression 173. Accordingly, the heat or heated air from heating element 117 (heating element chamber) may be provided to a front portion of cooking chamber 116 via aperture 180.

Removable bottom panel assembly 170 may include a front air deflector 190. Front air deflector 190 may be attached to panel 170. For instance, front air deflector 190 may be attached to a top surface 1721 of panel 172 and protrude generally along the vertical direction V. Further, front air deflector 190 may extend generally along the lateral direction L (e.g., predominantly parallel to aperture 180). According to at least some embodiments, front air deflector 190 is made from a second material different from the first material. In detail, front air deflector 190 may be made from a material different from that of panel 172. Advantageously, front air deflector 190 may include one or more materials different from those of panel 172, creating more favorable air flow patterns and reducing fatigue of certain parts of removable bottom panel assembly 170. Front air deflector 190 may be attached to panel 172 via fasteners (e.g., screws, bolts, clips, rivets, etc.). It should be noted that any suitable fastener or fasteners may be used to attach front air deflector 190 to panel 172.

Front air deflector 190 may include a base 192. Front air deflector 190 may be attached to panel 172 via base 192. For instance, base 192 may extend along the lateral direction L and the transverse direction T. Accordingly, as shown most clearly in FIG. 7, base 192 may be in planar contact with panel 172 (e.g., with top surface 1721 of panel 172). Base 192 may be attached to panel 172 proximate aperture 180. In some embodiments, base 192 is located closer to front end 174 of panel 172 than aperture 180. In other words, base 192 may be provided between aperture 180 and front end 174 of panel 172 along the transverse direction T. A length along the lateral direction L of base 192 may be greater than a length along the lateral direction L of aperture 180.

Front air deflector 190 may include a handle portion 194. Handle portion 194 may extend from base 192, e.g., at a predetermined angle with respect to base 192 (or panel 172). For instance, handle portion 194 may extend generally in the vertical direction V and the transverse direction T. The predetermined angle may be between about 25° and about 35° with respect to base 192 or a horizontal direction, such as the transverse direction T. In some examples, handle portion 194 extends toward a center of cooking chamber 116. Thus, the handle portion 194 may partially cover aperture 180. Additionally, or alternatively, front air deflector 190 may be referred to or operate primarily as a handle altogether. In detail, the design and positioning of front air deflector 190 may be particularly well suited to allow a user to easily grasp and lift to remove panel 172 from cooking chamber 116.

In detail, handle portion 194 may extend upward and rearward (e.g., along the vertical and transverse directions V and T) from base 192. In the case where base is provided between aperture 180 and front end 174 of panel 172, handle portion 194 extends to partially cover aperture 180. Accordingly, front air deflector 190 (e.g., handle portion 194) may define an outlet 186 together with aperture 180. Heat or heated air from heating element 117 may be directed into cooking chamber 116 via outlet 186. Advantageously, handle portion 194 may be angled toward the center of cooking chamber 116. Additionally, or alternatively, a circulated air pattern may be advantageously formed within cooking chamber 116 to more evenly cook or heat items (e.g., food) within cooking chamber 116. Further additionally or alternatively, handle portion 194 may be advantageously grasped by a user in order to easily remove panel 172 (or removable bottom panel assembly 170) from cooking chamber 116.

Front air deflector 190 may include side members 196 and 198. For instance, a first side member 196 may connect a first lateral end of base 192 to a first lateral end of handle portion 194. Similarly, a second side member 198 may connect a second lateral end of base 192 to a second lateral end of handle portion 194, the second lateral ends being opposite the first lateral ends along the lateral direction L. Side members 196 and 198 may provide rigidity to front air deflector 190 and assist in directing the heat or heated air from heating element 117 toward cooking chamber 116. Moreover, side members 196 and 198 may assist in locating front air deflector 190 with respect to panel 172 (and aperture 180) during assembly.

Oven appliance 100 may include a retention clip 200. It should be noted that retention clip 200 may or may not function as a traditional “clip.” For instance, as will be described in further detail below, retention clip 200 may passively restrain panel 172 from moving or expanding in the vertical direction V and transverse direction T. According to at least some embodiments, retention clip 200 is part of (e.g., included with) removable bottom panel assembly 170. For instance, panel 172, front air deflector 190, and retention clip 200 may collectively form removable bottom panel assembly 170. In other embodiments, retention clip 200 is installed within cooking chamber 116 to receive panel 172. Accordingly, retention clip 200 may be provided within cooking chamber 116. For instance, retention clip 200 may be fixed within cooking chamber 116 at a rear lower portion thereof. Retention clip 200 may interact with panel 172. In at least one example, retention clip 200 selectively receives panel 172 when panel 172 (e.g., removable bottom panel assembly 170) is in the installed position. For purposes of this disclosure, removable bottom panel assembly 170 is determined to be in the installed position when inserted into cooking chamber 116, forming bottom wall 119 of cooking chamber 116. For instance, retention clip 200 may define a receiving slot 208 into which rear end 176 of panel 172 is selectively inserted. For example, the rear end 176 of the panel may be selectively inserted into the receiving slot 208 such that the surface of the rear end 176 may abut, or may be interfaced, with the receiving slot 208.

Retention clip 200 may include a first support foot 202 and a second support foot 204. Referring briefly to FIGS. 5 and 9, first support foot 202 may be provided at a first lateral end 201 of retention clip 200. Similarly, second support foot 204 may be provided at a second lateral end 203 of retention clip 200, opposite first lateral end 201. Each of first support foot 202 and second support foot 204 may have similar design and construction, and as such, first support foot 202 will be described in full with the understanding that the description applies to second support foot 204 as well.

First support foot 202 may extend in the lateral direction L and the transverse direction T. In detail, first support foot 202 may be parallel with panel 172 (e.g., top surface 1721 of panel 172). According to at least some embodiments, first support foot 202 is attached to a first sidewall 1181. For instance, an outer lateral edge 205 of first support foot 202 may be attached to first sidewall 1181. In some embodiments, outer lateral edge 205 includes a tab which is inserted into a receiving notch formed in first sidewall 1181. However, any number of fastening means may be used to attach first support foot 202 to first sidewall 1181, such as screws, bolts, rivets, adhesives, or the like.

As mentioned above, second support foot 204 may be similarly designed as first support foot 202. For instance, second support foot 204 may be attached to a second sidewall 1182 opposite first sidewall 1181 (e.g., via an outer lateral edge 205). Additionally, or alternatively, a gap 206 may be formed between first support foot 202 and second support foot 204. Gap 206 may allow fluid communication between heating element 117 (e.g., heating element chamber) and cooking chamber 116 (e.g., at a rear of oven appliance 100). Gap 206 may be defined between first support foot 202 and second support foot 204 along the lateral direction L, and between rear end 176 of panel 172 and back wall 120. Accordingly, rear end 176 of panel 172 may be spaced apart from back wall 120 of cabinet 101 along the transverse direction T (e.g., when removable bottom panel assembly 170 is in the installed position, as shown in FIG. 8).

Retention clip 200 may include a restraining assembly 210. For instance, restraining assembly 210 may be attached to each of first support foot 202 and second support foot 204, thereby connecting first support foot 202 to second support foot 204. Restraining assembly 210 may selectively restrain rear end 176 of panel 172 along the vertical direction V and transverse direction T. In detail, when removable bottom panel assembly 170 is in the installed position, restraining assembly 210 may prohibit panel 172 from moving or shifting rearward along the transverse direction T (e.g., toward back wall 120) and upward along the vertical direction V (e.g., toward top wall 121). Restraining assembly 210 may extend laterally across cooking chamber 116. Thus, an entire lateral length of panel 172 (e.g., rear end 176) may be restrained by restraining assembly 210 when in the installed position.

Restraining assembly 210 may include a first locking crossbar 212. First locking crossbar 212 may protrude along the vertical direction V. For instance, first locking crossbar 212 may be defined along the vertical direction V and the lateral direction L (i.e., first locking crossbar 212 may extend along the lateral direction L). First support foot 202 and second support foot 204 may be connected to first locking crossbar 212. For instance, first support foot 202 and second support foot 204 may be substantially perpendicular to first locking crossbar 212. In some embodiments (e.g., as shown in FIG. 8), a junction of first locking crossbar 212 and first and second support feet 202, 204 may be filleted, rounded, or chamfered. Rear end 176 of panel 172 may be adjacent to first locking crossbar 212 when removable bottom panel assembly 170 is in the installed position. In some embodiments, rear end 176 abuts first locking crossbar 212 in the installed position. For example, as illustrated in FIG. 8, the rear end 176 may abut or be interfaced with the first locking crossbar 212. In still other embodiments, a gap (e.g., thermal expansion gap) may be provided or defined between rear end 176 and first locking crossbar 212 in the installed position. For instance, the gap may be any suitable size such that during operation thermal expansion of the panel 172, the retention clip 200, or a combination thereof may be accommodated.

Restraining assembly 210 may include a second locking crossbar 214. Second locking crossbar 214 may protrude from first locking crossbar 212. In detail, second locking crossbar 214 may protrude from a distal edge 213 of first locking crossbar 212. Distal edge 213 may be a top of first locking crossbar 212 (e.g., along the vertical direction V). Second locking crossbar 214 may protrude along the transverse direction T. Similar to first locking crossbar 212, second locking crossbar 214 may extend along the lateral direction L. Second locking crossbar 214 may be substantially perpendicular to first locking crossbar 212. In some embodiments (e.g., as shown in FIG. 8), a junction of first locking crossbar 212 and second locking crossbar 214 may be filleted, rounded, or chamfered.

Second locking crossbar 214 may be adjacent to panel 172, e.g., at or near rear end 176. In detail, when removable bottom panel assembly 170 is in the installed position, rear end 176 may be positioned beneath second locking crossbar 214 along the vertical direction V. In some embodiments, top surface 1721 of panel 172 contacts second locking crossbar 214 (e.g., in the installed position). For instance, panel 172 may clip or snap under second locking crossbar 214. In still other embodiments, a gap (e.g., thermal expansion gap) is provided or defined between top surface 1721 of panel 172 and second locking crossbar 214. For instance, the gap provided or defined between the top surface 1721 of the panel 172 and the second locking crossbar 214 may be any suitable size such that thermal expansion of the panel 172, the retention clip 200, or a combination thereof may be accommodated. As described above, first locking crossbar 212 and second locking crossbar 214 may collectively define receiving slot 208.

Restraining assembly 210 may include a rear air deflector 216. Rear air deflector 216 may protrude from second locking crossbar 214. In detail, rear air deflector 216 may protrude from a distal edge 215 of second locking crossbar 214. Rear air deflector 216 may protrude at an acute angle with respect to second locking crossbar 214. For instance, as shown in FIG. 8, rear air deflector 216 may protrude upward and rearward, e.g., along the vertical direction V and the transverse direction T, toward back wall 120. Accordingly, an acute angle (e.g., less than) 90° may be formed between second locking crossbar 214 and rear air deflector 216. Rear air deflector 216 may further extend along the lateral direction L. In some embodiments, the lateral edges of rear air deflector 216 may taper inward toward a distal edge 217 of rear air deflector 216. In some embodiments (e.g., as shown in FIG. 8), a junction of second locking crossbar 212 and rear air deflector 216 may be filleted, rounded, or chamfered.

A portion of rear air deflector 216 may be positioned over gap 206. For instance, distal edge 217 of rear air deflector 216 may be provided vertically above gap 206. Thus, heat or heated air from heating element 117 may be directed (at least partially) by rear air deflector 216 toward back wall 120 of cooking chamber 116. Advantageously, an even distribution of heat or heated air may be induced within cooking chamber 116, leading to improved heating characteristics and efficiencies.

Each of panel 172, front air deflector 190, and retention clip 200 may be coated with the predetermined enamel. As described briefly above, the predetermined enamel may be a waterproof coating, a heat resistant coating, a scratch resistant coating, a bond resistant coating, or the like. Additionally or alternatively, the predetermined enamel may add structural strength to each piece and increase rigidity under high heating. Further, the predetermined enamel may prevent deformation from uneven heating. Further, the predetermined enamel may allow each piece to be more easily cleaned (e.g., by hand or in a dishwasher appliance). Additionally or alternatively, different predetermined enamels may be applied to each piece. For instance, panel 172 may be coated in a first enamel, front air deflector 190 may be coated in a second enamel, and retention clip 200 may be coated in a third enamel. Moreover, any suitable combination of enamels may be applied to any combination of pieces, according to specific embodiments.

In some embodiments, a position of the removable bottom panel assembly 170 may impact heating of the cooking chamber 116. For instance, the position of the removable bottom panel assembly 170 may impact a heating rate, as described in more detail below, of the cooking chamber 116 during a cook cycle. In some embodiments, when the position of the removable bottom panel assembly 170 is a proper position, for instance, when the removable bottom panel assembly 170 is properly positioned within the oven appliance 100, heating patterns, and more particularly the heating rate of the cooking chamber 116, during a cook cycle may be approximately the same as expected heating patterns.

In some embodiments, a proper position of the removable bottom panel assembly 170 may include the panel 172 being attached to and passively restrained by the retention clip 200. In addition, a proper position of the removable bottom panel assembly 170 may include or refer to the ends or sides of the panel 172 being interfaced with, or butted against, an adjacent surface or wall of the oven appliance 100 such that no gaps or voids, for example, visible gaps or voids greater than 2 millimeters, are present between the two surfaces.

For example, in some embodiments, a proper position of the removable bottom panel assembly 170 may include the front end 174 of the panel 172 being interfaced with, or butted against, the door 104, or a surface thereof, such that no gaps or voids are present between the two surfaces. As another example, in some embodiments, a proper position of the removable bottom panel assembly 170 may include the rear end 176 of the panel 172 being interfaced with, or butted against, the back wall 120, or surfaces thereof, such that no gaps or, for example, visible gaps or voids greater than 2 millimeters, are present between the two surfaces. As another example, in some embodiments, a proper position of the removable bottom panel assembly 170 may include the first side 177 of the panel 172 being interfaced with, or butted against, the first sidewall 1181, or surfaces thereof, such that no gaps or voids are present between the two surfaces. As yet another example, in some embodiments, a proper position of the removable bottom panel assembly 170 may include the second side 178 of the panel 172 being interfaced with, or butted against, the second sidewall 1182, or surfaces thereof, such that no gaps or, for example, visible gaps or voids greater than 2 millimeters, are present between the two surfaces.

Conversely, in some embodiments, when the position of the removable bottom panel assembly 170 is an improper position, for instance, when the removable bottom panel assembly 170 is improperly positioned within the oven appliance 100, heating patterns, and more particularly, the heating rate of the cooking chamber 116, during the cook cycle may differ from the expected heating patterns.

In some embodiments, an improper position of the removable bottom panel assembly 170 may include the panel 172 not being correctly attached to or restrained by the retention clip 200. In addition, improper position of the removable bottom panel assembly 170 may include or refer to the ends or sides of the panel 172 not being interfaced with, or butted against, an adjacent wall or surface of the oven appliance 100. In this regard, an improper position of the removeable bottom panel assembly 170 may refer to the presence of gaps or voids between the two surfaces.

For example, in some embodiments, an improper position of the removable bottom panel assembly 170 may include the front end 174 of the panel 172 not being interfaced with, or butted against, the door 104, or a surface thereof, such that a gap or a void may be present between the two surfaces. As another example, in some embodiments, an improper position of the removable bottom panel assembly 170 may include the rear end 176 of the panel 172 not being interfaced with, or butted against, the back wall 120, or surfaces thereof, such that a gap or a void may be present between the two surfaces. As another example, in some embodiments, an improper position of the removable bottom panel assembly 170 may include the first side 177 of the panel 172 not being interfaced with, or butted against, the first sidewall 1181, or surfaces thereof, such that a gap or a void may be present between the two surfaces. As yet another example, in some embodiments, an improper position of the removable bottom panel assembly 170 may include the second side 178 of the panel 172 not being interfaced with, or butted against, the second sidewall 1182, or surfaces thereof, such that a gap or a void may be present between the two surfaces. As yet another example, an improper position of the removable bottom panel 170 may also include or refer to the panel 172 not being positioned within the cooking chamber 116 at all. For example, in some instances, the panel 172 may be removed from the cooking chamber 116, e.g., for cleaning of the panel 172, and may not be placed back into the cooking chamber 116 prior to operation. In this regard, when the panel 172 may be entirely outside of the cooking chamber 116, the removable bottom panel assembly 170 may be in an improper position.

In some cases, during replacement or reinstallation of the removable bottom panel assembly 170, the bottom panel assembly 170 may not be properly repositioned within the cooking chamber 116, for instance, the position of the bottom panel assembly 170 may be an improper position. This “improper positioning” of the bottom panel assembly 170 may correspond to inadequate heat transfer within the cooking chamber 116, for example, heat may transfer to food within the cooking chamber quicker, or slower, than anticipated. For instance, the improper positioning of the bottom panel assembly 170 may result in unwanted, or undesirable, heating patterns within the cooking chamber 116 that may lead to uneven cooking or browning of food items within the cooking chamber 116. For example, the food items may cook or brown unevenly approximately along the lateral direction L or approximately along the transverse direction T.

Thus, referring now to FIG. 10, a flow diagram of an algorithm 300 that may be used to operate an oven appliance, such as the oven appliance 100, according to one or more exemplary embodiments of the present subject matter is provided. The algorithm 300 described herein, and illustrated in FIG. 10, may be implemented on any suitable oven appliance, for example, to operate the oven appliance. For instance, a controller of the oven appliance, such as the controller 160 of the oven appliance 100, may be operable for implementing the functions of the algorithm 300 such as to operate the oven appliance.

In some embodiments, the algorithm 300 may include a process function 302 of initiating a cook cycle of an oven appliance, for example, a cook cycle of the oven appliance 100. Initiating a cook cycle of an oven appliance may generally include setting the desired control inputs, for instance, setting the desired cook mode, for example, a “bake” or “broil” mode, setting the desired cook temperature, or setting the desired cook time of the oven appliance. Particularly, in some embodiments, setting the desired control inputs may include receiving an input indicative of the desired control input of the oven appliance. For instance, the input may be received in response to user manipulation of a variety of controls of the oven appliance, for example, user manipulations of controls 112 of oven appliance 100.

In addition, in some embodiments, the algorithm 300 may include a process function 304 of measuring a first temperature, with a temperature sensor, for example, temperature sensor 113, of a cooking chamber, for example, cooking chamber 116. In addition, in some embodiments, the first temperature may be measured at a first predetermined time. Prior to placing food items within the cooking chamber of the oven appliance, it may be necessary for the cooking chamber of the oven appliance to be approximately at the desired cooking temperature. Thus, it may be essential that the cooking chamber be preheated to the desired cooking temperature. In some embodiments, the preheating of the cooking chamber may begin when the cook cycle is initiated, such as at process function 302. In this regard, the process function 304 may be executed during the preheating of the cooking chamber of the oven appliance. For instance, the process function 304 may measure a first temperature of the oven appliance at a first predetermined time during preheating of the oven appliance.

In some embodiments, the algorithm 300 may include a process function 306 of proceeding with, or continuing, the cook cycle, in response to the process function 304 being executed. For instance, proceeding with the cook cycle may include continuing to preheat the cooking chamber to the desired cooking temperature. Further, in some embodiments, the algorithm 300 may include a process function 308 of measuring a second temperature, with the temperature sensor, of the cooking chamber. In addition, in some embodiments, the second temperature may be measured at a second predetermined time. For example, the second predetermined time may occur after the first predetermined time, for instance, after the first predetermined time at any suitable time during the preheating of the cooking chamber.

Following the execution of process function 308, a heating rate of the oven appliance may be calculated. For instance, in some embodiments, the algorithm 300 may include a process function 310 of calculating the heating rate, for instance, based at least on the first temperature at the first predetermined time and the second temperature at the second predetermined time. Furthermore, in some embodiments, the process function 310 may include comparing the calculated heating rate to a reference heating rate. In some embodiments, the reference heating rate may be an empirically derived or otherwise predetermined heating rate of the cooking chamber. The predetermined heating rate of the oven appliance may be determined by or based on a variety of factors, for instance, cook time, cooking temperature, the type of heating element of the oven appliance (e.g., gas heating element or electric heating elements), etc. (e.g., programmed within the controller as a look-up table, chart, graph, or equation).

Further, in some embodiments, the algorithm 300 may include a decision function 312 that decides, for instance, determines, based on the heat rate calculated at process function 310, if the heating rate is indicative of a proper position or an improper position of the bottom panel assembly. As described above, when the position of the bottom panel assembly is an improper position, the calculated heating rate may differ from the reference heating rate. For example, the calculated heating rate may be greater than or less than the reference heating rate. Such a difference may impact cooking times and or cooking performance. In response to it being determined that the calculated heating rate differs from the reference heating rate, one or more actions may be executed, for instance, by a controller, such as the controller 160 of the oven appliance 100.

For instance, one action that may be executed in response to it being decided at decision function 312 that the position of the bottom panel assembly is an improper position may be the action of suspending, or canceling, the cook cycle and providing a first user notification, for instance, to a user of the oven appliance. In some instances, it may be determined that the difference between the calculated heating rate and the expected heating rate is great enough that the cooking of food items that may be placed in the cooking chamber may be negatively impacted. Thus, in such instances, the cook cycle may be suspended, for instance, the preheating or heating of the cooking chamber may be suspended, and a user notification that includes a first prompt may be provided. The first prompt may include an indication that the bottom panel assembly needs to be repositioned such that the position of the bottom panel assembly is a proper position, and the cook cycle needs to be restarted. Additionally, in some embodiments, in response to the cook cycle being suspended, a fault condition may be saved to a memory of a controller of the oven appliance, for instance, the memory of controller 160. The fault condition may be utilized in diagnosing issues, for instance, by an operator that may access the memory of the controller during maintenance of the oven appliance, that may be related to the heating rate of the cooking chamber, for instance, issues that may arise due to the position of the bottom panel assembly being an improper position.

In some embodiments, the first user notification may be provided on a user interface. For instance, the first user notification may be provided on display 103 of the user interface panel 102 or may be displayed on a remote user interface device, for example, a laptop computer, smartphone, tablet, personal computer, wearable device, smart speaker, smart home system, or various other suitable devices. The remote user interface device may be “remote” at least in that it is spaced apart from and not structurally connected to oven appliance, e.g., the remote user interface device is a separate, stand-alone device from the oven appliance which communicates with the oven appliance wirelessly. Any suitable device separate from the oven appliance that is configured to provide and/or receive communications, information, data, or commands from a user may serve as the remote user interface device, such as a smartphone, smart watch, personal computer, smart home system, or other similar device. For example, the remote user interface device may be a smartphone operable to store and run applications, also known as “apps,” and some or all of the algorithm functions and method steps disclosed herein may be performed by a smartphone app.

Another action that may be executed in response to it being decided at decision function 312 that the position of the bottom panel assembly is an improper position may be the action of continuing the operation of the cook cycle and providing a second user notification, for instance, to a user of the oven appliance. In some instances, it may be determined that there is a difference between the calculated heating rate and the expected heating rate, however, the difference may not be great enough to notably impact the cooking of the food items that may be placed within the cooking chamber of the oven appliance. Thus, in such instances, the cook cycle may be continued, for instance, the preheating or heating of the cook cycle may be continued and a second user notification that includes a second prompt may be provided. The second prompt may include an indication that the performance of the cook cycle may be less than optimal due to improper placement of the bottom panel assembly. In addition, in some embodiments, the second prompt may include recommendations to suspend the cook cycle and reposition the bottom panel assembly.

Yet another action that may be executed in response to it being decided at decision function 312 that the position of the bottom panel assembly is an improper position may be the action of adjusting the current cook cycle or running an adjusted cook cycle. In some embodiments, adjusting the cook cycle may include adjusting control inputs of the oven appliance such that the calculated heating rate may be closer to the reference heating rate. In such instances, the control inputs or settings of the oven appliance, for example, the cook time, the cook temperature, etc., may be adjusted in order to move the calculated heating rate closer to the reference heating rate of the oven appliance. In some embodiments, adjusting the cook mode may also include adjusting an output of a heating element, for example, the one or more heating elements 117, or a fan of the oven appliance 100 such that the calculated hated rate may be closer to the reference heating rate.

It should be appreciated that the one or more actions that may be executed in response to it being detected that the position of the bottom panel assembly is an improper position, may be based on the magnitude of the difference between the calculated cooking rate and the expected heating rate.

As one non-limiting example, reference is now made to FIG. 11, a chart or graph 400 representing oven temperature sensor data of an oven appliance with a removable bottom panel assembly. For the exemplary embodiment, the desired cook temperature of the exemplary oven appliance may be set to three hundred fifty degrees Fahrenheit (350° F.). Particularly, the table 400 illustrates a reference temperature data set of an oven appliance that includes a bottom panel assembly, wherein the position of the bottom panel assembly is a proper position, and a measured temperature data set of an oven appliance that includes a bottom panel assembly, wherein the position of the bottom panel assembly is an improper position. As illustrated in FIG. 11, the reference temperature sensor data may be represented by reference line 410, and the measured temperature sensor data may be represented by measured line 420.

Moreover, the reference line 410 may include a first reference point 412 and a second reference point 414, wherein the first reference point 412 corresponds to a first expected temperature at a first predetermined time, for example, two minutes, and wherein the second reference point 414 corresponds to a second expected temperature at a second predetermined time, for example, six minutes. The exemplary measured line 420 may include a third reference point 422 and a fourth reference point 424, wherein the third reference point 422 corresponds to a measured first temperature at the predetermined first time, for instance, two minutes, and wherein the fourth reference point 424 corresponds to a measured second temperature at the second predetermined time, for example, six minutes. As may be seen in FIG. 11, a heating rate of the measured line 420 may be greater than a heating rate of the reference line 410. For instance, the measured rate of temperature change between the first predetermined time and the second predetermined time may be greater than the reference rate of temperature change between the first predetermined time and the second predetermined time.

It should be understood that table 400 illustrated in FIG. 11 may be provided by way of example only. In alternative exemplary embodiments, the measured rate of temperature change may be less than the expected rate of temperature change. In such embodiments, the measured rate of temperature change being less than the expected rate of temperature change may also be indicative of an improper position of the bottom panel assembly.

Referring now to FIG. 12, embodiments of the present subject matter may include one or more methods for operating an oven appliance, such as the exemplary oven appliance 100 described above, as well as other possible exemplary oven appliances. The exemplary methods according to the present subject matter may include a method 500, for example, as illustrated in FIG. 10. A controller of the oven appliance, such as the controller 160 of the exemplary oven appliance 100, may be programmed to implement method 500, for example, the controller, such as controller 160, may be capable of and may be operable to perform any methods and associated method steps as disclosed herein.

In some embodiments, the method may include a step 510 of initiating a cook cycle of the oven appliance. In some embodiments, the step 510 of initiating a heat cycle may include activating a heating element, for example, one or more heating elements 117, to heat the cooking chamber of the oven appliance. As described above, in some embodiments, the step 510 may also include setting a cook time and a cook temperature of the oven appliance, among other things. In some embodiments the step 510 may be initiated in response to an input indicative of an initiation of the cook cycle, for instance, a user of the oven appliance selecting a cook mode, for example, a “bake” mode, setting a cook temperature, or setting a cook time at the user interface of the oven appliance.

In addition, in some embodiments, the method 500 may include a step 520 of measuring, with a temperature sensor, a first temperature of a cooking chamber, wherein the first temperature is measured at a first predetermined time. In some embodiments, after the initiation of the cook cycle, the oven appliance may preheat the cooking chamber of the oven appliance to the desired cooking temperature. During this time, the step 520 may be executed. For instance, a first temperature may be measured with a temperature sensor, such as the temperature sensor 113, at the first predetermined time, for example, at two minutes after the initiation of the cook cycle, such as illustrated by the third reference point 422 in FIG. 11.

Further, in some embodiments, the method 500 may include a step 530 of measuring, with the temperature sensor, a second temperature of the cooking chamber, wherein the second temperature is measured at a second predetermined time. In some embodiments, the second predetermined time may be different than the first predetermined time, for instance, the second predetermined time may be after the first predetermined time. In some embodiments, after the initiation of the cook cycle, the oven appliance may preheat the cooking chamber of the oven appliance to the desired cooking temperature. During this time, the step 530 may also be executed. For instance, a second temperature may be measured with the temperature sensor, such as the temperature sensor 113, at the second predetermined time, for example, at six minutes after the initiation of the cook cycle, such as illustrated by the fourth reference point 424 in FIG. 11.

In some embodiments, the method 500 may include a step 540 of calculating, based on the measured first temperature and the measured second temperature, a heating rate. For instance, step 540 may calculate the heating rate, for instance, the rate of temperature change between the first predetermined time and the second predetermined time. Furthermore, in some embodiments, the method 500 may also include a step of comparing the calculated heating rate to a reference heating rate. For instance, the calculated heating rate may be compared to the reference heating rate to determine if the calculated heating rate differs from the reference heating rate, for example, is greater than or less than the reference heating rate. For example, as illustrated in FIG. 11, the exemplary table 400 depicts a measured line 420 that includes a calculated heating rate that is greater than the reference heating rate of reference line 410.

In addition, in some embodiments, the method 500 may include a step 550 of determining, based on the calculated heating rate, a position of a bottom panel assembly of the oven appliance. In some embodiments, it may be determined, for instance, at step 550, that the calculated heating rate may be indicative of an improper position of the bottom panel assembly. For instance, when it is determined that the calculated heating rate differs from the expected heating rate, the calculated heating rate may be indicative of an improper position of the bottom panel assembly. In some embodiments, the method 500 may further include one or more actions, for instance, as described in more detail above with reference to algorithm 300, in response to the calculated heating rate being indicative of the improper position of the bottom panel assembly.

Alternatively, in some embodiments, it may be determined, for instance, at step 550, that the calculated heating rate is indicative of a proper position of the bottom panel. In such embodiments, the method 500 may include proceeding, or continuing, with the cook cycle in response to the calculated heating rate being indicative of the proper position.

Embodiments of the present subject matter advantageously provide a method that may detect when a bottom panel assembly of the oven appliance may be in an improper position. Particularly the method may include collecting temperature data of the cooking chamber to determine or calculate a heating rate of the cooking chamber. The collected data may be compared to expected temperature data to determine if the collected data indicates that the position of the bottom panel assembly is an improper position. In response to such a determination, appropriate actions may advantageously be taken.

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.

DETECTING IMPROPER POSITIONING OF A REMOVABLE BOTTOM PANEL OF AN OVEN APPLIANCE

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