The present invention relates to a circuit arrangement which provides enhanced safety for electrical appliances such as toasters, rotisseries, and toaster ovens.
Protective circuit arrangements have been provided in the past to protect electrical devices such as electrical appliances and personnel or users of the devices when undesirable conditions develop within the device. Examples of such arrangements are set forth in the applicant's prior U.S. Pat. No. 6,525,914—Protection System for Devices Connected to an Alternating Current Electrical Power Supply, and U.S. Pat. No. 6,829,123—Device Safety System and Method. While the systems set forth in these patents offer various levels and types of protection for electrical devices, they are, because of the number and type of electrical components involved, and assemble costs, quite expensive when considered as a part of the overall cost of the device in which they are provided for protection. Unfortunately the technology described in those documents was never incorporated into consumer appliances because the manufacturers that were contacted considered that the added cost would be inappropriate for market acceptance.
Manufacturers of electrical appliances are continually trying to reduce the cost of manufacturing the appliances. As the cost of manufacturing the appliance decreases, the relative cost of protective circuit arrangements such as those set forth in the above-mentioned patents becomes much greater, such that the manufacture becomes more reluctant to include them in the appliance. Rather than not include protective arrangements in an appliance, it is desirable to provide protection in a relatively less costly way. The need exists for a protective circuit configuration that addresses consumer safety issues to be available at a cost that could more readily be acceptable to this highly competitive industry, and thus would encourage appliance manufacturers to include it in their products.
While electrical appliances are designed to be reliable and safe to use, unsafe conditions can develop such as due to a failure in a component of the appliance, or due to miss-use of the appliance. For instance, an electrical toaster may present the following unsafe conditions. The elevator carriage may become jammed in the down position, thereby keeping the electrical heating elements activated. Excessive leakage currents from metal parts to electrically live parts such as the elements, may develop, such as caused by a build up of crumbs and grease between the metal parts and electrically live parts. Fire or flames developing within the toaster. A contact being made between the metal frame and electrically live parts by person sticking a metal object, such as a knife into the toaster. It is therefore desirability to include automatic protective features in certain consumer appliances that will contribute to both the protection of property and consumer safety.
In an October 2012 press release, the Consumer Product Safety Commission (CPSC) states that approximately 40% of the residential fires each year are caused by cooking equipment. Additionally, the National Fire Protections Association (NFPA) statistics indicate that 23% of these fires involve ovens or rotisseries, microwave ovens, and toaster/toaster ovens.
Another well known undesirable electrical hazard associated with consumer kitchen appliances such as toasters and toaster ovens is dangerous leakage current which can cause fires resulting in property damage, serious injury from electrical shock or result in electrocutions. Excessive electrical leakage current may occur between accessible metal part and electrically live parts due to contributing situations such as: insulation damage or failure, build up of conductive substances, and insertion of foreign bodies etc. all of which create hazardous conditions.
Fire is also a major safety issue for electrical appliances especially those containing heating elements. Toasters and toaster ovens for example, have a documented history of extremely hazardous fire related events that have and can lead to property destruction and deaths. If such a hazardous fire event occurs it is important to limit the time duration of the fire by removing the power source and if possible to contain the fire in the appliance compartment. For toasters having elevator carriages, it is necessary to maintain the carriage in the down position, so as to avoid it springing up and spreading flaming debris in the area around the toaster. An audible or visual alarm is desirable to bring attention to a hazardous condition.
Protecting the user and an appliance by removing electrical power is essential, for instance, when a consumer inserts a conductive implement into a typical toaster compartment that contains metal supports for the bread or bagel. Protection would be provided, since it would be extremely unlikely for the conductive implement to make contact with the electrically live heating element without also making contact with the metal supports. Protection is also desirable when combustible or conductive material enter the toaster compartment. Protection is also desirable in the case of insulation damage, and when a broken or damaged live electrical element makes contact with a metal case of the appliance.
It is an object of this invention to provide enhanced safety to consumer appliances, such as a toaster at a cost that will allow the general market product sales price be at a level the average consumer can afford. It is a further object of this invention to provide the maximum amount of safety at the lowest possible cost. The present invention offers a simplified but effective solutions for achieving the maximum amount of safety at an acceptable cost.
Toasters and Toaster ovens in particular can certainly achieve a higher level of safety, as they can easily incorporate the enhanced safety techniques of this invention.
In accordance with this invention enhanced safety features are provided to toasters and other electrical appliances. Power is removed from the appliance, when a fire (flame) occurs within the appliance. Removing the power source is essential to limit the time duration in the event of such an occurrence. Further, for elevator type toasters it is important to maintain the elevator carriage in the down position to avoid the spreading of flaming debris outside of the toaster when the elevator carriage pops up. Further, electrical power is removed from the accessible live parts of the appliance when excessive electrical leakage currents occur, or an electrically conductive contact is established between the metal frame and live parts. Further, an audible or visual alarm may be provided in the event of any of the above mentioned situations.
In setting forth the detailed description of the drawings, the same numerals will be used for generally corresponding elements in the various figures.
Referring to
Referring to
The addition of the alternative power disconnect relay 14 is necessary to ensure that the heater element power source will be removed under fault conditions in particular when the elevator carriage is maintained in the latched position after it should have been released under the control of timer control 10. In accordance with this invention, the timer control 10 will provide an input to disconnect relay 14 at a short interval of time after the time for releasing the elevator, to open the contacts 12 to disconnect the heating element 4. While the heating element 4 is de-activated, the power switch 8 remains activated, thereby preventing the release of the carriage, and the adverse consequences that could result from the release, such as discharging in the area of the toaster burning embers from a fire initiated in the toaster compartment. Detectors for other adverse conditions may be provided, which will provide an input signal to the alternative power disconnect relay 14, to open the contacts 12, thereby removing power from the heating element 4.
Referring to
The flame sensor 31 includes a flame responsive element which is positioned in the appliance to detect flame indicative of an incipient or actual fault condition. However, to position the flame responsive element. However, to protect to flames responsive element from excessive heat or potential physical damage, reflectors, refractors, fiber optics or other devices may be included in the appliance to direct a flame, indicative of an incipient or actual fault condition, to the flame responsive element, while locating the flame responsive element in a protected location.
The leakage current sensor 33, configured to sense a leakage current between the live circuit components within the appliance an the metal housing. This leakage current may be due to electrical insulation failure, or the insertion of a metal object in the appliance which establishes a conductive path between live circuit elements and the metal housing. The detection and alarm indication of excessive electrical leakage currents within the appliance could well prevent a serious hazardous event from occurring, and may provide early warning of pending fault conditions such as, insulation failure, carbonized path, and tracking that can lead to dangerous electrical arcing. Further, the build up of grease, crumbs or other electrically conductive substances would provide the consumer user a reason to clean the appliance.
The other sensor 35, is intended to indicate, that sensors which could detect other types of incipient or actual dangerous conditions in the appliance may be provided.
There have been reports of situations where the exposed metal case of an appliance has become electrically above ground potential as a result of supply cord insulation damage caused by being trapped between the appliance and another object. The control circuit shown in
Referring to the specific circuitry of the preferring embodiment of this invention, a DC power supply includes a diode 44 and a capacitor 46, and a voltage regulator formed by a resistor 64 and zener diode 66, which are standard and well known circuits.
In the event of jamming of the elevator carriage in the down position the heating elements 4 may continue to be activated and a fire could result. Should this situation occur, the timer control 74 can be suitably connected to provide a signal to the gate of SCR 42 thus energizing the coil of the alternative power disconnect relay 40 and remove power from the heating elements 4 by opening contacts 76.
If a flame or fire occurs within the toaster compartments a light sensitive resistor or similar light sensitive component 58 positioned within the toaster will detect the scattered or emitted light that is created and gate SCR 42 through a time delay circuit which includes a resistor 78, a capacitor 80, a resistor 81, a diode 82, a capacitor 84, a zener diode 86, and a resistor 88, into a conductive state energizing the coil of alternate power disconnect relay 40 and removing the power source from the heating elements 4 by opening contacts 76. It is important to maintain the elevator carriage in the down position to prevent the spreading of flaming debris. This is accomplished is the case of a mechanically latched solenoid 72 arrangement by removing, the power source to solenoid 72 or the timer control 74 when the coil of alternate power disconnect relay 40 is activated. Alternatively, in the case of a solenoid 72 electro magnet arrangement power may be maintained to the relay coil 40 through a diode 90, a diode 92 and a resistor 94.
It is also desirable to remove power from the toast if any contact is made between the metal casing of the toaster and electrically live parts. For example, a user of the toaster might try to dislodge a slice of bread with an electrically conductive implement Removal of the power is accomplished by detecting low level electrical current flow between the metal casing of the toaster and an electrically live part. A contact between the metal casing 96 and an electrically live part is detected by the circuit consisting of resistor 52 and diode 54. The detection of a low level electrical current through resistor 52 and diode 54 is applied as a forward bias to transistor 50, thereby providing a gating signal to SCR 42 and energizing the solenoid of alternate power disconnect relay 40, opening contacts 76 to de-energize the heating elements 4.
To further describe the circuit of the preferred embodiment of this invention, capacitor 98 and resistor 100 provide noise and detection level control. A series circuit of a light emitting diode 102 and a resistor 104 is connected in parallel with alternate power disconnect relay 40, thereby providing a visual fault display. An audible fault indication could be provided by using a piezo or similar type alarm connected in place of, or in parallel with the light emitting diode 102 and resistor 104.
If a fire in the toaster compartment occurs, it is important that the elevator carriage be held down and prevented from springing up and distributing flaming debris, the anode of diode 90 is shown connected to the elevator carriage and timer controller, it is intended to be connected to the bottom of hold down electromagnet 40 keeping it in the energized state. For pop-up toasters using a mechanically held down elevator carriage with a release solenoid, it can easily be accomplished by moving the source of solenoid power to the load side of contacts 76.
If the jamming of the elevator carriage in the down position occurs, the elements may continue to be energized and a fire could result. To avoid this possibility the timer signal is applied to the gate of SCR 42, energizing the relay 40 and removing power from the heating element.
The opportunity exists in most cases for integration of the described safety circuits into the existing appliance circuitry, the use of common circuitry would provide a further benefit of reducing cost and complexity.
The circuits described above are not suitable for appliances supplied by a three wire cord (L-N-G) in which the metal casing is grounded. Other techniques such as differential current sensing can be used.
However inclusion of the leakage current protection described above offers a high degree of protection for two wire appliances that suggests the need for a three wire cord with grounding may not be necessary. Replacing a three wire cord, with the two wire protective circuit arrangement of this invention will provide a cost savings for the appliance manufacturer.
The examples set forth above represent the basic circuit approach for achieving a substantially higher degree of safety, modifications to the basic concept may be necessary for certain applications to set sensor detection levels, provide improved immunity to electrical disturbances, adding appropriate time delay capacitors and surge suppression components.
While a preferred embodiment of the circuit arrangement of this invention which provides enhanced safety for electrical appliances such as toasters, rotisseries and toaster ovens has been shown, it should be apparent to those skilled in the art that what has been shown and described is considered at present to be a preferred embodiment of the circuit arrangement and system of this invention. While a preferred embodiment of the circuit arrangement of this invention has been shown and described other circuit arrangements are contemplated by this invention. In accordance with the Patent Statutes, changes may be made in the enhance safety arrangement for electrical appliances of this invention without actually departing from the true spirit and scope of this invention. The appended claims are intended to cover all such changes and modifications which fail in the true spirit and scope of this invention.
This application claims benefit of U.S. provisional application Ser. No. 61/615,215, filed Mar. 24, 2012, U.S. utility patent application Ser. No. 13/849,530, filed Mar. 24, 2013, and U.S. provisional application Ser. No. 61,659,509, filed Jun. 14, 2012.
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Entry |
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Legatti, Raymond L., co-pending U.S. Appl. No. 13/849,530, entitled Enhanced Safety for Electrical Appliances Such as Toasters, filed Sep. 25, 2013, having a common inventor as present invention. |
Number | Date | Country | |
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20130334203 A1 | Dec 2013 | US |
Number | Date | Country | |
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61615215 | Mar 2012 | US | |
61659509 | Jun 2012 | US |
Number | Date | Country | |
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Parent | 13849530 | Mar 2013 | US |
Child | 13917640 | US |