1. Field of the Invention
The present invention relates to an oven door including an exterior panel formed of plastic.
2. Description of the Related Art
An oven door includes an interior panel for sealing a heating chamber of the oven and an exterior panel spaced from the interior panel to provide a layer of insulation, e.g., solid and/or air, between the interior panel and the exterior panel. The exterior panel also aesthetically covers the interior panel.
The exterior panel is typically formed of several metal components that are separately formed and subsequently assembled together. The exterior panel also typically includes a glass pane for viewing the heating chamber of the oven. The material cost for manufacturing the metal components and the glass pane is relatively high. In addition, relatively high manufacturing costs are associated with forming the components and the glass panel separately and subsequently assembling the components and the glass panel.
Also, some consumers desire ovens having different colors. As one example, some consumers desire stainless steel ovens and are willing to pay higher prices for an oven that has a stainless steel appearance. As such, the exterior panel can be formed of stainless steel to provide this appearance; however, stainless steel is a relatively expensive material thereby increasing the cost to manufacture exterior panels formed of stainless steel. The exterior panel can also be formed of another type of metal and subsequently painted to either have a stainless steel appearance or to have another color desired by the consumer. Such paint adds cost not only for the paint itself but also for manufacturing costs associated with applying the paint to the exterior panel. The paint is also subject to scratching, chipping, cracking, etc.
In addition, a handle is connected to the exterior panel and extends away from the exterior panel for moving the oven door between open and closed positions. The handle typically includes a flat surface that abuts a flat surface of the exterior panel. A threaded fastener extends through the flat surface of the handle and the flat surface of the exterior panel to affix the handle to the exterior panel. As the handle is used over time, the interface between the abutting flat surfaces of the handle and the exterior panel begins to loosen such that the handle wobbles relative to the exterior panel. Such an occurrence gives an unwanted feel and appearance of low quality.
Accordingly, there remains opportunity to manufacture an oven door having an exterior panel having lower material and assembly costs and having a color desired by consumers. There also remains opportunity to manufacture an oven door having a handle that reliably connects to the exterior panel and has an aesthetic appearance.
The present invention includes an oven door for closing an opening to a heating chamber of an oven. The oven door comprises an interior panel for facing the heating chamber. The interior panel has a glass sheet for viewing the heating chamber. An exterior panel is affixed to the interior panel for facing away from the heating chamber and includes a frame portion formed of plastic defining an aperture aligned with the glass sheet for viewing the heating chamber. A non-opaque panel is fixed relative to the frame portion and extends across the aperture and has an inside surface facing the interior panel. The exterior panel has a masking portion formed of plastic and integrally formed with the frame portion and extending from the frame portion into the aperture along the inside surface of the non-opaque panel and defining a window for viewing the heating chamber through the glass sheet.
The present invention also includes an oven door for closing an opening to a heating chamber of an oven. The oven door comprises an interior panel for facing the heating chamber and an exterior panel formed of plastic and having an exterior side for facing away from the heating chamber. The exterior panel presents a pocket defined by a wall extending from the exterior side toward the interior panel and a bottom extending transversely from the wall spaced from the exterior side. A handle has a boss portion extending into the pocket for stabilizing the handle relative to the exterior panel and a gripping portion extending from the boss portion away from the exterior panel for moving the oven door between open and closed positions. The bottom is disposed between the boss portion of the handle and the interior panel. The handle has a post extending from the gripping portion through the boss portion and being connected to the interior panel for coupling the interior panel, the exterior panel, and the handle.
By forming the frame portion of the exterior panel from plastic, the costs associated with material and manufacturing of the frame portion is advantageously decreased. The manufacturing process of forming the frame portion is more efficient, and thus less costly, by decreasing or eliminating secondary assembly steps. Forming the exterior from plastic also allows the designer more styling freedom because plastic is relatively easy to form into intricate shapes. The plastic of the exterior panel also provides superior insulation to reduce the amount of heat that is transferred to the an exterior side of the exterior panel.
In addition, the plastic of the frame portion can be advantageously colored. Further, since the plastic is colored, as opposed to being painted, desired coloring of the frame portion is accomplished without secondary steps such as painting, thereby advantageously making the manufacturing process of the exterior panel more efficient and less costly. In addition, since the plastic itself is colored, the coloring is more durable than paint.
Finally, the interaction between the handle and the exterior panel advantageously increases the stability and durability of the oven door. By receiving the boss portion in the pocket, the exterior panel firmly retains the handle to increase the stability of the handle relative to the exterior panel. Also, since the bottom is disposed between the boss portion and the handle and since the post extends from the handle, the bottom of the exterior panel is retained between the handle and the interior panel when the post is connected to the interior panel. As such, the interior panel, the exterior panel, and the handle are coupled together when the post is connected to the interior panel.
Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
Referring to the Figures, wherein like numerals indicate like parts throughout the several views, an oven is generally shown at 10. The oven 10 includes at least one oven door 14, 16 for closing an opening to a heating chamber 12 of the oven. The oven 10 can be any type of oven such as, for example, a convection oven, a microwave oven, a toaster oven, etc.
The oven 10 shown in
The oven 10 can include one or more heating chambers 12 each enclosed by one or more oven doors 14, 16. With reference to
A first embodiment of the first oven door 14 is shown in
With reference to
The exterior panel 20 is affixed to the interior panel 18 and faces away from the heating chamber 12. Specifically, the exterior panel 20 has an exterior side 28 that faces outwardly relative to the rest of the oven 10 and has an aesthetically pleasing appearance. The exterior panel 20 includes a frame portion 30 defining an aperture 32 aligned with the glass sheet 26 of the interior panel 18 for viewing the heating chamber 12. The frame portion 30 typically has a one-piece construction. Insulation 34, such as that shown in
The exterior panel 20 can define a groove 36 and the interior panel 18 can define a flange 38 that extends into the groove 36 to couple the exterior panel 20 and the interior panel 18. In the alternative, or in addition, other complementary features and/or fastener 70s (not shown) can also attach the exterior panel 20 and the interior panel 18 to each other.
At least a portion of the exterior panel 20, including the frame portion 30, can be formed of plastic such as a polyester. The plastic can be glass filled or can be free of glass filling. One example of a type of suitable polyester is glass filled thermoplastic polyester commercially available from BASF Corporation in Florham Park, N.J. under the tradename Ultramid® B4040G3. However, it should be appreciated that the exterior panel 20 can be formed of any type of suitable material without departing from the nature of the present invention. The plastic of the exterior panel 20 can have any color. As one example, the plastic of the exterior panel 20 can simulate the look of metal such as stainless steel.
The non-opaque panel 22 is fixed relative to the frame portion 30 and extends across the aperture 32 defined by the frame portion 30. The non-opaque panel 22 has an inside surface 40 facing the interior panel 18. The non-opaque panel 22 can be, for example, transparent, speckled, screened, translucent, frosted, etc.
As set forth further below, the exterior panel 20 and/or the non-opaque panel 22 can be formed and/or combined by plastic injection molding. A plastic injection mold (not shown) is used for the plastic injection molding and, specifically, receives molten plastic to shape the molten plastic. However, it should be appreciated that the exterior panel 20 and/or the non-opaque panel 22 can be formed in any way without departing from the nature of the present invention.
The first oven door 14 typically includes a vent portion 42 for venting heated air from between the interior panel 18 and the exterior panel 20. The vent portion 42 is typically formed of the same type of material as the frame portion 30 and is typically integrally formed with the frame portion 30 of the exterior panel 20, i.e., formed together simultaneously or at substantially the same time so as to form a single part. Alternatively, the vent portion 42 can be formed separately from the frame portion 30 and subsequently attached to the frame portion 30. The vent portion 42 can be blended with the frame portion 30 so that the vent portion 42 and the frame portion 30 have a common surface appearance. Alternatively, the vent portion 42 and the frame portion 30 can have different surface texture and/or color.
In the first embodiment of the first oven door 14, with reference to
The masking portion 44 is typically formed of the same type of plastic as the rest of the exterior panel 20 as set forth above. However, it should be appreciated that the masking portion 44 can be formed of any type of suitable material without departing from the nature of the present invention. The plastic of the masking portion 44 can have any color and typically has a different color than the plastic of the frame portion 30. As one example, the color of the plastic of the masking portion 44 is black. Alternatively, the color of the plastic of the masking portion 44 can be the same as the color of the plastic of the frame portion 30.
With continued reference to
The masking portion 44 is typically recessed relative to the frame portion 30, as best shown in
In the first embodiment of the first oven door 14, the non-opaque panel 22 is typically formed of glass. Alternatively, the non-opaque panel 22 is formed of plastic. When formed of plastic, for example, the non-opaque panel 22 can be glass filled or can be free of glass filling. As one example, the non-opaque panel 22 can be formed from an unfilled polyethersufone commercially available from BASF Corporation in Florham Park, NJ under the tradename Ultrason® E2010. In the configuration where the non-opaque panel 22 is formed of plastic, the non-opaque panel 22 can be fixed to the masking portion 44 by, for example fusing, welding, overmolding, etc., in addition to the fixing configurations set forth above.
With continued reference to the first embodiment of the first oven door 14, the frame portion 30 and the masking portion 44 of the exterior panel 20 are typically simultaneously formed in the injection mold. For example, one shot of molten plastic can be injected into the injection mold to form the frame portion 30 and the masking portion 44, i.e., the frame portion 30 and the masking portion 44 are integrally formed of a single type of plastic have a single color and surface texture.
Alternatively, for example, a first shot of molten plastic can be injected into the injection mold to form the frame portion 30 and a second shot of molten plastic can be injected into the injection mold to form the masking portion 44. In such a configuration, the first shot and the second shot can include plastic of different type, color, and/or surface texture, i.e., the resulting frame portion 30 and masking portion 44 can have different plastic type, color, and/or texture. Alternatively, as set forth above, the masking portion 44 and the non-opaque panel 22 can be integrally formed and subsequently assembled to the frame portion 30, in which case the frame non-opaque panel 22 and the masking portion 44 can be formed by a first shot and a second shot, respectively, of molten plastic. In any event, it should be appreciated that the injection mold can receive more than two shots with the additional shots forming additional features. As one example, the vent portion 42 can be formed by a third shot so that the vent portion 42 and the frame portion 30 can include have different plastic type, color, and/or surface texture.
Regardless of whether the frame portion 30 and the masking portion 44 are formed from one or two shots of molten plastic, the non-opaque panel 22 can be subsequently attached to the frame portion 30 and/or the masking portion 44 after formation of the frame portion 30 and masking portion 44 in the injection mold, e.g., after the exterior panel 20 is removed from the injection mold. Alternatively, the non-opaque panel 22 can be inserted into the injection mold before the molten plastic is injected such that, upon injection into the injection mold, the molten plastic partially encapsulates the non-opaque panel 22, i.e., the non-opaque panel 22 is overmolded by the molten plastic of the exterior panel 20 in the injection mold. Specifically, in the scenario where a single shot forms the exterior panel 20, the single shot partially encapsulates the non-opaque panel 22. In the scenario where a first shot and a second shot form the exterior panel 20, the first and/or the second shot partially encapsulates the non-opaque panel 22.
With reference to
In the second embodiment of the first oven door 14, the masking portion 44 can be formed of plastic and integrally formed with the frame portion 30 of the exterior panel 20 and/or the non-opaque panel 22. In such a configuration, the masking portion 44 is typically formed of the same type of plastic as the rest of the exterior panel 20 as set forth above. However, it should be appreciated that the masking portion 44 can be formed of any type of suitable material without departing from the nature of the present invention. The plastic of the masking portion 44 can have any color and typically has a different color than the plastic of the frame portion 30. Alternatively, the color of the plastic of the masking portion 44 can be the same as the color of the plastic of the frame portion 30. As one example, the color of the plastic of the masking portion 44 is black.
When formed of plastic and integrally formed with the frame portion 30 and/or the non-opaque panel 22, the masking portion 44 can extend along inside surface 40 of the non-opaque panel 22. In the alternative to being integrally formed with the frame portion 30 and/or the non-opaque panel 22, the masking portion 44 can be formed separately from and subsequently combined with the exterior panel 20 and the non-opaque panel 22. In such a configuration, the masking portion 44 can be, for example, plastic, metal, a decal, etc. The masking portion 44 of such a configuration can be partially or fully encapsulated by the frame portion 30 and/or the non-opaque panel 22 during formation of the frame portion 30 and/or the non-opaque panel 22 or can be attached or adhered to the frame portion 30 and/or the non-opaque panel 22.
In the second embodiment of the first oven door 14, the frame portion 30 and the non-opaque panel 22 are typically simultaneously formed in the injection mold. For example, a first shot of molten plastic can be injected into the injection mold to form the frame portion 30 and a second shot of molten plastic can be injected into the injection mold to form the non-opaque panel 22. In such a configuration, the first shot and the second shot can include plastic of different type, color, and/or surface texture, i.e., the resulting frame portion 30 and non-opaque panel 22 can have different plastic type, color, and/or surface texture.
The first shot of molten plastic forming the frame portion 30 can also integrally form the masking portion 44 with the frame portion 30. Alternatively, a third shot of molten plastic, in addition to the first shot for the frame portion 30 and the second shot for the non-opaque panel 22, can be injected into the injection mold to integrally form the masking portion 44 with the frame portion 30 and/or the non-opaque panel 22. It should be appreciated that the injection mold can receive more than three shots with the additional shots forming additional features.
As set forth above, the masking portion 44 can alternatively be formed separately from the frame portion 30 and the non-opaque panel 22. For example, the masking portion 44 can be subsequently attached to the frame portion 30 and/or the non-opaque panel 22 after formation of the frame portion 30 and non-opaque panel 22 in the injection mold, e.g., after the frame portion 30 and the non-opaque panel 22 are removed from the injection mold. Alternatively, the masking portion 44 can be inserted into the injection mold before the molten plastic is injected such that, upon injection into the injection mold, the molten plastic partially encapsulates the masking portion 44, i.e., the masking portion 44 is overmolded by the molten plastic of the frame portion 30 and/or the non-opaque panel 22 in the injection mold.
With reference to
Alternatively, the construction of the interior panel 18, the exterior panel 20, and the non-opaque panel 22 of the second oven door 16 is like that of the second embodiment of the first oven door 14 in that the non-opaque panel 22 is integrally formed with the exterior panel 20. In such a configuration, the description of the interior panel 18, the exterior panel 20, and the non-opaque panel 22 of the second embodiment of the oven door 14, 16 above is also descriptive of the second oven door 16.
With reference to
With reference to
The handle 52 has a post 64 extending from the gripping portion 56 through the boss portion 54 and being connected to the interior panel 18 for coupling the interior panel 18, the exterior panel 20, and the handle 52. Specifically, the bottom 62 defines a hole 66, as shown in
As shown in
When the fastener 70 engages the post 64, e.g., when the threaded shank 74 threadedly engages the bore 68, the fastener 70 retains the interior panel 18, the exterior panel 20, and the handle 52 together. Specifically, with continued reference to
The handle 52 is typically formed of plastic such as, for example, a polyester. The plastic can be glass filled or can be free of glass filling. One example of a type of suitable polyester is glass filled polyethylene terepthalate commercially available from BASF Corporation in Florham Park, N.J. under the tradename Petra® 7010. However, it should be appreciated that the handle 52 can be formed of any type of suitable material without departing from the nature of the present invention. The handle 52 can be formed by, for example, gas assist molding; however, it should be appreciated that the handle 52 can be formed by any method without departing from the nature of the present invention.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.
The subject patent application claims priority to and all the benefits of U.S. Provisional Patent Application No. 61/371,074 which was filed on Aug. 5, 2010, the entire specification of which is expressly incorporated herein by reference.
Number | Date | Country | |
---|---|---|---|
61371074 | Aug 2010 | US |