Patent Application
20200305641
The present invention relates to a rack assembly that is mountable within a cavity of an appliance, and more particularly, a rack assembly that interchangeably supports a plurality of rack inserts.
Rack assemblies can be mounted within a cavity of an appliance for supporting various items within the cavity. For example, oven appliances often have one or more rack assemblies mounted within their oven cavities for supporting cookware, food, and other items, within the oven. Such rack assemblies typically comprise a rack body formed by a plurality of wires, which can be placed on ledges defined by side walls of the oven cavity. The wires of the rack body collectively form a support platform upon which cookware, food, and other items can be placed. The thermal mass of these wires increase the amount of energy needed to thermally regulate (e.g., heat) the oven cavity. Moreover, different-sized rack bodies are typically manufactured for different-sized oven cavities, which inhibits the ability to scale manufacture of the rack bodies.
In accordance with one aspect, a rack assembly is mountable within a cooking cavity of an appliance. The rack assembly includes a slide rack defining a well opening and configured to removably support a rack insert in or through the well opening. A telescoping slide is coupled to the slide rack such that the slide rack is slidable between a fully retracted position and a forward position relative to the cooking cavity when mounted therein.
In one example of the first aspect, the rack assembly further includes a plurality of rack inserts, each of the plurality of rack inserts being different from the others and being interchangeably supportable by the slide rack in or through the well opening. In one example, one or more of the plurality of rack inserts includes a pan, a tray, a basket, or a supplemental rack. In another example, one or more of the plurality of rack inserts has dimensions approximating dimensions of the well opening.
In another example of the first aspect, the slide rack is defined by a plurality of wires. In one example, the slide rack is planar and rectangular in shape. In another example, the plurality of wires defines a rectangular outer frame and a rectangular inner frame surrounding the well opening, the inner frame being coplanar with and spaced inward from the outer frame. In yet another example of the first aspect, the rack assembly further includes a base configured to mount the rack assembly in the cooking cavity, the slide rack being coupled to the base via the telescoping slide. In one example, the telescoping slide includes a main portion fixed to the base, and an extension portion fixed to the slide rack and slidably coupled to the main portion. In another example, the base is defined by a plurality of wires. In another example, the rack assembly further includes an auxiliary rack insert and an auxiliary support coupled to the base for removably supporting the auxiliary rack insert beneath the well opening in the slide rack when the slide rack is fully retracted. In one example, the auxiliary support is defined by a plurality of brackets, each the bracket having a vertical portion that extends downward from the base and a flange portion that extends inward from the vertical portion. In another example, the auxiliary rack insert has larger dimensions than the well opening. In yet another example, the auxiliary rack insert is a pan, and a method of cooking in a cooking cavity having the rack assembly includes the steps of filling the pan with water; placing a food item on the rack insert mounted in or through the well opening in the slide rack; and heating the cooking cavity to cook the food item on the rack insert therein, whereby drippings from the food item fall through the rack insert and into the water in the pan, thereby preventing the drippings from directly contacting dry surfaces within the cooking cavity and thus from generating smoke while cooking the food item. In one example, the food item is placed directly onto said rack insert with no intermediate cooking utensil or wrapping.
In still yet another example of the first aspect, the slide rack has a well opening area that is 50% or more of a total superficial area of the slide rack.
In another example of the first aspect, a cooking appliance includes a cooking cavity and the rack assembly mounted within the cooking cavity. The slide rack is fully received within the cooking cavity when in the filly retracted position and emerges at least partially from the cooking cavity when in the forward position. An area of the well opening is 50% or more of a total superficial area of the slide rack.
In accordance with a second aspect, a method of manufacturing cooking appliances includes supplying a first cooking appliance having a first cooking cavity with first horizontal dimensions; supplying a second cooking appliance having a second cooking cavity with second horizontal dimensions smaller than the first horizontal dimensions; supplying a rack assembly for the first cooking appliance, the rack assembly being configured to be mounted in the first cooking cavity and including a slide rack that defines a well opening therein and is configured to removably support a rack insert in or through the well opening, the slide rack having slide rack dimensions that approximate the first horizontal dimensions; and supplying a plurality of the rack inserts, identical to one another, having insert dimensions that approximate the second horizontal dimensions of the second cooking appliance as well as well opening dimensions of the well opening.
In one example of the second aspect, the method includes supplying the first cooking appliance to a first geographic market, and supplying the second cooking appliance to a second geographic market distinct from the first geographic market.
In another example of the second aspect, a first subset of the rack inserts is packaged respectively with individual units of the second cooking appliance, and a second subset of the rack inserts is packaged respectively with individual units of the rack assembly.
In yet another example of the second aspect, the slide rack has a well opening area that is 50% or more of a total superficial area of the slide rack.
Referring to
The appliance 10 in the illustrated embodiment corresponds to an oven appliance that is operable to perform one or more cooking operations (e.g., baking, broiling, etc.). For example, the appliance 10 can include one or more heating elements (e.g., gas burners or electric-resistive heating elements) within or outside of the cavity 12 that are independently or collectively operable to heat the cavity 12 to a predetermined temperature. The heating element(s) can be operated to maintain the cavity 12 at the predetermined temperature for a predetermined amount of time and/or until a user terminates the cooking operation. It is to be appreciated that a “cooking operation” of the appliance 10 can be any operation of the appliance 10 in which a temperature of the cavity 12 is elevated above ambient for a period of time. However, the appliance 10 may be a refrigerator, a freezer, or some other appliance in other embodiments.
The slide rack 20 is a rigid body that, as discussed further below, is configured to interchangeably support a plurality of rack inserts (e.g., pans, trays, baskets, supplemental racks, etc.). In the illustrated embodiment, the slide rack 20 is a “full width” rack having dimensions that approximate horizontal dimensions of the cavity 12. In particular, the slide rack 20 is a rectangular rack having a length L1 that is nearly equal to a distance x1 between the side walls 14d of the cavity 12, and a width W1 that is nearly equal to a depth y1 of the rear wall 14c of the cavity 12 from the door 16 when closed (for the purposes of this disclosure, a first dimension “approximates” or is “nearly equal” to a second dimension if the ratio between of the first and second dimensions (or its inverse) is between 0.90 and 1.0, preferably between 0.95 and 1.0). However, it is to be appreciated that the slide rack 20 may have different shapes in other embodiments.
The slide rack 20 in the illustrated embodiment is defined by a plurality of metal wires 24, which includes a front wire 24a, a rear wire 24b, opposed side wires 24c, 24d, and a plurality of cross-wires 24e. The front wire 24a, rear wire 24b, and side wires 24c, 24d collectively form a rectangular, outer frame 26 of the slide rack 20. Those wires may be joined or respective extents of the same wire to form a continuous perimeter loop defining the outer frame 26, as shown. Alternatively, they may be distinct wires joined together at their respective adjacent ends. Meanwhile, the plurality of the cross-wires 24e extend inward from the outer frame 26 and terminate at an inner frame 28 that defines a rectangular well opening 30 of the slide rack 20, preferably at the center of the slide rack 20. The well opening 30 is designed to accommodate various rack inserts when inserted therein and supported by the slide rack 20, as discussed further below.
The wires 24 of the slide rack 20 can be integrally formed from a single piece of metal wire, or separately formed and attached together in various manners such as by welding, adhesives, or fasteners. The wires 24 also can include or be made of other materials, and can be arranged differently than illustrated to form alterative shapes than those shown in the drawings. Moreover, the slide rack 20 may include other types of elements such as, for example, brackets. Broadly speaking, the slide rack 20 can be any rigid body that is slidable within the cavity 12 and defines a well opening 30 for accommodating a plurality of rack inserts.
The mounting assembly 22 includes a pair of telescoping slides 32 for slidably mounting the slide rack 20 within the cavity 12. Each slide 32 has a main portion 34 and an extension portion 36 that is fixed to the slide rack 20 and slidable relative to the main portion 34. In the illustrated embodiment, the main portion 34 and extension portion 36 of each slide 32 are elongated-metal brackets and are slidably coupled to each other via an intermediate bearing assembly 38. The bearing assembly 38 includes a first rail 40 fixed to the main portion 34, a second rail 42 fixed to the extension portion 36, and a plurality of ball bearings (not shown) between the first and second rails 40, 42 that permit the first and second rails 40, 42 to slide relative to each other. However, the main portion 34 and extension portion 36 of each slide 32 may comprise other shapes and materials, and may be slidably coupled to each other in a variety of different manners.
In some examples, the slides 32 of the rack assembly 18 can be mounted directly to the walls of the cavity 12. For instance, the main portions 34 of the slides 32 can rest directly upon ledges or guide rails 48 defined by (or attached to) the walls of the cavity 12. In addition or alternatively, the main portions 34 can be secured to the walls of the cavity 12 via fasteners (e.g., screws), latches, welding, or the like.
In other examples, the mounting assembly 22 can include a base 50 that supports the slide rack 20 and slides 32 and can be placed onto the guide rails 48 of the cavity 12 to mount the rack assembly 18 within the cavity 12. In particular, the main portions 34 of the slides 32 can be fixed to the base 50 such that the extension portions 36 of the slides 32 (and the slide rack 20 fixed to the extension portions 36) are slidable relative to the base 50. Similar to the slide rack 20, the base 50 can have a plurality of wires 54, which includes a front wire 54a, a rear wire 54b, and opposed side wires 54c, 54d that collectively define a rectangular wire subframe 56. The base 50 can further include one or more cross-wires 54e that extend across the base 50 to reinforce and mitigate sagging of the base 50. The wires 54 can be integrally formed from a single piece of metal wire, or separately formed and attached together in various manners such as by welding, adhesives, or fasteners. The wires 54 of the base 50 also can be made of or include a variety of different materials, and can be arranged in different manners than illustrated to form various other shapes. Moreover, the base 50 may be defined by other types of elements such as, for example, brackets. Broadly speaking, the base 50 can be any rigid body that supports the slides 32 and slide rack 20 described above.
The rack assembly 18 is configured such that when mounted within the cavity 12, the slide rack 20 can be slid relative to the cavity 12 and base 50 between a fully retracted position in which the slide rack 20 is located entirely within the cavity 12, and an extended position in which the slide rack 20 has been advanced forward from the fully retracted position, such that it can extend partially or completely out of the cavity 12.
As noted above, the slide rack 20 is configured to interchangeably support a plurality of rack inserts.
For example,
Meanwhile,
Each rack insert 64 can be removably supported by the slide rack 20 such that the rack insert 64 is suspended over, in, or through the well opening 30 of the slide rack 20. Moreover, the slide rack 20 and rack inserts 64 can include various types of coupling elements (e.g., brackets, flanges, tabs, hooks, wires, grooves, recesses, projections, etc.) that can engage each other to removably couple each rack insert 64 to the slide rack 20.
For example, the cooking basket 64d can be inserted through the well opening 30 of the slide rack 20 and hooked to the inner frame 28 using the hooks 92 depending from the cooking basket 64d. When hooked to the slide rack 20, the cooking basket 64d will hang below the well opening 30 at a depth corresponding to the length of the hooks 92.
As another example, the slide rack 20 in the illustrated embodiment (
One or more of the rack inserts 64 can have dimensions that approximate the dimensions of the well opening 30, such that the rack insert 64 will fit securely in the well opening 30 when mounted. For example, the outer frame 70 of the supplemental rack 64a in the illustrated embodiment is rectangular in shape and has a length L2 that is nearly equal to a length l of the well opening 30, and a width W2 that is nearly equal to a width w of the well opening 30. Accordingly, when the supplemental rack 64a is placed on the tabs 94 of the slide rack 20 in the well opening 30, the supplemental rack 64a will fit securely within the inner frame 28 of the slide rack 20, and will be constrained from shifting laterally. Moreover, the slide rack 20 and supplemental rack 64a will collectively form a continuous surface on which other elements (e.g., cooking trays, baking pans, etc.) can be placed. In particular, the cross-wires 68e of the supplemental rack 64a can align with the cross-wires 24e of the slide rack 20 such that the support area 72 of the supplemental rack 64a is continuous with and extended by the cross-wires 24e of the slide rack 20.
The cooking pan 64b, cooking tray 64c, and cooking basket 64d may be similarly dimensioned to fit securely within the well opening 30 when inserted in the well opening 30.
The plurality of rack inserts 64 supportable by the slide rack 20 can include additional or alternative rack inserts than those described above such as for example, glass baking pans, cooking trays with muffin insets, or non-perforated cooking trays. In some examples, the rack inserts 64 can all be substantially different from each other, such that each rack insert 64 is unique in structure and function. Alternatively, some rack inserts 64 may be similar in type to each other but vary in regards to material, coatings, size, thickness, and/or shape.
As can be appreciated from the above, the rack assembly 18 can accommodate a variety of different applications by altering which rack insert 64 is supported by the slide rack 20 based on the intended application. For instance, the supplemental rack 64a in
The well opening 30 in the slide rack 20 lowers the thermal mass of the rack assembly 18 as compared to a similar rack assembly having a conventional oven rack. This reduction in thermal mass is particularly advantageous for applications in which the rack assembly 18 is mounted within a temperature-controlled cavity (e.g., oven cavity or refrigerator compartment), since the reduction in thermal mass will reduce the energy needed to achieve and maintain a desired temperature for the cavity. Accordingly, the overall thermal mass of the rack assembly 18 and rack insert 64 can be tailored for each application by selecting the appropriate rack insert 64 for the application, thereby contributing only so much thermal mass as appropriate for the application.
Preferably, the slide rack 20 will have a relatively large well opening 30 in order to reduce the rack assembly's thermal mass as much as possible. For example, the slide rack 20 can have a well opening area that is preferably 50% or more, and more preferably 60% or more, of the rack's total superficial area calculated by multiplying its overall length (L1) and width (W1) dimensions for a substantially square or rectangular rack; i.e. the total area bound by the rack's outer perimeter.
Another advantage is that the rack assembly 18 can take advantage of rack inserts 64 already being manufactured as oven racks or oven-rack inserts for other markets where oven cavities (and therefore racks) are smaller. For example, oven cavities in the US are much larger than those in Europe and therefore, US oven racks also are larger than European ones. However, an oven rack or oven-rack accessory manufactured for use in a European-spec oven can now also be used in a US-spec oven as one of the rack inserts 64 disclosed herein, where it will be supported by the slide rack 20, which is sized to correspond to the US oven cavity. That is, the slide rack 20 of the rack assembly 18 can be dimensioned to approximate horizontal dimensions of a first cavity of a first appliance (e.g., a North American oven), while the rack inserts 64 supportable by the rack assembly 18 can be dimensioned to approximate dimensions of both the well opening 30 of the rack assembly 18 and a second cavity of a second appliance (e.g., a European oven) that is smaller than the first cavity. In this manner, racks and rack inserts already being manufactured for other markets now can see double duty as the rack inserts 64 disclosed herein, opening up a new market for existing products and taking advantage of economies of scale in manufacture.
For example, as discussed above the rack assembly 18 in the illustrated embodiment is configured to be mounted within the cavity 12 of the appliance 10, and the slide rack 20 of the rack assembly 18 is dimensioned to approximate horizontal dimensions of the cavity 12. In particular, the slide rack 20 has a length L1 that is nearly equal to the distance x1 between the side walls 14d of the cavity 12, and a width W1 that is nearly equal to the depth y1 of the rear wall 14c of the cavity 12 from the door 16 when closed. Moreover, the supplemental rack 64a is dimensioned to approximate dimensions of the well opening 30. In particular, the supplemental rack 64a has a length L2 that is nearly equal to the length l of the well opening 30, and a width W2 that is nearly equal to the width w of the well opening 30.
The dimensions of the rack assembly 18 and supplemental rack 64a can be predetermined such that the supplemental rack 64a fits not only within the well opening 30 of the rack assembly 18, but can also be mounted within a second cavity of a second appliance that is smaller than the cavity 12 of the appliance 10 above. For example,
The supplemental rack 64a can be mounted within the cavity 102 by placing the supplemental rack 64a onto ledges or guide rails 108 defined by (or attached to) the side walls 104d of the cavity 102. Moreover, the supplemental rack 64a can be dimensioned to approximate horizontal dimensions of the cavity 102. In particular, the length L2 of the supplemental rack 64a can be nearly equal to the distance x2 between the side walls 104d of the cavity 102, while the width W2 of the supplemental rack 64a can be nearly equal to the depth yz of the rear wall 104c of the cavity 102 from its door 106 when closed.
Thus, the rack assembly 18 can promote scaling of manufacture of the supplemental rack 64a, because the supplemental rack 64a can be used in both cavities 12 and 102 of the respective appliances 10 and 100. In particular, the appliance 10 and rack assembly 18 can be supplied to a first geographic market (e.g., U.S.), the appliance 100 can be supplied to a second geographic market (e.g., Europe), and a plurality of identical supplemental racks 64a can be made together on the same assembly line and supplied to both markets for use with both appliances 10, 100. Moreover, any of the other rack inserts 64 described above can be similarly dimensioned such that the rack inserts 64 are both directly mountable in the cavity 102 of appliance 100 and supportable by the rack assembly 18 within the cavity 12 of appliance 10.
In some examples, the rack assembly 18 can include an auxiliary support 110 that is coupled to the base 50 and configured to support an auxiliary rack insert 112, as shown in
In the illustrated embodiment, the auxiliary rack insert 112 is a rectangular pan having a pan body 114 and a flange or lip 116 that surrounds the perimeter of the pan body 114. Meanwhile, the auxiliary support 110 is defined by a plurality of metal brackets 118, which includes a rear bracket 118a and a pair of opposed side brackets 118b that extend forward from opposite ends of the rear bracket 118a to form a U-shaped body. Each bracket 118 of the auxiliary support 110 is fixed to the base 50 and has a vertical portion 120 that extends downward from the base 50. Moreover, each bracket 118 includes a flange portion 122 that extends inward from a bottom end of its vertical portion 120, perpendicular to the vertical portion 120. The U-shaped auxiliary support 110 defines an interior space 124.
The auxiliary rack insert 112 can be removably supported by the auxiliary support 110 by inserting the rack insert 112 into the interior space 124 and resting its lip 116 on the flange portions 122 of the auxiliary support 110. Moreover, the rack insert 112 can be dimensioned to approximate dimensions of the auxiliary support 110. In particular, the rack insert 112 can be rectangular and have a length L3 that is nearly equal to a distance x3 between the vertical portions 120 of the side brackets 118b, and a width W3 that is nearly equal to a distance y3 of the rear bracket 118 from the front ends of the side brackets 118b.
When supported by the auxiliary support 110, the auxiliary rack insert 112 can be disposed directly below the well opening 30 of the slide rack 20 (in its fully retracted state). In this manner, the auxiliary rack insert 112 can function as a crumb or drip tray that catches crumbs, grease or other foodstuff that fall from the rack insert 64 mounted to the primary slide rack 20 above. Moreover, water can be poured into the pan body 114 of the auxiliary rack insert 112 prior to initiating a cooking operation (e.g., broiling, baking, etc.) of the appliance 10. In particular, water can be poured into the pan body 114 such that the water covers a base 130 of the pan body 114 (e.g., with a depth of ¼ inch or more). A food item can then be placed directly on the rack insert 64 above (e.g., with no intermediate cooking utensil or wrapping), and a cooking operation can be initiated that heats the cavity 12 to cook the food item. By adding water into the pan body 114 prior to the cooking operation, smoke generated from crumbs, grease or other foodstuff falling into and contacting the pan body 114 during the cooking operation can be reduced. For example, when cooking proteins such as poultry or meat, fat is liquified and can drip from the food item through the rack insert 64 as grease. If that grease lands on a dry surface in a hot oven it will generate smoke. By configuring the auxiliary rack insert 112 as a drip pan and filling it with water, the grease drippings can fall into water, thereby preventing the drippings from directly contacting dry surfaces within the cavity 12 and thus from generating smoke while cooking the food item.
Preferably, the auxiliary rack insert 112 is larger in dimensions than the well opening 30 so that the auxiliary rack insert 112 extends under the entire well opening 30. For example, the length L3 of the rack insert 112 preferably is larger than the length/of the well opening 30, and the width W3 of the rack insert 112 is preferably larger than the width w of the well opening 30.
However it is to be appreciated that the auxiliary support 110 and rack insert 112 may comprise other shapes, sizes, and materials than those described above. Moreover, the rack insert 112 may correspond to a different type of rack insert such as, for example, any of the other rack inserts 64 described above. In some examples, the auxiliary rack insert 112 can be fixed to the auxiliary support 110, or removably coupled to the auxiliary support 110 by means other than those described above. Still further, the auxiliary support 110 may be slidably coupled to the base 50, similar to the primary slide rack 20.
In some examples, the rack assembly 18 may include a plurality of auxiliary rack inserts 112 that can be interchangeably supported by the auxiliary support 110. The rack inserts 112 can all be substantially different from each other, such that each rack insert 112 is unique in structure and function. Alternatively, some rack inserts 112 may be similar in type to each other but vary in regards to material, coatings, size, thickness, and/or shape.
The invention has been described with reference to example embodiments described above. Modifications and alterations will occur to others upon a reading and understanding of this specification. Example embodiments incorporating one or more aspects described above are intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.
