GB2581259A

GB2581259A - Door

Info

Publication number: GB2581259A
Application number: GB1918960.4A
Authority: GB
Inventors: Johnson Martin; Rogers Jim
Original assignee: AGA Rangemaster Ltd
Current assignee: AGA Rangemaster Ltd
Priority date: 2018-12-20
Filing date: 2019-12-20
Publication date: 2020-08-12
Anticipated expiration: 2039-12-20
Also published as: GB2581259B; GB201820811D0; GB201918960D0

Abstract

An oven door 1 comprises a door fascia 2 with an intermediate panel 3 fixed or fixedly secured to the door fascia defining a first cavity A between the door fascia and the intermediate panel. An inner panel 4 is removably secured to the intermediate panel and defines a second cavity B between the inner panel and the intermediate panel. The first cavity may contain insulating material I. Spacers (35, Fig. 3) may be located around the periphery of the intermediate or inner panels to maintain a gap between the intermediate and inner panels. The intermediate panel may be fixed to the door fascia by securements (2c, 26, Fig. 3). A portion of the intermediate panel may nest within the inner panel. The inner panel may be secured to the intermediate panel by resilient retaining means (34, Fig. 2) comprising retaining elements (34b, Fig. 2) on a side wall (32, Fig. 2) of the intermediate panel and receiving elements (43, Fig. 4) on a side wall (42, Fig. 4) of the inner panel. An oven, range oven, an oven door assembly, a kit of parts, and a method of installing an oven door assembly are also claimed.

Description

DOOR

This invention relates generally to a door, more particularly to a door for an oven, an oven door and a door assembly for an oven.

Through use, the interior surfaces of an oven cavity become soiled through deposits of fat, grease, oil, food, etc. Continued use of the oven, after soiling, causes the deposited material to be burnt-on or carbonised, rendering removal more difficult.

A soiled oven provides several disadvantages, one of which being that the oven is less efficient. This is a result of less effective heat distribution; requiring increased energy input and resulting in uneven cooking. Further, carbonised deposits present a fire risk and may taint the flavour of the food being cooked therein.

Therefore, in the case of current ovens, to mitigate these problems regular cleaning of the oven interior is required; including the oven door. In the case of an oven door, this requires cleaning of a glass sheet in the case of, for example, a fitted oven or in the case of a metal range oven it requires cleaning an iron/steel internal panel/door fascia. This can be a labour-intensive process, and often burnt-on/carbonised deposits cannot be fully removed or may require harsh and/or corrosive cleaning materials to do so.

It is therefore a first non-exclusive object of the invention to provide a door that overcomes, or at least mitigates, the aforementioned problems with known ovens.

According to a first aspect of the invention there is provided a door, for example an oven door, the door comprising a door fascia, an intermediate panel fixed or fixedly secured to the door fascia, wherein the intermediate panel and door fascia describe a first cavity therebetween, and a user removeable inner panel secured to the intermediate panel, wherein the user removable inner panel and intermediate panel describe a second cavity therebetween.

Having a user removeable inner panel relieves at least some of the issues associated with soiling of the interior surfaces of the oven and/or the door. The user removeable inner panel is preferably readily demounted or demountable by a user such that it can either be cleaned more effectively remote from the oven and/or such that it can be replaced by a new and/or clean inner panel.

Advantageously, the first and second cavities provide for greater insulation between an oven cavity and the door fascia than would otherwise be the case.

One of the greatest sources of heat loss to the environment is through the oven door.

In some ovens, the exterior, particularly the door, can reach temperatures in excess of that safe to touch. Aside from efficiency, minimising the external temperature is important such that the oven conforms to standards, for example European Standards (EN). In the UK, io British Standards state that a glass oven door (with the oven operating at 200°C) should reach a maximum temperature of 55°C above ambient (e.g. ca. 75°C absolute), whereas a metal oven door, or a metal surround surrounding a glass panel, should reach a maximum of 40°C above ambient (e.g. ca. 60°C absolute). Other countries may have stricter requirements. Clearly, reducing the external temperature of a door will be beneficial to reduce the risk of injury, especially in the circumstances where ovens are used for extended periods, such as may be the case with a metal, e.g. cast iron, range cooker.

Commonly, to achieve the maximum required temperatures, oven manufacturers create an air gap between layers of glass in the door and in some cases actively drive cool air through the gap. In the case of an iron or stainless-steel door, where no glass is present, manufacturers may provide an air gap between a door fascia and a fascia panel. A layer of insulation may be provided between the door fascia and the fascia panel.

In embodiments of the invention, an insulating material may be positioned, installed or located in the first cavity. The second cavity may be vacant, for example such that it describes an air gap. The second cavity may describe an air gap between an oven cavity of an oven to which the oven door is installed and the intermediate panel.

The door fascia may be metallic, for example an iron or stainless-steel. The intermediate panel and/or inner panel may be metallic, for example constructed from iron or stainless-steel. The intermediate panel and/or inner panel may be constructed from any suitable material, for example, plastic, fibre-reinforced plastic, carbon fibre reinforced plastic. The intermediate panel and inner panel may be constructed from the same or different material from one another and the door fascia. For example, the inner panel may be formed of metal, e.g. iron, steel, stainless steel, aluminium or alloys.

The door fascia may comprise a peripheral lip around the periphery of the door fascia. The peripheral lip may describe a central recessed portion, for example inboard of the peripheral lip.

The first cavity and second cavity may be adjacent one another. The first cavity and second cavity may be spaced and separated from one another by at least a portion of the intermediate panel. The first cavity and the second cavity may form a pair of adjacent cavities.

With the oven door closed, the second cavity may be located adjacent an oven cavity and the first cavity may be located adjacent the second cavity, between the second cavity and the door fascia. The second cavity may be spaced from the oven cavity by a portion of the inner panel The first cavity and/or second cavity may be a closed cavity or sealed cavity, e.g. a fluidly sealed cavity. The first cavity and second cavity may each be closed-off or sealed, e.g. from one another. The first cavity and second cavity may be closed-off or sealed from one another so as to prevent the passage of fluid therebetween.

In embodiments, the intermediate panel and/or inner panel comprise one or more spacer elements. The spacer element(s) may be arranged to maintain at least a portion of the intermediate panel and inner panel in spaced relationship. The spacer element(s) may be distributed about a periphery of the intermediate panel and/or inner panel. One or more spacer element(s) may be on the inner panel. One or more spacer element(s) may be on the intermediate panel. In embodiments, one or more spacer element(s) may be on the inner panel and one or more spacer element(s) may be on the intermediate panel. The spacer elements may be formed on the panels. The spacer elements may be formations on the panels. The spacer elements may be secured t the intermediate and/or inner panel.

In an embodiment the spacer elements comprise rivets or other fixing means.

Advantageously, maintaining the intermediate panel and inner panel in a spaced relationship reduces the number of heat conduction paths between an oven cavity and the door fascia, thereby reducing the potential for heat loss from an oven to which the door is installed.

The door may comprise a retaining means, or retainer, to secure the inner panel to the intermediate panel, i.e. to removably secure the inner panel to the intermediate panel. A component of the retaining means or retainer may be located on the inner panel and a complementary component of the retaining means may be located on the intermediate panel. For example, the intermediate panel and/or inner panel may comprise one or more retaining elements and the other of the intermediate panel and/or inner panel may comprise one or more receiving portions, the one or more retaining elements and one or more receiving portions being co-operable or cooperating to retain the inner panel on the io intermediate panel. The retaining elements are preferably user retractable, retaining elements. The retaining elements may be resiliently urged. The retaining elements may comprise male and female members. One or both of the male and/or female members may be resiliently urged. The retaining elements may comprise, for example, retaining pins and/or apertures. The inner panel and/or intermediate panel may comprise male members, e.g. resiliently urged retaining elements, and the other of the intermediate panel and/or inner panel may comprise female members, corresponding or co-operating therewith.

The one or more retaining elements may be secured to the intermediate panel and/or inner panel by one or more securing means, for example one or more rivets. One or more spacer elements, for example arranged to maintain at least a portion of the intermediate panel and inner panel in a spaced relationship, may be provided by the one or more rivets, for example the heads thereof.

The female member may be configured to receive a respective male member. The female member may be an aperture, the male member may be a retractable retaining element, for example a retractable spigot. The, preferably retractable, retaining element(s) and receiving portion(s) may be configured to removably secure the intermediate panel to the inner panel.

Each receiving portion may comprise a guide or ramp for guiding and/or retracting a respective retractable retaining element when securing the intermediate panel to the inner panel.

The intermediate panel and/or the inner panel may comprise a base portion, for example a substantially rectangular base portion. Each base portion may have a respective wall for example a sidewall extending from a periphery of the base portion. The second cavity may be described between the respective base portions of the intermediate panel and inner panel.

The intermediate panel may comprise a stepped or angled or inclined sidewall, such that the cross-sectional area at the peripheral edge of the side wall is greater than the cross-sectional area of the base portion.

In some embodiments, the intermediate panel may be nestable, for example at least partially nestable, within the inner panel.

In use the or a sidewall of the inner panel may bound the or a side wall of the intermediate panel.

The one or more retractable retaining element(s) and receiving portion(s) may be located on a respective sidewall of the inner panel and/or intermediate panel. In some embodiments, the sidewall of the inner panel and/or intermediate panel may comprise said or a one or more spacer elements.

The one or more retractable retaining element(s) and receiving portion(s) may be arranged such that the inner panel may only be secured to the intermediate panel in a predetermined orientation.

The sidewall of the inner panel and/or intermediate panel may comprise one or more locating guides and the sidewall of the intermediate panel and/or inner panel may comprise corresponding or co-operating guide receiving portion(s). The locating guides and guide receiving portions may be arranged such that the inner panel may only be secured to the intermediate panel in a predetermined orientation.

The intermediate panel may comprise a peripheral flange extending therefrom. The peripheral flange may extend about the, intermediate panel, for example about the side wall of the intermediate panel. A gasket or seal (hereinafter gasket) may be attached or secured to the flange.

The gasket may be configured, for example with the oven door closed, to abut or contact an exterior of the oven to which the oven door is attached, e.g. about the periphery of an oven cavity. The gasket may be arranged to seal the oven cavity from the external environment by providing a seal between the door and an exterior of the oven, for example with the oven door closed The gasket may extend around and/or about the or at least some of the peripheral flange.

The gasket may provide substantially all or the majority of the contact between the intermediate panel and door fascia. The gasket may provide a heat break between the inner panel and/or intermediate panel and the door fascia. The gasket may comprise an elastomeric material, for example rubber.

A peripheral rim or edge of the inner panel may be arranged to abut the or a flange of the intermediate panel. The intermediate panel may terminate in a peripheral flange. The inner panel may comprise a terminal edge. The terminal edge of the inner panel may lie or be located adjacent the peripheral flange of the intermediate panel. In an embodiment the peripheral flange of the intermediate panel extends beyond the outer boundary of the inner panel.

One or more edge trims or edge trim seals may be attached or secured to the peripheral rim or edge of the intermediate and/or inner panel. The one or more edge trim seals may be arranged to abut the or a flange of the inner and/or intermediate panel. The one or more edge trim seals may be configured to provide the or a principal point of contact between the inner panel and intermediate panel. The one or more edge trims or edge trim seals may comprise a thermally insulating material. The one or more edge trims or edge trim seals may comprise an elastomeric material, for example rubber or a foam material. The one or more edge trims or edge trim seals may provide a heat break between the inner panel and intermediate panel.

The door may comprise a peripheral seal or gasket, for example a rope seal or rope gasket. The peripheral seal or gasket may be arranged to extend around the periphery of the door fascia, for example adjacent the peripheral lip of the door fascia. The peripheral seal or gasket may lie inboard of the peripheral lip of the door fascia.

The peripheral seal or gasket may be configured, for example with the oven door closed, to abut or contact an exterior of the oven to which the oven door is attached, e.g. about the periphery of an oven cavity. The peripheral seal or gasket may be arranged to seal the oven cavity from the external environment by providing a seal between the door and an exterior of the oven, for example with the oven door closed.

The peripheral seal or gasket may be located between the peripheral lip of the door fascia and the peripheral rim of the inner panel, for example in interference fit therebetween.

A fascia panel may be located or fixed between the door fascia and the intermediate panel. The fascia panel may comprise a flat plate or member. The first cavity may be described between the intermediate panel and the fascia panel. The first cavity may be spaced from to the door fascia by the fascia panel.

A further cavity may be described between the fascia panel and the door fascia. The further cavity may be vacant, for example such that it describes an air gap. The further cavity may describe an air gap between the first cavity and the door fascia.

The further cavity may be a closed cavity or sealed cavity, e.g. a fluidly sealed cavity. The further cavity may be closed-off or sealed, e.g. from the first cavity and/or second cavity. The further cavity may be closed-off or sealed from the first cavity and/or second cavity so as to prevent the passage of fluid therebetween.

Spacing the first cavity from the door fascia has the advantage of minimising the transfer of heat therebetween.

The intermediate panel may be installed or secured to the door fascia. The inner panel may be secured to the door fascia via the intermediate panel.

The intermediate panel may comprise attachment apertures. The door fascia may comprise fixing apertures, for example threaded bores. One or more attachment apertures of the intermediate panel may be aligned with a respective fixing aperture on or in the door fascia.

The fascia panel may be fixed to the door fascia. The intermediate panel may be attached or fixed to the door fascia via the fascia panel. Each of the fascia panel and the intermediate panel may comprise one or more attachment apertures that are arranged concentrically with one another and with a fixing aperture on or in the oven door. The fixing point may comprise a recess, e.g. a threaded recess, in the door fascia.

The attachment apertures may receive a securement or fixing element, e.g. a screw or bolt, therethrough. The fixing point may receive a fixing element therein. The securement or fixing element may comprise a screw and screw post arrangement. The fixing point may receive one end of the screw post, for a male threaded end. The attachment apertures may receive a screw or bolt therethrough. The screw or bolt may be received within an end of the screw post, for example a female threaded end. A portion of the intermediate panel may be secured between the screw or bolt and the screw post.

io The intermediate panel may be fixed or secured to the door fascia via one or more securement or fixing elements. The one or more securement or fixing elements, for example screw post(s), may be of a greater length than the depth or length of the sidewall of the intermediate panel, for example such that the intermediate panel is suspended or spaced from or out of contact with the door fascia and/or fascia panel when fixed or secured to the is door fascia.

The one or more securement or fixing elements, for example screw post(s), may be of such a length or dimensioned, for example of a greater length than the depth or length of the sidewall of the intermediate panel, for example such that the peripheral edge or peripheral flange of the intermediate panel is suspended or spaced from or out of contact with the door fascia and/or fascia panel when fixed or secured to the door fascia.

Arranging the securement or fixing elements in such that the intermediate panel is suspended or spaced from or out of contact with the door fascia and/or fascia panel is advantageous in that the likelihood of rattle or vibration between the intermediate panel and door fascia and/or fascia panel is reduced. Additionally, such an arrangement minimises the number and/or extent of the heat conduction paths between an oven cavity and the door fascia.

The one or more securement of fixing element(s) may comprise one or more insulating washers. An insulating washer may be arranged between a or each respective securement or fixing element and the intermediate panel. An insulating washer may be arranged between a or each respective securement or fixing element and the fascia panel and/or door fascia.

The or each insulating washer may comprise a thermally insulating material. The or each insulating washer may comprise a foam material, for example a Polyurethane foam or Polystyrene foam. The or each washer may comprise an elastomeric material, for example a rubber material. The or each washer may comprise a fibre or fibrous material, for example fibreglass. The or each washer may comprise an inorganic material, for example a ceramic material.

Arranging one or more insulating washers between a securement and fixing element and the intermediate panel reduces the area of contact between the securement or fixing io element and the intermediate panel. Such an arrangement reduces the contact area between the securement or fixing element and the intermediate panel, thereby reducing the heat conduction path therebetween. Such an arrangement may also provide a vibration damper between the securement or fixing element and the intermediate panel.

Further, arranging one or more insulating washers between a securement and fixing element and the fascia panel and/or door fascia reduces the area of contact between the securement or fixing element and the fascia panel and/or door fascia. Such an arrangement reduces the contact area between the securement or fixing element and the fascia panel and/or door fascia, thereby reducing the heat conduction path therebetween. Such an arrangement may also provide a vibration damper between the securement or fixing element and the fascia panel and/or door fascia.

In some embodiments, the inner panel overlies or obscures the one or more attachment apertures, and retaining elements received therein. Advantageously, the inner panel inhibits or prohibits direct heating of the retaining elements by the oven.

The inner panel and/or the intermediate panel may be formed from metal, for example aluminium or iron. The inner panel and/or intermediate panel may be formed from an alloy. In an embodiment the inner and/or outer panel are formed from stainless steel.

According to another aspect of the invention there is provided an oven or cooker comprising an oven door as described above The oven or cooker may be a heat storage cooker or range cooker.

According to another aspect of the invention there is provided an oven door assembly comprising an intermediate panel fixable to a door fascia, e.g. of an oven door, and a user removable inner panel securable to the intermediate panel wherein, in use, the door fascia and intermediate panel together describe a first cavity therebetween, and the intermediate panel and inner panel together describe a second cavity therebetween.

In some embodiments, the first cavity may be arranged or configured to receive insulating material. The second cavity may be arranged to provide an air gap, for example between an oven cavity and the first cavity.

The oven door assembly may comprise a gasket or seal as described above attachable or securable to a flange of the intermediate panel.

In embodiments, the oven door assembly comprises a fascia panel as described above.

Another aspect of the invention provides an oven or cooker door comprising an oven door assembly as described above.

According to another aspect of the invention there is provided a kit of parts comprising an intermediate panel as described above fixable to a door fascia of an oven door, wherein, in use, the intermediate panel and door fascia are arranged to describe a first cavity therebetween, the kit of parts further comprising a user removable inner panel as described above securable to the intermediate panel, wherein, in use, the user removeable inner panel and intermediate panel are arranged to describe a second cavity therebetween.

In some embodiments, the kit of parts may comprise a gasket or seal, for example attachable or securable to the intermediate panel, in particular a flange thereof.

The kit of parts may comprise fixing means, e.g. one or more screws or bolts, for fixing the intermediate panel and/or inner panel to a door fascia.

The kit of parts may comprise insulating material for receipt or installation within the first and/or second cavity.

In embodiments, the kit of parts may comprise a fascia panel as described above. The fascia panel may be configured to be located or fixed between a door fascia and the intermediate panel.

According to another aspect of the invention there is provided a method of installing an oven door assembly on a door fascia, e.g. of an oven door, the method comprising fixing an intermediate panel to a door fascia such that together they describe a first cavity therebetween and securing a user removeable inner panel to the intermediate panel such that together they describe a second cavity therebetween.

The method may comprise fixing a fascia panel to the door fascia between the intermediate panel and the door fascia, wherein the first cavity is described between the intermediate panel and outer wall panel.

is In some embodiments, the method includes inserting insulating material into the first cavity.

The method may comprise inserting or locating insulating material within a recessed portion of the intermediate panel prior to fixing the intermediate panel to the door fascia.

Each of the fascia panel and the intermediate panel may comprise one or more attachment apertures that are arranged concentrically with one another and a recess, for example a threaded recess, of the door fascia. The method may comprise mounting the intermediate panel and outer wall panel to the door fascia by extending a retaining element through the concentric apertures and into the recess.

The inner panel and/or intermediate panel may comprise one or more retractable retaining elements and the intermediate panel and/or inner panel may comprise corresponding receiving portions, the method may comprise securing the inner panel to the intermediate panel by engaging the retractable retaining elements with the corresponding receiving portions.

It will be appreciated that in the context of the present invention, the term 'inner panel' refers to the innermost, inner facing or oven cavity facing panel when a door to which the assembly is attached is closed, in use.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings and, in particular, the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. For the avoidance of doubt, the terms "may", "and/or', "e.g.", "for example" and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, io whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

Embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings in which: Figure 1 is cross-sectional view of a door according to an embodiment of the invention; Figures 2 to 5 show the components of the door of Figure 1 in various stages of construction; Figure 6 is a cross-sectional view of a door according to another embodiment of the invention; Figure 7 is a close-up of a portion of the door of Figure 6; and Figure 8 is an exploded view of the door of Figure 6.

Referring now to Figure 1, there is shown a door 1 according to an embodiment of the invention and, in particular, an oven door, which is an iron door of a range cooker in this embodiment. The door 1 comprises a door fascia 2, an intermediate panel 3 fixed to the door fascia 2 and a user-removable inner panel 4 secured to the intermediate panel 3.

In the present embodiment, a fascia panel 2a is located between the door 2 and the intermediate panel 3 and is fixed to the door fascia 2. The intermediate panel 3 is secured to the door fascia 2.

A first cavity A is provided between the intermediate panel 3 and the fascia panel 2a. A second cavity B is provided between the intermediate panel 3 and the inner panel 4. In the present embodiment, a further cavity C is provided between the door fascia 2 and the fascia panel 2a. The first cavity A is adjacent the second cavity B and adjacent the further cavity C. Preferably the cavities are separate from one another, preferably meaning that there is little or no fluid communication therebetween.

In this description 'inwardly' and 'inner' individually or together refer to a direction into the oven, La pointing towards the oven cavity, and outwardly shall be construed appropriately, io except where the context requires otherwise.

Referring to Figures 1 and 3, the fascia 2 provides the outermost portion of the door 1 and is the portion of the door 1 which is visible when the door 1 is closed. The door fascia 2 is generally rectangular and presents a convex outer surface 21a of the door 2. The inner-facing surface 21b of the door fascia 2 presents a generally concave surface.

The inner facing surface 21b of the door fascia 2 comprises a rectangular peripheral lip 22 which extends around the periphery of the inner facing surface 21b. Inboard of the lip 22 is a substantially rectangular and substantially flat land 23 which extends about the inner facing surface 21b. Located in each of the corners of the flat land 23 are raised abutments 24 and raised bosses 25, each of which comprise a threaded bore 26.

Inboard of the flat land 23 are inwardly facing upper and lower ribs 27 (e.g. a pair of ribs 27) which extend across the inner facing surface 21b. A rib structure 28 is provided on a concave central portion 29. The rib structure 28 extends between the upper and lower ribs 27. The ribs 27 protrude inwardly beyond the peripheral lip 22.

The door fascia 2 comprises hinge portions H, extending from one edge of the door fascia 2, each of the hinge portions H having a bore to receive hinge pins P. The opposite edge of the door fascia 2 comprises a latch mechanism L (Figure 5) or a part thereof to allow the door 1 to be closed and locked to the oven, in use.

The door fascia 2 is integrally formed as a one-piece casting, for example cast from iron or steel. The convex outer surface 21a, at least, may be coated in a protective coating, for example enamel (for example a vitreous enamel or enamel paint). The convex outer surface 21a, may be powder coated or otherwise protected.

The fascia panel 2a is a planar sheet material 2b which is substantially rectangular. The fascia panel has an aperture 2c located at or proximate each corner. The fascia panel 2a is sized so as to be accommodatable between the ribs 27 of the door fascia 2. The fascia panel 2a is sized and the apertures 2c are located such that when located between the ribs 27, the apertures 2c communicate with the threaded bores 26 of the door fascia 2. The inner facing surface 21b, and specifically the concave central portion 29, and the fascia io panel 2a define therebetween the further cavity C. Referring to Figures 1 and 2, the intermediate panel 3 is substantially tray-shaped and has a substantially rectangular base portion 31 from which a peripheral wall 32 extends. The peripheral wall comprises successively a first wall portion 32a, a second wall portion 32b and a third wall portion 32c, terminating in a distal peripheral flange 32d. A first step 32e is provided between the first wall portion 32a and the second wall portion 32b, a second step 32f is provided between the second wall portion 32b and the third wall portion 32c and the flange 32d extends from the third wall portion 32c in a direction substantially parallel to the base portion 31. In this way, the intermediate panel 3 describes a successively decreasing cross-sectional area in an inwardly direction, when installed.

The flange 32d is provided with a gasket G, preferably an elastomeric (e.g. rubber) gasket G. The gasket G may be secured to the flange 32d in any convenient way but is typically provided with inner and outer flange members (not shown) which embrace the distal edge of the flange 31d.

The base portion 31 has, at or proximate each of its corners, a base aperture 33.

The peripheral wall 32, and specifically the first wall portion 32a, has located thereon plural retaining elements 34. Each retaining element 34 comprises an elongate body 34a which terminates at one end in a retaining spigot 34b. Each retaining spigot 34b extends through a wall aperture provided in the first wall portion 32a. The elongate body 34a is secured to the first wall portion 32a, for example by rivets or by welding, and has sufficient resilience to resiliently urge the retaining spigot 34b into engagement with the respective wall aperture. In the embodiment shown there are two retaining elements 34 on the intended lowermost portion of the first wall portion 32a and one each on the intended vertical portions of the lowermost wall portion 32a. Other locations, distributions or numbers of retaining elements 34 may be used.

The peripheral wall 32, and specifically the first wall portion 32a, has on each on the intended vertical portions of the lowermost wall portion 32a, a spacer element 35.

The intermediate panel 3 is typically formed from a single pressing of sheet material or as a cast material, for example from metal. Once formed, the retaining elements 34 are io secured thereto.

Referring now to Figures 1 and 4, the inner panel 4 has a substantially rectangular base portion 41 having a peripheral wall 42 extending therefrom. The peripheral wall 42 extends from the base portion 41 at or close to a right angle to a free edge 42a. Adjacent or proximate the free edge 42a there are located receiving apertures 43. As shown there is a receiving aperture 43 on each of the intended vertical portions of the peripheral wall 42 and two receiving apertures 43 on the intended lowermost portion of the peripheral wall 42. The two receiving apertures 43 on the intended lowermost portion of the peripheral wall 42 are located within a respective trench 44 which extends into the volume otherwise circumscribed by the peripheral wall 42, thereby to provide a spacer element 45. Other locations, distributions or numbers of receiving apertures 43 may be employed.

In use, and in order to assemble the door 1, the fascia panel 2a is located between the ribs 27 of the door fascia 2 such that the apertures 2c are aligned and in communication with the threaded bores 26 of the door fascia 2. Insulating material I (indicated by a dotted line in Figure 1) is located within the volume defined by the peripheral wall 32 of the intermediate panel, for example to fill the first cavity and thereby to extend from the base portion 31 of the intermediate panel 3 to the fascia panel 2a. In other embodiments the insulating material I may partially fill the first cavity A. The insulating material I may comprise a ceramic fibre or mineral wool mat or other high temperature insulation.

The intermediate panel 3 and fascia panel 2a are arranged such that the apertures 2c and base apertures 33 are aligned and the gasket G is brought into abutment with the flat land 23 of the door fascia 2 but inboard of the peripheral lip 22.

A fixing means, for example a bolt is inserted through each of the base apertures 33 and through respective apertures 2c to engage with, and be threadingly received within, the respective threaded bores 26, thereby to secure the intermediate panel 3, insulation I and fascia panel 2a to the door fascia 2.

Accordingly, the first cavity A is formed between the intermediate panel 3 and the door fascia 2 and substantively between the intermediate panel 3 and the fascia panel 2a. As will be appreciated, the first cavity A is provided with, e.g. preferably filled with, insulation material I. The further cavity C is formed between the inner facing surface 21b, and io specifically the concave central portion 29, and the fascia panel 2a. The further cavity C is preferably vacant, insofar as it provides an air gap, which insulates the door fascia 2.

As will be appreciated, with the intermediate panel 3 fixed to the door fascia 2, the gasket G abuts the door facia 22 about the entirety of the peripheral lip 32d and provides a thermal break between the intermediate panel 3 and the door fascia 2, The inner panel 4 is brought into engagement with the intermediate panel 3. The intermediate panel 3, and specifically the first wall portion 32a of the wall portion 32 of the intermediate panel 3, is of a size to be received within the peripheral wall 42 of the inner panel 4.

The spacer elements 35 and trenches/spacer elements 45 maintain a spacing between the first wall portion 32a of the intermediate panel 3 and the peripheral wall 42 of the inner panel 4.

As the intermediate panel 3 is further nested within the inner panel 4 the free edge 42a of the peripheral wall 42 will foul on the retaining spigots 34b of the retaining elements 34. The retaining spigots 34b are pushed into the volume defined by the peripheral wall 32 of the intermediate panel 3 against the urging of the elongate body 34a of the retaining elements 34, thereby allowing the peripheral wall 42 of the inner panel 4 to be pushed beyond, e.g. to ride over the retaining spigots 34b until the retaining spigots 34b engage the receiving apertures 43 and are urged by the resilient urging of the elongate body 34a to seat within the receiving apertures 43, thereby securing the inner panel to the intermediate panel 3, and completing the door 1.

To remove the inner panel 4, for the purposes of cleaning and/or replacement, the retaining spigots 34b are forced into the volume defined by the peripheral wall 32 of the intermediate panel 3 against the urging of the elongate body 34a of the retaining elements 34, thereby allowing the peripheral wall 42 of the inner panel 4 to be pulled from, e.g. to ride over, the intermediate panel 3. Once the inner panel 4 is clear, the retaining spigots 34b will, under the effect of the resilient urging by the elongate body 34a, protrude once more from the volume defined by the peripheral wall 32 of the intermediate panel 3.

As will be appreciated, the inner panel 4 provides, in concert with the intermediate panel 3 io the second cavity B. The second cavity B is vacant and provides an air gap between the interior of the oven and the intermediate panel 3. Moreover, the fixings which secure the intermediate panel 3 to the door fascia 2 are covered by the inner panel 4, and are within the second cavity B. Accordingly, there is no direct heat path from the oven to the fixings and thence to the door fascia 2. Furthermore, because of the gasket G the door fascia 2 is substantially thermally isolated from the oven, insofar as a direct path from the oven cavity to the door fascia 2 is concerned.

With the door 1 installed on an oven and in a closed position, the gasket G abuts an exterior surface of the oven about the periphery of an opening of the oven cavity (not shown). The gasket G thereby provides a seal between the oven cavity (not shown) and the external environment.

Preferably, and as shown, the retaining elements 34 and receiving apertures 43 are arranged such that the inner panel 4 can only be removably and securely located to the intermediate panel 3 in one orientation.

It will be further appreciated that the retaining elements 34 are protected from the harsh conditions of the oven cavity by being located within the volume defined by the peripheral wall 32 of the intermediate panel 3.

Referring now to Figures 6 to 8 there is shown a door 101 according to an embodiment of the invention and, in particular, an oven door, which is an iron door of a range cooker in this embodiment. The door 101 is similar to door 1 as described in Figures 1 to 5 wherein corresponding features are denoted by corresponding references and like features are denoted by like references increased by 100.

The door 101 comprises a door fascia 102, an intermediate panel 103 fixed to the door fascia 102 and a user-removeable inner panel 104 secured to the intermediate panel 103.

In the present embodiment, a first cavity A' is provided between the intermediate panel 103 and the door fascia 102. A second cavity B' is provided between the intermediate panel 103 and the inner panel 104. The first cavity A' is adjacent the second cavity B'.

The intermediate panel 103 is similar to intermediate panel 3, however there is no gasket G installed on peripheral flange 132d of intermediate panel 103. Further, instead of spacer element 35 of intermediate panel 3, the intermediate panel 103 of the present embodiment includes a different means for maintaining a spacing between the first wall portion 132a of intermediate panel 103 and the peripheral wall 142 of the inner panel 104.

The peripheral wall 132, and specifically the first wall portion 132a, has located, on an innermost surface thereof, plural retaining elements 134 (the innermost surface being that which faces cavity A') as per retaining elements 34. Each retaining element 134, in particular the elongate body 134a thereof, is secured to the innermost surface of the first wall portion 132a by a pair of rivets 134c which extend from the outermost surface of the first wall portion 132a, through the first wall portion 132a, such that the head of each rivet stands proud from the outermost surface of the first wall portion 132a. Advantageously, the head of each of the rivets 134c operates to maintain, in use, the spacing between the first wall portion 132a of the intermediate panel 103 and the peripheral wall 142 of the inner panel 104.

Fixing means, in the form of a screw Si and screw post S2 are provided for fixing the intermediate panel 103 to the door fascia 2. The screw post 52 has a female thread at a first end 321 and a male thread at a second end 322. Between the first and second ends S21, S22 is a hexagonal post S23. The fixing means also includes a pair of thermally insulative washers W, one arranged at the first end 321 and the other at the second end S22 of the screw post S2.

The inner panel 104 is similar to inner panel 4 but has peripheral wall 142 that comprises successively a first wall portion 142a and a second wall portion 142b. The second wall portion 142b terminates in a free edge 142c. A step 142d is provided between the first wall portion 142a and second wall portion 142b.

The free edge 142c is arranged to receive four edge trim seals 145, one on each major side thereof.

A rope seal R is configured to be located between the peripheral lip 22 of the door fascia 2 and the second wall portion 142b. In the present embodiment, the rope seal R is secured between the peripheral lip 122 of the door 102 and second wall portion 142b.

In use, and in order to assemble the door 2, the male thread at the second end 322 of each respective screw post S2 is threadingly received within a respective threaded bore 126 of the door fascia 102. A thermally insulative washer W is arranged between the hexagonal post 323 and the door fascia 102.

The insulating material I is located within the volume defined by the peripheral wall 132 of the intermediate panel 103, for example to at least partially fill the first cavity A' and thereby to extend substantially from the base portion 131 of the intermediate panel 103 to the door fascia 2.

The insulating material I of the present embodiment has four apertures D which are aligned and in communication with the threaded bores 26 of the door fascia 2. The insulating material I is as per the earlier embodiment The intermediate panel 103 is arranged such that the base apertures 133 are aligned and in communication with the threaded bores 126 of the door fascia 102 and the female thread at the first end 321 of the screw posts 32. A thermally insulative washer W is arranged between the first end 321 of each respective screw post 32 and the intermediate panel 103.

Each hexagonal post S23 is dimensioned such that the intermediate panel 103 is supported in a spaced relationship from the door fascia 2, i.e. such that the peripheral flange 132d of the intermediate panel 103 is spaced from the door fascia 2, describing gap AG therebetween. Advantageously, the gap AG provides a thermal break between the door fascia 102 and the intermediate panel 103.

To secure the intermediate panel 103 to the door fascia 2, a screw Si is extended through each of the base apertures 133 and is threadingly received within the female thread at the first end S21 of each screw post S2. This process secures both the intermediate panel 103 and insulation Ito the door fascia 2. In this case, a portion of the base portion 131 is secured between each respective screw Si and screw post S2.

Accordingly, the first cavity A' is formed between the intermediate panel 103 and the door fascia 2.

The edge trim seals 145 (which are preferably formed of a foam material, e.g. a polymeric foam material) are secured to the peripheral flange 132d of the intermediate panel 103. The inner panel 104 is brought into engagement with the intermediate panel 103 and the edge trim seals 145 abut the edge of the inner panel 104. Advantageously, this provides a thermal beak between the intermediate panel 103 and the inner panel 104 and helps to reduce (and preferably eliminate) any door rattle noise. The innermost surface of the wall 142a of the inner panel 104 bears against the heads of the rivets 134c which maintain the spacing between the first wall portion 132a of the intermediate panel 103 and the peripheral wall 142 of the inner panel 104. Indeed, a gap is provided around the entire periphery of the of the innermost surface of the inner panel 104 so as to thermally isolate the inner panel 104 from the intermediate panel 103 (except, of course, where specified above).

The securing of the inner panel 104 to the intermediate panel 103 by the retaining elements 134 and removal of the inner panel 104 from the intermediate panel 103 is affected in a similar manner to that of inner panel 4, intermediate panel 3 and retaining elements 34 of the earlier embodiment.

Because of the retention of the inner panel 104 on the intermediate panel 103 by the retaining spigots 134b, and the size of the intermediate panel 104 (e.g. the length of its peripheral walls 142a) the terminal edge Either before or after the intermediate panel 103 is secured to the door fascia 2 and/or the inner panel 104 is secured to the intermediate panel 103, the rope gasket R is located between the peripheral lip 22 of the door fascia 2 and the second wall portion 142b.

The second cavity B' is formed between the intermediate panel 103 and inner panel 104 in a similar manner to that of intermediate panel 3 and inner panel 4 of Figures 1 to 5. The advantages of cavity B' are similar to those of cavity B and will not be mentioned herein.

With the door 101 installed on an oven and in a closed position, the rope gasket R abuts an exterior surface of the oven about the periphery of an opening of the oven cavity (not shown). The rope gasket R thereby provides a seal between the oven cavity (not shown) and the external environment.

to We have surprisingly found that as well as making the oven door easier to maintain (e.g. clean), the inner panel 4, 104 also acts as an insulant and reduces the exterior temperature of the door fascia 2/102. In our tests we have determined that the exterior surface temperature of the door fascia 2/102 may be reduced to less than 55°C by use of the inner panel 4. This is a significant reduction because it potentially reduces the exterior surface temperature of the door fascia 2/102 to one at which injury is less likely to occur. Moreover, by losing less heat energy to the environment (e.g. by conduction to and convection from the oven door) an oven on which the door is installed will be more efficient.

It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention. For example, whilst a fascia panel is present between the intermediate panel and the door fascia, this need not be the case. In some embodiments, the fascia panel is not present and the first cavity extends between intermediate panel and a door fascia. The further cavity may include insulation.

The retaining elements may be located on the inner panel and may be pulled against the resilient body to facilitate disengagement.

Additionally, whilst it is described that the retaining elements and receiving portions are arranged such that the inner panel can only be secured to the intermediate panel in one orientation, this need not be the case. It will be appreciated that the retaining elements and receiving portions may be arranged such that the inner panel may be secured to the intermediate panel in any orientation.

In the foregoing where it is explained that the cavities are separable so as to at least inhibit communication therebetween (preferably meaning that there is little or no fluid communication therebetween) this does not mean that the cavities need be hermetically sealed. Rather the cavities are positioned and located relative to one another that there is no free flow communication therebetween..

It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described io herein.

Claims

CLAIMS1 A door, for example an oven door, the door comprising a door fascia, an intermediate panel and an inner panel, the intermediate panel being fixed or fixedly secured to the door fascia and a first cavity being located between the intermediate panel and the door fascia, the inner panel being removably secured to the intermediate panel, wherein the inner panel and intermediate panel describe a second cavity therebetween.
2. A door according to Claim 1, wherein an insulating material is located in the first cavity.
3. A door according to Claim 1 or 2, wherein the second cavity is vacant.
4. A door according to any of Claims, 1 2 or 3, wherein the first cavity and second cavity are adjacent and separated by at least a portion of the intermediate panel.
A door according to any preceding Claim, wherein the intermediate panel and/or the inner panel may comprise one or more spacers to maintain a gap between the inner panel and intermediate panel.
6. A door according to Claim 5, wherein said one or more spacers are located about the periphery of the intermediate panel and/or the inner panel.
7 A door according to Claim 5 or 6, wherein at least one of said one or more spacers is provided on the intermediate panel and at least one of said one or more spacers is provided on the inner panel.
8. A door according to any preceding Claim, wherein the intermediate panel is fixed to the door fascia by securements.
9. A door according to Claim 8, wherein the inner panel overlies the securements.
10. A door according to any preceding Claim, wherein at least a portion of the intermediate panel nests within the inner panel.
11. A door according to any preceding Claim, further comprising retaining means to removably secure the inner panel to the intermediate panel.
12. A door according to Claim 11, wherein a first component of said retaining means is provided on one of the intermediate panel and the inner panel and a complementary second component of said retaining means is provided on the other of the inner panel and the intermediate panel.
13.A door according to Claim 11 or 12, wherein the retaining means comprises a retaining element and a complementary receiving portion.
14. A door according to Claim13, wherein one or both of the retaining element and receiving portion are resiliently urged.
15. A door according to Claim 13 or 14, wherein the retaining element comprises a male member and the receiving portion comprises a female member.
16. A door according to any one of Claims 12 to 15, wherein the intermediate panel comprises a base portion and a side wall extending therefrom and the first component of said retaining means is provided on the side wall.
17. A door according to any one of Claims 12 to 16, wherein the inner panel comprises a base portion and a side wall extending therefrom and the second component of said retaining means is provided on the side wall.
18. A door according to any preceding Claim, wherein the inner panel is removably secured to the intermediate panel in a single orientation.
19. An oven comprising a door according to any preceding Claim.
20. A range oven comprising a door according to any one of Claims 1 to 17.
21. A range oven according to Claim 19, wherein the door fascia is a one-piece casting.
22 An oven door assembly comprising an intermediate panel fixable to an oven door fascia, and a user-removable inner panel secured to the intermediate panel wherein, in use, the door fascia and intermediate panel are fixed or fixable together and a first cavity is provided therebetween, and the intermediate panel and inner panel are removably secured together to describe a second cavity therebetween.
23 A kit of parts, the kit comprising an intermediate panel fixable to a door fascia of an oven door to provide a first cavity between the door fascia and the intermediate panel and a user removable inner panel removably securable to the intermediate to panel, wherein, in use, and when secured together the user removeable inner panel and intermediate panel describe a second cavity therebetween.
24. A method of installing an oven door assembly on an oven door fascia, the method comprising fixing an intermediate panel to a door fascia such that a first cavity is provided therebetween and securing a user-removeable inner panel to the intermediate panel such that together they describe a second cavity therebetween.
25. A method according to Claim 23 or 24, the method comprising actuating a resiliently urged retaining element on one or other of the intermediate panel and the inner panel and receiving the resiliently urged retaining element in the other of the inner panel and intermediate panel.