GB2614869A

GB2614869A - Electric range cooker

Info

Publication number: GB2614869A
Application number: GB2113047.1A
Authority: GB
Inventors: Mcginley Michael
Original assignee: Uk Innovations Group Ltd
Current assignee: Uk Innovations Group Ltd
Priority date: 2021-09-13
Filing date: 2021-09-13
Publication date: 2023-07-26
Also published as: GB202113047D0; WO2023037130A1

Abstract

An electric range cooker 40 comprises a housing 41, with ovens 28, 28´ defined within the housing, and hobs 16 & 17 on an upper surface of the housing. Each oven has a separate electric oven heating element (11, Fig. 2) and each hob has a separate electric hob heating element (10, Fig. 1). A control system 12 allows the operating temperature of each electric heating element to be controlled independently of the operating temperature of the other electric heating elements. A gas, oil, or solid fuel range cooker is converted into the electric range cooker by dismantling the cooker and installing the ovens, electrical heating elements, hobs, and control system in the housing. The oven heating elements may be mounted in a cassette (25, 25´, Fig. 5), and the hob elements may be combined with a support tray (31, Fig. 6) in a hob assembly (29, Fig. 6). Each oven and each hob may have a separate thermostat controlled by rotary switches. A kit of parts is also claimed.

Description

Electric Ramie Cooker This invention relates, in a first aspect thereof, to a fully controllable electric range cooker. In a second aspect, the invention relates to a method of converting a conventional range cooker to a fully controllable electric range cooker. In a third aspect the invention relates to a kit of parts for installation in a conventional range cooker thereby to convert it into a fully controllable electric range cooker. And in a fourth aspect, the invention relates to a fully controllable electric range cooker converted from a conventional range cooker.

Heat storage range cookers are traditionally made from cast iron coated with an aesthetic vitreous enamel finish. Cast iron is a material known for its high thermal mass, i.e. the ability to absorb and store heat. In addition to the provision of radiant heat for cooking, this high thermal mass also enables range cookers to provide residual heat into the room, thus serving a dual purpose as both cooker and room heater.

Range cookers provide a desirable form of cooking using radiant or indirect heat, as opposed to the standard fan assisted convection cooking utilised in most modern electric ovens. In range cookers, the heat charged iron ovens cook the food from all angles via an indirect heat source. This is considered to create superior results for roasting, baking and slow cooking. In addition, heat storage range cookers naturally vent the moisture inside the ovens creating a dry oven that cooks food without the condensation associated with convection ovens. The cookers generally comprise a hob and two or more ovens arranged to operate at different temperatures.

Disadvantages of conventional range cookers however include high running costs, limited controllability, excessive residual heat being emitted into the room in summer months, and limited or no independent control between the individual hobs and ovens. That is to say, the temperature of each individual hob or oven cannot be accurately controlled independently of the temperature of the other hobs or ovens. This is because conventional models use one single heat source (eg gas or oil fired burner, or conventional electric element), with heat travelling throughout the appliance via heat conduction within the cast iron.

Conventional models operating on oil, gas or solid fuel, often require a chimney, flue, combustion ventilation and adherence to multiple building control regulations in relation to flue termination, gas pipes, and oil lines. Conventional electrically operated models address some of these issues, but still have limited controllability and limited or no independent control between the individual hobs and ovens.

The present invention seeks to address the above issues by providing a fully controllable electric range cooker. The term "fully controllable" is used herein to denote an electric range cooker in which the operating temperature of each hob and each oven can be controlled independently of the operating temperature of the other hobs and ovens. This is achieved by using independent electric heating elements in the different areas of the appliance to allow focused indirect heat in the corresponding areas.

Therefore, according to a first aspect of the present invention there is provided a fully controllable electric range cooker comprising a housing, one or more ovens defined within the housing, and one or more hobs provided at an upper surface of the housing, wherein each oven has a separate electric oven heating element and each hob has a separate electric hob heating element, and further comprising a control system adapted to enable the operating temperature of each electric heating element to be controlled independently of the operating temperature of each other electric heating element.

Each electric oven heating element is preferably mounted in an oven element cassette. Each hob and its associated electric hob heating element is preferably 20 combined in a hob assembly, preferably comprising a hob support tray.

The control system preferably comprises a separate oven thermostat associated with each oven and a separate hob thermostat associated with each hob. The control system preferably also comprises a plurality of rotary switches adapted to facilitate the independent operation of each oven and each hob.

According to a second aspect of the present invention there is provided a method of converting a conventional range cooker to a fully controllable electric range cooker as hereinbefore described, said method comprising the steps of: (a) dismantling the conventional range cooker thereby to remove all components, leaving only a housing, and one or more ovens defined within the 30 housing; (b) installing in the housing a separate electric oven heating element for each oven; (c) installing in the housing a control system adapted to enable the operating temperature of each electric heating element to be controlled independently of the operating temperature of each other electric heating element; (d) installing in the housing a separate electric hob heating element for each 5 hob; and (e) installing in the housing one or more hobs.

In step (b), each electric oven heating element is preferably mounted in an oven element cassette. Steps (d) and (e) are preferably combined by installing in the housing one or more hob assemblies, each comprising a hob and a hob heating 10 element. Each hob assembly preferably further comprises a hob support tray.

In step (c), the control system preferably comprises a separate oven thermostat associated with each oven and a separate hob thermostat associated with each hob. The control system preferably further comprises a plurality of rotary switches adapted to facilitate the independent operation of each oven and each hob.

The conventional range cooker may be an oil, gas, or solid fuel fired range cooker, or alternatively may be a conventional electric range cooker. In the latter case, the conversion method relates solely to providing the full controllability, rather than also including a fuel conversion.

According to a third aspect of the present invention there is provided a kit of 20 parts for use in a method as hereinbefore described for converting a conventional range cooker into a fully controllable electric range cooker as hereinbefore described, said kit comprising: - one or more electric oven heating elements; - one or more electric hob heating elements; and -a control system adapted to enable independent control of each electric heating element.

The kit of parts preferably further comprises one or more oven element cassettes adapted for mounting the electric oven heating elements in the housing, and one or more hob assemblies adapted for mounting the electric hob heating elements in the housing. The control means preferably comprises a separate oven thermostat associated with each oven heating element, and a separate hob thermostat associated with each hob heating element. The control means preferably further comprises a plurality of rotary switches adapted to facilitate the independent operation of each oven and each hob.

According to a fourth aspect of the present invention there is provided a fully controllable electric range cooker as hereinbefore described, produced by converting a conventional range cooker according to a method as hereinbefore described, and/or using a kit of parts as hereinbefore described In order that the present invention may be clearly understood, preferred embodiments thereof will now be described in detail, though only by way of example, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of an electric hob heating element, being a component of a fully controllable electric range cooker according to the present 10 invention; Figure 2 is a perspective view of an electric oven heating element, being a component of a fully controllable electric range cooker according to the present invention; Figure 3 is a circuit diagram of a control system, being a component of a fully controllable electric range cooker according to the present invention; Figure 4 is a perspective view of a hob tray assembly, being a component of a fully controllable electric range cooker according to the present invention; Figure 5 is an exploded view of an oven assembly, being a component of a fully controllable electric range cooker according to the present invention; Figure 6 is an exploded view of a hob assembly, being a component of a fully controllable electric range cooker according to the present invention; and Figure 7 is a front view of a fully controllable electric range cooker according to the present invention.

Referring first to Figure 1, there is shown an electric hob heating element 10.

Referring to Figure 2, there is shown an electric hob heating element 11.

Referring to Figure 3, there is shown a control system 12.

Referring to Figure 4, there is shown a hob plate assembly 13 comprising top plate 14, support bar 15, left side hob 16 and right side hob 17.

Referring to Figure 5, there is shown an oven assembly 18 comprising: base plate 19, 100mm insulation pad 21,1/2" oven support rods 22,1/2" nuts 23, bottom oven support tray 24, bottom oven element cassette 25, 6mm dense insulation board 26, bottom (750W) electric oven heating element 11, 13x2mm flat rope seal 27, bottom cast iron oven 28, top oven element cassette 25', 12mm dense insulation board 26', top (1750W) electric oven heating element 11', and top cast iron oven 28'.

Referring to Figure 6, there is shown a hob assembly 29 comprising: hob tray 31, hob 16, hob chair 32, hob element base 33, hob tray cover 34, thermostat tray 35, insulation gasket 36, M10X40 threaded bars 37, hob element 10, and insulation pads 38.

Referring to Figure 7, there is shown a fully controllable electric range cooker having a housing 41, within which is defined the bottom (baking or simmering) oven 28 and the top (roasting) oven 28'. The top plate 14 of the housing 41 houses the left side (boiling) hob 16 and the right side (simmering) hob 17. The housing 41 also accommodates the control system 12.

A method according to the present invention, of converting a conventional range cooker to a fully controllable electric range cooker 40 will now be described with reference generally to Figures 1 to 7.

A conventional range cooker (not shown) is fully dismantled leaving only the housing 41, base plate 19 and ovens 28, 28'.

Using a hole saw, a 25mm hole is cut in the top left-hand corner of the rear panel of the top oven 28'. A further 2 x 5mm holes are drilled and a 28mm ID spigot (not shown) is attached for top oven 28' venting. The desired 28mm copper pipe assembly (not shown) is attached, and a self-tapping screw used to fix in place. The top oven 28' overheat thermostat bracket is then assembled. 2 x 5mm 20 holes are drilled in the rear panel of the top oven 28' and the overheat thermostat support fixed in place. The thermostat bracket is templated in place in the middle of the oven 28' so that the bottom of the bracket is 50mm from the top of the oven 28'. A corresponding hole is drilled in the left hand panel of the oven 28' to allow entry of the overheat thermostat horizontally.

The bottom oven 28 control thermostat bracket is then assembled. 2 x 5mm holes are drilled in the rear panel of the oven 28 and the lower oven 28 thermostat support fixed in place. The thermostat bracket is templated in place in the middle of the oven 28 so that the bottom of the bracket is 50mm from the top of the oven 28. A corresponding hole is drilled in the left hand panel of the oven 28 to allow entry of the overheat thermostat horizontally.

The oven 28, 28' assembly can then be carried out. The cooker base plate 19 is fitted to a pre levelled plinth. 3 x 1/2" BSW oven support rods 22 and 3 xY2" BSW nuts 23 are then fitted into the base plate 19 beneath the bottom oven 28. The bottom oven 28 is fitted to the oven support rods 22 and its position established with the front plate, level with the bottom oven 28. The front plate and bottom oven 29 are then removed and a 100mm foil back insulation pad 21 is fitted over the oven support rods 22. The bottom oven element support tray 24 is then fitted onto the oven support rods 22. The bottom oven element cassette 25, 6mm insulation pad 26 and 750w bottom oven element 11 are then fitted. The bottom oven 28 is then re-fitted and the bottom oven element cassette 25 adjusted until the flat rope seal 27 makes contact with the bottom oven 28. The oven 28 is then levelled and fixed to the front plate. 50mm thick fibre blanket cut outs are fitted around the bottom oven element cassette 25, with the element 11 tails exposed to the left hand side.

The oven elements 11, 11' are housed in purpose designed insulated cassettes 25, 25' that are adjusted up to the underside of the cast iron ovens 28, 28'. This improves the focus of the heat. The bottom oven support tray 24 allows for levelling of the bottom oven element cassette 25.

A 6mm insulation pad 26 is fitted to the top external surface of the bottom oven 28. The top oven element cassette 25', 3 x 6mm insulation pad 36' and, 1750w top oven element 11' are then fitted. 3 x 1/2" BSW socket end screws are adjusted up at 50mm above the external surface of the bottom oven 28. The top oven 28' is then fitted in place above the bottom oven 28. A countersunk M12 hex screw is engaged with the top oven element cassette 25' and adjusted up until the flat rope seal 27 makes contact. Care should be taken not to tighten the M12 hex nut, or the element cassette 25' will distort, affecting the position of the element 11'. The oven 28' is then levelled and fixed to the front plate. 50mm thick fibre blanket cut outs are provided around the upper oven element cassette 25', with the element 11' tails being exposed to the left hand side.

The oven 28, 28' insulation can then be installed. Insulation cut-outs are provided to the channels on the sides of the oven 28, 28' tunnels and between the oven 28, 28' tunnels. The 50mm foil backed insulation is wrapped over the top oven 28' from left to right. The top element 11' tails are pulled through the insulation blanket. 200mm wide aluminium tape is then used to fix the main blanket to the base blanket.

The rear panel of foil backed insulation is then fitted to the rear of the ovens 28, 28'.

200mm wide aluminium tape is then used to seal the rear side to the rear insulation panel. The extended length of aluminium tape is cut and folded in adjacent directions. Off-cuts are used to add additional materials at any gaps between the fully sealed oven 28, 28' system and the front plate, and sealed with aluminium tape as required.

The housing for the control system 12 can then be installed. The control box 12 will have been fully assembled and tested prior to installation and will not require adjustment. The control box 12 is fitted to the rear of the appliance front plate. A 6mm rubberized cooker flex is uncoiled and left in position for connection to mains supply when the cooker 40 has been fully assembled.

The control box 12 has labelled 3-way connector plugs and socket to facilitate easy connection of all oven elements 11, 11'.

The control system 12 is provided with bespoke rotary switches which allow for the main features of the system to be achieved using only two knobs. The twin element system (i.e. providing separate "twin" elements for the two ovens and the two hobs) allows the user to switch between predetermined temperatures in the same oven (at different intervals). The twin element system also achieves faster heat up times than alternative models.

The oven thermostats can then be installed. The top oven 28' control thermostat and eco mode thermostat are secured in the oven thermostat mounting plate and secured to the top of the oven 28' using 3 x M5 fixings or 2 x 5/16 BSW fixings. The top oven 28' overheat thermostat entry point is located by feeding a thin screwdriver from the inside of the oven 28' out through the insulation blanket. The top oven 28' overheat thermostat is then fed through the entry point and fitted into the bracket.

The bottom oven 28 thermostat entry point is located by feeding a thin screwdriver from the inside of the oven 28 out through the insulation blanket. The bottom oven 28 thermostat is fed through the entry point and fitted into the bracket. The top plate 14 can then be assembled. The hob tray support bar 15 is fitted to the underside of the appliance top plate 14 using the fixings provided. Care should be taken to tighten the nuts correctly and to ensure that lock nuts and spring washers are used. With the front lip of the appliance top plate 14 leant against a protected floor, the hob trays 31 are fitted one at a time. The insulation pad 38 is removed to give access to the hinge block fixing points. The hinge block fixings are then fitted through the holes provided, securing each hob tray 31 in place. Care should be taken to ensure that nuts are tightened correctly, and that lock nuts and spring washers are used The open channel between the hob support bar 15 and the top plate front 14 is then insulated using the rope provided. The exposed channels between the hob tray 31 cut outs and the top plate 14 is insulted using the rope provided. The open channel between the two hob trays 31 is insulated using the rope provided. The insulation pad 38 is then refitted.

The elements 10, 10' can then be connected. The connector terminals are used to connect the elements 10, 10' to the corresponding sockets before commencing assembly of the right side hob 17. The main control thermostat, eco mode thermostat and right side overheat thermostat are fed through the hob tray 31 cut out and inserted into the brackets. Care should be taken not to force the phials or unduly bend the wire.

The right side hob 17 can then be installed. With the top plate 15 fitted on the cooker 40, hob tray cover 34 is fitted to the base of the hob tray 31. A 30mm insulation disc is fitted, and then the hob element base 33 and thermostat tray 35 assembly are fitted. The 1500w right side hob element 10 is then fitted, passing the flexible tails through the cut out in the hob tray 31. Care should be taken to not force the connections, to prevent damage. 4 x M10 grub screws are then assembled into the hob chair 32 and the hob chair 32 fitted over the hob element base 33, aligning the 4 x countersunk holes with the 4 x M4 tapped holes in the hob element base 33. 4 x M4 x 50mm hex screws are then used to mount the hob element base 33 to the hob chair 32 A straightedge is then used to adjust the element base 33 and element 10 so they are approximately lOmm beneath the top surface of the hob chair 32. A 300mm level is then used to set the hob chair 12mm below the desired finished hob height, level in all directions. The element 10 height is then adjusted so that the element 10 is making contact with (but not supporting) the hob plate 13. A thin layer of high temperature silicone is applied to the enamel channel in the top plate 14 and the 8mm P-section rope seal is fitted by raising the hob chair 32 at each point and inserting the tail of the seal underneath. The 2mm hob gasket 36 is then fitted and the hob plate 13 is adjusted until its height is satisfactory. The hob plate 13 is then rotated clockwise so the welded studs engage in the hob plate 13 cut outs.

The hob plate 13 engages with the hob chair 32. Welded studs on the base of the hob plate 13 engage with holes in the hob chair 32. With a clockwise rotation a 'twist lock' assembly procedure is achieved. Critical to this is that the weight of the hob 17 is borne by the mechanically fixed (bolted) hob tray 31 and not suspended by the top plate 14 or another structure suspended by the top plate 14.

The hob chair 32 has 4 x levelling feet (grub screws) which suspend the hob element base 33, which in turn has an independent levelling mechanism through adjustment of height from the hob chair 32. Once assembled, this also serves as a clamp to hold the heating element 10 in place, once both parts are levelled. The suspended mounting assembly is centralised on the hot plate position, and the form of the heating element 10 allows for accurate thermostatic readings as compared to alternative element shapes. The mechanically fixed hob support tray 31 and hob support bar 14 utilise existing fixing points in the appliance housing 41, such as holes used for towel rail brackets and hinges.

The thermostat tray 35 can then be assembled. The main control thermostat, eco mode thermostat and right side overheat thermostat are fed through the hob tray 34 cut out and inserted into the brackets in order. Care should be taken not to force the phials or unduly bend the wire. The entry point to the left hand side is then plugged with ceramic blanket material.

Connector plugs are then used to connect the elements 10, 10' to the corresponding sockets including the right side element 10 before commencing assembly of the left side hob 16.

The left side hob 16 can them be assembled. The main control thermostat, eco mode thermostat and left side overheat thermostat are fed through the hob tray 31 cut out and the phials left above the hob plate 13 to allow assembly of the left side hob 16. Care should be taken not to force the phials or unduly bend the wire. All element connections and thermostats should now be connected and in position, aside from the thermostats for the right side hob element 10. All stages of the right side hob 17 assembly are then repeated for the left side hob 16.

Claims

-10 -Claims 1. A fully controllable electric range cooker comprising a housing, one or more ovens defined within the housing, and one or more hobs provided at an upper surface of the housing, wherein each oven has a separate electric oven heating element and each hob has a separate electric hob heating element, and further comprising a control system adapted to enable the operating temperature of each electric heating element to be controlled independently of the operating temperature of each other electric heating element.
2. An electric range cooker as claimed in claim 1, wherein each electric oven heating element is mounted in an oven element cassette.
3. An electric range cooker as claimed in claim 1 or claim 2, wherein each hob and its associated electric hob heating element is combined in a hob assembly.
4. An electric range cooker as claimed in claim 3, wherein each hob assembly further comprises a hob support tray.
5. An electric range cooker as claimed in any of the preceding claims, wherein the control system comprises a separate oven thermostat associated with each oven and a separate hob thermostat associated with each hob.
6. An electric range cooker as claimed in any of the preceding claims, wherein the control system comprises a plurality of rotary switches adapted to facilitate the 20 independent operation of each oven and each hob.
7. A method of converting a conventional range cooker to a fully controllable electric range cooker as claimed in any of claims 1 to 6, said method comprising the steps of: (a) dismantling the conventional range cooker thereby to leave a housing, and 25 one or more ovens defined within the housing; (b) installing in the housing a separate electric oven heating element for each oven; (c) installing in the housing a control system adapted to enable the operating temperature of each electric heating element to be controlled independently of the 30 operating temperature of each other electric heating element; (d) installing in the housing a separate electric hob heating element for each hob; and (e) installing in the housing one or more hobs.
8. A method as claimed in claim 7 wherein in step (b) each electric oven heating element is mounted in an oven element cassette.
9. A method as claimed in claim 7 or claim 8 wherein steps (d) and (e) are combined by installing in the housing one or more hob assemblies, each comprising 5 a hob and a hob heating element.
10. A method as claimed in claim 9 wherein each hob assembly further comprises a hob support tray.
11. A method as claimed in any of claims 7 to 10, wherein in step (c) the control system comprises a separate oven thermostat associated with each oven and a 10 separate hob thermostat associated with each hob.
12. A method as claimed in any of claims 7 to 11, wherein in step (c) the control system comprises a plurality of rotary switches adapted to facilitate the independent operation of each oven and each hob.
13. A method as claimed in any of claims 7 to 12 wherein the conventional range cooker is an oil, gas, or solid fuel fired range cooker.
14. A method as claimed in any of claims 7 to 12 wherein the conventional range cooker is an electric range cooker.
15. A kit of parts for use in a method as claimed in any of claims 7 to 14 for converting a conventional range cooker into a fully controllable electric range cooker as claimed in any of claims 1 to 6, said kit comprising: - one or more electric oven heating elements; - one or more electric hob heating elements; and - a control system adapted to enable independent control of each electric heating element.
16. A kit of parts as claimed in claim 15, further comprising one or more oven element cassettes adapted for mounting the electric oven heating elements in the housing.
17. A kit of parts as claimed in claim 15 or claim 16, further comprising one or more hob assemblies adapted for mounting the electric hob heating elements in the housing.
18. A kit of parts as claimed in any of claims 15 to 17, wherein the control means comprises a separate oven thermostat associated with each oven heating element, and a separate hob thermostat associated with each hob heating element.
-12 - 19. A kit of parts as claimed in any of claims 15 to 18, wherein the control means comprises a plurality of rotary switches adapted to facilitate the independent operation of each oven and each hob.
20. A fully controllable electric range cooker as claimed in any of claims 1 to 6, produced by converting a conventional range cooker according to a method as claimed in any of claims 7 to 14, and/or using a kit of parts as claimed in any of claims 15 to 19.