US20220065461A1

US20220065461A1 - Oven door architecture and method of assembly

Info

Publication number: US20220065461A1
Application number: US17/003,184
Authority: US
Inventors: Hussam Kubtan; Anthony Marquart
Original assignee: Electrolux Home Products Inc
Current assignee: Electrolux Home Products Inc
Priority date: 2020-08-26
Filing date: 2020-08-26
Publication date: 2022-03-03

Abstract

Provided is an oven door architecture capable of efficient cooling and one-directional assembly. The oven door assembly comprises an outer glass pane with mounting columns adhered to it. In one embodiment, a door shield is coupled to door shield locating features of the mounting columns. A glass pack comprising two more glass panes is then coupled to the door shield. A door liner is fastened over top of the assembly. The architecture of the assembly provides for two internal chambers capable of fluid communication with one another, an air intake, and an exhaust. In another embodiment, the oven door assembly has only an outer glass pane and an interior glass pane with a main chamber between them. This main chamber is in fluid communication with an intake and an exhaust, enabling the door to cool. All embodiments are capable of assembly in one direction with substantially no lateral movement. Moreover, the embodiments are highly configurable due to shared assembly interfaces and can be used on a variety of ranges, wall ovens, and the like.

Description

FIELD OF THE INVENTION

The present invention relates to the structure of an oven door and method for assembling the same. More particularly, described is oven door architecture capable of top down assembly and efficient cooling.

BACKGROUND OF THE INVENTION

Oven doors perform a number of functions in addition to merely closing an interior cavity of the oven. For instance, oven doors provide insulation to keep the air inside the oven hot, and to avoid heating the ambient air outside the oven. They provide a window to see into the oven for checking on the items inside without having to open the oven door and allow hot air to escape. Additionally, oven doors provide a means for ventilating the interior cavity.
To perform these functions, various features are included within the oven door architecture. When attached to ovens capable of self-cleaning via prolonged extreme temperatures (pyro ovens), oven doors can include multiple insulating panes of glass for containing the heat. When attached to ovens without self-cleaning capabilities (non-pyro ovens), an oven door structure may be tailored for less intense heat. For example, a non-pyro oven door may have fewer panes of heat insulating glass and fewer means for ventilating the oven cavity. Both styles may nevertheless possess at least one form of ventilation.
Mass producing oven doors with their many components and various styles poses a unique challenge. Traditional manufacturing of oven doors often uses various lateral motions and fastening steps, which add to manufacturing complexity and increased cycle times, which in turn lead to increased costs.

SUMMARY OF THE INVENTION

The following presents a simplified summary in order to provide a basic understanding of the embodiments described herein. This summary is not an extensive overview, nor is it intended to identify key or critical elements. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
The oven door described herein can be configured as a pyro oven door assembly or a non-pyro oven door assembly. A pyro oven door assembly can include an outer glass pane, such as a decorative glass pane, a handle, and a door panel or a door cap. The outer glass pane includes mounting columns adhered to one side thereof. A door shield is also provided and can engage door shield locating features provided on each of the mounting columns. A glass pack comprising a first glass pane, two vertical glass pack brackets, two horizontal glass pack brackets, and a second glass pane are also included in the pyro oven door assembly. The glass pack is coupled to the door shield via glass pane locating features, which substantially restricts lateral movement of the glass pack during assembly. The glass pack brackets include mating tabs and embosses which engage corresponding bracket slots and bracket holes provided on the door shield. A door liner is provided on a cavity facing side of the pyro oven door and can be secured using fasteners, compressing the entire assembly and holding the components together.
The pyro oven door assembly may be assembled along a single direction, such as a top-down, vertical direction substantially devoid of lateral movements, to couple the components. Additionally, the architecture of this assembly provides for a first chamber between the door liner and the door shield, and a second chamber between the door shield and outer glass pane. The first and second chambers are in fluid communication with one another, and the assembly has an intake at its bottom-side and an exhaust at or near the top-side. Thus, a volume of air is permitted to move into the intake, through each of the chambers, and out of the exhaust, thereby cooling the assembly.
The non-pyro oven door assembly similarly uses a decorative glass subassembly. However, the non-pyro oven door assembly does not need to withstand as much heat as the pyro oven door assembly, so it lacks a door shield and a glass pack. Rather, a door liner subassembly comprising a door liner and an interior glass pane adhered to the door liner is coupled directly to the mounting columns. This architecture leaves one main chamber within the non-pyro oven door assembly between the outer glass pane and the interior glass pane. The non-pyro oven door assembly also has an intake at a bottom-side and an exhaust at or near a top-side. Thus, a volume of air is permitted to move into the intake, through the main chamber, and out of the exhaust, thereby cooling the non-pyro oven door assembly.
Like the pyro oven door assembly, the non-pyro embodiment also possesses architecture which enables it to be assembled in one direction, such as a top-down, vertical direction with substantially no lateral movement. Thus, provided is oven door architecture capable of efficient cooling and one-directional assembly.
Other features and aspects will be apparent from the following detailed description, the drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals can be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.

FIG. 1 illustrates a perspective view of an assembled oven door in accordance with an aspect of the present disclosure.

FIG. 2 illustrates an exploded view of a non-pyro oven door assembly in accordance with an aspect of the present disclosure.

FIG. 3 illustrates a semi-exploded view of a pyro oven door assembly in accordance with an aspect of the present disclosure.

FIG. 4 illustrates a fully exploded view of the pyro oven door assembly of FIG. 3 in accordance with an aspect of the present disclosure.

FIG. 5 illustrates an exploded view of a door liner subassembly in accordance with an aspect of the present disclosure.

FIG. 6 illustrates a partial cross-sectional view of a door liner subassembly in accordance with an aspect of the present disclosure.

FIG. 7 illustrates an exploded view of a decorative glass subassembly in accordance with an aspect of the present disclosure.

FIG. 8 illustrates a perspective view of an assembled decorative glass subassembly in accordance with an aspect of the present disclosure.

FIG. 9 illustrates a perspective view of a door shield in accordance with an aspect of the present disclosure.

FIG. 10 illustrates an exploded view of a decorative glass subassembly and a door shield in accordance with an aspect of the present disclosure.

FIG. 11 illustrates a partial exploded view of the decorative glass subassembly and door shield of FIG. 10 in accordance with an aspect of the present disclosure.

FIG. 12 illustrates a partial assembled view of decorative glass subassembly and door shield of FIG. 10 in accordance with an aspect of the present disclosure.

FIG. 13 illustrates a partial exploded view of the decorative glass subassembly and door shield of FIG. 10 in accordance with an aspect of the present disclosure.

FIG. 14 illustrates a partial assembled view of decorative glass subassembly and door shield of FIG. 10 in accordance with an aspect of the present disclosure.

FIG. 15 illustrates a perspective view of a first glass pane being lowered onto a door shield in accordance with an aspect of the present disclosure.

FIG. 16 illustrates a perspective view of a vertical glass pack bracket being lowered onto a door shield in accordance with an aspect of the present disclosure.

FIG. 17 illustrates a partial exploded view of the vertical glass pack bracket being lowered onto a door shield in an accordance with an aspect of the present disclosure.

FIG. 18 illustrates a partial exploded view of the vertical glass pack bracket being lowered onto a door shield in an accordance with an aspect of the present disclosure.

FIG. 19 illustrates an exploded view of glass pack brackets and a door shield in accordance with an aspect of the present disclosure.

FIG. 20 illustrates an assembled view of a pyro oven door assembly with a door liner removed in accordance with an aspect of the present disclosure.

FIG. 21 illustrates a perspective, partial cross-sectional view of a glass pack assembly in accordance with an aspect of the present disclosure.

FIG. 22 illustrates a perspective view of a door liner being lowered onto a pyro oven door assembly in accordance with an aspect of the present disclosure.

FIG. 23 illustrates a partial cross-sectional view of a pyro oven door assembly in accordance with an aspect of the present disclosure.

FIG. 24 illustrates a partial perspective view of a door liner being lowered onto an oven door assembly in accordance with an aspect of the present disclosure.

FIG. 25 illustrates a partial perspective view of a door liner being lowered onto an oven door assembly in accordance with an aspect of the present disclosure.

FIG. 26 illustrates a rear perspective view of an assembled oven door assembly as herein disclosed.

FIG. 27 illustrates a cross-sectional view of the pyro oven door assembly (insulation removed for clarity) in accordance with an aspect of the present disclosure.

FIG. 28 illustrates a rear perspective view of the pyro oven door assembly with the door liner removed (insulation removed for clarity) in accordance with an aspect of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Example embodiments are described and illustrated herein. These illustrated examples are not intended to be a limitation on the present embodiments. For example, one or more aspects of the system can be utilized in other embodiments and other types of appliances. Example embodiments of an oven door architecture, such as a door for a self-cleaning, or pyro, oven and a non-self-cleaning, or non-pyro, oven, will be described more fully hereinafter with reference to the accompanying drawings. The embodiments described herein are highly configurable and share one or more assembly interfaces. Moreover, the disclosed embodiments can be employed with various ranges, wall ovens, and the like. Thus, the systems may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like, but not necessarily the same, elements in the various figures are denoted by like reference numerals for consistency. Terms such as “first,” “second,” “front,” and “rear” are used merely to distinguish one component (or part of a component or state of a component) from another. Such terms are not intended to denote a preference or a particular orientation.
FIG. 1 illustrates a perspective view of an oven door 100 comprising the architecture disclosed herein. The oven door 100 can be configured for use in an oven that includes a self-clean feature. In such an oven, the interior is subjected to high temperatures for about two to four hours, which subjects any soil and residue within the oven cavity to a thermal cracking process. This is known and pyrolytic cleaning. Thus, such an oven door is referred to as a self-clean oven door or a pyro oven door. Alternatively, the oven door 100 can be configured for use in an oven that does not include a self-clean feature. This type of oven is not capable of reaching the same high temperatures needed for pyrolytic cleaning. Thus, this type of oven door is referred to as a non-self-clean or non-pyro oven door. Differences between the pyro oven door architecture and the non-pyro oven door architecture will be described in greater detail herein. The oven door 100 can be used in connection with any suitable oven construction as known in the art, such as a built-in, wall-mounted, or freestanding oven. The oven door 100 is used to close an oven cavity of such an oven and is typically pivotally mounted to a housing of the oven such that the oven door 100 pivots about a horizontal axis adjacent a bottom portion of the oven cavity. However, the oven door 100 may be mounted to a left side frame or a right side frame of a front panel of the oven housing such that it can pivot about a vertical axis adjacent to a side of the oven cavity.
The oven door 100 includes a door panel 14 having a first, or outer side, and a second, or inner side. The outer side of the door panel 14 includes a handle 16 coupled thereto for grasping by a user to open and close the oven door 100. Coupled or mounted to an inner side of the door panel 14 is a first, or outer glass pane 12. The outer glass pane 12 can be a decorative glass pane coated with a non-reflective coating over at least a portion of its outer face, the side intended to face a user. This outer face may be tinted to facilitate the reflection of thermal energy back into the oven cavity and away from an exterior surface of the oven door 100. This helps minimize heat loss inside the oven cavity and reduce a temperature of the outer face of the outer glass pane 12. The outer glass pane 12, door panel 14, and handle 16 may comprise a decorative glass, or deco glass, subassembly 10.
Referring now to FIG. 2, an exploded view of a non-pyro oven door assembly 104 is illustrated in accordance with an embodiment of the present disclosure. The non-pyro oven door assembly 104 includes outer glass pane 12 having an outer face and an inner face. The outer face of the outer glass pane 12 can be secured to a door panel 14, as shown in FIG. 1, or alternatively, as shown in FIG. 2, to a door cap 15. A pair of mounting columns 17 is secured to the inner face of the outer glass pane 12. An inner glass pane 22 includes an inner face and an outer face. The outer face of the inner glass pane 22 is coupled to each of the mounting columns 17, whereas an inner face of the inner glass pane 22 is secured to a door liner 21. The inner glass 22 and door liner 21 can be provided as a door liner subassembly 20 (FIG. 5). The inner glass pane 22 can be made from a soda lime, borosilicate, or ceramic glass and can be coated on one or both faces with a substantially transparent, low-emissive, heat reflective coating. This coating results in the inner glass pane being a low-emissive glass pane which can effectively reflect heat from the oven cavity to reduce a temperature of the non-pyro oven door assembly 104 and to facilitate greater efficiency within the oven cavity. One or more fasteners 26 can be inserted through the door liner 21, the mounting columns 17, the door cap 15, and the handle 16. The fasteners 26 serve to bind the entire non-pyro oven door assembly 104 together. The door cap 15 in this embodiment includes exhaust ports 13, which will be described in greater detail below.
Referring now to FIG. 3, a semi-exploded view of a pyro oven door assembly 102 is illustrated in accordance with an embodiment of the present disclosure. The pyro oven door assembly 102 includes a decorative glass subassembly 10. The decorative glass subassembly 10 is comprised of an outer glass pane 12 and a door panel 14 adhered to a first side, or outer face, of the outer glass pane 12. A door shield 40 is coupled to a second side, or inner face, of the outer glass pane 12. The pyro oven door assembly 102 further includes a glass pack 30 coupled to the door shield 40. A door liner 21 encloses the door shield 40 and glass pack 30 between the door liner 21 and decorative glass subassembly 10. One or more fasteners 26 are included which pass through the door shield 40, mounting columns 17, door panel 14, and into a handle 16. The fasteners 26 serve to bind the entire pyro oven door assembly 102 together.
FIG. 4 illustrates the pyro oven door assembly 102 shown in FIG. 3 in a fully-exploded view. As shown in FIG. 4, the decorative glass subassembly includes the door panel 14, outer glass pane 12, and mounting columns 17. The glass pack 30 includes a middle glass pane 35, an inner glass pane 36, and plurality of brackets. The plurality of brackets can include two vertical brackets 31 and two horizontal brackets 32. The middle glass pane 35 and inner glass pane 36 of the glass pack can be made from a soda lime, borosilicate, or ceramic glass. At least one, and preferably both, of the middle glass pane 35 and inner glass pane 36 are coated on one or both faces with a substantially transparent, low-emissive, heat reflective coating. This coating results in a low-emissive glass pane which can effectively reflect heat from the oven cavity to reduce a temperature of the pyro oven door assembly 102 and to facilitate greater efficiency within the oven cavity. As shown in FIG. 3, when assembled, the plurality of brackets 31, 32 surrounds a periphery of the middle glass pane 35 and inner glass pane 36 to create an open space between the middle and inner glass panes 35, 36 that is sealed and substantially airtight. The inner glass pane 36 provides a barrier that protects the middle glass pane 35 from hot air circulating in the oven cavity. The door liner 21 is secured to the inner glass pane 36 and the fasteners 26 are provided to secure the assembly 102 together.
In the non-pyro door assembly 104, there is typically no glass pack as the oven cavity is not subjected to the high temperatures needed for self-cleaning. Thus, the door liner 21 can be provided as a door liner subassembly, as shown in FIG. 5. The door liner subassembly 20 comprises the door liner 21, an adhesive layer 11, and an interior glass pane 22. The adhesive layer 11 is applied to the door liner 21, such as within an adhesive channel 24 (FIG. 6) stamped around a central window opening in the door liner 21. The interior glass pane 22 includes a first face and a second face. The first face of the interior glass pane 22 is positioned over the adhesive layer 11 and within a window recess to cover the central window opening. The adhesive layer 11 thereby securing the interior glass pane 22 to the door liner 21. The interior glass pane 22 includes a heat reflective coating on its first face and optionally, on its second face to reflect heat within the oven cavity.
The door liner 21 comprises a compression flange 23 on its interior edge, or around the central window opening of the door liner 21. As will be explained in more detail below, the compression flange 23 facilitates an improved seal between the door liner 21 and the interior glass pane 22. Additionally, the door liner 21 includes a plurality of apertures 25, which allow for fasteners 26 to pass through the door liner 21 and bind the non-pyro oven door assembly 104 together. An intake opening 27 is provided at a lower end portion of the door liner 21 and one or more exhaust openings 28 are provided at an upper end portion of the door liner 21. The intake opening 27 and exhaust openings 28 facilitate cooling of the non-pyro oven door assembly 104 via a volume of air traveling through the oven door.
Referring now to FIG. 6, a partial cross-sectional view of the door liner subassembly 20 is shown. The adhesive channel 24 can be seen in greater detail. The profile, or depth and width, of the adhesive channel 24 allows for optimization of the amount of adhesive required. Specifically, the depth of the adhesive channel 24 controls an amount of adhesive provided between an edge portion of the interior glass pane 22 and the door liner 21. And because the width of the adhesive channel 24 extends beyond the edges of the interior glass pane 22, any excess adhesive can flow into this additional space, which will not affect the seal between the interior glass pane 22 and the door liner 21. Thus, the amount and spread of the adhesive layer 11 is controlled by the adhesive channel 24, which provides an improved structural and sealing bond between the door liner 21 and the interior glass pane 22.
Turning now to FIGS. 7 and 8 a decorative glass subassembly 10 is illustrated. The decorative glass subassembly 10 can be used in both the non-pyro oven door assembly 104 and the pyro oven door assembly 102. FIG. 7 shows an exploded view of the decorative glass subassembly 10. The decorative glass subassembly 10 comprises a door panel 14, a first adhesive layer 37, an outer glass pane 12, a second adhesive layer 38 and mounting columns 17. The door panel 14 is generally the outermost structure of the oven door assembly and includes an outer face, an inner face, and a window opening 39 provided therethrough. The outer face typically includes an oven door handle (not shown) secured thereto. During assembly, the outer face of the door panel 14 is positioned face down and the inner face of the door panel 14 is provided with the first adhesive layer 37. The first adhesive layer 37 is positioned around the window opening 39. The outer glass pane 12 is then lowered onto the inner face of the door panel 14 with the first adhesive layer 37 secured between the inner face of the door panel 14 and an outer face of the outer glass pane 12. An inner face of the outer glass pane 12 is then provided with the second adhesive layer 38. The second adhesive layer 38 is positioned at lateral edges of the outer glass pane 12. Specifically, at least one lateral strip of adhesive can be applied to each side edge portion of the outer glass pane 12. As depicted, the second adhesive layer 38 can also be applied in a substantially u-shaped configuration. Any suitable application or configuration of the first and second adhesive layer 37, 38 can be used. First and second mounting columns 17 are then lowered onto the inner face of the outer glass pane 12 with the second adhesive layered provided therebetween to secure the mounting columns 17 to the outer glass pane 12. The first and second mounting columns 17 can be manufactured, such as via injection molding, from a suitable plastic material capable of withstanding temperatures present within the oven door assembly.
FIG. 8 illustrates the above-described components of FIG. 7 in an assembled state. As will be described in greater detail below, the mounting columns 17 can include a plurality of locating features 18 for locating an adjacent structure, such as a door shield, upon assembly thereto. These locating features can include ledges, embosses, clips, snaps, tabs, and/or other like molded-in or coupling mechanisms. Moreover, while the decorative glass subassembly 10 has been described herein as including a door panel 14, it is to be appreciated that a door cap 15 or the like can be provided instead.
Turning now to FIG. 9, an example door shield 40 is depicted in accordance with an embodiment. The door shield 40 includes a plurality of locating and pre-fixation features to facilitate assembly of the oven door. More specifically, the door shield 40 includes a plurality of mounting column locating features 45, 46, 47 to facilitate location and pre-fixation of the door shield 40 to the mounting columns 17 during assembly. When the door shield 40 is coupled to the mounting columns 17 via the mounting column locating features, the door shield 40 is restricted from lateral movement.
The mounting column locating features include a pair of door handle apertures 45, each positioned at a top corner of the door shield 40 and including a downwardly extending portion, such as an emboss. As shown in FIGS. 11 and 12, The door handle apertures 45 are sized to each receive a corresponding boss 58 in the mounting columns 17. Each boss 58 includes at least one longitudinally extending rib, or web, 19 projecting radially outwards from an outer surface thereof. As shown in FIG. 12, the present example includes two radially opposed longitudinal ribs 19. A top surface of each longitudinal rib 19 is at a lower vertical height than a top surface of the corresponding boss 58. Thus, during assembly, the bosses 58 and the door handle apertures 45 are aligned and the door shield 40 is lowered onto the mounting columns 17 such that each boss 58 extends through its corresponding door handle aperture 45 until an emboss of the door handle aperture 45, or until a surface surrounding the door handle aperture 45, contacts the longitudinal rib 19. Thus, the bosses 58 and longitudinal ribs 19 support the location and alignment of the top portion of the door shield 40 via the door handle apertures 45. It is to be appreciated that any structure can be formed on or near an exterior portion of the boss 58 to serve as a stop for the door shield 40 during assembly. When the door handle is secured to the oven door assembly, fasteners for the door handle extend through the bosses 58, the door handle apertures 45, and corresponding apertures in the door panel 14 or door cap 15 and into the door handle.
The mounting column locating features on the door shield 40 further include two or more height setting embosses 46 that protrude towards a direction of the mounting columns 17 when in an assembled state. The door shield 40 includes opposing outer side edges 54, 55 and at least one height setting emboss 46 is positioned proximate one outer side edge 54 of the door shield 40 and at least one other height setting emboss 46 is positioned proximate the opposing outer side edge 55 of the door shield 40. As shown in FIG. 9, there are preferably two height setting embosses 46 spaced apart and positioned proximate each of the outer side edges of the door shield 40. The height setting embosses 46 are configured to contact corresponding features on the mounting columns 17, such as projections 56 and ramps 57 (FIG. 10) in order to maintain a predetermined distance between the door shield 40 and the mounting columns 17 and to provide contact and support to the door shield 40 during assembly. The height setting embosses 46 further serve to strengthen the material of the door shield 40 at the side edges. The door shield 40 also includes a plurality of embosses 48 near a top portion of the door shield 40 and near a bottom portion of the door shield 40 to provide additional strength to the material of the door shield 40.
The mounting column locating features on the door shield 40 further include two or more stepped portions or seats 47 located at opposing side edges of the door shield 40. The seats 47 serve as locating features during assembly of the oven door and mitigate the door shield 40 from sinking or sliding within the pyro oven door assembly 102. As shown in FIGS. 13 and 14, the seats 47 are formed as a cutaway or stamped portion of the door shield and include horizontal edges extending inwardly from opposing side edges of the door shield 40. When in an assembled state with the mounting columns 17, as shown in FIG. 14, each seat 47 contacts and rests upon a corresponding ledge 59 projecting from each mounting column 17.
Turning back to FIG. 9, a window opening 60 in the door shield 40 is formed by opposing vertical interior edges 61 and opposing horizontal interior edges 62. Formed at each of the vertical and horizontal interior edges 61, 62 are glass pane locating features, such as upwardly bent tabs 50 and 51. The tabs 50, 51 can be formed as portions bent upwards from the material of the door shield 40, such as via a stamping process. The tabs 50, 51 can be positioned at a central portion of each of the interior edges 61, 62 as shown in FIG. 9. However, the tabs 50, 51 can be formed as any suitable shape located at any position near the interior edges, as desired. During assembly, after the door shield 40 is positioned on and properly aligned with the mounting columns 17, the first glass pane 35 is lowered onto the door shield 40 to cover the window opening 60. See FIGS. 15 and 16. The glass pane locating features define a space for the first glass pane 35 to be positioned. Additionally, because the glass pane locating features extend upwardly from the door shield 40, these features not only facilitate positioning of the first glass pane 35, but also constrain lateral movement of the first glass pane 35 to aid a top down assembly process.
As mentioned above, in a pyro oven door assembly 102, the first glass pane 35 is part of a glass pack 30, which is bounded by two vertical brackets 31 and two horizontal brackets 32. Turning now to FIGS. 16-18, an interaction between the door shield 40, first glass pane 35, and vertical and horizontal brackets 32 are shown in greater detail in accordance with an embodiment. Near each interior edge 61, 62 of the door shield 40, a bracket locating feature is provided. The bracket locating feature preferably includes at least one first bracket locating feature and at least one second bracket locating feature, the first and second bracket locating features being different from each other. For instance, as shown in FIG. 17, the first bracket locating feature can be a slot 52 configured to receive a first mating feature, such as a tab 33, on a corresponding bracket. The second locating feature, on the other hand, can be a hole 53, as shown in FIG. 18. The hole 53 is configured to receive a second mating feature, such as an emboss 34, projecting from the corresponding bracket. Thus, the first and second mating features are also different from each other. By using different first and second bracket locating features and different first and second mating features, determining which direction to insert the bracket is simplified. Additionally, the two vertical brackets 31 have the same configuration and when assembled, are rotationally symmetrical about a center of the pyro oven door assembly 102; meaning either may be used on the left or right side of the door shield 40 by simply rotating it 180°. Likewise, the two horizontal brackets 32 have the same configuration and when assembled, are rotationally symmetrical about the center of the pyro oven door assembly 102; meaning either may be used on the top or bottom side of the door shield 40, again by simply rotating 180°. The use of brackets having the same configuration, each with two different mating features streamlines manufacturing of the oven door assembly components and alleviates alignment errors during assembly.
After the first glass pane 35 is in place on the door shield 40, each bracket 31, 32 is coupled to the door shield 40 by mating each of the mating features to the corresponding bracket locating features on the door shield 40. FIG. 19 illustrates how each bracket 31, 32 is aligned with the door shield 40. Each bracket 31, 32 includes a flange portion, on which the first and second mating features are provided, and a u-shaped portion, as better seen in FIGS. 21 and 22. The u-shaped portion is configured to keep the first glass pane 35 and the second glass pane 36 at a predetermined distance from each other. The vertical brackets 31 are of a length corresponding to the vertical dimension of the glass panes. Likewise, the horizontal brackets 32 are of a length corresponding to the horizontal dimension of the glass panes. When the brackets 31, 32 are coupled to the door shield 40, a first leg of the u-shaped portion of each bracket 31, 32 engages a surface of the first glass pane 35. Thus, the first glass pane 35 is fully contained between the door shield 40 and the brackets 31, 32.
Once each of the brackets 31, 32 are in place, the second glass pane 36 is lowered onto the brackets 31, 32 such that a surface of the second glass pane 36 engages, or rests upon, a second leg of the u-shaped portion. See FIG. 20. Because the vertical and horizontal brackets 31, 32 extend around the entire perimeter of the first and second glass panes 35, 36, air between the first and second glass panes 35, 36 is sealed therebetween. In other words, the brackets 31, 32 prevent airflow between the first and second glass panes 35, 36. This structure helps to insulate an outer surface of the oven door assembly 104 from the high cooking and/or cleaning temperatures within the oven cavity. As shown in FIG. 21, the second leg of the u-shaped portion has an upwardly extending edge. Thus, when the second glass pane 36 is lowered onto the brackets 31, 32, the upwardly extending edge restricts lateral movement of the second glass pane 36.
Once the second glass pane 36 is in place, the door liner 21 is lowered onto the assembly, as shown in FIG. 22. As described with respect to FIG. 5, the door liner 21 comprises a compression flange on its interior edge, or around the central window opening of the door liner 21. FIG. 23 shows a partial cross-section of the compression flange 23 of the door liner 21 contained within a pyro oven door assembly 102. As discussed herein, the door shield 40 is coupled to the mounting columns 17 in a spaced apart relationship; the glass pack 30 is coupled to the door shield 40; and the door liner 21 is coupled to the deco glass subassembly to enclose the pyro oven door assembly 102. In this assembled state, the compression flange 23 is deflected by the glass pack 30, thereby creating a pressure between the two components and an improved seal.
FIGS. 24 and 25 illustrate how the components of the oven door assemblies described herein are secured together via the door liner 21. FIG. 24 depicts an upper corner of the pyro oven door assembly 102 with the door liner 21 removed. The door liner 21 includes a fastener aperture 25, which aligns with corresponding apertures provided through each of the door shield 40, mounting columns 17, and door panel 14. The opposing top corner of the pyro oven door assembly 102 includes the same configuration. Thus, at each of the top corners, a fastener can be provided through each of the aligned apertures in the aforementioned components and into the door handle 16 to bind the entire pyro oven door assembly 102 together. FIG. 25 shows a bottom corner of the pyro door assembly 102 with the door liner 21 removed. Rather than a singled aligned aperture to bind each of the components together as in the top corner, the bottom corner includes a plurality of connections. For instance, each of the door liner 21 and the door shield 40 include corresponding fastener apertures 63 and 64, respectively to secure the two components together. Similarly, the door liner 21 and the door panel 14 include corresponding fastener apertures 65 and 66, respectively. It is to be appreciated that any suitable fastener arrangement to secure the oven door assemblies can be utilized.
FIG. 26 illustrates a rear perspective view of an assembled oven door assembly 100. The intake 106 positioned at a bottom portion of the assembly is in fluid communication with the exhaust vents 108 positioned at an upper rear portion of the assembly. A volume of ambient air from the environment can travel into the intake 106, through the oven door assembly 100, and exit through the exhaust vents 108. This airflow facilitates cooling in the oven door, which assists in maintaining an external surface of the oven door assembly 100 within acceptable limits. This intake 106 and exhaust 108 configuration may be provided on both the pyro oven door assembly 102 and non-pyro oven door assembly 104.
Turning now to FIG. 27, the oven door architecture described herein includes a dual cooling structure. The door liner assembly is divided into a first chamber 43 and a second chamber 44. The first chamber 43 is the space defined between the door shield 40 and the door liner 21 surrounding the glass pack 30. The second chamber 44 is the space defined between the deco glass assembly 14 and the door shield 40. Because the glass pack 30 consumes a considerable volume of the first chamber 43, the first chamber 43 is smaller than the second chamber 44. As a result, as air is pulled through the door intake 106, or the open area in the bottom side of the door, most of the air travels through larger chamber 44 and a smaller portion of air is diverted to the first chamber 43 via intake vents 109 in the door shield 40 (FIG. 20). Both the first chamber 43 and the second chamber 44 open to the exhaust vents 108. This allows a slower current of air to circulate around the glass pack 30, pulling some hot air with it and exhausting it out of the door liner 21.
FIG. 28 shows a perspective view of a pyro oven door assembly 102 with the door liner 21 removed to better illustrate the airflow through the assembly. As previously discussed, air enters through the intake as shown by arrows 70. When the airflow encounters the glass pack, the brackets prevent the air from flowing between the first and second glass panes, and thus, the airflow travels outwards as shown by arrows 71, towards the sides of the pyro oven door assembly 102. Once the glass pack barrier has been passed, the airflow moves upwards as shown by arrows 72 between the glass pack and the sides of the pyro oven door assembly. Finally, upon reaching the exhaust vents, the airflow exits the assembly to the environment, or into ductwork of the appliance (not shown) along a path illustrated by arrows 73. The amount of cooling in the first chamber can be controlled by restricting air volume and speed via strategically positioned insulation blocks (not shown).
In the non-pyro oven door assembly, no door shield or glass pack components are included. Thus, a gap between the decorative glass, or outer glass pane, 12 and the door liner 21 acts as an airflow channel, which allows the warmer air in the air column to rise unobstructed to the top of the assembly. To further aid this flow, the intake at the bottom of the assembly features an open architecture that allows unobstructed air intake. Exhaust vents 13 provided through a top portion of the door panel or door cap 15 allow the warm air to escape through a top of the door, which creates the flow that pulls in cool, ambient air from the bottom.
Each of the oven door architectures described herein are assembled in a fully top down manner. In other words, no lateral moves are need for positioning and pre-fixating the parts relative to one another. This one-directional assembly method simplifies assembly and can reduce the cost of automation. Additionally, having several pre-fixation interfaces makes the door architecture conducive for automated assembly processes.
Numerous embodiments have been described herein. It will be apparent to those skilled in the art that the above methods, architecture, and apparatuses may incorporate changes and modifications without departing from the general scope of this invention. It is intended to include all such modifications and alterations as far as they come within the scope of the appended claims or the equivalents thereof.

Claims

What is claimed is:

1. An oven door assembly comprising:

a handle;

an outer glass pane coupled to the handle via a door panel or door cap;

an inner glass pane; and

a door liner subassembly, the door liner subassembly comprising:

a door liner;

an inner glass pane; and

an adhesive layer provided between the door liner and the inner glass pane,

the door liner including an adhesive channel configured to accommodate the adhesive layer,

the adhesive channel having a depth configured to control an amount of adhesive positioned between the door liner and the inner glass pane and a width configured to accommodate excess adhesive.

2. The oven door assembly of claim 1, further comprising a pair of mounting columns coupled to the outer glass pane.

3. The oven door assembly of claim 1, wherein the door liner includes a compression flange provided around an interior perimeter of a window opening in the door liner.

4. The oven door assembly of claim 1, wherein the door liner includes at least one intake opening at a lower portion and at least one exhaust opening at an upper portion, and the at least one intake opening and at least one exhaust opening are in fluid communication.

5. The oven door assembly of claim 4, wherein an unobstructed airflow channel is provided between the outer glass pane and the door liner and is configured to allow air entering the at least one intake opening to flow unobstructed to the at least one exhaust opening.

6. The oven door assembly of claim 1, wherein the oven door assembly is adapted to be assembled substantially along a single direction.

7. An oven door assembly comprising:

an outer glass pane;

first and second mounting columns coupled to the outer glass pane, each mounting column having at least one door shield locating feature;

a door shield coupled to the first and second mounting columns via the door shield locating features, the door shield having a glass pane locating feature;

a first glass pane coupled to the door shield, the glass pane locating feature configured to restrict lateral movement of the first glass pane when coupled to the door shield; and

a door liner coupled to the door shield.

8. The oven door assembly of claim 7, wherein the door shield includes mounting column locating features configured to mate with the door shield locating features on the first and second mounting columns.

9. The oven door assembly of claim 7, further comprising a second glass pane and a plurality of glass pack brackets secured between the first and second glass panes.

10. The oven door assembly of claim 9, wherein the plurality of glass pack brackets includes first and second vertical brackets and first and second horizontal brackets.

11. The oven door assembly of claim 9, wherein the door shield includes a plurality of bracket locating features and each of the plurality of glass pack brackets includes at least one mating feature configured to mate with a corresponding bracket locating feature.

12. The oven door assembly of claim 9, wherein the plurality of glass pack brackets are configured to restrict lateral movement of the second glass pane during assembly.

13. The oven door assembly of claim 7, comprising a first air flow chamber formed between the door liner and the door shield and a second air flow chamber formed between the outer glass pane and the door shield, the first and second air flow chambers being in fluid communication.

14. The oven door assembly of claim 13, wherein airflow can be diverted from the second air flow chamber into the first air flow chamber via vents provided in the door shield.

15. The oven door assembly of claim 13, wherein air moving through the second chamber travels at a higher speed than air moving through the first chamber.

16. An oven door assembly comprising:

an outer glass pane;

a door shield coupled to the outer glass pane, the door shield comprising at least one air intake vent;

a glass pack coupled to the door shield; and

a door liner secured to the door shield;

an intake opening positioned at a lower portion of the oven door assembly;

an exhaust opening positioned at an upper portion of the oven door assembly;

a first chamber defined between the door liner and the door shield; and

a second chamber defined between the outer glass pane and the door shield,

the second chamber being in fluid communication with the first chamber; and

the intake opening and the exhaust opening being in fluid communication with the first chamber and the second chamber; wherein a volume of air entering the intake opening would be divided and travel through the first chamber and the second chamber, and exit through the exhaust opening.

17. The oven door assembly of claim 16, wherein:

the first chamber is smaller than the second chamber, so less than half of the volume of air entering the intake opening would travel through the first chamber; and

the remaining volume of air would travel through the second chamber.

18. The oven door assembly of claim 16, wherein the glass pack resides within the first chamber; and the volume of air traveling through the first chamber would travel around a periphery of the glass pack.

19. The oven door assembly of claim 16, wherein the volume of air traveling through the second chamber would travel at a higher rate of speed than that through the first chamber.

20. The oven door assembly of claim 16, wherein the volume of air would be divided by the at least one air intake vent in the door shield.