BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] The present disclosure is related to oven doors. More particularly, the present disclosure is related to oven doors that have locking mechanisms and a glass panel that provides a full view of the interior content of an oven when the oven door is in a closed position.

2. Description of Related Art

[0002] Most residential and professional kitchens include one or more ovens having an oven door through which contents can be placed into the oven. The oven door includes a door-frame that has a hinge, an exterior handle, a gasket or seal, a locking mechanism, and, often a small window.

[0003] The hinge pivotally secures the frame of the door to the oven. The exterior handle allows the user to open and close the door by pivoting the door about the hinges. The gasket or seal seals the frame to the wall of the oven when in the closed position to reduce the heat transfer between the frame and the oven wall. The small window allows a partial view of the contents of the oven can be seen.

[0004] Unfortunately, the structural and functional requirements of the door-frame have previously only allowed oven windows of a small size. The small size of the prior art oven windows can result in an obstructed view of the inside of the oven and can result in poor lighting of the interior contents. Thus, prior art oven users have found it difficult to see the contents during the cooking process. [0005] Currently, oven doors are assembled utilizing a number of parts that are susceptible to degradation over time when in the presence of high temperatures. This is especially prevalent in ovens that utilize a self-clean cycle in which temperatures are ordinarily much higher than those typically used during the cooking process. The wear and tear of degradation undesirably results in repair costs and/or replacement of the oven in whole.

[0006] Accordingly, it has been determined by the present disclosure that there is a need for oven doors that overcome, alleviate and/or mitigate one or more or other deleterious effects of prior art oven doors.

BRIEF SUMMARY OF THE INVENTION

[0007] An oven door including a frame including a shroud and a pair of side rails for holding in place a glass pane; a hinge for securing the frame to an oven; and a mechanism for holding the oven door in a closed position relative to the oven, in which the glass pane provides a full view of the interior contents of the oven when the oven door is in the closed position.

[0008] A method for assembling an oven door, including applying a first exposed side of an adhesive tape to an edge of an outer glass pane; rolling the adhesive tape on the outer glass pane; applying a pair of hinges to a second exposed side of adhesive tape; inserting a first single sided low-e glass with the coating facing up; inserting two pieces of double coated low-e glass; and securing a handle to the outer glass panel with the adhesive tape.

[0009] The above-described and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS [0010] FIG. 1 is a view of an exemplary embodiment of an interior side of an oven door according to the present disclosure in combination with a prior art oven, the door being shown in an open position.

[0011]FIG. 2 is a side perspective view of an exterior side of the oven door of FIG. 1.

[0012] FIG. 3 is a top perspective view of the exterior side of the oven door of FIG. 1.

[0013] FIG. 4 is a bottom perspective view of the exterior side of the oven door of FIG. 1 in a partially assembled state.

[0014] FIG. 5 is a top perspective view of the exterior side of the oven door of FIG. 1 in the partially assembled state.

[0015] FIG. 6 is a first side perspective view of the exterior side of the oven door of FIG. 1 in the partially assembled state.

[0016] FIG. 7 is a second side perspective view of the exterior side of the oven door of FIG. 1 in the partially assembled state.

[0017] FIG. 8 is a bottom perspective view of the exterior side of the oven door of FIG. 1 illustrating a side rail portion of the door in the partially assembled state.

[0018] FIG. 9 is a bottom perspective view of the interior side of the oven door of FIG. 1 illustrating the side rail portion in the partially assembled state.

[0019] FIG. 10 is a perspective of a hinge mechanism for use with the oven door according of FIG. 1. [002O] FIG. 11 is a view of the side rail portion of FIG. 9 having the hinge mechanism of FIG. 10 during assembly.

[0021] FIG. 12 is a view of the side rail portion of FIG. 9 having the hinge mechanism of FIG. 10 after assembly.

[0022] FIG. 13 is a section view taken along lines 13-13 of FIG. 12.

[0023] FIGS. 14 and 15 are graphs illustrating a comparison of the temperatures on the inside and outside of a prior art oven door during a typical a self-cleaning cycle.

[0024] FIGS. 16 and 17 are graphs illustrating a comparison of the temperatures on the inside and outside of the oven door of FIG. 1 during the typical a self- cleaning cycle.

[0025] FIG. 18 is an alternative embodiment of the oven door according to the present disclosure.

[0026] FIG. 19 is an exemplary embodiment of a method according to the present disclosure of assembling an oven door according to the present disclosure.

[0027] FIG. 20 is an alternative exemplary embodiment of a method according to the present disclosure of assembling an oven door according the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0028] Referring to the drawings and in particular to FIGS. 1 through 3, an exemplary embodiment of a full-view oven door 10 according to the present disclosure is shown in combination with a prior art oven 12. In FIG.1 , door 10 is shown in an open position.

[0029] Advantageously, oven door 10 eliminates the need for costly and complex glass, glass seals, and glass spacers of the prior by using a simple combination of four glass sheets held in place by metallic spacers. It has been determined by the present disclosure that door 10 having the simple combination of four panes of glass spaced apart by metallic spacers provides excellent thermal properties without the need for the expensive low expanding glasses of the prior art and eliminates the need for the expensive and complex high temperature plastic molded parts of the prior art. Moreover, oven door 10 provides a full-view oven door wherein essentially the entire interior of the oven cavity can be viewed and yet allows the oven to include a high temperature self-cleaning cycle.

[003O]As used herein, "full-view" as defined in the present disclosure means a complete, unobstructed view of the entirety of the interior of the oven from any visual angle outside of the oven door. As used herein, "transparency" means light transmission. "Translucent" means surface area that allows light there through. As used herein, the term self-cleaning cycle refers to a cycle of oven 12, wherein the oven increases its internal temperatures to more than 600 ⁰ F (degrees Fahrenheit) and more commonly more than 800 ⁰ F for a predetermined period of time, such as about three to four hours, so as to burn off or pyrolitically clean the interior surfaces of the oven. In the United States, the Underwriters Laboratory (UL) Standards for Safety require ovens having such self-cleaning cycle capability to include a door that is locked during the cleaning cycle to prevent inadvertent exposure to the cleaning cycle temperatures.

[0031] Advantageously, oven door 10 also functions with oven 12 having a door lock or holder 14 and is capable of withstanding the high temperatures of such self-cleaning cycles. Thus, door 10 not only provides a full-view of the inside 16 of oven 12, but also allows for use of the self-cleaning cycle of the oven. [0032] As illustrated in FIGS. 1 through 3, oven door 10 includes a frame 18, a pair of hinges 20, one or more glass panes 22, a lock opening 24, and, preferably, a handle 26.

[0033] Frame 18 includes a first side rail 28, a second side rail 30, and a shroud 32. Hinges 20 extend from first and second side rails 28, 30 so as to engage with oven 12 in a known manner. In the illustrated embodiment, hinges 20 are known lift off hinges. The oven door 10 is virtually entirely translucent in that the glass portion is translucent but the shroud 32 and first and second side rails 28, 30 are not translucent.

[0034] Shroud 32 includes one or more vent openings 34 disposed therein. Vent openings 34 provide fluid communication between ambient room air and spaces between the one or more glass panes 22. Additionally, shroud 32 includes lock opening 24, which is configured for receipt of lock 14 defined in oven 12. In this manner, door 10 is UL compliant when used with oven 12 having a self-cleaning cycle.

[0035] In use, shroud 32 is configured to engage oven electronics such as light switch (not shown) and/or lock 14. Thus, shroud 32 is preferably formed of a material having sufficient rigidity to engage lock 14. In a preferred embodiment, shroud 32 is a stamped metal shroud such as brushed stainless steel.

[0036] The detailed construction of the exemplary embodiment of door 10 is described by way of simultaneous reference to FIGS. 4 through 13.

[0037] In the illustrated embodiment, door 10 includes four glass panes 22, namely a first or outer glass pane 22-1 ,a second or inside or "inner" glass pane 22-4, a third or middle glass pane 22-2, and a fourth or middle glass pane 22-3 best seen in FIGS. 9 and 13. [0038] Glass panes 22 can be any glass suitable for use with the temperatures of oven 12. In preferred embodiment, outer glass pane 22-1 is a non-reflective decorative glass pane made of an uncoated sheet of common .125 clear float glass. Third and fourth glass panes 22-2 and 22-3 are a low-emissive glass panes having a soda-lime glass sheet with a metal-oxide coating (not shown) on one side. Preferably, third and fourth glass panes 22-2, 22-3 are positioned in door 10 such that the coating faces the interior 16 of oven 12. Advantageously, glass panes 22 have a uniform transparency.

[0039] Inner glass pane 22-4 is a low-emissive glass pane having a soda-lime glass sheet with a metal-oxide coating on each side. Thus, inner glass pane 22- 4 is positioned in door 10 such that coating faces both the interior 16 of oven 12, while the other coating faces the exterior of the oven.

[0040] It should be recognized that frame 18 and glass panes 22 are described herein as being made of particular materials. Of course, it is contemplated by the present disclosure for frame 18 and panes 22 to be made of any known material suitable for use with the temperatures and stresses generated by oven 12.

[0041] In a preferred embodiment shown in FIG. 9, inner glass pane 22-4 has an inner surface 36 that is substantially planar to an inner surface 38 of frame 18. It has been determined by the present disclosure that maintaining inner surfaces 36 and 38 substantially planar to one another advantageously allows door 1- to be useable as a work surface when the door is opened. For example, when checking the internal temperature of a roast the user can temporarily rest the cooking pan containing the roast on inside surfaces 36, 38 with the substantially planar surface providing a stable support surface of the pan.

[0042]As shown in FIGS. 10 through 12, hinge 20 may be any known hinge in the art suitable for connecting oven door 10 to oven 12. For example, it is contemplated herein that hinge 18 may be, by way of example, a spring arm hinge or a cam-arm hinge.

[0043] Side rails 28, 30 are described with reference to FIGS. 5 and 13. The side rails 28 and 30 are mirror images of one another and, thus, for purposes of clarity only a detail description of side rail 30. As seen in FlG. 1 , the distance between the side rails is no less than the opening in the oven.

[0044] Side rail 30 includes an inner U-shaped channel 40, an outer U-shaped channel 42, a plurality of spacer bars 44, an L-shaped channel 46, and a bottom bar 48. Outer U-shaped channel 42 includes a slot 50 positioned and configured to receive hinge 18.

[0045] Inner U-shaped channel 40, as well as handle 26 and one of spacer bars 44, are connected to outer glass pane 22-1 by way of adhesive tape 52. Here, channel 40 is secured to glass pane 22-1 so that the open face of the u-shaped channel faces away from the outer glass pane. Outer U-shaped channel 42 is secured over inner u-shaped channel 40 to define a substantially rectangular opening therein.

[0046] Adhesive tape 52 can be any adhesive tape sufficient to withstand the thermal stresses imparted to door 10 by oven 12, as well as the mechanical stresses imparted to door 10 during use of the oven. In a preferred embodiment, tape 52 is a double coated acrylic foam tape such as, but not limited to, VHB™ tape that is commercially available from the Minnesota Mining and Manufacturing or 3M™ Company.

[0047] Spacer bars 44 and L-shaped channel 46 are secured to a side of outer U- shaped channel 40 to define a plurality of pane receiving slots (S). Slots S are positioned and configured to loosely receive glass panes 22-2, 22-3, and 22-4 therein. Preferably, spacer bars 44 and L-shaped channel 46 are mechanically fastened to channel 40 such as by one or more machine screws (not shown), which can in some embodiments also secure outer U-shaped channel 42 to inner U-shaped channel 40. Similarly, bottom bar 48 is mechanically fastened to spacer bars 44 such as by one or more machine screws (not shown). It should be recognized that bars 48, 44 and channels 40, 42, 46 are described above by way of example only as being mechanically fastened to one another. Of course, it is contemplated by the present disclosure for bars 48, 44 and channels 40, 42, 46 to be secured to one another in any desired manner.

[0048] It has also be determined that door 10 can easily be converted to fit a wide range of prior art ovens 12 by merely changing the position of U-shaped channels 40, 42 with respect to one another so as to increase the width of the rectangular opening formed therein.

[0049] In the partially assembled state shown in FIG. 8, spacer bars 46 provide elongated pane receiving slots (S) that are open at a top end of door 10, but are closed at the bottom end of the door by bottom bar 48. In this manner, glass panes 22-2, 22-3, and 22-4 can be slid into slots (S) until the glass pane contacts bottom bar 48 as shown in FIG. 9. Once glass panes 22-2, 22-3, and 22-4 have been positioned in slots (S), shroud 32 is secured over the open top end of the slots as shown in FIGS. 2-3.

[0050]Thus, glass pane 22-1 is the pane that is furthest from interior 16 of oven 12 so as to have the lowest heat exposure. Here, glass pane 22-1 is secured to side rails 28, 30 using adhesive tape 52. However, glass panes 22-2, 22-3, and 22-4, which are exposed to higher heat from oven 12, are loosely held in slots (S) to allow for thermal expansion without the need for costly spacers or seals of the prior art. Moreover, the area between the glass panes 22-1 , 22-2, 22-3, and 22-4 is open to ambient air allowing for heat dissipation between the panes.

[0051] In some embodiments, door 10 can include a high temperature seal 54 for sealing the door to oven 12 as shown in FIG. 12. [0052] FIGS. 14 through 17 illustrate a comparison of the temperatures on the inside and outside of a prior art oven door as compared to those of oven door 10 according to the present disclosure during a self-cleaning cycle.

[0053] The graphs of FIGS. 14 through 17 plot the temperature in a plurality of locations in degrees Fahrenheit versus time in minutes.

[0054] FIGS. 14 and 15 illustrate the temperatures on the inside and outside of a prior art oven door during a typical a self-cleaning cycle, respectively, while FIGS. 16 and 17 illustrate the temperatures inside and outside of oven door 10 during the typical self-cleaning cycle, respectively.

[0055] The temperature testing was performed using the self-cleaning cycle of a known prior art oven, namely a Monogram Wall Oven Model No. ZET 1 SM1 S, which is commercially available from the General Electric Company.

[0056] The temperatures on the inside of the prior art door (FIG. 14) and of door 10 (FIG. 16) were measured in seven locations, namely the top left inside (TLI) corner of the door, the top right inside (TRI) corner of the door, the center inside (Cl) of the door, the inside temperature of the oven (Ol), the bottom left inside (BLI) corner of the door, the bottom right inside (BRI) corner of the door, and the top center inside (TCI) of the door.

[0057] Similarly, the temperatures on the outside of the prior art door (FIG. 15) and of door 10 (FIG. 17) were measured in seven locations, namely the top left outside (TLO) corner of the door, the top center outside (TCO) of the door, the top right outside (TRO) corner of the door, the outside center (CO) of the door, the bottom left outside (BLO) corner of the door, the bottom right outside (BRO) corner of the door, and the room temperature (RO). [0058] When comparing the graphs of FIGS. 14 and 16, it can be seen that the inside temperature measurements during the self-cleaning cycle of a GE Monogram Wall Oven with a prior art door and during the self-cleaning cycle of the same GE Monogram Wall Oven with oven door 10 according to the present disclosure, show similar results. More specifically, it is seen in both graphs, the temperature measurements range between approximately 600 and 800 degrees Fahrenheit.

[0059] Moveover, when comparing the graphs of FIGS. 15 and 17, it can be seen that the outside temperature measurements during the self-cleaning cycle of a GE Monogram Wall Oven with a prior art door and during the self-cleaning cycle of the same GE Monogram Wall Oven with oven door 10 according to the present disclosure, also show similar results. For example, in both ovens, the maximum recorded exterior temperature is less than 115 degrees Celsius during the self-cleaning cycle. Thus, the simple construction of door 10 ensures that the first or outside glass pane 22-1 is insulated from the heat within oven 12 to a comparable amount as the prior art oven door, but does so without the need for the expensive low expanding glasses and complex designs of the prior art. Thus, door 10 is configured to withstand the temperatures experienced during typical self-cleaning cycles in a simple and cost effective manner, while providing a full-view of the interior of the oven.

[0060] Further, it has been determined by the present disclosure that prior art oven 12 can be retrofitted to include oven door 10 according to the present disclosure by simply removing the prior art door by lifting off the hinges attaching hinges 20 to the oven 12. This is in contrast to the oven doors of the prior art in which the sealing must be removed from the oven door to the oven peripheral wall via a custom adaptor.

[0061] Referring now to FIG. 18, an additional preferred embodiment of door 10 according to the present disclosure is shown. In this embodiment, door 10 includes all of the parts shown and discussed above in regards to the alternate embodiments of the door 10 as shown in FIGS. 2 through 13. However, in this embodiment, door 2 only has two glass panes 22, namely inner glass pane 222-1 and outer glass pane 222-4. One glass pane 22 is a tempered pane of low-e, such as PPG's Sungate 500, and the second glass pane 22 is a high performance glass pane having a silver based coating. In one embodiment, inner glass pane 222-1 is a tempered pane of low-e, and outer glass pane 222-4 is a high performance glass pane having a silver based coating.

[0062] It is believed that the glass structure of oven door 10 of FIG. 18, provides a better transparency than the glass structures of the prior art, while retaining the same temperature resistance during a self-cleaning cycle of an oven. For example, the glass structure of oven doors of the prior art provide a light transmission or transparency of approximately 60% to 70%. However, it is believed the glass structure of door 10 provides a light transmission or transparency of 78% to 85%, while not exceeding a temperature of 115 degree Celsius during an oven's self-cleaning cycle.

[0063] Referring now to FIG. 19, a method 100 according to the present disclosure of assembling oven door 10 is shown.

[0064] First, in a positioning step 102, outer glass pane 22-1 is positioned on a work surface. In a first adhesive preparation step 104, adhesive tape 52 is prepared for use by removing backing from one side of the tape to expose the adhesive. The exposed sides of the two strips of adhesive tape 52 are then placed on two appropriate and parallel edges of outer glass pane 22-1 in a tape application step 106.

[0065] In some embodiments, tape application step 106 can include a rolling step 108, wherein a roller can be used to apply pressure seating the tape to outer glass pane 22-1. [0066] In further embodiments, a tape inspection step 110 can be included wherein outer glass pane 22-1 can be inspected to ensure proper positioning, alignment, and appearance of tape 52.

[0067] Once tape 52 is properly positioned on outer glass pane 22-1 , method 100 further includes a second adhesive preparation step 112. During second adhesive preparation step 112, adhesive tape 52 is further prepared for use by removing the backing from the second side of the tape to expose the adhesive.

[0068] Method 100 includes a side rail application step 114 in which side rails 28, 30 are secured to opposing sides of outer glass pane 22-1. In a preferred embodiment, side rail application step 114 includes securing inner U-shaped channel 40 to tape 52. Once inner U-shaped channel 40 is secured to tape 52, outer U-shaped channel 42 having spacer bars 44, L-shaped channel 46, and bottom bar 48 positioned thereon can be secured to inner U-shaped channel 40 using desired connector such as, but not limited to, one or more machine screws (not shown).

[0069]When securing outer U-shaped channel 42 to inner U-shaped channel 40, slots 50 in the outer U-shaped channel 42 are aligned to a bottom edge of the outer glass pane 22-1. Then, hinges 18 are positioned within side rails 28, 30 so that the hinges extend through the slots 50.

[0070] After side rails 28, 30 are secured to outer pane 22-1 , glass panes 22-2, 22-3, and 22-4 are positioned within slots (S) in first and second glass insertion steps 116 and 118.

[0071] During first glass insertion step 116, second and third glass panes 22-2 and 22-3 are positioned in door 10 such that the coating faces the interior 16 of oven 12. During second glass insertion step 118, inside glass pane 22-4 is positioned in door 10 such that one coating faces both the interior 16 of oven 12, while the other coating faces the exterior of the oven.

[0072] After completing glass insertion steps 116, 118, method 100 includes a shroud fastening step 120 in which shroud 32 is positioned and secured to door 10 so that lock opening 24 is on the upper side of the door and on the same side inside glass pane 22-4 and slots 50.

[0073] In embodiments of door 10 having handle 26, method 100 includes additional positioning, adhesive preparation and inspection steps for securing the handle to outer glass pane 22-1.

[0074] Referring now to FIG. 20, method 100 can include a second positioning step 122, where the inner glass pane 22-4 is positioned on a work surface, a first adhesive preparation step 124, where adhesive tape 52 is prepared for use by removing backing from one side of the tape to expose the adhesive and the exposed side of the adhesive tape is placed on a side of outer glass pane 22-1 opposite side rails 28, 30 in a tape application step 126.

[0075] In some embodiments, tape application step 126 can include a rolling step 128, wherein a roller can be used to securely and evenly bond the exposed side of the adhesive tape to outer glass pane 22-1.

[0076] In further embodiments, a tape inspection step 130 can be included wherein outer glass pane 22-1 can be inspected to ensure proper positioning, alignment, and appearance of tape 52.

[0077] Once tape 52 is properly positioned on outer glass pane 22-1 , method 100 further includes a second adhesive preparation step 132. During second adhesive preparation step 132, adhesive tape 52 is further prepared for use by removing the backing from the second side of the tape to expose the adhesive. [0078] Once exposed, method 100 includes a handle application step 134 in which handle 26 is secured to outer glass pane 22-1.

[0079] While the present disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the disclosure will include all embodiments falling within the scope of the appended claims.