Housing for household appliance with external panel having integrated reinforcement

A household appliance is provided having a plurality of decorative external panels that provide reinforcement to and an exterior face of the appliance. At least one of the panels has a main body portion and an interior body portion integrally formed together from a common sheet of material. The interior body portion has a plurality of integral structural reinforcements formed from bending the sheet of material in the interior body portion adjacent the main body portion. The integral structural reinforcements can include a pair of opposed parallelly extending pillars each defining a columnar volume, and a pair of opposed rearwardly bent flanges each being bent to engage the pair of pillars to form a box frame adjacent to and integral with the main body portion. In preferred embodiments, the plurality of reinforced external panels together can define a chassis of the appliance.

FIELD OF THE INVENTION

The present disclosure is directed to structural reinforcement of a household appliance, and more specifically to structural reinforcement of a food cooking apparatus, such as having a reinforced-decorative external panel.

BACKGROUND

Conventionally, household appliances include an interior frame or chassis supporting functional elements and providing a general shape of the appliance. The frame or chassis can be supported where suitable, such as by internal bracing. Decorative external body panels are attached to the frame or chassis to enclose the functional elements and provide the resultant outer appearance and footprint for the appliance. The external panels typically provide little or no structural support to the appliance, but instead are merely provided according to a desired aesthetic appearance.

BRIEF SUMMARY

According to an aspect, a household appliance includes a chassis and a decorative external panel providing reinforcement to said appliance. The decorative external panel comprises a main body portion and an interior body portion integrally formed together from a common sheet of material. The interior body portion comprises a first integral structural reinforcement formed from bending said sheet of material in said interior body portion.

According to another aspect, a decorative external panel at least partially defines a chassis of a household appliance and includes a main body portion and an interior body portion integrally formed together from a common sheet of material. The interior body portion comprises a first integral structural reinforcement formed from bending said sheet of material in said interior body portion to provide reinforcement to said appliance.

According to yet another aspect, a decorative external panel for a household appliance includes a main body portion and an interior body portion integrally formed together from a common sheet of material. The interior body portion comprises a plurality of integral structural reinforcements formed from bending said sheet of material in said interior body portion to provide reinforcement to said appliance. The plurality of integral structural reinforcements together form a box frame of integral structural reinforcement adjacent to and integral with the main body portion. The box frame defines a plurality of respective columnar volumes of the plurality of integral structural reinforcements.

The foregoing and other features of the invention are hereinafter described in greater detail with reference to the accompany drawings.

DETAILED DESCRIPTION

The present disclosure relates to a three-dimensional structure having an external appearance at least partially provided by an external panel having integrated structural reinforcement. The three-dimensional structure includes a chassis to which the external panel is affixed. Use of the external panel having integrated reinforcement provides benefits compared to use of a conventional external panel lacking integrated reinforcement and attached to intervening support bracing disposed between the conventional external panel and a chassis. The external panel having integrated reinforcement provides a more efficient assembly process and, when attached to the chassis, provides one or more of increased torsional rigidity, edge and corner rigidity, support against compression, and impact deflection as compared to conventional external panels lacking integrated reinforcement.

The three-dimensional structure can be a part of an appliance, such as a commercial or household appliance. For example, a kitchen appliance such as a cooking appliance can include the three-dimensional structure. In other embodiments, the three-dimensional structure could be included in a dish washing appliance or clothes washing appliance, for example, among others.

Turning now toFIG.1, a cooking appliance10, such as a kitchen range, is illustrated having a fan and heating elements for heating an interior oven cavity12defined by an oven muffle14. The muffle14is mounted to and supported by an appliance chassis42as known in the art. The appliance chassis can support a decorative external body11which can be at least partially comprised of the decorative external panels as disclosed herein, which panels can be mounted to the chassis42to provide the appliance's outward appearance. Alternatively, in a preferred embodiment the decorative external body11supplied by the external panels as herein disclosed itself constitutes the appliance chassis42, owing to integrated reinforcement features of those panels as will be described. A food item15to be cooked is illustrated within the oven cavity12. The heating elements for heating the oven cavity12and cooking the food item15can include one or more of a broil heating element16, a bake heating element18, and a convection heating element20. The broil heating element16is disposed at (i.e., in or adjacent) an upper portion of the oven cavity12. The bake heating element18is disposed at (i.e., in or adjacent) a lower portion of the oven cavity12, generally opposite the broil heat element16. The convection heating element20is disposed at (i.e., in or adjacent) a back portion of the oven cavity12.

The convection heating element20is part of a convection heating system22including the convection heating element20and an associated motive element for moving heated air, such as the convection fan24.

One or more additional heating elements or fans can be provided in other embodiments, and/or one or more of them can be omitted.

The cooking appliance10includes a control system30, which while illustrated at an upper-rear location of the appliance10can be otherwise suitably located in other embodiments. The control system30is schematically illustrated atFIG.2and is provided for controlling operation of the heating elements16,18, and20and of the fan24. As will be understood by one having ordinary skill in the art, the control system30of the cooking appliance10can be configured to operate any one of the heating elements16,18and20and the fan24separately from one another or in conjunction with any one or more of the other of the heating elements16,18and20and the fan24. The control system30includes at least a processor34and a storage36, such as a memory, which in other embodiments can be integral with the processor34. A user can control aspects of the cooking appliance10via a user interface40communicatively coupled to the control system30.

Turning briefly toFIG.3, a conventional decorative panel which can be used with the cooking appliance10to provide an outward appearance is illustrated at60. This external panel60includes a main body portion62having at least one structural reinforcement64attached thereto. The main body portion62is not unitary or integrally formed with structural reinforcement64. Instead, the structural reinforcement64is separately formed and then fastened to an inner side66of the main body portion62by fasteners70, such as screws or rivets. The structural reinforcement64includes intervening members, such as brackets72, that are affixed between the panel60and the chassis42. Because the intervening members72in such conventional constructions are coupled to the structural reinforcement64(of panel60) and to the chassis42via respective sets of fasteners at each end, this construction provides reduced structural support due to the multiple points of attachment at opposing ends of the bracket72. In addition to higher part-count, this results in lower torsional rigidity, lower impact deflection and lesser support against compression.

Turning now toFIG.4, structure of the cooking appliance10is shown in additional detail, but with an alternative decorative external panel46according to the present application. Aspects of the cooking appliance10, such as external top structure, are removed to better show other structural aspects of the cooking appliance10lying underneath. For example, the hob and other upper appliance structure that would normally be in-place have been removed in order to better visualize structural features at an inner side50of the external panel46.

As shown at bothFIGS.4B and5A, the external panel46as disclosed herein is a unitary component formed of a single sheet of material (preferably metal) that integrates reinforcing features with a main panel body in a unitary construction. The sheet can be made of any suitable metal, such as aluminum, which can have one or more coatings applied thereto, such as paint or other protective coatings applied to either the outer side or inner side, or both.

Generally, as shown inFIG.4Aa household appliance can be provided such that a plurality of external panels46as herein described are assembled together to form a self-reinforced chassis42of the appliance, essentially in the form of a box-frame defined by fastened-together left- and right-side and rear external panels46having integral structural reinforcement52as herein described. In this manner, the decorative external panels46themselves define the appliance chassis42, to which other internal elements can be secured during assembly. For example, as seen inFIG.4Aa divider90can be supported between the opposing side external panels46a,46bin order to divide the interior chassis space between an oven-cavity section92and a storage-drawer section94. The divider90also can provide lateral support to the opposing side external panels46a,46b, helping to fix their spacing from one another forward of the rear external panel46c. When installed, the oven muffle14that defines cooking cavity12, a cooking hob (not shown) and oven door43(seeFIG.1) also will be affixed to chassis42defined by the assembled external panels46as shown inFIG.4A. The integral structural reinforcement52in such panels46ensures robust structural integrity to the panels such that they can be assembled to constitute the appliance chassis without additional interior support beams and braces, or a separate internal chassis frame made from such parts. This is particularly advantageous because the chassis itself is reduced largely to the decorative, external panels of the appliance, without the need to incorporate internal reinforcement.

Alternatively, in a less preferred embodiment shown inFIG.4B, the external panels46can be engaged and coupled to one or more internal chassis-support elements42(seeFIG.4) such as an internal beam or brace of a chassis frame. In this embodiment, the panel46can be mounted directly to the chassis support element42, e.g. via integral structural reinforcement52, preferably absent intervening structural members such as separately formed and fastened-in brackets, bars, beams, load bearing panels, etc.

To prepare an external panel46as contemplated herein, a single sheet of material (preferably metal) is bent back over on itself against or adjacent an inner side of the sheet at one or more locations of that panel46that define terminal upper and lower ends/edges112,114and terminal lateral side ends/edges90of that panel46. Additional bends introduced into the sheet metal behind the main body portion54collectively define an interior body portion80of the panel46, and introduce additional shapes and structures that provide both reinforcement and affixation structure for attaching the panel46directly to adjacent such panels46to define a chassis42, or to underlying chassis support elements42in embodiments where present. In this application, all such structures of the panel46introduced behind the main body portion54via bends in the panel46can be referred to as integral structural reinforcement52formed in an interior body portion80of the panel46(as opposed to the main body portion54of the panel46). All structural reinforcing features of the integral structural reinforcement52(to be described) are formed integral with one another in and as part of the interior body portion80, which also provides affixation structure to secure the panel46to adjacent panels46or to other chassis support elements42without intervening brackets, as will be described. Fasteners extending through the main body portion54to attach the interior body portion80thereto are not necessary and are avoided.

That is, a main body portion54and features of the structural reinforcement52are integrally formed together. The features making up the structural reinforcement52are formed from bending terminal ends of the sheet backward against an inner side50of the sheet (i.e. inner side84of the main body portion), thus forming said reinforcement features which are integral with one another and with the main body portion54of the panel46. The bent portions forming the structural reinforcement52contribute rigidity and stiffness to that panel46, thus increasing the overall structural robustness of the assembled appliance against transient external loads as may be encountered during transport.

The main body portion54has an outer side86visible from the outside, and opposite the inner side84seen inFIGS.4B and5A, which faces inward of the appliance10. The outer side86provides an external decorative surface of the appliance10and can be seamless to provide a generally flush or smooth appearance. This is due to the integral structural reinforcement52allowing omission of fasteners through the main body portion54to engage the panels46to one another or to separate underlying chassis support elements42if present, or as might otherwise have been required to affix a separately-applied reinforcement to the inner side84of the panel46.

As shown, the structural reinforcement52features disposed at the inner side50of the panel46are formed from bends that proceed over less than a full extent of the inner side84of the main body portion54. In other embodiments, structural reinforcement52features can extend more fully across the inner side84of the main body portion54.

Turning now to the features of the structural reinforcement52, said reinforcement features are formed of the same single sheet as the main body portion54, in and defining the interior body portion80thereof. Particularly, as generally noted above, the structural reinforcement52comprises oppositely folded side portions89(FIG.5A), which have been folded rearwardly and generally towards a center of the inner side84of the main body portion54, such as to overlay the inner side84. As used herein, aspects overlaying one another may or may not be in direct contact with one another. The side portions89generally overlay the main body portion54in order to provide a relative flat structure of the panel46adjacent both its lateral edges, prior to reaching structural reinforcement features formed of bends that result in the structural reinforcement52protruding away from the main body portion54, at locations directed more toward the center of the panel46.

As shown atFIG.5A, the sheet forming the panel46can be fully bent rearward over its full vertical extent or height at or adjacent the lateral side ends thereof forming opposed continuous bends92. Each noted bend92generally forms a U-shaped configuration of folded metal defining and at the respective side edge90of the panel46, wherein the edge90is formed at and as the apex of the ‘U.’ Additional integral structural reinforcement52features can be incorporated into the sheet metal, e.g. via additional bends, in the interior body portion80remote and recessed inward from the bends92defining the edges90. Such additional structural reinforcement52, together with and as part of the interior body portion80of the panel46, is integrated together with the main body portion54of the panel, integrally affixed thereto via the bends92which join the main body and interior body portions54and80. This is contrary to conventional structures, wherein individual reinforcement features are attached to a main body portion of an external panel at discrete fastening locations as in the conventional panel60illustrated atFIG.3. Moreover, due to the bends92, the lateral side edges90of the external panel46lack free-floating distal peripheral sheet-metal edges, which otherwise could be easily impacted and more easily damaged during manufacturing, shipment, transport, installation, etc. In some embodiments, one or both of the lateral-edge bends92can be discontinuous and extend less then fully along the full height of the panel46at its respective lateral side edges90.

It will be appreciated that the terms lateral, upper, lower, horizontal, vertical, inner and outer are used with respect to the orientation of the illustrations in the figures and that the panel46can be otherwise aligned for use, where suitable. For example, the lateral edges90can be reconfigured as opposed upper and lower edges in some embodiments.

Turning now additionally toFIGS.5B and6A, example structural reinforcements52are described in detail. Notably,FIG.5Billustrates a horizontal cross-section of the panel46inFIG.5A, withFIG.6Aillustrating a vertical cross-section of that panel46.

First, inwardly of the bends92, the illustrated external panel46includes a pair of opposed multi-layer thick lateral regions91having a plurality of layers of the external sheet46laid against one another. That is, the resulting dual-layer (or optionally multi-layer—e.g. if multiple accordion-style layers are folded over one-to-the-next) regions adjacent edges90provide additional robustness and structural (e.g. torsional and bending) rigidity to the panel46; and thus to the entire appliance10when assembled thereto. Each such multi-layer thick region91preferably extends along a majority of the adjacent lateral edge90, and preferably along the full extent thereof. Further, the multi-layer thick lateral regions91can have equal horizontal extents compared to one another, extending horizontally/laterally the same distance from the adjacent lateral edge90to a respective pillar100.

Each multi-layer thick region91further includes a crimp line93that extends vertically and is defined by crimping the multi-layer thick region91so that portions thereof formed from the interior body portion80are compressed against the inner side84of the main body portion54. The crimp lines93are disposed laterally inward of each the respective lateral edges90, and extend longitudinally along the main body portion54in a direction generally parallel to those edges90. The pair of opposed crimp lines93adds further structural support and torsional rigidity to the external panel46.

In other embodiments, fewer or more crimp lines93can be included, or they can be omitted. Further still, crimp lines93can extend transverse or non-parallel to one another or to the respective pillars100or edges90. They also need not necessarily be linear in every instance. In some embodiments one or both of the multi-layer thick regions91can have other than equal horizontal dimensions.

Referring still toFIGS.4,5A,5B and6A, the interior body portion80includes additional integral structural reinforcement52in the form of at least one vertical pillar100and at least one horizontal bent flange102. As depicted, the external panel46includes at least a pair of opposed pillars100adjacent the respective lateral edges90of the panel46, although any suitable number can be formed in the interior body portion80from the single sheet of the external panel46.

Each pillar100is integrally formed with and as part of interior body portion80. In the illustrated embodiment, each pillar100extends generally vertically adjacent to a side edge90of the external panel46and has a respective central axis104(FIG.5A) that extends longitudinally vertically along the main body portion54, which axis104is laterally inwardly spaced from a respective side edge90.

Each of the illustrated pillars100extends generally parallel to a longitudinal extension direction of the respective lateral edges90and transverse, such as generally orthogonal to, vertical top and bottom edges112and114of the external panel46. Further, each pillar100extends fully between the top edge112to the bottom edge114.

In some embodiments, one or more pillars can extend other than parallel to one another and/or in other directions, and need not necessarily be disposed adjacent to the respective lateral edges90of the panel46and/or one or more of the pillars100can be disposed laterally-outwardly closer to the respective adjacent lateral edge90of the external panel46than the other of the pillars100. In some embodiments, one or more pillars can extend less than fully between the top and bottom edges112and114.

One or more holes110(FIG.4B) can be provided through one or more sides of each pillar100to allow for attachment of the external panel46to an underlying chassis support element42if present, via the pillar100. Alternatively, other structure such as bracing91for the divider90between an oven-cavity section92and a storage-drawer section94can be affixed to the external panel(s)46via its (their) pillars100in a similar manner. Any suitable fastener can be used, and or an alternative method of coupling, such as welding, adhesive, etc. Each pillar100is configured to engage against the engaged structure (e.g. bracing91, adjacent external panels46or underlying chassis support elements42if present) directly. Importantly, however, other than conventional fasteners such as screws or rivets, there is no intermediate bracing or bracket structure affixing the pillars100to any adjacent panels46or underlying chassis support elements42to which the pillars are mounted.

Turning briefly toFIG.5B, the pillars100will be further described, referring to a single pillar100, but applicable to any illustrated or non-illustrated pillar. The pillar100defines a columnar volume106that extends along and is partially enclosed by the inner side84of the main body portion54, such as along a full vertical extent of the rear side84. The columnar volume106is defined at least at a majority of its periphery by the interior body portion80. The inner side84of the main body portion54also defines a periphery of the columnar volume106extending along the pillar central axis104. The illustrated central volume106is empty but in other embodiments can be filled, such as by a foam, for example a heat resistant foam, or other suitable filler. Foams or other fillers can be used to provide additional structural robustness to the pillar100; e.g. improving its stiffness or rigidity.

The inward terminal end of the interior body portion80of the panel46, e.g. just beyond the side of the pillar100remote from the adjacent edge90, can include a distal support end116providing a multi-layer thick section of the external panel46having two layers of the single sheet laid against one another (or optionally multi-layer—e.g. if multiple accordion-style layers are folded over one-to-the-next). That is, laterally inward of the sides of the pillar100, a longitudinally extending distal support end116is provided, bent outward from the pillar100and extending towards the remote side edge90of the panel46. This distal support end116provides a continuous section of structural support for the pillar100against the main body portion54along the full longitudinal and vertical height of the main body portion54. In other embodiments, the distal support end116can extend along less than a full vertical height of the main body portion54and/or can be omitted.

Still looking toFIG.5B, the illustrated pillars100each have a rectangular cross-section taken along a horizontal plane. In the illustrated embodiments, the pillars100also each have a constant shape along their full longitudinal lengths.

In other embodiments, however, various other shaped pillars can be formed, such as having a cross-section being cylindrical, elliptical, etc. In some embodiments, additional or different bends and folds in the interior body portion80can introduce additional or modified structural rigidity or support, for example tuned for a particular application or aligned in a particular location or direction, based on known or anticipated load transients for the appliance10. In some embodiments, the columnar volume106and the pillar100can extend along less than a full vertical extent of the rear side84. In some embodiments, a pillar can be formed having a non-constant shape along its full longitudinal length. In some embodiments two or more pillars of an external panel46can have different shapes and/or cross-sectional profiles as compared to one another.

Turning again toFIG.6A, and also still toFIGS.4,5A and5B, the interior body portion80further includes additional integral structural reinforcement52in the form of the at least one rearwardly bent flange102bent from a peripheral top or bottom edge112,114of the external panel46. The flange102is further turned downward to engage at least one pillar100of the pair of pillars100. That is, the bent flange102extends from an edge112,114of the external panel46that is transverse the lateral edge90from which the adjacent pillar100extends. The rearward and downward turning provides at least a partial box-flange extending laterally adjacent the upper edge112.

As mentioned, the flange102is rearwardly turned and engages at least one pillar100at its first lateral edge, and preferably also engages the opposing pillar100at its opposed lateral edge, thereby forming a cooperative bracing structure such as a box brace between the opposed vertical pillars100and the lateral flange102extending horizontally therebetween adjacent the top or bottom edge112,114. The engagement provides enhanced rigidity and renders the external panel46materially self-supporting in both vertical and horizontal/lateral directions, while also introducing material structural and torsional stability and support to the appliance10as a whole, particularly from transient loads that may be experienced in transport.

As illustrated, the depicted external panel46includes a pair of flanges102extending inwardly towards a center of the inner side84of the main body portion54, from opposed peripheral (in the illustrated embodiment, top and bottom) edges112and114. That is, the external panel46preferably provides a pair of opposed rearwardly bent and parallelly extending box-flanges102each having opposing distal ends120configured to engage the opposing pillars100.

The flanges102each at least partially define a horizontally extending columnar volume103(FIG.6A) defined between the flange102and the inner side84of the main body portion54. Similar to the columnar volumes106, the illustrated volumes103are empty but in other embodiments can be filled, such as by a foam, for example a heat resistant foam, or other suitable filler.

As depicted, the flanges102extend generally horizontally, while the pillars100extend generally vertically, thereby defining a completed box-brace structure or box-frame, formed integrally with and as part of the otherwise decorative external panel46. In other embodiments, alternate alignments can be suitable. For example, one or more of the flanges102can be aligned other than parallel to one another and/or orthogonal to the pillars100, and/or one or more of the pillars100can be aligned other than parallel to one another and/or orthogonal to the pair of flanges102. For example, a pair of pillars100can extend transversely to one another, and/or a pair of distal flange ends120can extend transversely to one another.

To provide a secure engagement of the pillars100with the flanges102, the pillars100and flanges102can be laid onto one another, either directly or indirectly, and can be affixed to one another at the rear of the panel46to provide robust integral vertical and horizontal support for the panel46. For example, any one or more suitable face portions or edges of each of the pillars100and flanges102can be affixed to one another, such as via welding, adhesives, and/or other suitable bonding method. Additionally or alternatively, fasteners can be used, such as rivets, screws, etc. This affixation can provide greater corner stability than conventional external panels lacking integrated structural reinforcement.

For example, as depicted atFIG.5A, the distal end120of each illustrated flange102engages the inner lateral sides122of the adjacent pillar100. Additionally, at least one flange102or at least one pillar100can overlay the other of the at least one flange102and the at least one pillar100. For example, turning toFIGS.6B(illustrating another horizontal cross-section of the panel46, but along a flange102) and7, lateral side extensions111of the distal end120can be bent forward toward the inner side84(and toward the main body portion54). The lateral side extensions111each have an outer face engaging the respective inner lateral side122of the respective pillar100, which faces/sides can be affixed to one another, as mentioned above, by any suitable method.

Turning now specifically toFIG.7, depicted is a view of a single sheet134of unitary construction prior to being bent or folded to form the external panel46as described above. The section of the single sheet134forming the main body portion54is disposed centrally of the unfolded sheet134. The side portions of the single sheet134that will form the opposing interior body portions80and the integral structural reinforcements52therein for the finished panel46(FIG.5A) are disposed laterally of the main body portion54, and terminate laterally at what will ultimately form the respective distal support ends116. Imaginary apices118(which optionally can be provided as score marks if desired to facilitate easier bending) providing the apex of the U-shaped bends92(FIG.5A) and the edges90(FIG.5A) are illustrated in broken lines for reference. The crimp lines93and the bend lines227of the pillars100(FIG.5A) also are illustrated in broken lines for reference (which also optionally can be provided as score marks if desired to facilitate easier bending). Extending vertically outwardly from the top and bottom of the unfolded single sheet are the sections that will form the opposed upper and lower flanges102(FIG.5A). The distal ends120of these sections include the opposed side extensions111that are to be bent forwardly towards the main body portion54.

In use, in some embodiments, two or more of the side external panels46, and/or other panels including one or more of the aforedescribed integral features can be included in a respective cooking appliance at any suitable side of the cooking appliance, for example affixed to one another to define a reinforced chassis42for the appliance. In some embodiments the external panel46can be a rear or side external panel. An external panel46as disclosed herein also can be provided and used as a front external panel, having a central cutout in the main body portion54in register with the cooking cavity opening defined at the front of the oven muffle14, over which the door43will open and close in order to provide access to the oven cavity12. In some embodiments the external panel46can be affixed to underlying chassis support elements42. Although pillars100are illustrated in the disclosed embodiments as running vertically, it also is possible that one or more panels46for an appliance is/are rotated 90 degrees, such that the pillars100thereof extend generally horizontally. In some embodiments multiple external panels can be included having integral features as aforedescribed, where at least one of the panels is aligned at a 90 degree rotation relative to at least one other panel.

In use after being formed by suitable bending or folding operations, the resultant illustrated external panel46has one or more of torsional rigidity, vertical and horizontal stiffness, impact deflection and compression resistance being greater than typical conventional external panels lacking integrated structural reinforcement. The folding or bending operations forming the external panel46enables precise pillars100and flanges102to be formed to provide unique support profiles to provide these structural properties. The external panel46also utilizes fewer parts and thus provides fewer elements in stackup tolerance to more closely control outer and thickness dimensions and mating surfaces of the end product. These effects combine to enable fabrication of an appliance utilizing the external panels46as its support chassis42, as well as to aid efficient manufacturing of the end product, for example a three-dimensional structure or appliance, based on reduced part-count. Further, subsequent internal structure or feature redesign can include easier modification due to fewer parts to redesign.

Turning now toFIGS.8A-8C,9A-9E and10, specific additional embodiments of external panels are depicted, each having one or more different integral features at a respective interior body portion thereof than the interior body portion80of the side external panel46that has been described to this point. Any of the external panels of the additional embodiments could be used with one another or with the side external panel46described above, and thus any of the external panels of the additional embodiments could be used with the cooking appliance10shown atFIGS.1and4. The various embodiments of the external panels ofFIGS.8A-8C,9A-9E and10are similar to the side external panel46described above, except as otherwise indicated. Aspects of any of the various embodiments of the external panels ofFIGS.8A-8C,9A-9E and10can be combined with one another and/or with aspects of the side external panel46described above, where suitable.

Looking first toFIGS.8A-8C, each figure discloses a different pillar arrangement adjacent a side edge of the external panel146. AtFIG.8A, a folded-over distal support end (numbered116with respect to the external panel46) defining a further dual-layer structure with the main body portion (numbered54with respect to the external panel46) is omitted from the respective pillar150of external panel146. AtFIG.8B, the distal support end216of the external panel246is turned inwardly towards the respective pillar200, so that it extends laterally outwardly towards the adjacent side edge290. Similar to the pillar100shown atFIG.6A, the pillar200ofFIG.8Bprovides a multi-layer thick section having a pair of layers of the single sheet laid against one another. Here, however, the multi-layer section extends a substantial width of the pillar itself, as opposed to adjacent the lateral edge of that pillar200. InFIG.8Cthe interior body portion of the external sheet346includes a pair of adjacent and parallel pillars300spaced form one another adjacent to a common edge390of the panel346. Between the pillars300is an intermediate multi-layer thick section344having a pair of layers of the single sheet laid against one another. The most laterally-inward pillar300includes a distal support end316in the illustrated embodiment.

Turning next toFIGS.9A-9E, each figure discloses a different flange arrangement extending from the upper peripheral edge of the respective external panel.FIG.9Ashows the flange402having a multi-layer thick section430and a crimp line432disposed vertically outwardly of the bent flange402.FIG.9Billustrates a box flange502having an additional inwardly/forwardly bent section510as compared to the flange102depicted atFIG.6B. The flange502generally fully encloses a cross-section of the respective horizontally extending columnar volume503. The section510at the distal end520of the flange502is directed towards the rear side584of the main body portion554.FIG.9Cillustrates a similar box flange602, but having a distal support end616, similar to the distal support end116of the pillar100atFIG.6A.FIG.9Dillustrates the flange702being bent back along and against itself and along and against the rear side784of the main body portion754instead of forming a horizontally extending columnar volume. That is, the flange702atFIG.9Dprovides a multi-layer thick angle-iron section of a pair of layers of the single sheet laid upon one another.FIG.9Edepicts a flange802having a distal support end816being inwardly bent and upwardly directed into the columnar volume803, fully enclosing a cross-section of the columnar volume803with the bent sections of the flange802. Likewise, this distal support end816and the main body portion854provide a multi-layer thick section.

Finally, turning toFIG.10, a rear side of another external panel946is depicted. Different from the external panel46depicted atFIG.5A, in this embodiment the pillars900do not extend the full height of the panel946, whereas the opposing flanges902extend laterally over upper and lower vertical ends of the pillars900to form an alternative box-frame configuration. That is, the pillars900extend between interior faces of the flanges102. This is opposite the construction inFIG.5A, where the pillars100do extend the full height of the panel46, with the flanges102there extending between interior faces of the opposing pillars100.

In summary, in a preferred embodiment a household appliance10is provided having an oven cavity12defined by a muffle14, a chassis42supporting the oven cavity12and formed of a plurality of decorative external panels46with integrated structural reinforcement52, wherein at least one of the panels46provides an exterior face of the household appliance10. The at least one panel46has a structure including a main body portion54and an interior body portion80integrally formed together from a common sheet of material, said interior body portion80comprising a plurality of integral structural reinforcements52formed from bending said sheet of material in said interior body portion80adjacent the main body portion54. The integral structural reinforcements52include a pair of opposed parallelly extending pillars100each defining a columnar volume106, and a pair of opposed rearwardly bent flanges102each being bent to engage the pair of pillars100to form a box frame adjacent to and integral with the main body portion54.