Abstract:
A home appliance having an oven with a broil element, the home appliance including an appliance body; an oven cavity defined within the appliance body; a broil element mounted within the oven cavity; a broil element reflector mounted to a wall of the oven cavity; and a mounting arrangement formed integrally with the broil element reflector for mounting the broil element within the oven cavity.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates broadly to home appliances having ovens with electric resistive broil elements and, more particularly, to a home appliance, particularly a range, having an improved mounting arrangement for a broil element. 
     Most every electric range that includes an oven has internal resistive bake and broil elements which are generally curved tubular members that produce heat upon electrical activation. The bake elements are mounted to the floor of the oven cavity while the broil elements are mounted to the roof or top wall of the oven cavity. Typically, a reflector element will be between the broil element and the top wall of the oven for enhanced heating and for mounting the broil element to the oven cavity. 
     In the past, such broil elements have been difficult to install which also means that they are difficult to remove and replace during repair. As explained more fully below, the old method used two separate brackets that were attached to the reflector with screws that pass into the top wall of the cavity that make installation difficult. Further, such mounting brackets could allow warping or deflection of the broil element during heating. 
     Currently, there is a need for an improved and more secure arrangement to mount the broil element to the top wall of the cavity. 
     SUMMARY OF THE INVENTION 
     The present invention is intended to provide an improved arrangement for mounting a broil element to a broil reflector and in turn to the top wall of the oven cavity that will make installation and removal a more straightforward operation. 
     The present invention is also intended to provide such a mounting arrangement that will retain the element at specific locations to prevent warping or deflection of the broil element during heating. 
     The present invention is also intended to provide cost savings by removing the need for separate brackets and wireforms for mounting the broil element to the top wall of the oven cavity. 
     To those ends, the present invention is directed to a home appliance having an oven with a broil element. The home appliance includes an appliance body and an oven cavity defined within the appliance body. A broil element is mounted within the oven cavity and a broil element reflector mounted to a wall of the oven cavity. A mounting arrangement is formed integrally with the broil element reflector for mounting the broil element within the oven cavity. 
     Preferably, the broil element is a serpentine electrical resistance element, the reflector is a planar sheet and the mounting arrangement includes a plurality of tabs projecting outwardly from the planar sheet engaged with predetermined portions of the broil element. 
     It is preferred that the broil element is a tubular member and the plurality of tabs include a cutout for receiving a tubular portion of the broil element. Further, the cutouts may include an entry opening and a support surface, wherein the entry opening is vertically above the support surface. 
     It is further preferred that the oven cavity defines a centerline wherein a predetermined number of tabs include cutouts open toward the oven centerline and a predetermined number of tabs include cutouts open away from the oven centerline. 
     Preferably, the reflector is a planar metal sheet and the mounting arrangement includes a plurality of tabs cut in the planar metal sheet, the tabs being bent into a generally perpendicular relationship with the planar sheet, with the tabs projecting outwardly from the planar sheet and engaged with predetermined portions of the broil element. 
     Preferably, the oven cavity is defined by a plurality of interconnecting walls, including generally vertical side walls and a generally horizontal top wall, with the broil element reflector being mounted to the top wall, and wherein the mounting arrangement includes a plurality of tabs cut in the planar metal sheet and bent into a generally perpendicular relationship with the planar sheet, with the tabs projecting generally vertically downwardly from the planar sheet and engaged with predetermined portions of the broil element. 
     The serpentine broil element may include a plurality of runs joined by a plurality of loops at a plurality of corners and each of the tabs are adjacent predetermined corners of the broil element. Further, it is preferred that the serpentine broil element includes a plurality of runs joined by a plurality of loops at a plurality of corners and each of the tabs are adjacent each of the loops. 
     Preferably, the broil element includes eight runs joined by seven loops defining fourteen corners, and the plurality of tabs includes seven tabs adjacent predetermined corners of the broil element, wherein a respective tab is at a respective corner adjacent each of the respective loops. 
     It is preferred that the serpentine broil element includes a plurality of runs joined by a plurality of loops at a plurality of corners and the plurality of tabs adjacent predetermined corners of the broil element. Preferably, the broil element includes eight runs joined by seven loops defining fourteen corners, and the plurality of tabs includes seven tabs adjacent predetermined corners of the broil element, wherein a tab is at a corner adjacent each of the respective loops. 
     The present invention is also directed to a range for cooking, the range having an oven with a broil element. The present range includes a range body and an oven cavity defined within the range body. A broil element is mounted within the oven cavity and a broil element reflector mounted to a wall of the oven cavity. A mounting arrangement is formed integrally with the broil element reflector for mounting the broil element within the oven cavity. 
     Preferably, the broil element is a serpentine electrical resistance element, the reflector is a planar sheet and the mounting arrangement includes a plurality of tabs projecting outwardly from the planar sheet and engaged with predetermined portions of the broil element. 
     It is preferred that the broil element is a tubular member and each of the tabs includes a cutout for receiving a tubular portion of the broil element. The cutouts may include an entry opening and a support surface, wherein the entry opening is vertically above the support surface. 
     Preferably, the oven cavity defines a centerline and a predetermined number of tabs include cutouts open toward the oven centerline and a predetermined number of tabs include cutouts open away from the oven centerline. 
     It is preferred that the reflector is a planar metal sheet and the mounting arrangement includes a plurality of tabs cut in the planar metal sheet with the tabs being bent into a generally perpendicular relationship with the planar sheet, with the tabs projecting outwardly from the planar sheet and engaged with predetermined portions of the broil element. 
     Preferably, the oven cavity is defined by a plurality of interconnecting walls, including generally vertical side walls and a generally horizontal top wall, with the broil element reflector being mounted to the top wall, and wherein the mounting arrangement includes a plurality of tabs cut in the planar metal sheet and bent into a generally perpendicular relationship with the planar sheet, with the tabs projecting generally vertically downwardly from the planar sheet and engaged with predetermined portions of the broil element. 
     It is preferred that the serpentine broil element includes a plurality of runs joined by a plurality of loops at a plurality of corners and the plurality of tabs are adjacent predetermined corners of the broil element. It is further preferred that the serpentine broil element includes a plurality of runs joined by a plurality of loops at a plurality of corners and the each of the plurality of tabs are adjacent each of the loops. 
     Preferably, the broil element includes eight runs joined by seven loops defining fourteen corners, wherein the plurality of tabs includes seven tabs adjacent predetermined corners of the broil element, with a tab at a corner adjacent each of the respective loops. It is further preferred that the serpentine broil element includes a plurality of runs joined by a plurality of loops at a plurality of corners and the plurality of tabs are adjacent predetermined corners of the broil element. Finally, the broil element may include eight runs joined by seven loops defining fourteen corners, and wherein the plurality of tabs includes seven tabs adjacent predetermined corners of the broil element, wherein a tab is at a corner adjacent each of the respective loops. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of a prior oven illustrating the prior broil element mounting structure; 
         FIG. 2  is a side view of a range broken open to illustrate a broil element according to one preferred embodiment of the present invention; 
         FIG. 3  is a front perspective view of a broil element and associated mounting structure illustrated in  FIG. 1 ; 
         FIG. 4  is top-plan view of a reflector having broil element mounting tabs cut therein; and 
         FIG. 5  is a perspective view of the broil element reflector illustrated in  FIG. 4  showing the tabs bent to an operational position. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Turning now to the drawings and, more particularly to  FIG. 1 , a prior art range is illustrated at  30  and defines an oven cavity. A resistive broil element  34  is mounted to a top wall of the oven cavity  32  for heating and cooking food on a rack (not shown) below the broil element  34 . The broil element  34  is plugged into electrical connections at the rear of the oven  32 . As is known with resistive cooking elements, the broil element is serpentine in shape and, due to the mounting structure, appears in  FIG. 1  as a series of four U-shaped members. Nevertheless, it will be understood by those skilled in the art that connecting portions of the broil element  34  are hidden due to the bracket structure and a single, tubular rod forms the serpentine broil element. 
     The broil element  34  is mounted to a reflector  36  that is in turn mounted to the top wall of the oven  32  using two brackets  38 ,  44 . A front bracket  38  is a generally elongate planar member that extends traversely across the top wall of the oven  32  from one lateral extent of the broil element  34  to the other. The bracket  38  is attached to the reflector  36  using screws  42 . A linear array of oval openings  40  are defined in the bracket  44  in order to accommodate the entire U-shaped structure of the broil element  34 . 
     A similar rear bracket  44  is mounted to the reflector  36  using screws  48 . The rear bracket  44  is configured like the front bracket  38  as a generally elongate, planar member having a series of oval openings  46  through which a portion of the broil element  34  can pass. 
     As can be seen from the above, the brackets  38 ,  44  are screwed to the reflector  36  and ultimately the top wall of the oven  32 . The brackets  38 ,  44  support the U-shaped portions of the broil element  34  in a loose manner and such support is improved upon by the present invention. 
     Turning now to  FIG. 2 , a range is illustrated generally at  10  and includes a floorstanding, boxlike range body  12  defining an oven  16 . The oven  16  is covered by a door  26 . A range top  14  or cooktop is on top of the range body  12  above the oven  16 . As seen in the open portion of the range  10 , a broil element  50  extends across a top wall  22  of the oven  16 . Tabs  126 ,  124  at the front and rear of the broil element  50  support the broil element  50 . 
     Turning now to  FIG. 3 , an interior of the oven  16  is illustrated from the vantage point of an open door. The oven  16  includes sidewalls  18 , a rear wall  20 , a top wall  22  and a bottom wall (not shown). The opening to the oven  16  is surrounded by a gasket  28 . An imaginary, horizontally extending centerline  24  divides the oven into left and right portions for the purposes of the present discussion. In that regard, when the present discussion refers to a left-to-right progression, the perspective is from the viewer&#39;s left to the viewer&#39;s right. 
     With continued reference to  FIG. 3 , the broil element  50  is plugged into the rear wall  20  of the oven  16  at a first electrical connector  52  on one end and a second electrical connector  54  on the other. The broil element  50  is a tubular member formed into a series of runs and loops joined by corner portions or, for brevity, corners. There are eight linear runs, and seven loops defining a serpentine structure. As will be seen, tabs are provided at specific, predetermined locations to support the broil element  50  in a manner that will resist twisting and warping when the resistive broil element  50  is heated to operational temperature. 
     Proceeding from left to right in  FIG. 3 , a first linear run  56  extends from the left electrical connector  52  from back to front and is joined to a first loop  72  at a first corner  86 . The first loop  72  curves the broil element  50  back into a second run  58  that extends from a second corner  88 , front to back, to a third corner  90  adjacent the rear wall  20  of the oven  16 . A second loop  74  extends from the third corner  90  at the second run  58  to a fourth corner  92  wherein the broil element  50  is turned to extend from back to front through the third run  60 . The third loop  76  joins the third run  60  at a fifth corner  94  and bends the broil element  50  to a sixth corner  96  where it is reversed and attaches to the fourth run  62  to extend from front to back. The fourth run  62  ends at a seventh corner  98  and bends into the fourth loop  78  that goes through the centerline  24  of the oven. As will be seen, the remaining portion of broil element  50  is a mirror image of the first portion. 
     From the centerline  24 , the fourth loop  78  extends to the eighth corner  100  where it once again turns to extend from back to front through the fifth run  64 . The fifth run  64  ends at the ninth corner  102  and the broil element  50  extends through the fifth loop  80  to the tenth corner  104 . From there, the broil element  50  extends from front to back through the sixth run  66  ending at the eleventh corner  106  where the sixth loop  82  extends to the twelfth corner  108 . From the twelfth corner  108 , the seventh run  68  extends from back to front ending at the thirteenth corner  110 . The seventh and final loop  84  extends from the thirteenth corner  110  to the fourteenth corner  112  to reverse direction of the broil element  50  to again extend from front to back along the eighth run  70  to the second electrical connector  54 . 
     A plurality of tabs project outwardly from the reflector  128  to support the tubular broil element  50 . As seen in  FIGS. 3 ,  4  and  5 , each tab  114 ,  116 ,  118 ,  120 ,  122 ,  124 ,  126  is a generally rectangular member having a cutout to receive a portion of the tubular broil element  50 . As seen in  FIG. 4 , the tabs are cut from a sheet of metal which becomes the reflector  128 . Each tab has the same structure, so explanation of one tab will suffice to explain the entire set of seven tabs. For example, and with reference to  FIG. 5 , each tab is a generally rectangular member having a cutout  134  defining a cutout opening  136  leading to a support surface  138 . When in use, the opening  136  to the cutout is vertically above the support surface  138  such that the broil element  50  can slide in the cutout  134  and move generally downwardly to rest on the support surface  138 . The broil element tube portion must be lifted or raised in order to exit the respective tab. As seen in  FIG. 4 , each of the tabs is cut into the sheet metal and, as seen in  FIG. 5 , bent upwardly to define the respective tab. A shield  130  extends along one edge of the reflector  128  and is folded in the direction of the tab folds, to extend downwardly from the top wall  22  of the oven  16 . 
     Returning to  FIG. 3 , and extending from left to right, a first tab  114  is at the first corner  86  with the opening  134  facing the centerline  24  of the oven  16 . A second tab  116  is at the fourth corner  92  with the cutout facing away from the centerline  24  of the oven  16 . A third tab  118  is at the sixth corner  96  with the tab cutout  136  facing the centerline  24  of the oven  16 . While the tabs are discussed as being at the corners, the tabs are adjacent the corners and support a portion of a run rather than a corner of the tubular broil element  50 . 
     A fourth tab  120  is at the eighth corner  100  with a cutout  136  facing the centerline  24  of the oven  16 . A fifth tab  122  is adjacent the ninth corner  102  with the cutout  136  facing the centerline  24  of the oven  16 . A sixth tab  124  is at the eleventh corner  106  with the cutout  136  facing away from the centerline  24  of the oven  16 . A seventh and final tab  126  is adjacent the fourteenth corner  112  with the cutout opening  136  facing the centerline  24  of the oven  16 . 
     Based on the foregoing, it can be seen that the broil element  50  is supported at seven different places with tabs that, for the most part, reverse direction of the cutout as proceeding from left to right across  FIG. 3 . The exception is the fifth tab  122  and sixth tab  124  which are at the eighth corner  100  and the ninth corner  102 , respectively. Further, despite the presence of the fourth tab  120 , the other tabs are place symmetrically on either side of the centerline  24 . Since there are seven loops and seven tabs, no loop is left unsupported and, as such, the present mounting arrangement provides stability to the broil element  50 . Accordingly, the broil element  50  will resist warping or deflection during heating because the present tabs allow for more free expansion of the broil element  50  than did the prior mounting structure illustrated in  FIG. 1 . 
     By the above, the present invention provides an improved and simplified mounting arrangement for a broil element in an oven that is more cost-effective to produce and enhances the structural strength and rigidity of a broil element. 
     It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. While the present invention is described in all currently foreseeable embodiments, there may be other, unforeseeable embodiments and adaptations of the present invention, as well as variations, modifications and equivalent arrangements, that do not depart from the substance or scope of the present invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.