Abstract:
An oven door assembly having a minimum number of required components parts is constructed by attaching a pair of spaced hinge assemblies, preferably through a tab and slot arrangement to the first panel, and positioning a central window pack on a first panel. A second panel is then snap-fit directly through the hinge assemblies to the first panel, thereby indirectly securing the second panel to the first panel through the hinge assemblies with the window pack therebetween.

Description:
BACKGROUND OF INVENTION 
     1. Field of Invention 
     The present invention pertains to the art of cooking appliances and, more particularly, the construction and assembly of an oven door which includes components that are snap-fit together in order to simplify assembly and reduce production costs. 
     2. Discussion of Prior Art 
     Ovens and their general construction are well known. In general, an oven includes a cooking cavity having an opening which is selectively closed by a door assembly. Usually, ovens are of two general configurations, the ovens are either built-in units, i.e. into a cabinet or wall, or the oven is a free standing range including a cooktop. The doors furnished with ovens can be composed of multiple components which can include a sealing panel, thermal insulation, a window, an intermediate panel, an outer panel, handles, hinges and, in some instances, a decorative face covering. In order to join all of the aforementioned components into a door, a large number of fasteners or welds are typically required. 
     A major disadvantage of this known arrangement is the number of assembly operations and fasteners required to construct the oven door. The relatively large number of parts, and complexity of construction increases manufacturing costs. As the home appliance industry is highly competitive, reducing the number of component parts and simplifying construction could lead to a tremendous cost and efficiency savings. However, the overall assembly must still be structurally sound and reliable. Although attempts have been made to simplify the overall construction of an oven door, there exists a need in the art for an improved oven door construction assembly. 
     SUMMARY OF THE INVENTION 
     An oven door constructed in accordance with the present invention overcomes the disadvantages in the art by reducing the number of components and simplifying the overall construction of an oven door. Specifically, the oven door of the present invention includes a first panel adapted to seal the oven cavity of a cooking appliance, a hinge assembly secured to the first panel, at least one internal door component positioned against the first panel, and a second panel which is snap-fit to the hinge assembly securing the internal door component in position. 
     Preferably, the hinge assembly is secured to the first panel by first positioning a tab located on a first end of the hinge assembly in a slot provided on an edge portion of the first panel. The hinge assembly is then rotated so as to be positioned against the first panel. Once the hinge assembly is in place, the internal door component(s) is installed in at central portion of first panel. In the most preferred embodiment of the invention, a pre-assembled internal component taking the form of a window pack is utilized. More specifically, the window pack includes an interlocking frame assembly which utilizes matching L-shaped frame elements designed to secure two glass panes in a spaced relationship. Each of the L-shaped frame elements includes a tab and slot structure designed to snap-fit the frame elements into a substantially rectangular support for the glass panes. Once the internal door components are in position, a second panel is snap-fit to the hinge assembly thereby securing the window pack between the first and second panels. 
     Based on the above, it should be readily apparent that the invention provides for an oven door assembly having a minimum number of required component parts and employs constructions steps which simplifies the construction process and leads to an overall cost savings for the manufacturer. In any event, additional objects, features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment of the invention, when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a wall oven including multiple oven cavities having associated, identical door assemblies constructed in accordance with the present invention; 
     FIG. 2 is an exploded view of the door assembly shown in FIG. 1; 
     FIG. 3 is an exploded view of a window pack incorporated in the door assembly of FIG. 2; 
     FIG. 4 is an enlarged view of a portion of the window pack of FIG. 3; 
     FIG. 5 is an enlarged, cross-sectional side view of a frame connection utilized in the window pack of FIGS. 3 and 4; 
     FIG. 6 is a perspective, partly assembled view of the door assembly of the invention; 
     FIG. 7 is a cross-sectional view of a snap-fit connection portion of the door assembly of the invention in an initial connection stage; and 
     FIG. 8 is a cross-sectional view similar to that of FIG. 7, but depicting the snap-fit connection in a final connection stage. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With initial reference to FIG. 1, an oven door assembly constructed in accordance with the present invention is generally shown at  1 . Although the actual cooking appliance to which door assembly  1  can be applied can vary, the invention is shown in connection with a cooking appliance  2  depicted as a wall oven. In the embodiment shown, cooking appliance  2  constitutes a dual oven wall unit which includes identically constructed upper and lower oven door assemblies  1 . Cooking appliance  2  further includes a structural frame  3  supporting an upper cooking cavity  4  and a lower cooking cavity  5 . According to the present invention, an associated door assembly  1  is provided to selectively provide access to a respective one of upper and lower cooking cavities  4  and  5 . Although cooking appliance  2  is depicted as a wall oven, it should be understood that door assembly  1  is not limited to this model type and can be incorporated into various types of oven configurations, e.g., cabinet mounted ovens and ranges. 
     Cooking appliance  2  is shown to incorporate an upper control panel  12 . In the embodiment shown, control panel  12  includes first and second rows of oven control buttons  13  and  14  for programming, in combination with a numeric pad  15  and a display  17 , particular cooking operations for oven cavities  4  and  5  respectively. Since the general programming and operation of cooking appliance  2  is known in the art and does not form part of the present invention, these features will not be discussed further here. 
     FIG. 2 is an exploded view of door assembly  1  according to the preferred embodiment and illustrates the various internal components of door assembly  1 . The major internal components are: a first panel  67 , hinge assemblies  68  and  69 , a window pack  70 , a second panel  71 , and an outer panel  73 . Outer panel  73  has associated therewith a handle  74  (see FIG. 1) and a decorative cover  75  to complete the assembly. The construction and interconnection of these components will now be described in detail. 
     First panel  67  is preferably, substantially rectangular and includes a multi-level base portion  80 , a window opening  81 , and a peripheral edge portion  82 . More specifically, peripheral edge portion  82  is defined by a top portion  84 , a bottom portion  85 , a left side portion  86  and a right side portion  87 . Top portion  84  includes a first end  89  having a pair of adjacent slots  90  and a second end  91  having matching slots  92 . Bottom portion  85  includes a first end  93  having a slotted opening  94  having both vertical and horizontal components and a second end  95  having a matching opening  96  which also extends in two, substantially perpendicular planes. Slots  90  and  92 , as well as openings  94  and  96 , are provided in connection with the mounting of the hinge assemblies  68  and  69  to the first panel  67  as will be detailed more fully below. 
     Hinge assemblies  68  and  69  are substantially identically constructed and therefore a detailed description will now be provided in connection with the construction of hinge assembly  68  and it is to be understood that hinge assembly  69  is correspondingly constructed. Hinge assembly  68  is constituted by a hinge bar  103  having a first end  104  and a second end  105 . A pivoting hinge arm  107  projects forward from second end  105  of hinge bar  103 . Hinge arm  107  is adapted to extend through opening  94  and to be interconnected with the frame  3  of cooking appliance  2  to pivotally mount door assembly  1  across a respective oven cavity  4 ,  5 . In the most preferred embodiment, hinge bar  103  is constituted by an elongated U-shaped channel member including opposing side portions  109  and  110  joined through a web  111  (also see FIGS.  7  and  8 ). Each of side portions  109  and  110  includes a plurality of snap elements  113 , such as holes, arranged at spaced locations between first end  104  and second end  105 . In addition, first end  104  including at least one tab element  118  and, preferably, a pair of adjacent tab elements  118 . 
     Reference will now be made to FIGS. 2-5 in describing the preferred construction of window pack  70  of door assembly  1 . In a manner known in the art, window pack  70  is provided to enable a consumer to view the contents of a particular cooking cavity  4 ,  5 . As shown, window pack  70  includes a substantially rectangular metal frame  135  and opposing panes of glass  140  and  141 . In a preferred embodiment, frame  135  includes substantially identical L-shaped frame elements  145  and  146 . Each L-shaped frame element  145 ,  146  includes a long leg portion  147  and a short leg portion  148 . Additionally, each frame element  145 ,  146  includes a pair of generally U-shaped tracks  155  and  156  joined by a web  158 . Tracks  155  and  156  are adapted to receive and maintain glass panes  140  and  141  in a spaced relationship. A plurality of glass retainer elements  160  are stamped into tracks  155  and  156  to support each glass pane  140 ,  141  within a respective track  155 ,  156 . Glass retainer elements  160  are simply defined by bent, preferably metal tab portions of tracks  155  and  156  which function to bias glass panes  140  and  141  in order to substantially reduce the effects of vibration caused by operation of door assembly  1 . To aid assembly, a tab element  165  having a spring retaining portion  166  is provided at the terminal end of each long leg portion  147  and a matching slot  170  is provided at the terminal end of each short leg portion  148 . 
     During assembly of window pack  70 , each of glass panes  140  and  141  are inserted into a respective one of tracks  155  and  156  of an L-shaped frame element  145 ,  146  such that glass panes  140  and  141  rest against respective retainer elements  160 . The opposing L-shaped frame elements  145  and  146  are positioned such that one short leg portion  148  is arranged adjacent to a corresponding long leg portion  147 . Once positioned in this manner, each of tab elements  165  is interengaged with an associated slot  170 . In this manner, frame elements  145  and  146  are snap-fittingly interconnected to form window pack  70 . 
     Referring mainly to FIG. 2, second panel  71  is preferably, substantially rectangular in shape and includes a base portion  176  having a window opening  177 . Base portion  176  is preferably formed with an in-turned top lip  180 , an in-turned bottom lip  181 , an out-turned right side lip  182  and an out-turned left side lip  183 . As shown, each of right and left side lips  182  and  183  includes a plurality of snap members  185  arranged at spaced locations there along. In the preferred embodiment shown, snap members  185  are constituted by dimpled, resilient tab portions of right and left side lips  182  and  183 . 
     Outer panel  73  is preferably formed of metal and defines a substantially rectangular member including a window opening  190 . As will be discussed more fully below, outer panel  73  is adapted to encompass first and second panels  67  and  71 , with hinge assemblies  68  and  69  and window pack  70  sandwiched therebetween. Decorative panel  75  is optionally provided and preferably constitutes a glass panel having a substantially opaque outer area  192  and a substantially clear inner window area  193 . Although decorative panel  75  is preferably made of glass, various other materials could be employed for decoratively covering the outer surface of outer panel  73 . However, no decorative panel  75  need be provided. 
     Reference will now be made to FIGS.  2  and  6 - 8  in describing the preferred manner in which door assembly  1  is assembled. Initially, hinge assemblies  68  and  69  are secured to first panel  67  by positioning tab elements  118  within respective slots  90  and  92  on first panel  67 . Hinge assemblies  68  and  69  are then rotated into contact with first panel  67  until hinge arms  107  project through openings  96 . Next, pre-assembled window pack  70 , constructed as previously described, is positioned onto first panel  67  between hinge assemblies  68  and  69  such that window panes  140  and  141  are exposed in opening  81 . A gasket (not shown) may be provided as a seal between the perimeter of window pack  70  and opening  81 . In addition to window pack  70 , thermal insulation (not shown) of a type well known in the art is also be preferably incorporated into door assembly  1  to reduce any heat transfer from a respective oven cavity  4 ,  5  to the exterior. 
     After window pack  70  is positioned on first panel  67 , second panel  71  is secured to first panel  67  through hinge assemblies  68  and  69 . More specifically, snap members  185  on the left panel edge  182  are engaged with associated snap elements  113  on hinge assembly  68 . Second panel  71  is subsequently rotated into contact with hinge assembly  69 , wherein the snap members  185  of right panel edge  183  are snap-fit to the associated snap elements  113  on hinge assembly  69 , wherein window pack  70  is secured therebetween. 
     Referring to FIG. 2, after second panel  71  is secured to first panel  67  through hinge members  68  and  69 , outer panel  73  is secured to first panel  67  and second panel  71 . In general, outer panel  73  and decorative panel  75  simply complete the overall oven door assembly  1 , with outer panel  73  actually extending around and being attached, preferably through the use of screws (not shown) to first panel  67 . Outer panel  73  is preferably a metal panel having a substantially rectangular area including a window opening  190  which is aligned with opening  177 . Decorative panel  75  is preferably a glass panel having a substantially opaque outer area  192  and a substantially clear inner window area  193 . Although decorative panel  75  is illustrated as glass, any suitable material for covering the outer surface of outer panel  73  would be acceptable, particularly since panel  75  is for decorative purposes and is an optional part for oven door assembly  1 . Finally, handle  74  is secured to door assembly  1  completing the construction. 
     Based on the above, it should be readily apparent that the invention provides for an oven door assembly having relatively few component parts which are assembled in a simplified construction process, leading to a significant cost savings. In any event, it should be understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof Additionally, it should be recognized that the use of terms such as top, bottom, left and right have been presented for illustrative purposes only and should not limit the scope of the present invention. Instead, the invention is only intended to be limited by the scope of the following claims.