Patent Publication Number: US-2012031389-A1

Title: Oven door

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The subject patent application claims priority to and all the benefits of U.S. Provisional Patent Application No. 61/371,074 which was filed on Aug. 5, 2010, the entire specification of which is expressly incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an oven door including an exterior panel formed of plastic. 
     2. Description of the Related Art 
     An oven door includes an interior panel for sealing a heating chamber of the oven and an exterior panel spaced from the interior panel to provide a layer of insulation, e.g., solid and/or air, between the interior panel and the exterior panel. The exterior panel also aesthetically covers the interior panel. 
     The exterior panel is typically formed of several metal components that are separately formed and subsequently assembled together. The exterior panel also typically includes a glass pane for viewing the heating chamber of the oven. The material cost for manufacturing the metal components and the glass pane is relatively high. In addition, relatively high manufacturing costs are associated with forming the components and the glass panel separately and subsequently assembling the components and the glass panel. 
     Also, some consumers desire ovens having different colors. As one example, some consumers desire stainless steel ovens and are willing to pay higher prices for an oven that has a stainless steel appearance. As such, the exterior panel can be formed of stainless steel to provide this appearance; however, stainless steel is a relatively expensive material thereby increasing the cost to manufacture exterior panels formed of stainless steel. The exterior panel can also be formed of another type of metal and subsequently painted to either have a stainless steel appearance or to have another color desired by the consumer. Such paint adds cost not only for the paint itself but also for manufacturing costs associated with applying the paint to the exterior panel. The paint is also subject to scratching, chipping, cracking, etc. 
     In addition, a handle is connected to the exterior panel and extends away from the exterior panel for moving the oven door between open and closed positions. The handle typically includes a flat surface that abuts a flat surface of the exterior panel. A threaded fastener extends through the flat surface of the handle and the flat surface of the exterior panel to affix the handle to the exterior panel. As the handle is used over time, the interface between the abutting flat surfaces of the handle and the exterior panel begins to loosen such that the handle wobbles relative to the exterior panel. Such an occurrence gives an unwanted feel and appearance of low quality. 
     Accordingly, there remains opportunity to manufacture an oven door having an exterior panel having lower material and assembly costs and having a color desired by consumers. There also remains opportunity to manufacture an oven door having a handle that reliably connects to the exterior panel and has an aesthetic appearance. 
     SUMMARY OF THE INVENTION AND ADVANTAGES 
     The present invention includes an oven door for closing an opening to a heating chamber of an oven. The oven door comprises an interior panel for facing the heating chamber. The interior panel has a glass sheet for viewing the heating chamber. An exterior panel is affixed to the interior panel for facing away from the heating chamber and includes a frame portion formed of plastic defining an aperture aligned with the glass sheet for viewing the heating chamber. A non-opaque panel is fixed relative to the frame portion and extends across the aperture and has an inside surface facing the interior panel. The exterior panel has a masking portion formed of plastic and integrally formed with the frame portion and extending from the frame portion into the aperture along the inside surface of the non-opaque panel and defining a window for viewing the heating chamber through the glass sheet. 
     The present invention also includes an oven door for closing an opening to a heating chamber of an oven. The oven door comprises an interior panel for facing the heating chamber and an exterior panel formed of plastic and having an exterior side for facing away from the heating chamber. The exterior panel presents a pocket defined by a wall extending from the exterior side toward the interior panel and a bottom extending transversely from the wall spaced from the exterior side. A handle has a boss portion extending into the pocket for stabilizing the handle relative to the exterior panel and a gripping portion extending from the boss portion away from the exterior panel for moving the oven door between open and closed positions. The bottom is disposed between the boss portion of the handle and the interior panel. The handle has a post extending from the gripping portion through the boss portion and being connected to the interior panel for coupling the interior panel, the exterior panel, and the handle. 
     By forming the frame portion of the exterior panel from plastic, the costs associated with material and manufacturing of the frame portion is advantageously decreased. The manufacturing process of forming the frame portion is more efficient, and thus less costly, by decreasing or eliminating secondary assembly steps. Forming the exterior from plastic also allows the designer more styling freedom because plastic is relatively easy to form into intricate shapes. The plastic of the exterior panel also provides superior insulation to reduce the amount of heat that is transferred to the an exterior side of the exterior panel. 
     In addition, the plastic of the frame portion can be advantageously colored. Further, since the plastic is colored, as opposed to being painted, desired coloring of the frame portion is accomplished without secondary steps such as painting, thereby advantageously making the manufacturing process of the exterior panel more efficient and less costly. In addition, since the plastic itself is colored, the coloring is more durable than paint. 
     Finally, the interaction between the handle and the exterior panel advantageously increases the stability and durability of the oven door. By receiving the boss portion in the pocket, the exterior panel firmly retains the handle to increase the stability of the handle relative to the exterior panel. Also, since the bottom is disposed between the boss portion and the handle and since the post extends from the handle, the bottom of the exterior panel is retained between the handle and the interior panel when the post is connected to the interior panel. As such, the interior panel, the exterior panel, and the handle are coupled together when the post is connected to the interior panel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
         FIG. 1  is a perspective view of an oven including a first oven door and a second oven door; 
         FIG. 2  is an exploded view of an exterior panel, a non-opaque panel, and a handle of a first embodiment of the first oven door; 
         FIG. 3  is another exploded view of the first embodiment of the first oven door; 
         FIG. 4  is an exploded view of an exterior panel, a non-opaque panel, and a handle of a second embodiment of the first oven door; 
         FIG. 5  is an exploded view of the second oven door; and 
         FIG. 6  is a cross-sectional view through line  6  of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the Figures, wherein like numerals indicate like parts throughout the several views, an oven is generally shown at  10 . The oven  10  includes at least one oven door  14 ,  16  for closing an opening to a heating chamber  12  of the oven. The oven  10  can be any type of oven such as, for example, a convection oven, a microwave oven, a toaster oven, etc. 
     The oven  10  shown in  FIG. 1  includes a first oven door  14  and a second oven door  16 . The oven  10  can include one, two, or more oven doors without departing from the nature of the present invention. The oven door can be hinged, such as the first oven door  14  shown in  FIG. 1 , or can slide, such as the second oven door  16  shown in  FIG. 1 . It should be appreciated that the adjectives “first” and “second” are used herein merely to distinguish between the two oven doors  14 ,  16  shown in  FIG. 1  and are not meant to delineate order or importance, i.e., the oven  10  can include the second oven door  16  without including the first oven door  14 . 
     The oven  10  can include one or more heating chambers  12  each enclosed by one or more oven doors  14 ,  16 . With reference to  FIG. 1 , the first oven door  14  encloses one heating chamber  12 , such as, for example, a convection heated chamber, and the second oven door  16  encloses another heating chamber  12 , such as, for example, a warming drawer  50  or a broiler. 
     A first embodiment of the first oven door  14  is shown in  FIGS. 2 and 3 , a second embodiment of the first oven door  14  is shown in  FIG. 4 , and an embodiment of the second oven door  16  is shown in  FIG. 5 . Common features of the first and second embodiments of the first oven door  14  and the embodiment of the second oven door  16  are identified with like numerals. 
     With reference to  FIGS. 3 and 5 , the oven door  14 ,  16  includes an interior panel  18 , an exterior panel  20 , and a non-opaque panel  22 . The interior panel  18  faces the heating chamber  12  and is typically directly exposed to the heating chamber  12 . The interior panel  18  typically has a metal frame  24  surrounding a glass sheet  26  for viewing the heating chamber  12 . 
     The exterior panel  20  is affixed to the interior panel  18  and faces away from the heating chamber  12 . Specifically, the exterior panel  20  has an exterior side  28  that faces outwardly relative to the rest of the oven  10  and has an aesthetically pleasing appearance. The exterior panel  20  includes a frame portion  30  defining an aperture  32  aligned with the glass sheet  26  of the interior panel  18  for viewing the heating chamber  12 . The frame portion  30  typically has a one-piece construction. Insulation  34 , such as that shown in  FIG. 5 , can be disposed between the frame portion  30  of the exterior panel  20  and the interior panel  18 . 
     The exterior panel  20  can define a groove  36  and the interior panel  18  can define a flange  38  that extends into the groove  36  to couple the exterior panel  20  and the interior panel  18 . In the alternative, or in addition, other complementary features and/or fastener  70   s  (not shown) can also attach the exterior panel  20  and the interior panel  18  to each other. 
     At least a portion of the exterior panel  20 , including the frame portion  30 , can be formed of plastic such as a polyester. The plastic can be glass filled or can be free of glass filling. One example of a type of suitable polyester is glass filled thermoplastic polyester commercially available from BASF Corporation in Florham Park, N.J. under the tradename Ultramid® B4040G3. However, it should be appreciated that the exterior panel  20  can be formed of any type of suitable material without departing from the nature of the present invention. The plastic of the exterior panel  20  can have any color. As one example, the plastic of the exterior panel  20  can simulate the look of metal such as stainless steel. 
     The non-opaque panel  22  is fixed relative to the frame portion  30  and extends across the aperture  32  defined by the frame portion  30 . The non-opaque panel  22  has an inside surface  40  facing the interior panel  18 . The non-opaque panel  22  can be, for example, transparent, speckled, screened, translucent, frosted, etc. 
     As set forth further below, the exterior panel  20  and/or the non-opaque panel  22  can be formed and/or combined by plastic injection molding. A plastic injection mold (not shown) is used for the plastic injection molding and, specifically, receives molten plastic to shape the molten plastic. However, it should be appreciated that the exterior panel  20  and/or the non-opaque panel  22  can be formed in any way without departing from the nature of the present invention. 
     The first oven door  14  typically includes a vent portion  42  for venting heated air from between the interior panel  18  and the exterior panel  20 . The vent portion  42  is typically formed of the same type of material as the frame portion  30  and is typically integrally formed with the frame portion  30  of the exterior panel  20 , i.e., formed together simultaneously or at substantially the same time so as to form a single part. Alternatively, the vent portion  42  can be formed separately from the frame portion  30  and subsequently attached to the frame portion  30 . The vent portion  42  can be blended with the frame portion  30  so that the vent portion  42  and the frame portion  30  have a common surface appearance. Alternatively, the vent portion  42  and the frame portion  30  can have different surface texture and/or color. 
     In the first embodiment of the first oven door  14 , with reference to  FIGS. 2 and 3 , the exterior panel  20  has a masking portion  44  typically formed of plastic. The masking portion  44  is typically integrally formed with the frame portion  30  as shown in  FIGS. 2 and 3 , i.e., formed together simultaneously or at substantially the same time so as to form a single part. Alternatively, the masking portion  44  is integrally formed with the non-opaque panel  22  such that the masking portion  44  and the non-opaque panel  22  in combination are assembled to the frame portion  30  in the aperture  32 . In any event, the masking portion  44  extends from the frame portion  30  into the aperture  32  along the inside surface  40  of the non-opaque panel  22  and defines a window  46  for viewing the heating chamber  12  through the glass sheet of the interior panel  18 . 
     The masking portion  44  is typically formed of the same type of plastic as the rest of the exterior panel  20  as set forth above. However, it should be appreciated that the masking portion  44  can be formed of any type of suitable material without departing from the nature of the present invention. The plastic of the masking portion  44  can have any color and typically has a different color than the plastic of the frame portion  30 . As one example, the color of the plastic of the masking portion  44  is black. Alternatively, the color of the plastic of the masking portion  44  can be the same as the color of the plastic of the frame portion  30 . 
     With continued reference to  FIGS. 2 and 3 , non-opaque panel  22  is formed separately from the exterior panel  20  and the exterior panel  20  supports the non-opaque panel  22 . The non-opaque panel  22  can be fixed to the masking portion  44  of the exterior panel  20 . As one example, the non-opaque panel  22  can be adhered to the masking portion  44 . For example, the non-opaque panel  22  can be adhered to the masking portion  44  with an adhesive; however, it should be appreciated that the non-opaque panel  22  can be adhered to the masking portion  44  with any type of adhesive without departing from the nature of the present invention. In the alternative to adhering, the non-opaque panel  22  can be, for example, overmolded, fastened, mechanically retained, etc., to the masking portion  44  and/or the rest of the exterior panel  20 . 
     The masking portion  44  is typically recessed relative to the frame portion  30 , as best shown in  FIG. 2 , so that the non-opaque panel  22  is flush with the frame portion  30  along the exterior side  28  when supported by the exterior panel  20 , as shown in  FIG. 1 . In other words, the masking portion  44  defines a recess  48  that receives the non-opaque panel  22 . Alternatively, the masking portion  44  is positioned relative to the frame portion  30  such that the non-opaque panel  22  is not flush, i.e., is stepped, with the frame portion  30  along the exterior side  28  when supported by the exterior panel  20 . 
     In the first embodiment of the first oven door  14 , the non-opaque panel  22  is typically formed of glass. Alternatively, the non-opaque panel  22  is formed of plastic. When formed of plastic, for example, the non-opaque panel  22  can be glass filled or can be free of glass filling. As one example, the non-opaque panel  22  can be formed from an unfilled polyethersufone commercially available from BASF Corporation in Florham Park, NJ under the tradename Ultrason® E2010. In the configuration where the non-opaque panel  22  is formed of plastic, the non-opaque panel  22  can be fixed to the masking portion  44  by, for example fusing, welding, overmolding, etc., in addition to the fixing configurations set forth above. 
     With continued reference to the first embodiment of the first oven door  14 , the frame portion  30  and the masking portion  44  of the exterior panel  20  are typically simultaneously formed in the injection mold. For example, one shot of molten plastic can be injected into the injection mold to form the frame portion  30  and the masking portion  44 , i.e., the frame portion  30  and the masking portion  44  are integrally formed of a single type of plastic have a single color and surface texture. 
     Alternatively, for example, a first shot of molten plastic can be injected into the injection mold to form the frame portion  30  and a second shot of molten plastic can be injected into the injection mold to form the masking portion  44 . In such a configuration, the first shot and the second shot can include plastic of different type, color, and/or surface texture, i.e., the resulting frame portion  30  and masking portion  44  can have different plastic type, color, and/or texture. Alternatively, as set forth above, the masking portion  44  and the non-opaque panel  22  can be integrally formed and subsequently assembled to the frame portion  30 , in which case the frame non-opaque panel  22  and the masking portion  44  can be formed by a first shot and a second shot, respectively, of molten plastic. In any event, it should be appreciated that the injection mold can receive more than two shots with the additional shots forming additional features. As one example, the vent portion  42  can be formed by a third shot so that the vent portion  42  and the frame portion  30  can include have different plastic type, color, and/or surface texture. 
     Regardless of whether the frame portion  30  and the masking portion  44  are formed from one or two shots of molten plastic, the non-opaque panel  22  can be subsequently attached to the frame portion  30  and/or the masking portion  44  after formation of the frame portion  30  and masking portion  44  in the injection mold, e.g., after the exterior panel  20  is removed from the injection mold. Alternatively, the non-opaque panel  22  can be inserted into the injection mold before the molten plastic is injected such that, upon injection into the injection mold, the molten plastic partially encapsulates the non-opaque panel  22 , i.e., the non-opaque panel  22  is overmolded by the molten plastic of the exterior panel  20  in the injection mold. Specifically, in the scenario where a single shot forms the exterior panel  20 , the single shot partially encapsulates the non-opaque panel  22 . In the scenario where a first shot and a second shot form the exterior panel  20 , the first and/or the second shot partially encapsulates the non-opaque panel  22 . 
     With reference to  FIG. 4 , in the second embodiment of the first oven door  14 , the non-opaque panel  22  is integrally formed with the exterior panel  20 , i.e., formed together simultaneously or at substantially the same time so as to form a single part. The non-opaque panel  22  is typically formed of plastic. The non-opaque panel  22  can be formed from the same type of plastic as that of the exterior panel  20  or can be formed from a different type of plastic than that of the exterior panel  20 . The plastic can be glass filled or can be free of glass filling. One example of a type of suitable plastic for the non-opaque panel  22  is an unfilled polyethersufone commercially available from BASF Corporation in Florham Park, NJ under the tradename Ultrason® E2010. However, it should be appreciated that the non-opaque panel  22  can be formed of any type of suitable material without departing from the nature of the present invention. 
     In the second embodiment of the first oven door  14 , the masking portion  44  can be formed of plastic and integrally formed with the frame portion  30  of the exterior panel  20  and/or the non-opaque panel  22 . In such a configuration, the masking portion  44  is typically formed of the same type of plastic as the rest of the exterior panel  20  as set forth above. However, it should be appreciated that the masking portion  44  can be formed of any type of suitable material without departing from the nature of the present invention. The plastic of the masking portion  44  can have any color and typically has a different color than the plastic of the frame portion  30 . Alternatively, the color of the plastic of the masking portion  44  can be the same as the color of the plastic of the frame portion  30 . As one example, the color of the plastic of the masking portion  44  is black. 
     When formed of plastic and integrally formed with the frame portion  30  and/or the non-opaque panel  22 , the masking portion  44  can extend along inside surface  40  of the non-opaque panel  22 . In the alternative to being integrally formed with the frame portion  30  and/or the non-opaque panel  22 , the masking portion  44  can be formed separately from and subsequently combined with the exterior panel  20  and the non-opaque panel  22 . In such a configuration, the masking portion  44  can be, for example, plastic, metal, a decal, etc. The masking portion  44  of such a configuration can be partially or fully encapsulated by the frame portion  30  and/or the non-opaque panel  22  during formation of the frame portion  30  and/or the non-opaque panel  22  or can be attached or adhered to the frame portion  30  and/or the non-opaque panel  22 . 
     In the second embodiment of the first oven door  14 , the frame portion  30  and the non-opaque panel  22  are typically simultaneously formed in the injection mold. For example, a first shot of molten plastic can be injected into the injection mold to form the frame portion  30  and a second shot of molten plastic can be injected into the injection mold to form the non-opaque panel  22 . In such a configuration, the first shot and the second shot can include plastic of different type, color, and/or surface texture, i.e., the resulting frame portion  30  and non-opaque panel  22  can have different plastic type, color, and/or surface texture. 
     The first shot of molten plastic forming the frame portion  30  can also integrally form the masking portion  44  with the frame portion  30 . Alternatively, a third shot of molten plastic, in addition to the first shot for the frame portion  30  and the second shot for the non-opaque panel  22 , can be injected into the injection mold to integrally form the masking portion  44  with the frame portion  30  and/or the non-opaque panel  22 . It should be appreciated that the injection mold can receive more than three shots with the additional shots forming additional features. 
     As set forth above, the masking portion  44  can alternatively be formed separately from the frame portion  30  and the non-opaque panel  22 . For example, the masking portion  44  can be subsequently attached to the frame portion  30  and/or the non-opaque panel  22  after formation of the frame portion  30  and non-opaque panel  22  in the injection mold, e.g., after the frame portion  30  and the non-opaque panel  22  are removed from the injection mold. Alternatively, the masking portion  44  can be inserted into the injection mold before the molten plastic is injected such that, upon injection into the injection mold, the molten plastic partially encapsulates the masking portion  44 , i.e., the masking portion  44  is overmolded by the molten plastic of the frame portion  30  and/or the non-opaque panel  22  in the injection mold. 
     With reference to  FIG. 5 , the second oven door  16  includes a drawer  50  extending from the interior panel  18  for sliding into and out of the oven  10 . The construction of the interior panel  18 , the exterior panel  20 , and the non-opaque panel  22  of the second oven door  16  is like that of the first embodiment of the first oven door  14  in that the non-opaque panel  22  is formed separately from the exterior panel  20  and the exterior panel  20  supports the non-opaque panel  22 . The description of interior panel  18 , the exterior panel  20 , and the non-opaque panel  22  of the first embodiment of the first oven door  14  above is also descriptive of the second oven door  16  shown in  FIG. 5 . 
     Alternatively, the construction of the interior panel  18 , the exterior panel  20 , and the non-opaque panel  22  of the second oven door  16  is like that of the second embodiment of the first oven door  14  in that the non-opaque panel  22  is integrally formed with the exterior panel  20 . In such a configuration, the description of the interior panel  18 , the exterior panel  20 , and the non-opaque panel  22  of the second embodiment of the oven door  14 ,  16  above is also descriptive of the second oven door  16 . 
     With reference to  FIGS. 1-6 , the oven door  14 ,  16  includes a handle  52  fixed to the exterior panel  20 .  FIG. 6  is a cross-sectional view through line  6  of  FIG. 1 , i.e., through the first oven door  14 , for exemplary purposes and a similar cross-sectional view through the second oven door  16  is similar to  FIG. 6 . The handle  52  includes a boss portion  54  engaging the exterior panel  20  and a gripping portion  56  extending away from the boss portion  54  and the exterior panel  20  for moving the oven door  14 ,  16  between open and closed positions. The gripping portion  56  is typically sized and shaped so as to be easily gripped by hand. The boss portion  54  is typically hollow. 
     With reference to  FIG. 6 , the exterior panel  20  presents a pocket  58  and the boss portion  54  extends from the gripping portion  56  into the pocket  58  for stabilizing the handle  52  relative to the exterior panel  20 . The pocket  58  is defined by a wall  60  and a bottom  62 . The wall  60  extends from the exterior side  28  of the exterior panel  20  toward the interior panel  18 . The bottom  62  extends transversely from the wall  60  spaced from the exterior side  28 . The boss portion  54  of the handle  52  abuts the wall  60  so that the wall  60  firmly supports the boss portion  54  in the pocket  58 . 
     The handle  52  has a post  64  extending from the gripping portion  56  through the boss portion  54  and being connected to the interior panel  18  for coupling the interior panel  18 , the exterior panel  20 , and the handle  52 . Specifically, the bottom  62  defines a hole  66 , as shown in  FIGS. 2-4 , and the post  64  extends through the hole  66  toward the interior panel  18  for coupling to the interior panel  18 . The post  64  abuts the interior panel  18 . 
     As shown in  FIG. 6 , the post  64  defines a bore  68  and a fastener  70  extends into the bore  68  and engages the interior panel  18 . Specifically, the fastener  70  includes a head  72  disposed on a side of the interior panel  18  opposite the exterior panel  20 . A threaded shank  74  extends from the head  72  through the interior panel  18  toward the exterior panel  20  and threadedly engages the bore  68 . 
     When the fastener  70  engages the post  64 , e.g., when the threaded shank  74  threadedly engages the bore  68 , the fastener  70  retains the interior panel  18 , the exterior panel  20 , and the handle  52  together. Specifically, with continued reference to  FIG. 6 , the bottom  62  is disposed between the hollow boss portion  54  and the interior panel  18  so that, when the handle  52  is connected to the interior panel  18 , the bottom  62  is retained between the interior panel  18  and the boss portion  54  of the handle  52  to couple the interior panel  18 , the exterior panel  20 , and the handle  52  together. As such, the interior panel  18 , the exterior panel  20 , and the handle  52  are coupled together when the post  64  is connected to the interior panel  18 . 
     The handle  52  is typically formed of plastic such as, for example, a polyester. The plastic can be glass filled or can be free of glass filling. One example of a type of suitable polyester is glass filled polyethylene terepthalate commercially available from BASF Corporation in Florham Park, N.J. under the tradename Petra® 7010. However, it should be appreciated that the handle  52  can be formed of any type of suitable material without departing from the nature of the present invention. The handle  52  can be formed by, for example, gas assist molding; however, it should be appreciated that the handle  52  can be formed by any method without departing from the nature of the present invention. 
     The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings, and the invention may be practiced otherwise than as specifically described.