Patent Publication Number: US-11029036-B2

Title: Interlocking door frame assembly for an appliance

Description:
FIELD OF THE INVENTION 
     The present subject matter relates generally to door assemblies for appliances, and more particularly, to interlocking door frame assemblies for an oven appliance. 
     BACKGROUND OF THE INVENTION 
     Conventional residential and commercial oven appliances generally include a cabinet that includes a cooking chamber for receipt of food items for cooking. Multiple heating elements are positioned within the cooking chamber to provide heat to food items located therein. The heating elements can include, for example, radiant heating elements, such as a bake heating assembly positioned at a bottom of the cooking chamber and/or a separate broiler heating assembly positioned at a top of the cooking chamber. 
     Conventional oven appliances further include a door that is pivotally mounted over an opening of the cooking chamber, e.g., to insulate and provide selective access to the cooking chamber. In order to permit viewing of food items during cooking, oven doors typically have a number of glass window panes mounted within a frame. Traditionally, door assemblies required complex assembly fixtures to align the outer door glass properly and utilize some form of adhesive to hold the glass in place. Other alternatives consist of additional bracketry to clamp the glass and are not typically easy to install together. As a result, safely securing such window panes within a window frame is typically a costly process that requires many components and long assembly times. In addition, existing assembly processes are not capable of quickly and simply obtaining a flush appearance to the front of the door while accounting for manufacturing variances and tolerances. 
     Accordingly, an improved door assembly for an appliance would be useful. More particularly, an interlocking door frame assembly that enables simplified assembly with fewer components would be particularly beneficial. 
     BRIEF DESCRIPTION OF THE INVENTION 
     Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention. 
     In a first example embodiment, a door assembly for providing selective access to a chamber of an appliance is provided. The door assembly includes a first frame member defining an alignment recess, the alignment recess defined at least in part by a locating surface. A second frame member defines a locking protrusion having a seating face, the locking protrusion being configured for receipt within the alignment recess. A mechanical fastener engages the second frame member to urge the seating face of the second frame member into engagement with the locating surface of the first frame member. 
     In a second example embodiment, an oven appliance defining a vertical, a lateral, and a transverse direction is provided. The oven appliance includes a cabinet, a cooking chamber positioned within the cabinet, and a door assembly rotatably mounted to the cabinet for providing selective access to the cooking chamber. The door assembly includes a first frame member defining an alignment recess, the alignment recess defined at least in part by a locating surface. A second frame member defines a locking protrusion having a seating face, the locking protrusion being configured for receipt within the alignment recess. A mechanical fastener engages the second frame member to urge the seating face of the second frame member into engagement with the locating surface of the first frame member. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures. 
         FIG. 1  is a front, perspective view of an oven appliance according to an exemplary embodiment of the present subject matter. 
         FIG. 2  is a schematic, cross sectional view of the exemplary oven appliance of  FIG. 1 , taken along Line  2 - 2  in  FIG. 1 . 
         FIG. 3  is a perspective view of a door assembly that may be used with the exemplary oven appliance of  FIG. 1  according to an exemplary embodiment of the present subject matter. 
         FIG. 4  is a side view of the exemplary door assembly of  FIG. 3  according to an exemplary embodiment. 
         FIG. 5  is a perspective view of an outer door assembly of the exemplary door assembly of  FIG. 3  according to an exemplary embodiment. 
         FIG. 6  is a perspective view of a first frame member and a second frame member of the exemplary outer door assembly of  FIG. 5 , with the first frame member removed to reveal a locking protrusion of the second frame member. 
         FIG. 7  is an exploded view of the exemplary first frame member and second frame member of  FIG. 6  according to an exemplary embodiment. 
         FIG. 8  is a bottom perspective view of the exemplary first frame member of  FIG. 6  according to an exemplary embodiment. 
         FIG. 9  is another exploded view of the exemplary first frame member and second frame member of  FIG. 6  according to an exemplary embodiment. 
         FIG. 10  is perspective view of the exemplary first frame member and second frame member of  FIG. 6  with the first frame member illustrated in phantom for clarity. 
         FIG. 11  is a perspective view of the exemplary second frame member of  FIG. 6 . 
         FIG. 12  is a close-up view of a locking protrusion of the exemplary second frame member of  FIG. 6  according to an exemplary embodiment. 
     
    
    
     Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention. 
     DETAILED DESCRIPTION 
     Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
       FIG. 1  provides a front, perspective view of an oven appliance  100  as may be employed with the present subject matter. Oven appliance  100  generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined. As illustrated, oven appliance  100  includes an insulated cabinet  102 . Cabinet  102  of oven appliance  100  extends between a top  104  and a bottom  106  along the vertical direction V, between a first side  108  (left side when viewed from front) and a second side  110  (right side when viewed from front) along the lateral direction L, and between a front  112  and a rear  114  along the transverse direction T. 
     Within cabinet  102  is a single cooking chamber  120  which is configured for the receipt of one or more food items to be cooked. However, it should be appreciated that oven appliance  100  is provided by way of example only, and aspects of the present subject matter may be used in any suitable cooking appliance, such as a double oven range appliance. Thus, the example embodiment shown in  FIG. 1  is not intended to limit the present subject matter to any particular cooking chamber configuration or arrangement. Indeed, aspects of the present subject matter may be applied to door assemblies for any suitable appliance. 
     Oven appliance  100  includes a door  124  rotatably attached to cabinet  102  in order to permit selective access to cooking chamber  120 . Handle  126  is mounted to door  124  to assist a user with opening and closing door  124  in order to access cooking chamber  120 . As an example, a user can pull on handle  126  mounted to door  124  to open or close door  124  and access cooking chamber  120 . One or more transparent viewing windows  128  ( FIG. 1 ) may be defined within door  124  to provide for viewing the contents of cooking chamber  120  when door  124  is closed and also assist with insulating cooking chamber  120 . 
     In general, cooking chamber  120  is defined by a plurality of chamber walls  130  ( FIG. 2 ). Specifically, cooking chamber  120  may be defined by a top wall, a rear wall, a bottom wall, and two sidewalls  130 . These chamber walls  130  may be joined together to define an opening through which a user may selectively access cooking chamber  120  by opening door  124 . In order to insulate cooking chamber  120 , oven appliance  100  includes an insulating gap defined between the chamber walls  130  and cabinet  102 . According to an exemplary embodiment, the insulation gap is filled with an insulating material  132 , such as insulating foam or fiberglass, for insulating cooking chamber  120 . 
     Oven appliance  100  also includes a cooktop  140 . Cooktop  140  is positioned at or adjacent top  104  of cabinet  102  such that it is positioned above cooking chamber  120 . Specifically, cooktop  140  includes a top panel  142  positioned proximate top  104  of cabinet  102 . By way of example, top panel  142  may be constructed of glass, ceramics, enameled steel, and combinations thereof. One or more grates  144  are supported on a top surface of top panel  142  for supporting cooking utensils, such as pots or pans, during a cooking process. 
     Oven appliance  100  may further include one or more heating elements (identified generally by reference numeral  150 ) for selectively heating cooking utensils positioned on grates  144  or food items positioned within cooking chamber  120 . For example, referring to  FIG. 1 , heating elements  150  may be gas burners  150 . Specifically, a plurality of gas burners  150  are mounted within or on top of top panel  142  such that grates  144  support cooking utensils over gas burners  150  while gas burners  150  provide thermal energy to cooking utensils positioned thereon, e.g., to heat food and/or cooking liquids (e.g., oil, water, etc.). Gas burners  150  can be configured in various sizes so as to provide e.g., for the receipt of cooking utensils (i.e., pots, pans, etc.) of various sizes and configurations and to provide different heat inputs for such cooking utensils. According to alternative embodiments, oven appliance  100  may have other cooktop configurations or burner elements. 
     In addition, heating elements  150  may be positioned within or may otherwise be in thermal communication with cooking chamber  120  for regulating the temperature within cooking chamber  120 . Specifically, an upper gas heating element  154  (also referred to as a broil heating element or gas burner) may be positioned in cabinet  102 , e.g., at a top portion of cooking chamber  120 , and a lower gas heating element  156  (also referred to as a bake heating element or gas burner) may be positioned at a bottom portion of cooking chamber  120 . Upper gas heating element  154  and lower gas heating element  156  may be used independently or simultaneously to heat cooking chamber  120 , perform a baking or broil operation, perform a cleaning cycle, etc. The size and heat output of gas heating elements  154 ,  156  can be selected based on the, e.g., the size of oven appliance  100  or the desired heat output. Oven appliance  100  may include any other suitable number, type, and configuration of heating elements  150  within cabinet  102  and/or on cooktop  140 . For example, oven appliance  100  may further include electric heating elements, induction heating elements, or any other suitable heat generating device. 
     A user interface panel  160  is located within convenient reach of a user of the oven appliance  100 . For this example embodiment, user interface panel  160  includes knobs  162  that are each associated with one of heating elements  150 . In this manner, knobs  162  allow the user to activate each heating element  150  and determine the amount of heat input provided by each heating element  150  to a cooking food items within cooking chamber  120  or on cooktop  140 . Although shown with knobs  162 , it should be understood that knobs  162  and the configuration of oven appliance  100  shown in  FIG. 1  is provided by way of example only. More specifically, user interface panel  160  may include various input components, such as one or more of a variety of touch-type controls, electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. User interface panel  160  may also be provided with one or more graphical display devices or display components  164 , such as a digital or analog display device designed to provide operational feedback or other information to the user such as e.g., whether a particular heating element  150  is activated and/or the rate at which the heating element  150  is set. 
     Generally, oven appliance  100  may include a controller  166  in operative communication with user interface panel  160 . User interface panel  160  of oven appliance  100  may be in communication with controller  166  via, for example, one or more signal lines or shared communication busses, and signals generated in controller  166  operate oven appliance  100  in response to user input via user input devices  136 . Input/Output (“I/O”) signals may be routed between controller  166  and various operational components of oven appliance  100  such that operation of oven appliance  100  can be regulated by controller  166 . In addition, controller  166  may also be communication with one or more sensors, such as temperature sensor  168  ( FIG. 2 ), which may be used to measure temperature inside cooking chamber  120  and provide such measurements to the controller  166 . Although temperature sensor  168  is illustrated at a top and rear of cooking chamber  120 , it should be appreciated that other sensor types, positions, and configurations may be used according to alternative embodiments. 
     Controller  166  is a “processing device” or “controller” and may be embodied as described herein. Controller  166  may include a memory and one or more microprocessors, microcontrollers, application-specific integrated circuits (ASICS), CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of oven appliance  100 , and controller  166  is not restricted necessarily to a single element. The memory may represent random access memory such as DRAM, or read only memory such as ROM, electrically erasable, programmable read only memory (EEPROM), or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller  166  may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software. 
     Although aspects of the present subject matter are described herein in the context of a single oven appliance, it should be appreciated that oven appliance  100  is provided by way of example only. Other oven or range appliances having different configurations, different appearances, and/or different features may also be utilized with the present subject matter, e.g., double ovens, standalone cooktops, etc. Moreover, aspects of the present subject matter may be used in any other consumer or commercial appliance which includes a door, particularly those with viewing windows. 
     Referring now to  FIGS. 3 and 4 , a door assembly  200  which may be used with oven appliance  100  will be described according to exemplary embodiments of the present subject matter. Specifically, door assembly  200  may replace door  124  of oven appliance  100 , or may be used as a door for any other suitable appliance. Although specific embodiments of door assembly  200  are described herein as being used with oven appliance  100 , it should be appreciated that door assembly  200  may include different configurations and may be used with other appliances while remaining within the scope of the present subject matter. 
     As illustrated, door assembly  200  includes an outer door assembly (or a front panel) and an inner door assembly (or a rear panel) that are joined together. Each of the front panel and the rear panel may include one or more class window panes, insulating features, etc. However, as used herein the term “door assembly,” generally refers to the outer door assembly, though aspects of the present subject matter may also be applied to the inner door assembly. 
     Also, it should be appreciated that due to the similarity between door  124  and door assembly  200 , like reference numerals may be used to refer to the same or similar features. Furthermore, it should be appreciated that door assembly  200  is described as defining a vertical direction V, a lateral direction L, and a transverse direction T. According to exemplary embodiments, such directions correspond to the same directions of oven appliance  100  when door assembly  200  is in the closed position. 
     Referring now also generally to  FIGS. 5 through 12 , door assembly  200  will be described in more detail. For example, as best shown in  FIG. 5 , door assembly  200  may generally include a top frame member  202 , a bottom frame member  204 , a first side frame member  206 , and a second side frame member  208 . In general, top frame member  202  and bottom frame member  204  both extend between a left end  210  and a right end  212  along the lateral direction L. First side frame member  206  and second side frame member  208  extend from a top end  214  and a bottom end  216  along the vertical direction V. 
     As explained in more detail below, frame members  202 - 208  may be joined together to form a completed frame of door assembly  200 . According to exemplary embodiments, a glass window pane  218  may be positioned within the completed frame as described in more detail below. Although these windows are referred to herein as glass panes, it should be appreciated that these transparent windows may be constructed of any suitably rigid and temperature resistant material, e.g., such as acrylic glass or Plexiglass. 
     As illustrated, frame members  202 - 208  are joined using a plurality of interlocking joints  220 . As explained in detail below, interlocking joints  220  facilitate a quick and easy assembly of door assembly  200 . Specifically, interlocking joints  220  are used to connect the various frame members  202 - 208  at the respective corners of door assembly  200  such that frame members  202 - 208  are mated and align in all three component directions (i.e., the V-L-T directions) and sit flush with each other for a clean appearance. Notably, interlocking joints  220  facilitate such assembly while compensating for manufacturing variations and tolerances. In addition, interlocking joints  220  and the described method of assembling door assembly  200  may eliminate the need for complex assembly fixtures, expensive and cumbersome adhesives, or additional brackets for positioning and securing windowpane  218 . Furthermore, frame members  202 - 208  and windowpane  218  may be interchangeable such that one or all are constructed from different materials, may use different colors, or may be easily serviced and replaced. 
     Referring now specifically to  FIGS. 6 through 12 , the design and operation of interlocking joints  220  for joining two or more frame members will be described according to exemplary embodiments of the present subject matter. Specifically, to simplify explanation of aspects of the present subject matter, the discussion herein is primarily focused on the joining of top frame member  202  to first side frame member  206 . However, it should be appreciated that the same or similar interlocking joints  220  may be used to couple other corners of door assembly  200 . 
     Although the description herein refers to the joining of top frame member  202  to first side frame member  206 , it should be appreciated that door assembly  200  may include any suitable number of frame members joined together using any suitable number of interlocking joints  220 . For example, illustrations herein describe a door assembly  200  having four frame members  202 - 208 . However, according to alternative embodiments, door assembly  200  may include only two frame members. For example, according such an embodiment, the bottom frame member could be U-shaped, thereby forming three sides of door assembly  200 , and window pane  218  could slide into the U-shaped bottom frame member before a second, top member is joined to bottom frame member using interlocking joints  220  on the left and right sides of the top frame member. Other frame configurations are possible and within the scope of the present subject matter. 
     As shown in the figures, the first frame member, e.g., illustrated as top frame member  202  may generally define an alignment recess  230 . Specifically, alignment recess  230  is illustrated as a void or slot defined in a bottom end  232  of top frame member  202  along the vertical direction V. Notably, alignment recess  230  may be defined by one or more locating surfaces of top frame member  202 . Specifically, top frame member  202  may define a front locating surface  234  and a side locating surface  236 . For reasons that will become more evident below, according to an exemplary embodiment, front locating surface  234  may generally extend substantially within a plane defined by the lateral direction L in vertical direction V. In addition, side locating surface  236  may generally extend substantially within a plane defined by the transverse direction T and the vertical direction V. It should be appreciated that as used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within a ten percent margin of error. 
     According to exemplary embodiments, front locating surface  234  may be precisely positioned at a known distance from a front surface  238  of top frame member  202  along the transverse direction T. In addition, side locating surface  236  may be precisely positioned at a known distance from a side surface  240  of top frame member  202  along the lateral direction L. In this manner, as described in more detail below, when first side frame member  206  is positioned directly against these two locating services  234 ,  236 , flush alignment between top frame member  202  and first side frame member  206  can be achieved quickly and accurately. 
     Referring still to  FIGS. 6 through 12 , the second frame member, e.g., first side frame member  206  that is joined to top frame member  202  may generally define a locking protrusion  250 . Specifically, as illustrated, locking protrusion  250  extends from a top end face  252  of first side frame member  206 . According to the illustrated embodiment, locking protrusion  250  generally defines a front seating face  254  that faces forward along the transverse direction T and a side seating face  256  that faces outward along the lateral direction L. In general, locking protrusion  250  is sized such that it may slide into or be received within the alignment recess  230 . 
     More specifically, according to exemplary embodiments, locking protrusion  250  may be positioned within alignment recess  230  such that front seating face  254  is aligned with or engages front locating surface  234  of top frame member  202 . Similarly, side seating face  256  of locking protrusion  250  may be aligned with or engaged against side locating surface  236 . Notably, similar to the dimensions of alignment recess  230  and top frame member  202 , front seating face  254  may be precisely positioned at a known distance from a front surface  238  of first side frame member  206  along the transverse direction T. In addition, side seating face  256  may be precisely positioned at a known distance from a side surface  240  of first side frame member  206  along the lateral direction L. It should be appreciated that as used herein, front surface  238  and side surface  240  may be used interchangeably to refer to the front or side surfaces, respectively, of any one of frame members  202 - 208  or door assembly  200  in general. 
     Notably, according to an exemplary embodiment, it is desirable that the angle between locating surfaces  234 ,  236  and the angle between seating faces  254 ,  256  be substantially similar. Specifically, as best illustrated  FIG. 6 , front seating face  254  and side seating face  256  may be separated by a face angle  258 . According to an exemplary embodiment, face angle  258  is between about 60 and 120 degrees. According to still another embodiment, face angle  258  is approximately 90 degrees. According to an exemplary embodiment, a locating surface angle (not identified in the figures) is substantially identical to face angle  258 . 
     As best shown in  FIG. 6 , door assembly  200  may include a perimeter groove for securely receiving window pane  218 . Specifically, frame members  202 - 208  may each define an elongated groove  260  that extends around a perimeter of door assembly  200  and is sized for snuggly or securely receiving window pane  218 . Notably, in order to position window pane  218  proximate front surface  238  of door assembly  200 , groove  260  may be defined in part by a forward flange  262  defined on each of frame members  202 - 208 . According to the illustrated embodiment, forward flange  262  defines a flange thickness  264  along the transverse direction T that is very small. For example, according to exemplary embodiments, flange thickness  264  may be less than 20%, less than 10%, less than 5%, or less, than a door assembly thickness  266  measured along the transverse direction T. 
     Door assembly  200  may further include features for urging first side frame member  206  into flush alignment with top frame member  202 . In this regard, for example, door assembly  200  may include a mechanical fastener  270  that is configured for engaging first side frame member  206  to urge front seating face  254  into engagement with the front locating surface  234 . In addition, or alternatively, mechanical fastener  270  may urge first side frame member  206  such that side seating face  256  engages or is seated against side locating surface  236 . In this manner, when a user installs mechanical fastener  270 , frame members  202 - 208  may be joined to form a complete frame with flush joints on both front surfaces  238  and side surfaces  240 . 
     Referring now specifically to  FIGS. 9 and 10 , mechanical fastener  270  may be set screw  272  that is received within a fastener hole  274  defined within top frame member  202 . In this manner, as set screw  272  is advanced through fastener hole  274 , it pushes against locking protrusion  250  to establish firm contact between locating services  234 ,  236  and seating faces  254 ,  256 . 
     Notably, in order to urge locking protrusion  250  along both the lateral direction L and the transverse direction T, it may be desirable that set screw  272  engages locking protrusion  250  at an angle relative to the lateral direction and the transverse direction T. In this regard, for example, locking protrusion  250  defines an interior surface  280  that faces toward fastener hole  274 . According to the illustrated embodiment, interior surface  280  is angled at approximately 45 degrees relative to front seating face  254 . In this manner, set screw  272  engages interior surface  280  to urge locking protrusion  250  directly toward a corner of door assembly  200 , e.g., where front surface  238  and side surface  240  are joined. However, it should be appreciated that according to alternative embodiments, the angle of interior surface  280  may vary while remaining within the scope of the present subject matter. For example, if it is desirable only to align door assembly  200  along front surface  238 , interior surface  280  may extend substantially within a plane defined by the vertical direction V and the lateral direction L. By contrast, if it is desirable and to align door assembly  200  along side surface  240 , interior surface  280  may be oriented substantially parallel to a plane defined by the vertical direction V and the transverse direction T. 
     Notably, locking protrusion  250  may further define features for ensuring proper engagement of top frame member  202  and first side frame member  206  along the vertical direction V. In this regard, according to the illustrated embodiment, interior surface  280  defines a tapered surface  282  that is engaged by set screw  272  to draw locking protrusion  250  into alignment recess  230 , i.e., urging first side frame member  206  upward and into top frame member  202 . In this regard, as best illustrated in  FIG. 12 , tapered surface  282  may define a taper angle  284  measured relative to the vertical direction. According to an exemplary embodiment, tapered surface  282  may define taper angle  284  of between 40 and 80 degrees. According to the illustrated embodiment, taper angle  284  is approximately 60 degrees. Thus, as set screw  272  is advanced into fastener hole  274 , first side frame member  206  is urged upward along the vertical direction V into top frame member  202 , e.g., such that bottom end  232  of top frame member  202  engages top end face  252  of first side frame member  206 . 
     As explained herein, door assembly  200  includes frame members  202 - 208  which are joined at their corners by interlocking joints  220 . Interlocking joints  220  each include an alignment recess  230  for receiving a locking protrusion  250 . Focusing for example on an upper left interlocking joint  220  of door assembly  200 , when set screw  272  passes through top frame member  202  into alignment recess  230 , it engages locking protrusion  250  to push first side frame member  206  into alignment along front surface  238  of door assembly  200  and into alignment along side surface  240  of door assembly  200 . In addition, top frame member  202  and first side frame  206  are drawn together in firm engagement such that little or no seam is visible between the two. The resulting door assembly  200  is easy to assemble, is cost-effective, and provides a desirable appearance for the consumer. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.