Patent Abstract:
A home appliance having an oven with a bake element, the home appliance including an appliance body, an oven cavity defined within the appliance body, a bake element operationally associated within the oven cavity, a bake element retainer supporting the bake element and mounted adjacent the oven cavity, and a mounting arrangement formed integrally with the bake element retainer for mounting the bake element within the oven cavity.

Full Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates broadly to home appliances having ovens with electric resistive bake elements and, more particularly, to a home appliance, particularly a range, having an improved mounting arrangement for a bake element. 
         [0002]    Most every electric range that includes an oven has internal resistive bake elements and broil elements which are generally curved tubular members that produce heat upon electrical activation. The bake elements are mounted under the floor of the oven cavity while the broil elements are mounted to the roof or top wall of the oven cavity. Typically, a retainer will be between the bake element and the bottom of the oven for enhanced heating, due to its reflectivity, and for mounting the bake element under the oven cavity. 
         [0003]    In the past, such bake elements have been difficult to install which also means that they are difficult to remove and replace during repair. In the past, the bake element had to be removed with the entire bake assembly. In addition, advances in oven fascias have reduced the available space under the oven door area for inserting and removing the bake element, making it even more difficult to access and remove the bake element. Installation of the bake element was no easier. The old method used brackets that were attached to the retainer with screws that pass into cavity wall that made installation difficult. Further, such mounting brackets could allow warping or deflection of the bake element during heating. 
         [0004]    Currently, there is a need for an improved and more secure arrangement to mount the bake element within the oven, below the oven cavity floor. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention is intended to provide an improved arrangement for mounting a bake element to a bake element retainer and in turn to the oven cavity structure that will make installation and removal a more straightforward operation. 
         [0006]    The present invention is also intended to provide such a mounting arrangement that will retain the bake element at specific locations to prevent warping or deflection of the bake element during heating. 
         [0007]    The present invention is also intended to provide cost savings by removing the need for separate brackets and wireforms for mounting the bake element within the oven cavity. 
         [0008]    To those ends, a home appliance having an oven with a bake element includes an appliance body and an oven cavity defined within the appliance body. A bake element is operationally associated within the oven cavity. A bake element retainer supports the bake element and is mounted adjacent the oven cavity. A mounting arrangement is formed integrally with the bake element retainer for mounting the bake element within the oven cavity. 
         [0009]    Preferably, the bake element is formed as a serpentine electrical resistance element, the retainer is formed as a planar sheet and the mounting arrangement includes a plurality of tabs projecting from the planar sheet and engaged with predetermined portions of the bake element. 
         [0010]    It is preferred that the bake element is a tubular member and each of the tabs includes a cutout for receiving a tubular portion of the bake element. Preferably, the cutouts are formed with an entry opening and a support surface, wherein the entry opening has one of a u-shape and a c-shape. It is also preferred that a plurality of tabs with u-shaped cutouts are at a front portion of the bake element retainer and a plurality of tabs with c-shaped cutouts are at a rear portion of the bake element retainer. It is preferable 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. 
         [0011]    Preferably, the retainer is a planar sheet and the mounting arrangement includes a plurality of tabs in the planar sheet and in a generally perpendicular relationship with the planar sheet, with the tabs projecting from the planar sheet and engaged with predetermined portions of the bake element. 
         [0012]    It is further preferred that the oven cavity is defined by a plurality of interconnecting walls, including generally vertical side walls and a generally horizontal bottom wall, the bake element retainer being mounted to the range under the bottom wall, wherein the mounting arrangement includes a plurality of tabs in a planar sheet and extending in a generally perpendicular relationship with the planar sheet, with the tabs projecting generally vertically upwardly from the planar sheet and engaged with predetermined portions of the bake element. 
         [0013]    Preferentially, the serpentine bake 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 bake element. Further, the serpentine bake element may include a plurality of runs joined by a plurality of loops at a plurality of corners and the plurality of tabs are arranged in a manner wherein a tab is adjacent each of the loops. It is further preferred that the bake element includes eight runs joined by seven loops defining fourteen corners, and wherein the plurality of tabs includes nine tabs adjacent predetermined corners of the bake element, wherein a tab is at a corner adjacent each of the respective loops. 
         [0014]    Preferably, the serpentine bake 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 bake element. It is further preferred that the bake element includes eight runs joined by seven loops defining fourteen corners, and wherein the plurality of tabs includes nine tabs adjacent predetermined corners of the bake element, wherein a tab is at a corner adjacent each of the respective loops. 
         [0015]    The present invention preferably further includes a stop member releaseably mounted to the bake element retainer to both prevent forward motion of the bake element and to reflect heat back toward the bake element during operation. 
         [0016]    The present invention is also directed to a range having an oven with a bake element. The present range includes a range body, an oven cavity defined within the range body and a bake element operationally associated within the oven cavity. A bake element retainer supports the bake element and is mounted adjacent the oven cavity. A mounting arrangement is formed integrally with the bake element retainer for mounting the bake element within the oven cavity. 
         [0017]    Preferably, the bake element is formed as a serpentine electrical resistance element, the retainer is a planar sheet and the mounting arrangement includes a plurality of tabs projecting from the planar sheet and engaged with predetermined portions of the bake element. 
         [0018]    It is preferred that the bake element is a tubular member and each of the tabs includes a cutout for receiving a tubular portion of the bake element. It is further preferred that the cutouts are formed with an entry opening and a support surface, wherein the entry opening has one of a u-shape and a c-shape. In addition, a plurality of tabs with u-shaped cutouts are preferably at a front portion of the bake element retainer and a plurality of tabs with c-shaped cutouts are preferably at a rear portion of the bake element retainer. Preferentially, 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. 
         [0000]    21. It is further preferred that the retainer is a planar sheet and the mounting arrangement includes a plurality of tabs in the planar sheet and in a generally perpendicular relationship with the planar sheet, with the tabs projecting from the planar sheet and engaged with predetermined portions of the bake element. 
         [0019]    Preferably, the oven cavity is defined by a plurality of interconnecting walls, including generally vertical side walls and a generally horizontal bottom wall, the bake element retainer being mounted to the range under the bottom wall, wherein the mounting arrangement includes a plurality of tabs in a planar metal sheet and extending in a generally perpendicular relationship with the planar sheet, with the tabs projecting generally vertically upwardly from the planar sheet and engaged with predetermined portions of the bake element. 
         [0020]    It is preferred that the serpentine bake 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 bake element. Preferably the serpentine bake element includes a plurality of runs joined by a plurality of loops at a plurality of corners and the plurality of tabs are arranged in a manner wherein a tab is adjacent each of the loops. Further, the bake element may include eight runs joined by seven loops defining fourteen corners, and the plurality of tabs may include nine tabs adjacent predetermined corners of the bake element, wherein a tab is at a corner adjacent each of the respective loops. 
         [0021]    It is further preferred that the serpentine bake 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 bake element. Preferably, the bake element includes eight runs joined by seven loops defining fourteen corners, and wherein the plurality of tabs includes nine tabs adjacent predetermined corners of the bake element, wherein a tab is at a corner adjacent each of the respective loops. 
         [0022]    The present invention preferably further includes a stop member releaseably mounted to the bake element retainer to both prevent forward motion of the bake element and to reflect heat back toward the bake element during operation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]      FIG. 1  is a perspective view of the oven cavity of a home appliance according to the preferred embodiment of the present invention; 
           [0024]      FIG. 2  is a front perspective view of the front appliance illustrated in  FIG. 1  with a lower cover plate removed; 
           [0025]      FIG. 3  is a perspective view of the bake element mounted in an oven cavity according to the preferred embodiment of the present invention; 
           [0026]      FIG. 4  is a perspective view of the oven illustrated in  FIG. 3  with the front fascia of the oven removed; 
           [0027]      FIG. 5  is a perspective view of the stop member according to the preferred embodiment of the present invention; 
           [0028]      FIG. 6  is a perspective view of the bake element retainer according to the preferred embodiment of the present invention; and 
           [0029]      FIG. 7  is a top plan view of the bake element retainer illustrated in  FIG. 6  during manufacture. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0030]    Turning now to the drawings and more particularly to  FIG. 1  and  FIG. 2 , a range is illustrated generally at  10  and includes a floor-standing, box-like range body  12  defining an oven  14 . The lower portion of the range body  12  is illustrated to focus on the bake element retainer of the present invention. The oven  14  is open to the atmosphere through an access opening  16 . The oven cavity is defined in the range body  12  by side walls  18 , a floor  22 , a back wall (not shown) and a roof (not shown). A rack  20  is mounted to the side walls  18  and extends traversely across the oven  14  for food support during cooking. A generally planar fascia  24  attached to the front of the oven  14  is a metal sheet having various opening and shapes to provide a covering for the skeletal frame  32  of the oven  14 . 
         [0031]    A lower panel  28  is sculpted from a planar sheet to cover a lower opening  30  in the fascia  24  to allow access under the floor  22  where the bake element  34  is mounted. The lower bake element access  30  is defined by a curved opening in the fascia  24  having smoothly turned corners  26 . These corners  26  make it more difficult to remove anything from under the floor  22  of the oven  14 . The present invention seeks to accommodate such corners  26  by reducing the amount of range structure necessary for insertion or removal during installation or removal of the bake element  34 . 
         [0032]    In the past, the entire bake element assembly  130 , as seen in  FIG. 4 , had to be removed through the area available under the floor  22  and between the frame  32  and fascia  24  for working access to the bake element  34 . 
         [0033]    Turning now to  FIG. 3 , the bake element  44  is plugged into the front wall (not shown) of the oven  14  at a first electrical connector  46  on one end and a second electrical connector  48  on the other. The bake element  44  is a tubular member formed into a series of runs and loops joined by 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 bake element  44  in a manner that will resist twisting and warping when the resistive bake element  44  is heated to operational temperature. 
         [0034]    Proceeding from left to right in  FIG. 3 , a first linear run  50  extends from the left electrical connector  46  from front to back and is joined to a first loop  66  at a first corner  80 . The first loop  66  curves the bake element  44  back into a second run  52  that extends from a second corner  82 , back to front, to a third corner  84  adjacent the front wall (not shown) of the oven  14 . A second loop  68  extends from the third corner  84  at the second run  52  to a fourth corner  86  wherein the bake element  44  is turned to extend from front to back through the third run  54 . A third loop  70  joins the third run  54  at a fifth corner  88  and bends the bake element  44  to a sixth corner  90  where it is reversed and attaches to the fourth run  56  to extend from back to front. The fourth run  56  ends at a seventh corner  92  and bends into the fourth loop  72  that goes through the centerline CL of the oven. As will be seen, the remaining portion of bake element  44  is a minor image of the first portion. 
         [0035]    From the centerline CL, the fourth loop  72  extends to the eighth corner  94  where it once again turns to extend from front to back through the fifth run  58 . The fifth run  58  ends at the ninth corner  96  and the bake element  44  extends through the fifth loop  74  to the tenth corner  98 . From there, the bake element  44  extends from back to front through the sixth run  60  ending at the eleventh corner  100  where the sixth loop  76  extends to the twelfth corner  102 . From the twelfth corner  102 , the seventh run  62  extends from front to back ending at the thirteenth corner  104 . The seventh and final loop  78  extends from the thirteenth corner  104  to the fourteenth corner  106  to reverse direction of the bake element  44  to again extend from back to front along the eighth run  64  to the second electrical connector  48 . 
         [0036]    A plurality of tabs project outwardly from the retainer  34  to support the tubular bake element  44 . As seen in  FIGS. 3 ,  4  and  5 , each tab  108 ,  110 ,  112 ,  114 ,  116 ,  118 ,  120 ,  122 ,  124  is a generally rectangular member having a cutout to receive a portion of the tubular bake element  44 . As seen in  FIG. 6  and  FIG. 7 , the tabs are cut from a sheet of metal which becomes the retainer  34 . Each tab has the same structure, except for the cutouts, so explanation of one tab will explain the entire set of seven tabs. For example, and with reference to  FIG. 6 , each tab is a generally rectangular member having either a U-shaped cutout  126  or a C-Shaped cutout  128  each cutout leading to a support surface. As seen in  FIG. 6 , each of the tabs is cut into the sheet metal and, as seen in  FIG. 7 , each of the tabs is bent upwardly to a generally 90° angle with the planar sheet to define the respective tab. 
         [0037]    Returning to  FIG. 3 , and extending from left to right, a first tab  108  is at the first corner  80  with a C-shaped cutout  128  facing the centerline CL of the oven  14 . A second tab  110  is at the fourth corner  86  with a U-shaped cutout  126 . A third tab  112  is at the fifth corner  88  with a C-shaped cutout  128  facing the centerline CL of the oven  14 . 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 bake element  44 . 
         [0038]    A fourth tab  114  is at the sixth corner  90  with a C-shaped cutout  128  facing away from the centerline CL of the oven  14 . A fifth tab  116  is adjacent the eighth corner  94  with a U-shaped cutout  126 . A sixth tab  118  is at the ninth corner  96  with a C-shaped cutout  128  facing away from the centerline CL of the oven  14 . A seventh tab  120  is adjacent the tenth corner  98  with a C-shaped cutout  128  facing the centerline CL of the oven  14 . An eighth tab  122  is adjacent the eleventh corner  100  and has a U-shaped cutout  126 . The ninth and final tab  124  is adjacent the fourteenth corner  106  and has a C-shaped cutout  128  facing the centerline CL of the oven  14 . 
         [0039]    Based on the foregoing, it can be seen that the bake element  44  is supported at nine different places with tabs that include U-shaped cutouts  124  near the front of the oven  14  and tabs that include C-shaped cutouts  128  near the rear of the oven  14 , as seen in  FIG. 3 . Since there are seven loops and nine tabs, no loop is left unsupported and, as such, the present mounting arrangement enhances the stability of the bake element  44 . Accordingly, the bake element  44  will resist warping or deflection during heating because the present tabs allow for more free expansion of the bake element  44  than did the prior mounting structure. 
         [0040]      FIG. 4  illustrates the oven  14  without the fascia thereon and more precisely discloses the stop member  36  illustrated in  FIG. 5 . The stop member  36  includes a generally elongate planar structure having two small inturned side walls  38  projecting away from the planar body of the stop member  36 . Two openings  40  are provided for screws  42  or other fasteners to extend therethrough to mount the stop member  36  to the retainer  34  for ease of removal once the lower cover panel  28  is removed as seen in  FIG. 1  and  FIG. 2 . The stop member  36  both restrains the bake element  44  from sliding forward and reflects heat onto the bottom of the oven cavity. 
         [0041]    By the above, the present invention provides an improved and simplified mounting arrangement for a bake element in an oven that is more cost-effective to produce and enhances the structural strength and rigidity of the bake element. 
         [0042]    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.

Technology Classification (CPC): 5