Abstract:
A grate assembly includes a cook top defining a support surface, and a grate that includes a projection extending from a peripheral portion. The projection is configured to support a cooking vessel on the grate. The peripheral portion is configured to support the grate on the support surface. A hole is formed in one of the peripheral portion of the grate or the support surface of the cook top. An insert is disposed within the hole and between the support surface of the cook top and the peripheral portion of the grate.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates generally to an appliance, and more particularly, to a grate apparatus and method such as for a cook top stove. 
         [0002]    A cooking appliance includes gas and/or electric heating elements for heating and cooking food. The cook top may be made out of ceramic or metal. Often the metal cook top is coated with enamel for added durability. Either a natural gas or propane gas cooking unit is generally used. 
         [0003]    In a first type, a gas burner is provided which is arranged under a cook top surface that is typically a closed glass-ceramic panel. In this type, the gas burner heats the ceramic cook top that in turn heats a cooking vessel. A second type of gas cooking unit utilizes a conventional atmospheric gas burner, i.e. that with an open flame, which is inserted through an opening in the cook top. 
         [0004]    A grate is utilized to provide separation between the cooking vessel and the burner. The grate is often made of metal or other hard material. The grate must have a surface for resting a cooking vessel, and feet for raising the grate above the cook top. The cooking grate must be arranged so that it is directly above the gas burner and relatively fixed in position, so that the energy transfer from the burner to the cooking vessel is optimized. The grate prevents damage to the burner and maintains an optimal cook distance between the cook top and the cooking vessel and therefore must be sturdy and withstand the high temperatures associated with its location. 
         [0005]    The hard material or metal of the grate can scratch or mar the enamel coating or glass-ceramic cook top. Particularly where the grate can move in relation to the cook top. These scratches not only reduce the visual aesthetics of the cook top, but in the case of a glass-ceramic cook top, weaken the structural integrity of the cook top increasing the possibility of breaking. It has therefore been a concern to reduce or eliminate the marring and scratching of the cook top. 
         [0006]    One practice has been to glue inserts made of silicone or another soft material onto the bottom or feet of the grate so as to cushion the interface between the grate and the cooking area. The feet are regions of the bottom of the grate which are formed to be lower than the rest of the periphery to allow point contact with the cook top. This creates a more stable interface and prevents rocking of the grate on the cook top. 
         [0007]    Another arrangement has a foot holding device for maintaining the grate in position on the cook top. The foot holding device includes a plurality of foot holders for mating with the feet of the cooking grate. Forming depressed regions in the surface of the cook top forms the foot holders. The depressed regions are formed to fit the shape of the respective feet of the grate and the foot ends are inserted into the depressions for retention. This limits removal and can be difficult to clean the cook top as grease and other debris may settle into the depressed regions. 
         [0008]    Grates have traditionally been hard to clean due to the intense heat associated with their use and the resulting effect it has on food and grease spills. The food and grease often becomes cooked onto the surface and becomes difficult to remove. Generally, harsh chemicals or mechanical methods had been employed with generally poor results in cleaning the grates. 
         [0009]    Self-clean ovens have become very common. Further, with the temperature, cycle time and material improvements self-clean ovens are very effective at removing debris from the interior surfaces of the oven. 
         [0010]    Placing the grates from a gas cook top into the oven during a self-clean cycle is very effective in cleaning the grates. However, the temperature in the self-clean cycle often degrades the interface between the cook top and the grate. During the high temperatures of the self-clean cycle the soft material often oxidizes or sublimes into carbon ash, or the bonding agent between the soft material and the grate fails. 
         [0011]    Thus, there exists a need in the art for a grate assembly that provides a sturdy support for cooking vessels and includes an interface that will not mar or scratch a cook top employing the gas burners and can be easily cleaned in the self-clean cycle of a self-clean oven. 
         [0012]    There also exists a need in the art for a method of cleaning a grate for supporting cooking vessels by placing the grate in a self-clean oven during a self-clean cycle. Further, the interface for preventing marring or scratching of the cook top by the grate should be able to maintain pliability during the cleaning method. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0013]    As described herein, each of the embodiments of the invention overcomes one or more of the above or other disadvantages in the art. 
         [0014]    In an embodiment, a grate assembly includes a cook top defining a support surface, and a grate that includes a projection extending from a peripheral portion. The projection is configured to support a cooking vessel on the grate. The peripheral portion is configured to support the grate on the support surface. A hole is formed in one of the peripheral portion of the grate or the support surface of the cook top. An insert is disposed within the hole and between the support surface of the cook top and the peripheral portion of the grate. 
         [0015]    In an embodiment, the invention provides a method of cleaning a grate for a burner assembly of a cook top, the burner assembly including a gas burner and a grate for supporting a cooking vessel. The method includes placing the grate into a self-clean oven for at least one cycle of a self-clean feature of the oven, and removing the grate from the self-clean oven. The method further includes supporting the grate on an interface between the cook top and the grate. The interface includes a plurality of pliable inserts in holes, each insert including a shank portion and a head portion. The head portion has a cross section greater than the shank portion, and the shank portion is positioned within a respective one of the holes. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The following figures illustrate examples of embodiments of the invention. The figures are described in detail below. 
           [0017]      FIG. 1  is a perspective view of a cooking appliance incorporating a grate assembly in accordance with an embodiment of the present invention. 
           [0018]      FIG. 2  is a detail exploded view of the grate assembly of the cooking appliance of  FIG. 1 . 
           [0019]      FIG. 3  is a front view of an insert of the grate assembly of  FIG. 1 . 
           [0020]      FIG. 4  is a detail, partial cross sectional view of another embodiment of the present invention. 
           [0021]      FIG. 5  is a detail view of another embodiment of the present invention. 
           [0022]      FIG. 6  is a bottom view of another embodiment of the present invention. 
           [0023]      FIG. 7  is a detail, partial cross sectional view of the grate assembly of  FIG. 6 . 
           [0024]      FIG. 8  is a detail, partial cross sectional view of another embodiment of the grate assembly of  FIG. 6 . 
           [0025]      FIG. 9  is a front view of an alternate embodiment of an insert of the grate assembly of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0026]    Embodiments of the invention are described below, with reference to the figures. Throughout the figures, like reference numbers indicate the same or similar components. References to preferred embodiments are for illustration and understanding, and should not be taken as limiting. 
         [0027]    With initial reference to  FIGS. 1 and 2 , the present invention is incorporated in a cooking appliance  100 , which is shown as a domestic range. It is to be understood that the present invention could also be used in connection with an island-type or other countertop mounted cook top. In any event, for exemplary purposes, cooking appliance  100  is shown to include a cabinet  104  within which is formed an interior oven cavity. The oven cavity may be capable of performing a self-clean cycle, as is known in the art. Cooking appliance  100  further includes a cook top  102  that is formed from metal or a glass/ceramic-based material. An upper portion of a front panel  112  defines an upper front face  114  that includes a plurality of controls. Arranged below upper front face  114  is an oven door  108  having a handle  110 . In a manner known in the art, door  108  can be pivoted to access the interior oven cavity of cooking appliance  100 . Also, as shown, cooking appliance  100  includes a lower drawer  106  for use in storing pans and the like. 
         [0028]    In the figures, upper front face  114  is provided with a plurality of element control knobs  130 ,  132 ,  134  and  136 . Element control knobs  130 ,  132 ,  134  and  136  are used to control the operation of gas burner heating elements  140 ,  142 ,  144  and  146  respectively. Heating elements  140  and  142  are fitted with grates  141  and  143  respectively. Similarly, heating elements  144  and  146  are fitted with grates  145  and  147 . In general, the construction and operation of cooking appliance  100 , as described until this point, is known in the art. Further, the form, number and location of each of the elements described may change based on preference and use. To this end, additional details of this construction or operation will not be provided here. 
         [0029]    Traditionally, cleaning the grates  141 ,  143 ,  145  and  147  is labor intensive and often requires caustic chemicals and harsh abrasives to remove the food and grease cooked onto the grate due to the high operational temperatures involved. By placing the grate into an oven during the self-clean cycle it was found that the grates would become very clean and not lose any luster as harsh chemicals and abrasives were not employed. According to one aspect of the present invention, the grate is cleaned by removing the grate from the cook top surface and removing the bumpers or feet from the grate prior to placing in an oven for the duration of a self-clean cycle. 
         [0030]    Reference will now be made to one of the element assemblies, which include grate  141 , and heating element  140  but is representative of the each of the element assemblies including grates  141 ,  143 ,  145  and  147  and heating elements  140 ,  142 ,  144  and  146 . Referring to  FIG. 2 , grate  141  includes a peripheral edge  148  and a plurality of projections  118  extending from edge  148  toward a center portion  120  of the respective grate  141 . Projections  118  form surfaces for resting a cooking vessel (not shown) above gas heating element  140 . As shown, each grate interfaces with cook top  102  at  150 . 
         [0031]    In an embodiment of the invention interface  150  is a plurality of inserts  162  as shown in  FIGS. 2 and 3 . Insert  162  is matingly inserted in a hole  168  in the cook top  102 . Holes  168  are located to correspond to the peripheral edge  148  of grate  141  when grate  141  is resting on the cook top  102  during normal operation as shown in  FIG. 1 . The insert  162  has a head portion  164  and a shank portion  166 . Head portion  164  is substantially larger in cross-section than shank portion  166 . Shank  166  is inserted into hole  168 . Preferably shank  166  has a bulge  170  or area larger than hole  168  to prevent easy removal of insert  162  from cook top  102 . Bulge  170  should be located a distance  163  from head portion  164  which is less than or equal to the thickness of cook top  102 . Thus the retention force of bulge  170  on the underside of cook top  102  creates a sealing force between head portion  164  and the upper side of cook top  102 . This seal prevents food and other debris from becoming lodged between insert  162  and cook top  102 , and facilitates cleaning the cook top surface.  FIG. 9  shows an alternate embodiment of insert  162  where shank  166  is considerably longer then bulge  170  and like numbers indicate similar features. 
         [0032]    Alternatively, as shown in  FIG. 4  the shank portion  166  of insert  162  and hole  168  of cook top  102  may be correspondingly threaded such that when insert  162  is fully threaded in hole  168  a seal is created between head portion  164  and the cook top surface. 
         [0033]    In another alternate embodiment shown in  FIG. 5 , an insert  182  includes a head portion  184  and is located on cook top  102  to correspond to the peripheral edge  148  of grate  141  when resting on the cook top  102  during normal operation as shown in  FIG. 1 . Insert  182  is adhered or otherwise secured to cook top  102  at interface  186 . 
         [0034]    In other embodiments of the invention, interface  150  is a plurality of inserts  152 , as shown in  FIGS. 6 ,  7  and  8 . In these aspects of the invention insert  152  is matingly inserted in a hole  158  on the bottom of peripheral edge  148  of grate  141 . Insert  152  has a head portion  154  and a shank portion  156 . Head portion  154  is substantially larger in cross-section than shank portion  156 . Shank  156  is removably inserted into hole  158 . In an embodiment shank  156  and hole  158  are correspondingly threaded, but any means for removable retention of insert  152  is acceptable. Insert  152  is made of a material that will not mar or scratch the cook top, such as silicone. In this embodiment, insert  152  is removed from grate  141  before grate  141  is placed in an oven cavity for cleaning during the self-clean cycle. 
         [0035]    In the embodiment shown in  FIG. 8 , insert  152  is matingly inserted in hole  158  on the bottom of peripheral edge  148  of grate  141 . Shank  156  is inserted into hole  158 . Shank  156  contains a bulge  157  a distance from head  154  less than or equal to the thickness of wall  159  of peripheral edge  148 . Further, bulge  157  is greater in diameter than hole  158 . Thus, bulge  157  creates a retaining force for insert  152 . However, any means for retention of insert  152  may be used. Insert  152  is made of any material that will not mar or scratch the cook top and can withstand temperatures in the 800-900 degree Fahrenheit (425-480 degree Celsius) range, such as graphite foil, or flexible graphite also known as GRAFOIL™. In this embodiment, the insert  152  remains with the grate  141  when placed in an oven for cleaning during the self-clean cycle. Other suitable materials for the insert  152  include ceramic wool, silica gel, and/or another pliable structure, including a structure formed of an inorganic material or compound. 
         [0036]    This written description uses examples to disclose embodiments of the invention, including the best mode, and to enable a person of ordinary skill in the art to make and use embodiments of the invention. It is understood that the patentable scope of embodiments of the invention is defined by the claims, and can include additional components occurring to those skilled in the art. Such other components and examples are understood to be within the scope of the claims.