Patent Document

FIELD OF THE INVENTION  
       [0001]     This invention pertains to solenoid control valves, and more particularly to gas solenoid control valves for use in an appliance such as a gas range.  
       BACKGROUND OF THE INVENTION  
       [0002]     In a typical appliance such as a gas range, a manifold is employed to distribute a gaseous fuel to a plurality of valves that are individually associated with a burner. The gas first enters a manifold at a manifold input. From there, the gas is distributed inside the manifold such that the gaseous fuel is available to each of the multiple manifold outputs.  
         [0003]     From the manifold outputs the gas is expelled into a number of individual interconnecting tubes. The gas flows through each of these interconnecting tubes until reaching the inputs of a number of individual valves. Each valve selectively permits or denies the gas to be released from the valve output. If the gas is released, the gas leaves the valve through the valve output and flows through a burner connector to the burner. At the burner, the gas is ignited so that the range can be utilized by a user to, for example, prepare a meal.  
         [0004]     Unfortunately, when the above-described manifold in the typical appliance is used, numerous gas connections and fittings within the gas range are required. For instance, a gas connection must be formed between a gas delivery conduit and the manifold input, between each of the manifold outputs and one end of each of the interconnecting tubes, between the other end of each of these interconnecting tubes and the valve input for each of the gas control valves, between each of the valve outputs for each of the gas control valves and one end of each of the burner connectors, and finally between the other end of each of the burner connectors and the input of each of the burners. These gas connections are time consuming to formulate and are a potential source of gas leaks. In a high-line range having multiple oven cavities, the number of connections for each oven&#39;s bake burner and broiler burner significantly increases the cost of production of such ranges and the potential for leaks at each of these multiple connection points multiplies.  
         [0005]     Therefore, an apparatus that can selectively deliver gas to a burner on a gas range using a minimal number of gas connections would be desirable. The invention provides such an apparatus. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.  
       BRIEF SUMMARY OF THE INVENTION  
       [0006]     In one aspect, the invention provides an apparatus for selectively distributing a gas in a gas range. The apparatus comprises a housing and a plurality of solenoids. The housing has a gas input, a manifold, and a plurality of gas outputs. The plurality of solenoids reside in the manifold and are individually activatable to release the gas from one of the plurality of outputs. Therefore, the gas is selectively distributed in the gas range.  
         [0007]     In another aspect, the invention provides an apparatus for selectively distributing gas to a plurality of burners. The apparatus comprises a housing and a plurality of solenoids. The housing has a gas input, a manifold, and a plurality of gas outputs. Each of the plurality of solenoids resides in the manifold and sealingly engages an associated gas output to prevent fluid communication between the manifold and the gas output. The solenoids are individually activatable to permit fluid communication between the manifold and the gas output.  
         [0008]     In a further aspect, the invention provides a method of reducing a number of connections within a gas appliance having a plurality of burners. A valve housing having a single gas inlet, a manifold, and a plurality of gas outlets is provided. A plurality of solenoids, each selectively sealingly engaging one of the plurality of gas outlets, is then incorporated into the manifold of the valve housing. A gas delivery conduit is next coupled to the gas inlet of the valve housing and a burner connector is coupled to each of the plurality of gas outlets.  
         [0009]     Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:  
         [0011]      FIG. 1  is a perspective view of an exemplary embodiment of a solenoid valve constructed in accordance with the teachings of the present invention as found in a typical double gas range;  
         [0012]      FIG. 2  is a cross-sectional view of the solenoid valve of  FIG. 1 .  
         [0013]      FIG. 3  is a partially-exploded perspective view of a solenoid in the solenoid valve of  FIG. 2 ;  
         [0014]      FIG. 4  is an exploded perspective view of the solenoid of  FIG. 3  with a spring, a bushing, and a plug;  
         [0015]      FIG. 5  is an exploded perspective view of the solenoid valve of  FIG. 1 ;  
         [0016]      FIG. 6  is a perspective view of the solenoid valve of  FIG. 5  when the solenoid valve has been assembled;  
         [0017]      FIG. 7  is a perspective view of the solenoid valve of  FIG. 5 , taken from a different viewpoint, when the solenoid valve has been assembled;  
         [0018]      FIG. 8  is a cross-sectional view of the solenoid valve of  FIG. 7  taken along line  8 - 8 ; and  
         [0019]      FIG. 9  is a cross-sectional view highlighting the disengagement of the sealing flange and the plug in the solenoid valve of  FIG. 8 . 
     
    
       [0020]     While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0021]     Referring to  FIG. 1 , an embodiment of a solenoid valve  10  for selectively distributing a gaseous fuel constructed in accordance with the teachings of the present invention is illustrated. To provide a context for the present invention, the solenoid valve  10  is shown disposed within, or operating as a part of, an appliance, such as a high-line gas range  12  having multiple oven cavities  13 ,  15 . However, those skilled in the art will recognize that such operating environment to which the present invention is particularly well suited is presented by way of example, and not by way of limitation. The gas range  12  includes, among other things, a plurality of surface burners  14 , a plurality of surface burner selectors  16 , a bake burner  17  and a broiler burner  19  in oven cavity  13 , a bake burner  21  in oven cavity  15 , a cooking mode and temperature selector  23  for oven cavity  13 , a temperature selector  25  for oven cavity  15 , a gas delivery conduit  18  for receiving the gaseous fuel from an external source, burner connectors  20  at each burner  17 ,  19  and  21 , and gas connections  22 .  
         [0022]     In this exemplary environment, the solenoid valve  10  of the present invention includes a gas input  28  coupled to and receiving gas from the gas delivery conduit  18 . Each of the three gas outputs  34  are coupled by gas connections  22  to the burner connectors  20  for each burner  17 ,  19 , and  21 . The valve  10  individually controls the output of gas to each of the connected burners  17 ,  19 ,  21  based on inputs received from the cooking mode and temperature selector  23  and the temperature selector  25 . As will be recognized by those skilled in the art, the cooking mode and temperature selector  23  operates to control which burner  17 ,  19  in oven cavity  13  is used and the temperature of the cavity itself. For example, if a user wanted to bake a cake, the selector  25  would command the valve  10  to supply gas to the bake burner  17 . The selector  25  would then monitor the temperature of the cavity  13 , and would command the valve  10  to stop supplying gas to burner  17  when the temperature of cavity  13  reaches the preset temperature set by the user. If the user were to select the broiler, the selector  25  would command the valve  10  to supply gas to the broiler burner  19 .  
         [0023]     Referring now to  FIG. 2 , the solenoid valve  10  comprises a housing  24  that defines a gas input  28 , a plurality of gas outputs  34 , and a manifold  30 . To control the flow of gas out of each of the gas outputs  34 , the valve  10  includes a plurality of solenoids  26  positioned within the manifold  30 . The manifold  30  is sealed by a gasket  44  positioned under cover  46 , which is secured to the housing  24  by securing members such as, for example, screws  48 , rivets, nuts, and the like. The electrical connectors  76  of each of the solenoids  26  are exposed through the cover  46  for external connection to the solenoid control circuitry.  
         [0024]     The gas input  28  is connectable to the gas delivery conduit  18  (see  FIG. 1 ). As such, when the gas is delivered by the gas delivery conduit  18  and reaches the gas input  28 , the gas flows into the housing  24  via the gas input  28  until the gas occupies the manifold  30 . The gas is then allowed to flow out of each the gas outlets  34  when the solenoid  26  withdraws the plug  62  from the sealing flange  38  as will be described more fully below.  
         [0025]     The gas outputs  34  are fashioned to expel the gas that is residing in or flowing into the manifold  30 . Each of the gas outputs  34  is coupled to a burner connector  20  and each of the burner connectors  20  is coupled to a burner  17 ,  19 , or  21  in the gas range  12 . Thus, the gas can, when desired, flow through the gas delivery conduit  18 , into the gas input  28 , into and through manifold  30 , out of the gas output  34 , into and through the burner connectors  20 , and arrive at burners  17 ,  19 ,  21  (depending on which one or ones of the solenoids  26  are commanded open). At that time, the gas escaping the burners  17 ,  19 ,  21  can be ignited such that a user can employ the gas range  12  to heat food and the like.  
         [0026]     In a preferred embodiment, the gas delivery conduit  18 , the gas input  28 , the gas outputs  34 , the burner connectors  20 , and the burners  14  (collectively referred to as “components”) can be threaded such these components are threadably mateable with each other. Such threaded mating of the components prevents gas leaks. In preferred embodiments, the threaded mating is supplemented with Teflon tape, sealant, and/or other products to further promote and ensure the formation of a gas seal between the components. Methods of connecting the components, using threaded mating or otherwise, are well known in the art.  
         [0027]     As show in  FIGS. 3 and 4 , one of the plurality of solenoids  26  found in solenoid valve  10  is displayed. Each solenoid  26  comprises a solenoid bobbin  50 , an armature  52 , a sound damper  54 , a solenoid frame  56 , a spring  58 , a bushing  60 , and a plug  62 .  
         [0028]     Referring specifically to  FIG. 3 , the solenoid bobbin  50  includes a coil portion  64 , a spring seat  66 , and a base  68 . The spring seat  66  and the base  68  are secured to opposing ends of the coil portion  64 . The spring seat  66  includes a first armature opening  70  dimensioned to receive the armature  52 . The base  68  includes a coil wire securing slot  72 , securing flanges  74 , electrical connectors  76 , and a second armature opening  78  dimensioned to receive the armature  52 . The first and second armature openings  70 ,  78  and the coil portion  64  of the solenoid bobbin  50  form an armature channel  80 .  
         [0029]     To assemble the solenoid  26 , the armature  52  is inserted into the armature channel  80 . The sound damper  54  is then moved toward the base  68  until the sound damper and the base are engaged and a pin  82  on the base is slideably received in sound damper aperture  84 . Thereafter, the solenoid frame  56  is biased toward the solenoid bobbin  50  until the pin  82  is slideably received by and snapped into the pin notch  86 , the spring seat  66  is slideably received by the spring seat notch  88 , and the solenoid frame  56  otherwise engages the base  68  and/or the solenoid bobbin  50 . In this arrangement, the sound damper  54  and the solenoid frame  56  together restrict the armature  52  from sliding through or out of the first armature opening  70 . Additionally, the armature channel  80  only permits the armature  52  to travel rectilinearly (e.g., up and down, back and forth) within the armature channel  80 .  
         [0030]     When the solenoid bobbin  50 , the armature  52 , the sound damper  54 , and the solenoid frame  56  have been assembled, as illustrated in  FIG. 4 , the spring  58 , the bushing  60 , and the plug  62  can be secured to the armature  52 . Such securement is performed by fitting the spring  58  around and onto the spring seat  66 , inserting the armature  52  through a bushing aperture  90 , and inserting the armature  52  through a plug aperture  92  until the armature flange  94  snaps into the plug aperture. Because of the respective dimensions of the plug aperture  92  and the armature flange  94 , once the armature flange has been forcibly inserted through the plug aperture  92 , a great deal of effort is required to disengage the two components from each other. Therefore, rectilinear motion of the armature  52  is likewise experienced by the plug  62 . The spring  58  biases the plug  62  away from the spring seat  66 , which, when installed in the valve  10 , forms a seal against the sealing flange  38  (see  FIG. 8 ).  
         [0031]     The coil portion  64  on the solenoid bobbin  50  has a coil of wire (not shown) inside. This coil of wire is coupled to the electrical connector  76  at flange  74 . When a voltage is applied to terminals  96  of the electrical connector  76 , a current flows through the coil of wire and a magnetic field is generated within the solenoid bobbin  50 . The magnetic field biases the armature  52  towards the sound damper  54 . As a result, the spring  58  is compressed and the plug  62  is also drawn toward the sound damper  54 . When installed in the valve  10 , this action withdraws the plug  62  from the sealing flange  38  to allow gas to flow out of gas outlet  34  (see  FIG. 9 ) as illustrated by flow lines  106 .  
         [0032]     As illustrated in  FIG. 5 , solenoids  26  are each inserted into manifold  30  through manifold opening  32 . When the plug  92  on the solenoids  26  engages one of the sealing flanges  38  (see  FIG. 2 ), a gas seal is formed and insertion of that solenoid  26  into the manifold can be halted. Engagement of the plug  62  and the sealing flange  38  will at least partially compress the spring  58  to ensure a bias force is applied on the seal. After the solenoids  26  have been positioned within manifold  24 , the solenoids are secured inside the manifold  24  by engaging the securing flanges  74  and the coil wire securing slot  72  ( FIGS. 3 and 4 ) to corresponding slots and flanges (not shown) on and inside the manifold  30 .  
         [0033]     Once the solenoids  26  have been inserted inside the manifold  30 , the gasket notches  98  and gasket slots  100  on gasket  44  are aligned with shafts  42  and terminals  96  such that the gasket  44  engages the housing  24 . The cover  46  is then secured to the housing  24  by aligning cover apertures  102  and cover slots  104  with shafts  42  and terminals  96 . Thereafter, screws  48  are inserted through the cover apertures  102  and into shafts  42 . As the screws are threadably driven into the shafts  42 , the cover  46  is drawn toward the housing  24 , the gasket  44  is compressed between the cover  46  and the housing  24 , and a gas seal in formed. In other words, the manifold  30  is sealed proximate the manifold cavity opening  32 . Therefore, the solenoids  26  are encapsulated within the manifold  30  of the housing  24  and, resultantly, within the solenoid  10 .  FIGS. 6 and 7  illustrate the completed valve assembly  10 .  
         [0034]     After assembly, the solenoid valve  10  is disposed within or coupled to the gas range  12  as depicted in  FIG. 1 . Notably, the solenoid valve  10  requires far fewer gas connections  22  compared to gas ranges that are known in the art. For instance, when the solenoid valve  10  is employed in the gas range  12 , the solenoid valve only needs a gas connection  22  between the gas delivery conduit  18  and the gas input  28 , between the gas outputs  34  and the burner connector  20 . In contrast, in the typical gas range, gas connections must be made between a gas delivery conduit and the manifold input, between a manifold output and one end of the interconnecting tube, between another end of the interconnecting tube and the valve input, between the valve output and one end of the burner connector, and finally between another end of the burner connector and the burner. Thus, the solenoid valve  10  operates in the gas range  12  using fewer gas connections  22  since such connections are undesirably subject to gas leakage as well as time consuming to form.  
         [0035]     In operation, when solenoid valve  10  is used in the gas range  12  and a user operates one of the selectors  23 ,  25 , a voltage is applied to terminals  96  on the associated one of the solenoids  26 . The voltage induces current to flow through the wire that is coiled inside the solenoid bobbin  50 . When that current flows through the wire, a magnetic field is produced in and around the solenoid bobbin  50  such that the armature  52  is drawn toward the sound damper  54 . As the armature  52  is increasingly forcibly biased toward the sound damper  54 , as progressively shown in FIGS.  8  (quiescent state) and  9  (activated state), the spring  58  is compressed until the plug  62  disengages from the sealing flange  38 . Therefore, the gas is free to flow, as shown by the gas flow arrows  106 , from the manifold  30  to the gas output  34 . After leaving gas output  34 , the gas is directed through the burner connector  20  and to the associated burner where the gas is ignited.  
         [0036]     When desired by the user and/or when controlled by the gas range  12  itself, the flow of gas to the burner(s) can be terminated. If the user chooses to shut off the range  12 , the user simply manipulates the appropriate selector  23 ,  25  to an off or lower temperature position. The voltage applied to the terminals  96  is removed and the magnetic field dissipates. When this happens, the spring  58  expands to bias the armature  52  away from the sound damper  54  until the plug  62  re-engages with the sealing flange  38  and forms a gas seal (see  FIG. 8 ). Since no more gas is permitted to flow, the flame in the gas range  12  is extinguished. Of course, the process of engaging and disengaging the plug  62  and the sealing flange  38  can be repeated by each of the solenoids  26 .  
         [0037]     All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.  
         [0038]     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.  
         [0039]     Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Technology Category: 2