COOKTOP WITH FLUSH-FIT CONSOLE ASSEMBLY

BACKGROUND OF THE DISCLOSURE

[0001] The present disclosure generally relates to a cooking appliance, and more specifically, to a cooktop with an edge-to-edge upper glass substrate and a console assembly with a general flush fit with respect to the glass substrate.

[0002] Various types of cooking appliances include glass or glass-ceramic cooktops. By way of example, both conventional electric cooktops, as well as induction cooktops are offered in variations in which a single piece of glass-ceramic covers and encloses all of the associated heating elements, collectively, resulting in a smooth, seamless cooking surface. Typically, such appliances (whether in the form of a stand-alone cooking hob or a range), include a metal frame encircling the edges of the glass-ceramic substrate on all sides (or at least the side and rear sides). In such configurations, the frame can be of a thin, metallic structure bent into the shape of the frame, including inner and outer flanges that meet the sides of the appliance and extends downwardly to meet the cooking surface. Such structure positions the cooking surface below the upper surface of the appliance. Additionally, front consoles or control panels associated with these appliances may similarly include upper surfaces positioned above the cooking surface. In some instances, consoles may include an interior surface that abuts the side edge of the glass-ceramic substrate, resulting in a visible seam and an associated visible gap that can trap debris or allow the incursion of liquid or must be sealed with a visible sealing element.

SUMMARY OF THE DISCLOSURE

[0003] According to one aspect of the present disclosure, a cooktop includes an upper glass substrate defining a cooking surface, at least one electric cooking element positioned beneath the upper glass substrate, and a front cover unit defining a unitary front portion and top portion. The top portion extending from a front edge, at an intersection with the front portion, to a rear edge disposed over the cooking surface. The top portion at least partially overlies, and is positioned parallel to, a portion of the cooking surface.

[0004] According to another aspect of the present disclosure, a cooking appliance includes a cooktop having an upper glass substrate defining a cooking surface, first and second lateral edges, and a front edge extending between the first and second lateral edges and at least one electric cooking element positioned beneath the upper glass substrate. The cooktop also has a front cover unit defining a unitary front portion and top portion. The top portion extends from a front edge, at an intersection with the front portion, to a rear edge disposed over the cooking surface, with the top portion extending over the front edge to at least partially overlie a portion of the cooking surface and being positioned parallel thereto. The cooking appliance further includes an outer casing defining first and second lateral sides of the cooktop extending rearwardly from the front cover unit, wherein the first and second lateral edges of the upper glass substrate are positioned generally flush with the first and second sides of the outer casing, respectively.

[0005] According to yet another aspect of the present disclosure, a cooking appliance includes a cooktop having an upper glass substrate defining a cooking surface, first and second lateral edges, and a front edge extending between the first and second lateral edges and a front cover unit defining a unitary front portion and top portion. The top portion includes an upper planar member extending between a front edge at an intersection with the front portion and a rear edge of the top portion and defining the upper surface. A lower planar member extends from the rear edge back toward the front edge in a position parallel with the upper planar member, and a lower extension is joined with the lower planar member and extends perpendicular thereto away from the upper planar member. The rear edge is disposed over the cooking surface, with the top portion extending over the front edge to at least a partially overlie a portion of the cooking surface and being positioned parallel thereto. An outer casing defines first and second lateral sides of the cooktop that extends rearwardly from the front cover unit with the first and second lateral edges of the upper glass substrate being positioned generally flush with the first and second sides of the outer casing, respectively. The cooking appliance further includes a frame member at least partially supporting the upper glass substrate with the lower extension extending along a portion of the frame member and is coupled thereto.

[0006] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In the drawings:

[0008]FIG. 1 is a perspective view of a cooking appliance according to an aspect of the disclosure;

[0009]FIG. 2 is a perspective assembly view of a cooktop associated with the appliance according to a further aspect of the disclosure;

[0010]FIG. 3 is a side cross-section view of a portion of the cooktop showing a front cover thereof;

[0011]FIG. 4 is a detail view of the area indicated in FIG. 3;

[0012]FIG. 5 is a rear perspective view of the front cover of the cooktop; and

[0013]FIG. 6 is a side perspective view of the front cover.

[0014] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.

DETAILED DESCRIPTION

[0015] The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a cooking appliance. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0016] For purposes of description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise, the term "front" shall refer to the surface of the element closer to an intended viewer, and the term "rear" shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0017] The terms "including," "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by "comprises a . . . " does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0018] Ordinal modifiers (i.e., “first”, “second”, etc.) may be used to distinguish between various structures of a disclosed article in various contexts, but such ordinals are not necessarily intended to apply to such elements outside of the particular context in which they are used and that, in various aspects different ones of the same class of elements may be identified with the same, context-specific ordinal. In such instances, other particular designations of the elements are used to clarify the overall relationship between such elements. Ordinals are not used to designate a position of the elements, nor do they exclude additional, or intervening, non-ordered elements or signify an importance or rank of the elements within a particular class.

[0019] For purposes of this disclosure, the term "coupled" (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

[0020] For purposes of this disclosure, the terms “about”, “approximately”, or “substantially” are intended to mean that a value of a parameter is close to a stated value or position. However, minor differences may prevent the values or positions from being exactly as stated. Thus, unless otherwise noted, differences of up to ten percent (10%) for a given value are reasonable differences from the ideal goal of exactly as described. In many instances, a significant difference can be when the difference is greater than ten percent (10%), except as where would be generally understood otherwise by a person of ordinary skill in the art based on the context in which such term is used.

[0021]Referring to FIGS. 1-6, reference numeral 10 generally designates a cooktop. The cooktop 10 includes an upper glass substrate 12 defining a cooking surface 14, at least one electric cooking element 16 (FIG. 2) positioned beneath the upper glass substrate12, and a front cover unit 18 defining a unitary front portion 20 and top portion 22. The top portion 22 extends from a front edge 24, at an intersection with the front portion 20, to a rear edge 26 disposed over the cooking surface 14. The top portion 22 at least partially overlies, and is positioned parallel to, a portion of the cooking surface 14.

[0022]With reference to FIGS. 1 and 2, an example of the present cooktop 10 is shown as an induction cooktop 10 in which the electric cooking element 16 is one of a number of power-delivery induction coils 16 arranged in an array below the cooktop substrate 12. In an example, the cooktop substrate 12 can be of a glass-ceramic material of various known compositions for closed, electric cooktops and for induction cooktops in particular. In one implementation, the cooktop 10 according to the present disclosure can be a stand-alone unit (e.g., a cooking hob appliance). Alternatively, and as shown in the Figures, the cooktop 10 can be included with an oven 28 (such as a conventionally heated electric oven) in an arrangement generally referred to as a “range”. In any such arrangement, the cooktop 10 can be referred to as being included in a cooking appliance 30 and as shown in FIG. 1, the cooking appliance 30 can further include an outer casing 32 that defines first and second lateral sides 34a and 34b of that extend rearwardly from the front cover unit 18. In such an arrangement, the upper glass substrate 12 can define first and second lateral edges 36a and 36b that are positioned generally flush with the first and second sides 34a and 34b of the outer casing 32, respectively. The rear edge 36c of the upper glass substrate 12 can be flush with a rear surface 34c of the outer casing 32. In this manner, the cooktop 10 can be characterized as having an “edge-to-edge” glass substrate 12 that lacks an outer frame that surrounds the edges and adjacent inward areas of the glass substrates in typical cooktop arrangements.

[0023] As shown in FIG. 1, the front cover unit 18 can define the only feature that extends over a portion of the cooking surface 14. In this manner, it may be desirable to position the upper surface 38 of the top portion 22 as close as possible to the cooking surface 14 to maintain the generally seamless appearance achieved by the edge-to-edge arrangement discussed above, while still overlapping the cooking surface 14 such that there is no vertical seam or gap to be filled, or otherwise capture dirt or debris and/or present in inlet for liquids. Similarly, in various implementations, including the depicted variation, in which the upper surface 38 of the top portion 22 extends in a generally uninterrupted manner to the front edge 24 and corresponding transition to the front portion 20 of the cover unit 18, the planar nature of the upper surface 38 may lack the geometric features associated with a frame or other comparable member often used in connection with glass substrates 12. Accordingly, the structure of the top portion 22 may be configured beneath or opposite the upper surface 38 can be configured to provide desired levels of structural rigidity for the top portion 22 of the cover unit 18 while maintaining the flush, seamless appearance shown in FIG. 1.

[0024] As shown particularly in FIGS. 3-5, the front cover 18 can comprise a unitary piece of sheet material, such as stainless steel or the like and can be bent into the depicted shape shown in FIGS. 5 and 6 (including with variations, in particular, to the front portion 20). In this manner, the front cover 18 further define integral bent portions 40 at the front edge 24 and the rear edge 26, among other locations, depending on the particular shape of the front cover 18. In particular, and as particularly shown in FIGS. 4 and 5, the top portion 22 can include an upper planar member 42, on which the upper surface 38 is defined. The upper planar member 42 extends between the front edge 24 and the rear edge 26. The top portion 22 can further include a lower planar member 44 that extending from the rear edge 26 back toward the front edge 24 in a position parallel with the upper planar member 42. Due to the construction of the front cover 18, discussed above, the upper planar member 42 and the lower planar member 44 are unitarily joined together along the rear edge 26 of the top portion 22, with the rear edge 26 of the top portion 22 being defined as the above-described bent portion 40, which extends between the upper planar member 42 and the lower planar member 44. As shown, the lower planar member 44 can be positioned in contact with the upper planar member 42 opposite the upper surface 38 of the top portion 22. In this manner, the section of the top portion 22 adjacent the rear edge 26 and generally overlying the cooking surface 14 can include two layers of the sheet material from which the front cover 18 is constructed, which can increase the rigidity of the top portion 22.

[0025]Further, the unitary connection of the upper planar member 42 and the lower planar member 44 by the bent segment 40 that defines the rear edge 26 can further increase the rigidity of the top portion 22, particularly along the rear edge 26, which may be the portion thereof most vulnerable to deflection. Even further, the bent segment 40 along the rear edge 26 can provide improved aesthetics, while providing a smoother edge. In this respect, it is noted that the rear edge 26 can be compressed to bring the lower planar member 44 into an extended contact with the upper planar member 42, but that some variation between the positions of the lower planar member 44 from the upper planar member 42 may be present such that the two may not be in contact immediately adjacent the rear edge 26 and/or may have some variance from being completely parallel (e.g., +/- 1°), while still being considered parallel for the purposes of this disclosure.

[0026]As further shown, the top portion 22 can further include a lower extension 46 joined with the lower planar member 44 at an additional bent portion 40 and extending perpendicular thereto away from the upper planar member 42. Again, it is noted that some variation from perpendicular may be realized (e.g., +/- 2°), while still falling with the general meaning of perpendicular, as used herein. In one aspect, the presence of the lower extension 46 and the corresponding integral connection with the lower planar member 44 can further increase the rigidity of the top portion 22, including along the longitudinal mid portion thereof, to help maintain the planar appearance of the upper surface 38. Additionally, the cooking appliance 30 can further include a frame member 48 at least partially supporting the upper glass substrate 12 (including along the front edge 36d of the upper glass substrate 12) by way of the frame member 48 extending between the lateral sides 34a and 34b of the outer casing 32 in a location disposed within an interior 50 of the front cover 18, as shown in FIG. 3 and FIG. 5). The lower extension 46 can extend along at least a portion of the frame member 48 in contact therewith and, in at least one implementation, can be coupled therewith to provide additional support for the top portion 22. In one such implementation, at least one spring clip 52 can couple the lower extension 46 to the frame member 48. In one aspect, multiple spring clips 52 can be coupled with the frame member 48 and can capture respective portions of the lower extension 46 at regular intervals therealong. Additionally, in the illustrated example, the spring clips 52 are coupled with the frame member 48 by screws 54 that engage with the frame member 48, although other fastening means can be used, including but not limited to rivets, adhesives, or integral formation with the frame member 48.

[0027]As further shown in FIG. 5, the cooktop 10 can include a sealing strip 56 captured between the top portion 22 of the front cover unit 18 and the cooking surface 14. This arrangement can prevent liquid, for example, present on the cooking surface 14 from leaking into the interior 50 of the front cover 18, while maintaining the sealing strip 56 in a position generally concealed from view, thus maintaining the generally seamless appearance achieved by the present arrangement. In particular, the above-describe configuration of the top portion 22, in which the top portion 22 extends over and past the front edge 36d of the glass substrate 12 overlie the portion of the cooking surface 14 adjacent the front edge 36d. In various implementations, the rear edge 26 of the top portion 22 can extend past the front edge 36d of the glass substrate 12 by between about 13 and 22 mm and, in a specific example, by about 17 mm. The above-described doubling of the top portion 22 by way of the parallel upper planar member 42 and lower planar member 44 can be such that the upper surface 38 of the front cover 18 can be positioned within about 5 mm of the cooking surface 14 and, in one example, at a distance of about 3.5 mm from the cooking surface 14 (e.g., +/- 5%). In such implementations, the sheet metal material of the front cover 18 can be about 1 mm thick and the sealing member can have a thickness of about 1.5 mm (all measurements +/- 5%). As further shown, the front cover 18 can be configured to extend across the entire lateral width of the cooking appliance 30 such that the top portion 22 extends laterally to align with the lateral edges 36a and 36b of the upper glass substrate 12, which are aligned with the lateral sides 34a and 34b of the outer casing 32. A pair of side covers 58 can be assembled with the front cover 18 to enclose the interior 50 adjacent the lateral sides 34a and 34b of the outer casing 32, with which the side covers 58 can be flush or overlapping. The front cover 18 can be included in a front console assembly 60, along with the side covers 58. In one implementation, the console assembly 60 can further include at least one control device 62 mounted to the front cover 18. As shown, the control devices 62 can include control knobs that are configured for controlling the heat generation achieved by the cooking elements 16. Such control devices 62 can be indirectly mounted with the front cover 18 by being wholly or partially supported by the frame member 48 or another internal component of the cooking appliance 30. In a further example, the control devices 62 can include a digital input and/or display mounted along the front portion 20 or the top portion 22.

[0028]Returning to FIG. 3, the assembly of the cooktop 10 includes the above-mentioned cooking elements 16, which are shown in the form of a plurality of induction coils. The cooking elements 16 can be retained on a support 64 that coupled with one or more internal structures or elements of the cooktop 10 or related cooking appliance 30. A plurality of spacing members 66 are positioned outside of and generally surrounding the cooking elements 16 and provide at least partial support for the glass substrate 12. As discussed above, when the glass substrate 12 is assembled with the spacing members 66, it is positioned along or to define the uppermost surface of the cooktop 10 and to extend laterally and rearwardly to align with the corresponding surfaces 34a, 34b, and 34c of the cooking appliance 30. The console assembly 60 is then mounted to the cooktop 10 and/or cooking appliance 30 with the top portion 22 extending over the front edge 36d of the glass substrate 12. In this manner, the sealing member can be positioned along the cooking surface 14 prior to such assembly, or can be fixed (i.e., by way of a pressure-sensitive adhesive or the like to the lower planar member 44. The side covers 58 can be assembled with the front cover 18 before or after the assembly of the front cover 18 with the cooktop 10.

[0029] The invention disclosed herein is further summarized in the following paragraphs and is further characterized by combinations of any and all of the various aspects described therein.

[0030] According to another aspect of the present disclosure, a cooktop includes an upper glass substrate defining a cooking surface, at least one electric cooking element positioned beneath the upper glass substrate, and a front cover unit defining a unitary front portion and top portion. The top portion extends from a front edge, at an intersection with the front portion, to a rear edge disposed over the cooking surface. The top portion at least partially overlies, and is positioned parallel to, a portion of the cooking surface.

[0031]In the cooktop of ¶ [0030], the top portion can include an upper planar member extending between the front edge and the rear edge and defining the upper surface and a lower planar member extending from the rear edge back toward the front edge in a position parallel with the upper planar member.

[0032]In the cooktop of ¶ [0031], the upper planar member and the lower planar member can be unitarily joined together along the rear edge of the top portion.

[0033]In the cooktop of ¶ [0032], the upper planar member and the lower planar member can be unitarily joined, with the rear edge of the top portion being defined as a bent segment extending between the upper planar member and the lower planar member.

[0034]In the cooktop of ¶¶ [0032] or [0033], the lower planar member can be positioned in contact with the upper planar member opposite the upper surface of the top portion.

[0035]In the cooktop of one of ¶¶ {0032} - [0034}, the top portion can further include a lower extension joined with the lower planar member and extending perpendicular thereto away from the upper planar member.

[0036]The cooktop of ¶ [35] can further include a frame member at least partially supporting the upper glass substrate, wherein the lower extension extends along a portion of the frame member in contact therewith, and a spring clip coupling the lower extension to the frame member.

[0037]The cooktop of any of ¶¶ [0030} to [0036}, can further include a sealing strip captured between the top portion of the front cover unit and the cooking surface.

[0038]In the cooktop of any of ¶¶ [0030} to [0037}, the front cover can be included in a front console assembly further including at least one control device mounted, [directly or indirectly, to the front cover.

[0039]In the cooktop of any of ¶¶ }0030} to [0038}, the front cover can comprise a unitary piece of sheet material defining integral bent portions at the front edge and the rear edge.

[0040]The cooktop of any of ¶¶ [0030} to [0038}, can further include an outer casing defining first and second lateral sides of the cooktop that extend rearwardly from the front cover unit, and the upper glass substrate can define first and second lateral edges positioned generally flush with the first and second sides of the outer casing, respectively.

[0041] According to another aspect of the present disclosure, a cooking appliance includes a cooktop having an upper glass substrate defining a cooking surface, first and second lateral edges, and a front edge extending between the first and second lateral edges and at least one electric cooking element positioned beneath the upper glass substrate. The cooktop also has a front cover unit defining a unitary front portion and top portion. The top portion extends from a front edge, at an intersection with the front portion, to a rear edge disposed over the cooking surface, with the top portion extending over the front edge to at least partially overlie a portion of the cooking surface and being positioned parallel thereto. The cooking appliance further includes an outer casing defining first and second lateral sides of the cooktop extending rearwardly from the front cover unit, wherein the first and second lateral edges of the upper glass substrate are positioned generally flush with the first and second sides of the outer casing, respectively.

[0042]The cooking appliance of ¶ [0041}can be a range that further includes an oven cavity positioned below the cooktop.

[0043]In the cooking appliance of ¶¶ [0041} or [0042}, portions of the first and second lateral edges of the upper glass substrate can further be flush with respective first and second ends of the top portion of the cover unit.

[0044]In the cooking appliance of any of ¶¶ [0041} to [0043}, the top portion of the front cover can includes an upper planar member extending between the front edge and the rear edge and defining the upper surface, a lower planar member extending from the rear edge back toward the front edge in a position parallel with the upper planar member, a lower extension joined with the lower planar member and extending perpendicular thereto away from the upper planar member.

[0045]The cooking appliance of ¶ [44} can further include a frame member at least partially supporting the upper glass substrate with the lower extension extending along a portion of the frame member in contact therewith and a spring clip coupling the lower extension to the frame member.

[0046]The cooking appliance of any of ¶¶ [0041} to [0045}, can further include a sealing strip captured between the top portion of the front cover unit and the cooking surface.

[0047]In the cooking appliance of any of ¶¶ [0041} to [0046}, the front cover can be included in a front console assembly further including at least one control device mounted [directly or indirectly] to the front cover.

[0048]In the cooking appliance of any of ¶¶ [0041} to [0047}, the front cover can comprise a unitary piece of sheet material defining integral bent portions at the front edge and the rear edge.

[0049] According to another aspect of the present disclosure, a cooking appliance includes a cooktop having an upper glass substrate defining a cooking surface, first and second lateral edges, and a front edge extending between the first and second lateral edges and a front cover unit defining a unitary front portion and top portion. The top portion includes an upper planar member extending between a front edge at an intersection with the front portion and a rear edge of the top portion and defining the upper surface. A lower planar member extends from the rear edge back toward the front edge in a position parallel with the upper planar member, and a lower extension is joined with the lower planar member and extends perpendicular thereto away from the upper planar member. The rear edge is disposed over the cooking surface, with the top portion extending over the front edge to at least partially overlie a portion of the cooking surface and being positioned parallel thereto. An outer casing defines first and second lateral sides of the cooktop that extend rearwardly from the front cover unit with the first and second lateral edges of the upper glass substrate being positioned generally flush with the first and second sides of the outer casing, respectively. The cooking appliance further includes a frame member at least partially supporting the upper glass substrate with the lower extension extending along a portion of the frame member and is coupled thereto.

[0050] It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

[0051] It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0052] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.