Electric heating – Heating devices – Combined with container – enclosure – or support for material...
Reexamination Certificate
1999-05-07
2002-11-05
Pelham, Joseph (Department: 3742)
Electric heating
Heating devices
Combined with container, enclosure, or support for material...
C219S521000, C219S406000, C099S385000, C099S391000, C099S401000
Reexamination Certificate
active
06476360
ABSTRACT:
TECHNICAL FIELD
The present invention relates generally to heating appliances such as toasters or toaster ovens, and more specifically to a shell structure for a heating appliance that includes an open end panel through which components may be inserted during assembly of the heating appliance.
BACKGROUND OF THE INVENTION
A conventional heating appliance, such as a toaster or toaster oven, generally includes a shell formed from three separate panels. a bottom panel and two end panels. During manufacture of the toaster, these panels, along with a plurality of electrical and mechanical components, are assembled to construct the toaster.
FIG. 1
is an isometric view of a conventional toaster
200
with its external case (not shown) removed to illustrate a shell
202
. The toaster
200
is described merely as an example of a conventional toaster, and other similar prior art configurations will be understood by those skilled in the art. The shell
202
is formed from a bottom panel
204
, a rear end panel
206
and a front end panel
208
. Each end panel
206
,
208
is attached to the bottom panel
204
through tabs (not shown) that are inserted in respective slots
210
,
212
in the bottom panel, as shown for the end panel
208
. A first outer heating element
214
and second outer heating element
216
are mounted between the end panels
206
,
208
, each heating element generating heat to toast food items during operation of the toaster. The heating elements
214
,
216
include respective first terminals
217
,
219
extending through corresponding apertures in the front end panel
208
and also typically includes a second terminal (not shown) extending through a corresponding aperture (not shown) in the rear end panel
206
. Each of the electrical terminals is adapted to receive a respective power signal that is applied to circuitry (not shown) on the heating element
214
,
216
to generate heat for toasting food items. To provide added mechanical support for the heating elements
214
,
216
, a stringer (not shown) is typically attached between the end panels
206
,
208
along the top edge of each heating element. A center heating element
218
is positioned between the outer heating elements
214
,
216
, and generates heat to toast respective food items between the element
218
and the outer heating elements
214
,
216
. The center heating element
218
also typically includes a terminal
221
extending through an aperture in the front end panel
208
and a terminal (not shown) extending through an aperture (not shown) in the rear end panel
206
. None of the electrical terminals
217
,
219
,
221
contact the front panel
208
.
The toaster
200
further includes an outer bread guard
220
positioned inside the end panel
214
, and an identical outer bread guard
222
positioned inside the side panel
216
. Two inner bread guards
224
and
226
are positioned on both sides of the center heating element
218
. Each of the bread guards
220
-
226
includes a horizontal member
228
and vertical members
230
, as shown for the bread guard
220
. A first bread cavity
232
is defined between the bread guards
220
and
224
, and a second bread cavity
234
is defined between the bread guards
222
and
226
. The bread guards
216
-
222
function to protect bread placed between the bread guards from the heating elements
214
-
218
during operation of the toaster
200
.
A first bread tray (not shown) is contained within the first bread cavity
232
and functions to support a piece of bread as it is lowered into and raised from the bread cavity. A second bread tray (not shown) is similarly positioned within the second bread cavity
234
to support another piece of bread in that bread cavity. Each of the bread trays includes a lever
234
extending through slots
224
and
226
, respectively, in the front end panel
208
. The levers
234
are pushed down to lower the respective pieces of bread on the bread trays into the bread cavities
232
,
234
. As the bread trays are pushed down, the outer bread guards
220
,
222
move toward the center of the corresponding bread cavity
232
,
234
, as shown for the bread guard
222
. In this way, the bread guards
220
-
226
position the bread towards the centers of the bread cavities
232
and
234
so that the bread placed on the bread trays is positioned for optimum toasting. The toaster
200
further includes an electronic circuit
236
mounted on the bottom panel
204
. Although not shown in
FIG. 1
, the circuit
236
is typically coupled to the terminals
217
-
221
and other components of the toaster
200
to control its operation.
During manufacture of the toaster
200
, the heating elements
214
,
216
, and
218
, bread guards
220
-
226
, and a plurality of other electrical and mechanical components must be assembled. It is desirable to automate as much of the manufacturing process as possible in order to reduce the cost and increase the reliability of the toaster
200
. With the conventional shell
202
, however, automating the assembly process is difficult due, in part, to the order in which components must be assembled. For example, as previously described the heating elements
214
-
218
include respective terminals
217
-
221
that extend through apertures in the end panels
206
,
208
. As a result, to position the heating elements
214
-
218
between the panels
206
,
208
, one end panel is typically mounted to the bottom panel
204
and then the terminals inserted in the corresponding apertures in that end panel. The terminals at the opposite ends of the elements
214
-
218
are thereafter inserted in the corresponding apertures in the other end panel
206
,
208
and this panel is attached to the bottom panel
204
. As will be understood by those skilled in the art, this process is difficult to automate.
In addition to difficulties presented in automating manufacture, the conventional shell
202
is not very sturdy once assembled. This is due primarily to the end panels
206
,
208
being fastened to the bottom panel
204
through tabs located at one end. While the end panels
206
,
208
could be fastened more securely to the bottom panel
204
to make the shell
202
more sturdy, such as by welding the end panels to the bottom panel, this would increase the cost of manufacturing the toaster
200
. Another difficulty presented by the conventional shell
202
is the positioning of the heating elements
214
,
216
near the ends of the end panels
206
,
208
. When the heating elements
214
,
216
become hot during operation, a significant amount of heat may be radiated outward away from the cavities
232
,
234
. This outward radiated heat may heat an external case (not shown) enclosing the shell
202
to an unacceptably high temperature. It is desirable for the external case to have “cool touch” sides, meaning that the sides of the case remain cool even during operation. A panel (not shown) may be placed between the heating elements
214
,
216
and the external case, but this requires additional labor and parts, which increase the cost of the toaster
200
.
There is a need for a shell structure for a heating appliance that is relatively sturdy, enables automated assembly of the toaster, and enables cool-touch sides to be easily constructed.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a shell for a heating appliance includes first and second side panels and front and rear end panels. The front end panel has first and second sub panels and each sub panel has a vertical edge. The vertical edges of the first and second sub panels are spaced apart to form an opening between the vertical edges that allows the insertion of components through the opening during assembly of the heating appliance. Each sub panel includes an aperture extending to the corresponding vertical edge. The aperture is adapted to receive a portion of one of the components that extends beyond an outer surface of the sub panel. Each side panel may include a mounting panel formed at a bottom edge of the side panel
Gurevich Leon
Huggler Peter
Dorsey & Whitney LLP
Salton Inc.
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