DOMES AND ARCHES

Abstract

A modular dome structure (5) for a masonry oven, which includes a plurality of interlocking wall modules (60) abutting one another to form a wall of the dome and a base (7) upon which the wall modules are mounted. Each wall module (60) is formed of a plurality of blocks (63) hingedly interconnected together and shaped so as to form an arch segment of the dome wall when facing surfaces of adjacent blocks (63) of the wall module (60) abut and interlock with one another.

Claims

1. A modular dome structure comprising a plurality of wall modules abutting one another to form a wall of the dome and a base upon which the wall modules are mounted, wherein each wall module comprises a plurality of bricks formed at least in part of a refractory material which are hingedly interconnected together by a flexible spine that is at least partially embedded within the brick, each wall module being shaped so as to form an arch segment of the dome wall when facing surfaces of adjacent blocks of the wall module abut one another.

2. (canceled)

3. The modular dome structure of claim 1, wherein each wall module comprises a first, mounting end which is mounted to the base and a second end opposite the first end.

4. The modular dome structure of claim 3, wherein at least one of the blocks in each wall module tapers toward the inside of the dome such that the wall module forms an arch segment.

5. The modular dome structure of claim 3, wherein the flexible spine extends from the first end of the wall module to its second end.

6. The modular dome structure of claim 5, wherein each wall module comprises a first registration feature at its first end, in registration with a second registration feature of the base to locate the wall module on the base.

7. (canceled)

8. The modular dome structure of claim 3 comprising a lid mounted on the free end of each wall module.

9. The modular dome structure of claim 8, wherein the structure comprises a chimney or flue in fluid communication with a door opening the aperture for evacuating combustion gases.

10. The modular dome structure of claim 1, wherein the flexible member or spine comprises one or more wires, e.g. one or more twisted multifilament wires.

11. The modular dome structure of claim 1, wherein the blocks of adjacent wall modules describe an interlocking pattern.

12-17. (canceled)

18. The modular dome structure of claim 1 comprising: a removeable hood mounted over the wall modules; and a thermally insulative and/or fire-retardant material either comprised within the hood or between the inner wall of the dome and the hood.

19. (canceled)

20. The modular dome structure of claim 1 comprising a fire resistant filler in one or more spaces described between adjacent blocks.

21. The modular dome structure of claim 1, wherein the base comprises an aperture for receiving or communicating with a gas burner.

22. The modular dome structure of claim 1 comprising an insulating material in or beneath the base and/or surrounding the wall modules.

23. An oven comprising the modular dome structure of claim 1.

24-30. (canceled)

31. An arch segment comprising a plurality of bricks including a refractory material which are hingedly interconnected together by a flexible spine at least partially embedded within each brick, wherein the bricks are shaped such that the arch segment is movable from a first, substantially flat configuration to a second, arched configuration when facing surfaces of adjacent bricks abut one another.

32. The arch segment of claim 31, wherein at least one of the bricks tapers toward an intended inner side of the arch segment.

33. The arch segment of claim 31, wherein the flexible spine extends from a first, mounting end of the arch segment to a second, free end thereof.

34-35. (canceled)

36. The arch segment of claim 31, wherein the flexible spine comprises one or more wires.

37. The arch segment of claim 31, wherein at least one brick is offset relative to an adjacent brick such that the arch segment interlocks, in use, with another arch segment to provide an interlocking structure.

38-40. (canceled)

41. A modular dome structure comprising: a plurality of wall modules abutting one another to form a wall of the dome; a base upon which the wall modules are mounted; a removeable hood mounted over the wall modules; and a thermally insulative and/or fire-retardant material either comprised in the hood or between the inner wall of the dome and the hood; wherein each wall module comprises a plurality of blocks hingedly interconnected together and shaped so as to form an arch segment of the dome wall when facing surfaces of adjacent blocks of the wall module abut one another.

Description

[0065] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

[0066] FIG. 1 is an isometric view of an oven incorporating aspects of the invention;

[0067] FIG. 2 is an enlarged isometric view of the oven of FIG. 1 with some of the panels omitted to illustrate the flue ducting;

[0068] FIG. 3 is a front view of the hood of the oven of FIGS. 1 and 2 with the chimney omitted;

[0069] FIG. 4 is a front view of a hood according to another example with the chimney omitted;

[0070] FIG. 5 is an isometric view of a modular dome structure forming the core of the oven of FIGS. 1 and 2;

[0071] FIG. 6 is a top view of the modular dome structure of FIG. 5;

[0072] FIG. 7 is a plan view of the outer side of one of the wall modules of the modular dome structure of FIGS. 5 and 6, shown in a flat configuration;

[0073] FIG. 8 is a side view of the wall module of FIG. 7;

[0074] FIG. 9 is an isometric view from an outer side of the wall module of FIGS. 7 and 8, formed into an arch segment;

[0075] FIG. 10 is an isometric view of an inner side of the wall module of FIG. 9;

[0076] FIG. 11 is an isometric view of one of the floor slabs of the modular dome structure of FIGS. 5 and 6;

[0077] FIG. 12 is a plan view of the registration plate of the modular dome structure of FIGS. 5 and 6;

[0078] FIG. 13 is a front view of an oven including the hood of FIG. 4 over the modular dome structure of FIGS. 5 and 6, without a stand.

[0079] Referring now to FIGS. 1 to 3, there is shown an oven 1 including a stand 2, a hood 3 and a chimney 4. Beneath the hood 3, the oven 1 includes a modular dome structure 5 forming a masonry core of the oven 1. The modular dome structure 5 (shown more clearly in FIGS. 5 and 6) includes a plurality of wall modules 6 mounted to a base 7 and a lid 8 mounted on the wall modules 6.

[0080] The stand 2 includes a subframe 20 upon which the base 7 of the dome structure 5 is mounted. The subframe 20 includes a pedestal 20a, three legs 21 diverging from the pedestal 20a and an intermediate shelf 22 connected to an intermediate part of each leg 21 to provide structural stability. Each leg 21 is formed of a length of sheet metal, which is bent to form a pair of flanks 23 extending along the length of the leg 21 and flanges 24 extending from each of the outer longitudinal edges of the flanks 23 and substantially perpendicularly thereto. The shelf 22 is substantially triangular in plan, with a peripheral wall 25 to stiffen the subframe 20. It will be appreciated that this stand 2 is purely optional; it may be omitted or replaced with any suitable design.

[0081] The hood 3 is formed of a plurality of panels 30, formed of stainless steel in this example, which extend from the top of the hood 3 to the base 7. The panels 30 are secured together along their edges by a series of rivets 31. The hood 3 also includes a door surround 32 and a trapezoidal door panel 33 with a handle 34 secured to and extending from the centre of the door panel 33. The door surround 32 includes an arch-shaped panel 35 and a brim panel 36 projecting from the arch-shaped panel 35 over the door panel 33. Insulative layers (not shown) are also included on a rear side of the arch-shaped panel 35 and behind the door panel 33. The door panel 33 in this example is unattached to the door surround 32 and includes an orthogonal foot portion 33a to keep it upright when it is placed against the door surround 32 to cover the door opening.

[0082] As shown in FIG. 2, the door surround 32 is flat, while the panels 30 bow away from the door surround 32 to create a gap 32a therebetween. The hood 3 includes flue ducting 37, which extends from the door panel 33 to the panels 30, surrounding the apex of the hood 3 to create a plenum therebetween, with the gap 32a between the panels 30 and the door surround 32 providing an inlet thereto. As shown more clearly in FIG. 3, the arch-shaped panel 35 includes a pair of registration tabs 38 depending from each of its lower limbs and an aperture 39 at its apex, which provides an outlet of the plenum described by the flue ducting 37.

[0083] The chimney 4 includes a cylindrical flue 40 projecting from the top of the hood 3 and in fluid communication with the aperture 39 of the hood 3. The chimney 4 also includes a conical cowl 41 secured to the open top 42 of the flue 40. The cowl 41 is secured to the flue 40 by three connecting members 43, such that a space is created therebetween to allow for the passage of combustion gases. In use, combustion gases escaping from the door opening pass through the gap 32a between the panels 30 and the door surround 32, into the plenum described between the flue ducting 37 and panels 30, through the aperture 39 of the hood 3, up the cylindrical flue 40 and out through the space between the open top of the cylindrical flue 40 and the cowl 41.

[0084] FIG. 4 illustrates an alternative hood 103, which is similar to the hood 3 described above, wherein like features are labelled with like references with the addition of a preceding ‘1’. The hood 103 in this example differs from the hood 3 described above in that it is formed as a singled piece 130 from a composite material, instead of the use of the aforementioned panels. The internal and external shape and dimensions are similar and, as such, one aspect of the invention provides interchangeable hoods 3, 103 for use with the same core structure 5. An example of this is illustrated in FIG. 13, which illustrates an oven 101 resting atop a pedestal 120a without any legs 21 or shelf 22. It will be appreciated that, whilst the shape of the pedestal 120a matches that of the base 7, this need not be the case. The oven 101 may rest on a special purpose table (not shown), a brick support structure (not shown) or any other suitable, non-flammable substrate.

[0085] Turning now to FIGS. 4 to 9, the wall modules 6 forming the modular dome structure 5 in this example include ten arch segment wall modules 60, a pair of side doorframe modules 61 and an upper doorframe module 62. However, it will be appreciated that the number of wall modules 6 may vary, for example in the case of larger or smaller ovens (not shown). The side doorframe modules 61 include a series of castellations 61a and the upper doorframe module 62 includes a single castellation 62a. In the assembled condition, the side doorframe modules 61 support the upper doorframe module 62 to describe a door opening.

[0086] Each of the arch segment wall modules 60, shown more clearly in FIGS. 6 to 9, includes a series of blocks or bricks 63, hereinafter bricks 63, which are offset or staggered from one another to provide a series of castellations 64 along its length. The bricks 63 are hingedly interconnected by a pair of flexible spines 65, in the form of a stainless steel wire in this example, which are embedded within each brick 63 adjacent its outer side 63a. A pair of keys 66 are also secured to the lowermost, largest brick 63, at a mounting end of each arch segment wall module 60. A similar key (not shown) is also included on the base of each side doorframe module 61. Each key 66 is in the form of a projection or lug having a head 66a and a neck 66b. In this example, each key 66 is aligned with one of the spines 65 and may be secured thereto, although this is not necessary.

[0087] The use of spines 65, particularly a pair of spines 65 and the use of wire, provides advantages over conventional reinforcing techniques. More specifically, these spines 65 provide a reinforcing structure that extends along the entire wall of the dome structure 5, from the base to the top. This provides a more robust reinforcement than conventional reinforcing or filament reinforcing. Conventional oven manufacturing techniques fail to optimise the orientation of such filaments. These filaments are also susceptible to falling out of the matrix forming the wall of the oven 1, which could fall into the food being cooked with the oven 1.

[0088] In this example, the bricks 63 are formed of a moulded refractory material. The process of manufacturing the arch segment wall modules 60 includes introducing a pliable or mouldable refractory material into a mould (not shown), which describes a plurality of block or brick cavities (not shown) and inserting the flexible spines 65 into the mould (not shown), such that they are embedded within the material in each brick cavity (not shown). Once the pliable or mouldable material has hardened or set, a moulded arch segment wall module 60 is removed from the mould (not shown). The keys 66 can then be inserted into the largest brick 63. In some examples, an insert (not shown) with an internal thread is inserted during the moulding process, or is subsequently forced into a blind hole drilled into the brick 63.

[0089] Each brick 63 is substantially rectangular with longitudinal and lateral sides 63b, 63c that converge from the outer side 63a of the brick 63 to an inner side 63d thereof. Convergence of the longitudinal sides 63b creates a taper in each brick 63 of the arch segment wall module 60, which provides a divergence in the longitudinal sides 63b between each consecutive brick 63. This divergence, together with the hinged connection provided by the flexible spine 65, enables the arch segment wall module 60 to be movable from a first, substantially flat configuration (shown in FIGS. 6 and 7) to a second, e.g. arched, configuration (shown in FIGS. 8 and 9). This is achieved by pivoting the bricks 63 relative to one another about the hinged connection provided by the flexible spine 65, until their longitudinal sides 63b abut one another.

[0090] Convergence of the lateral sides 63c creates a taper along the length of the arch segment wall modules 60. This taper enables a curved profile to be created about the periphery of the modular dome structure 5 as the arch segment wall modules 60 are brought into abutment with one another. In addition, the lateral sides 63c converge from the lowermost, mounting brick 63 to the uppermost brick 63, such that the length of each consecutive brick 63 along the arch segment wall modules 60 reduces. It will be appreciated by those skilled in the art that this will create a modular dome structure 5 having a substantially hemispheric profile, as illustrated more clearly in FIG. 5.

[0091] The base 7 includes a polygonal insulative block (not shown), an oven floor 71 and a registration plate 72 between the insulative block (not shown) and oven floor 71. The oven floor 71 includes a peripheral floor slab 71a, which sits atop a further, circular insulative block (not shown) that matches the inside of the modular dome structure 5. The peripheral floor slab 71a has a circular recess that receives four quarter-circular floor slabs 71b, 71b′ 71c. The oven floor 71 also includes a door slab 71d, which sits atop a correspondingly shaped insulative block (not shown) and abuts the peripheral floor slab 71a. One of the floor slabs 71c, shown in FIG. 11, includes an aperture A through its thickness. The other three floor slabs 71b, 71b′ include a pair of identical, quarter-circular floor slabs 71b and one quarter-circular floor slab 71b′ having a truncated part-circular side that coincides with a flat side of the door slab 71a.

[0092] The registration plate 72, shown more clearly in FIG. 12, has a substantially polygonal periphery, with eleven straight edges and a rounded front, with a peripheral wall 72a depending from its periphery. The registration plate 72 includes an aperture B through its thickness, a plurality of wall module registration slots 73, 74, 75, 76, 77 and a pair of hood registration slots 78a, 78b. The wall module registration slots 73, 74, 75, 76, 77 are inboard of the periphery of the registration plate 72. The aperture B is on the left side of the registration plate 72, in the orientation shown in FIG. 12. It will be appreciated by those skilled in the art that the configuration of the registration plate 72 will vary, depending on the size and/or configuration of the oven 1. For example, the number, position, size and configuration of the wall module registration slots 73, 74, 75, 76, 77 and hood registration slots 78a, 78b may vary.

[0093] The wall module registration slots 73, 74, 75, 76, 77 include a pair of spaced initiating slots 73, a series of five right-sided slots 74, a series of four left-sided slots 75, a right-side door slot 76 and a left-side door slot 77. The right-sided slots 74 are distributed about the periphery of the registration plate 72 on the right side of the initiation slot 73, while the left-sided slots 75 are distributed about the periphery on the left side of the initiation slot 73. The right-side door slot 76 is at the end of the series of right-sided slots 74 and the left-side door slot 77 is at the end of the series of left-sided slots 75.

[0094] Each initiating slot 73 includes a circular enlarged portion 73a and a necked portion 73b extending from the enlarged portion 73a toward the periphery of the registration plate 72. Each right-sided slot 74 includes a first enlarged portion 74a and a necked portion 74b extending from the enlarged portion 74a toward the initiating slot 73. Each right-handed slot 74 also includes a second enlarged portion 74c in an intermediate part of the necked portion 74b. Similarly, each left-sided slot 75 includes a first enlarged portion 75a, a necked portion 75b extending from the enlarged portion 75a toward the initiating slot 73 and a second enlarged portion 75c in an intermediate part of the necked portion 75b. The right-side door slot 76 includes an enlarged portion 76a and a necked portion 76b extending from the enlarged portion 76a toward the last right-sided slot 74 in the series. Similarly, the left-side door slot 77 includes an enlarged portion 77a and a necked portion 77b extending from the enlarged portion 77a toward the last left-sided slot 75 in the series.

[0095] The lid 8, shown more clearly in FIGS. 4 and 5, is circular in plan with a flat apex 80. The lid 8 includes a series of threaded holes 81, the uppermost brick 63 of each arch segment wall module 60 also includes a threaded hole 67 and the upper doorframe module 62 also includes a series of threaded holes 68. The threaded holes 81, 67, 68 may be provided by threaded inserts, embedded during the moulding process or forced into holes after the moulding process. In the assembled condition, shown more clearly in FIGS. 2 and 3, the holes 81 in the lid 8 are aligned with the holes in each arch segment wall module 60.

[0096] In order to assemble the oven 1, the head 66a of each key 66 of a first arch segment wall module 60 is inserted into the enlarged portion 73a of a respective one of the initiating slots 73. The first arch segment wall module 60 is then forced outwardly such that the neck 66b of each key 66 slides into the necked portion 73b of the initiating slot 73 and abuts the end of the initiating slot 73. Then, the head 66a of each key 66 of a second arch segment wall module 60 is inserted into one of the enlarged portions 74a, 74c of the right-sided slots 74 and the second arch segment wall module 60 is forced toward the first arch segment wall module 60 until their castellations 64 engage. Similarly, the head 66a of each key 66 of a third arch segment wall module 60 is inserted into one of the enlarged portions 75a, 75c of the right-sided slots 75 and the third arch segment wall module 60 is forced toward the first arch segment wall module 60 until their castellations 64 engage. It will be appreciated by those skilled in the art that the use of two keys 66 ensures both the location and orientation of each arch segment wall module 60.

[0097] As indicated by the numbers on the registration plate, three further arch segment wall modules 60 are mounted to the base 7 in a similar fashion, alternating between the right-sided slots 74 and left-sided slots 75 as indicated by the sequence numbers N on the registration plate 72. As indicated by sequence number 7, the floor insulation block (not shown), the peripheral floor slab 71a and quarter-circular floor slabs 71b, 71b′, 71c are then placed on the registration plate 72, with the apertures A, B aligned. The remaining arch segment wall modules 60 are then mounted to the base 7, as described above and as indicated by the sequence numbers N. However, this sequence is but one example. For example, the floor insulation block (not shown) and floor slabs 71a, 71b, 71b′, 71c may be placed on the registration plate 72 after the first arch segment wall module 60 and before the others.

[0098] After all of the arch segment wall modules 60 have been installed, the side doorframe modules 61 are installed on the base 7 by inserting the keys (not shown) into the door slots 76, 77 and forcing the side doorframe modules 61 toward the adjacent arch segment wall modules 60 until their castellations 61a, 64 engage. The door slab 71d is then placed on the registration plate 72 in front of the peripheral floor slab 71a, over sequence number 14. The upper doorframe module 62 is then placed onto the side doorframe modules 61 such that the castellation 62a register with the uppermost castellation 64 of the adjacent arch segment wall modules 60.

[0099] The lid 8 is mounted onto the upper, free ends of the arch segment wall modules 60 and the upper doorframe module 62. A series of plates or locking bands (not shown) are secured to each hole pair 81, 67 and 81, 68 to secure the lid 8 relative to the arch segment wall modules 60. The wall modules 6 are inboard of the periphery of the base 7, thereby creating a ledge. A fire resistant filler or mortar is then inserted between the blocks or the spaces described between adjacent bricks 63 and the wall modules 6 of the modular dome structure 5 is covered with an insulative material (not shown).

[0100] The hood 3, 103 is then placed over the so-covered modular dome structure 5, such that the lower edge of the hood 3, 103 rests on the ledge and the tabs 38, 138 are inserted into the hood registration slots 78a, 78b. The chimney 4 is then mounted to the hood 3, 103 and the oven 1 is ready for use.

[0101] It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention. For example, the arch segment wall modules 60 may have more or less spines 65 and/or keys 66 and/or bricks 63. The bricks 63 need not be offset and/or hinged to one another. The modular dome structure 5 need not be substantially hemispherical. It may be pyramidal or any other polygonal shape or otherwise.

[0102] The registration plate 72 may be replaced with a base having some other form of registration feature(s) or keyways formed therein or may be omitted entirely. The registration feature(s) of the base may comprise a projection, ridge or key and/or the registration features of the wall modules 60 may comprise a recess, notch or keyway. Alternatively, the registration features of the wall modules 60 may comprise a projection, ridge or key and/or the registration feature(s) of the base may comprise a recess, notch or keyway. In such cases, the wall modules 60 may merely rest on the base or registration plate 72. Additionally or alternatively, the modular dome structure 5 may comprise a strap secured to and wrapped around at least some of the wall modules 60 and/or the base.

[0103] In some examples, the modular dome structure 5 is replaced with a unitary structure over which the hoods 3, 103 may be removably mounted. It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.