Electro-mechanical energy regulator providing enhanced simmer performance

Abstract

An electro-mechanical energy regulator for controlling an application of power supplied to a heating element of a cooking appliance that provides simmer operation is provided. The temperature and/or mode of operation is made via a user interface knob that is coupled to a switching control cam. This cam has an outer profile configured to drive a switching element via a power switch cam follower to close two power line contacts to power a heater. The heater drives a bimetal element whose deflection forces a temperature control switching element to close to enable power to flow to the heating element. The regulator also includes a cooking mode selector operable to open and close a pair of electrical contacts coupled in series with the heating element, and a diode coupled in parallel with the pair of electrical contacts.

Claims

1. An electro-mechanical energy regulator for controlling an application of power supplied to a heating element of a cooking appliance based on a user selection of a temperature and/or mode of operation via a user interface knob that is coupled to a switching control cam having an outer profile configured to drive a switching element via a power switch cam follower to close two power line contacts to power a heater to drive a bimetal element whose deflection resulting from heating thereof forces a temperature control switching element to close to enable power to flow to the heating element, comprising: a cooking mode selector operable to open and close a pair of electrical contacts coupled in series with the heating element; and a diode coupled in parallel with the pair of electrical contacts.

2. The regulator of claim 1, wherein the cooking mode selector is an auxiliary switch control cam, and wherein a position of the pair of electrical contacts is controlled via an auxiliary switch cam follower operatively coupled to the auxiliary switch control cam.

3. The regulator of claim 2, wherein an outer surface of the auxiliary switch control cam is configured to cause the auxiliary switch cam follower to close the pair of electrical contacts during normal cooking modes and to cause the auxiliary switch cam follower to open the pair of electrical contacts during simmer cooking modes.

4. The regulator of claim 3, wherein the diode is shorted out by the pair of electrical contacts to allow full wave power flow to the heating element during the normal cooking modes, and wherein the diode allows only half wave power flow to the heating element during the simmer cooking modes.

5. The regulator of claim 2, wherein the auxiliary switch control cam is operatively coupled to the switching control cam such that rotation of the user interface knob also operates to rotate the auxiliary switch control cam.

6. The regulator of claim 5, wherein the auxiliary switch control cam and the switching control cam are a single cam having at least two cam tracks, one of the at least two cam tracks operatively coupled to the power switch cam follower and another of the at least two cam tracks operatively coupled to the auxiliary switch cam follower.

7. The regulator of claim 5, wherein the auxiliary switch control cam and the switching control cam are a single cam having a single cam track operable to control both the power switch cam follower and the auxiliary switch cam follower.

8. The regulator of claim 1, wherein the cooking mode selector is a push button operable to close the auxiliary switch contacts upon user activation of the push button.

9. An electric power controller for controlling a cooking temperature of a heating element of a cooking appliance, comprising: an infinite switch having a pair of electrical inputs and a pair of electrical outputs configured to control a duty cycle of power application to the heating element in both a cooking and a simmer mode of operation; a pair of electrical contacts coupled in series with one of the pair of electrical outputs of the infinite switch and the heating element; and a diode coupled in parallel with the pair of electrical contacts.

10. The controller of claim 9, wherein the infinite switch includes a user rotatable switching control cam having an outer profile configured to drive a switching element via a power switch cam follower to close two power line contacts to power a heater to drive a bimetal element whose deflection resulting from heating thereof forces a temperature control switching element to close to enable power to flow between the pair of electrical outputs to the heating element.

11. The controller of claim 10, wherein the infinite switch includes an auxiliary switch control cam, and wherein a position of the pair of electrical contacts is controlled via an auxiliary switch cam follower operatively coupled to the auxiliary switch control cam.

12. The controller of claim 11, wherein an outer surface of the auxiliary switch control cam is configured to cause the auxiliary switch cam follower to close the pair of electrical contacts during normal cooking modes and to cause the auxiliary switch cam follower to open the pair of electoral contacts during simmer cooking modes.

13. The controller of claim 12, wherein the diode is shorted out by the pair of electrical contacts to allow full wave power flow to the heating element during the normal cooking modes, and wherein the diode allows only half wave power flow to the heating element during the simmer cooking modes.

14. The controller of claim 11, wherein the auxiliary switch control cam is operatively coupled to the user rotatable switching control cam such that rotation of the user interface knob also operates to rotate the auxiliary switch control cam.

15. The controller of claim 14, wherein the auxiliary switch control cam and the user rotatable switching control cam are a single cam having at least two cam tracks, one of the at least two cam tracks operatively coupled to the power switch cam follower and another of the at least two cam tracks operatively coupled to the auxiliary switch cam follower.

16. The controller of claim 14, wherein the auxiliary switch control cam and the user rotatable switching control cam are a single cam having a single cam track operable to control both the power switch cam follower and the auxiliary switch cam follower.

17. The controller of claim 10, wherein the infinite switch includes a push button operable to close the pair of electrical contacts upon user activation of the push button.

18. An electro-mechanical energy regulator, comprising: a first electrical input coupled to a first power line contact; a first electrical output coupled to a second power line contact, the first electrical output configured to be coupled to a first contact of an electrical load; a rotatable power switch cam operably coupled to a first cam follower to open and close a first connection between the first power line contact and the second power line contact; a second electrical input coupled to a third power line contact; a fourth power line contact coupled to a first auxiliary contact; a second electrical output coupled to a second auxiliary contact, the second electrical output configured to be coupled to a second contact of the electrical load; a diode electrically coupled between the first auxiliary contact and the second electrical output; a rotatable auxiliary switch control cam operably coupled to an auxiliary switch control cam follower to open and close a second connection between the first auxiliary contact and the second auxiliary contact; wherein the rotatable power switch cam and the rotatable auxiliary switch control cam are operably coupled together; and wherein a third electrical connection between the third and fourth power line electrical contacts is controlled by a bimetal element and a heater that is energized when the first power line contact and the second power line contact are closed.

19. The regulator of claim 18, wherein the first and the second auxiliary contacts are closed during a cooking mode of operation to enable bidirectional power flow between the first and the second electrical outputs.

20. The regulator of claim 18, wherein the first and the second auxiliary contacts are open during a simmer mode of operation to enable unidirectional power flow between the first and the second electrical outputs.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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:

(2) FIG. 1 is a simplified schematic representation of an embodiment of an electro-mechanical energy regulator, or infinite switch, used in a cooking appliance to provide enhanced, long term, simmer performance;

(3) FIG. 2 is a voltage waveform diagram illustrating normal cooking cycle, i.e. non-simmer, performance of the infinite switch of FIG. 1; and

(4) FIG. 3 is a voltage waveform diagram illustrating simmer cooking cycle performance of the infinite switch of FIG. 1.

(5) 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

(6) Turing now to the drawings, there is illustrated in FIG. 1 a simplified schematic diagram of an embodiment of the electro-mechanical energy regulator, also known as an infinite switch 10, constructed in accordance with the teachings of the present invention. It should be noted that while the following description will describe such embodiment in the context of a cooking appliance, such description should be taken by way of example and not by way of limitation. Also, such description will describe the representative embodiment shown in the drawings in the context of the functional operation and construction thereof, but should not be taken as limiting such functional operation or construction to that shown in the illustrated embodiment.

(7) As shown in FIG. 1, the infinite switch 10 is utilized in a cooking appliance as a control mechanism for application and control of power from two power phase lines 12, 14 of the input line power from the utility for 240 volt operation. This application of power is based on a user selection of a temperature and/or mode of operation via a user interface knob that is coupled to a cam 16. As the cam 16 is rotated, its outer profile will drive switching element 18 via its cam follower 20 to close contacts 22, 24. Once closed, power from power phase line 14 is available to the heater 26 to drive the bimetal element 28. Deflection of the bimetal element 28 resulting from the heating thereof will force switching element 30 to close contacts 32, 34. When both of the contact sets 22, 24 and 32, 34 are closed, the heating element load 36 is energized, as will be discussed in the various modes more fully below, to heat the food to be cooked thereon.

(8) As will be recognized by those skilled in the art familiar with infinite switches in the appliance industry, e.g., the M Series energy regulators available from Robertshaw Controls Company of Carol Stream, Ill., the control of the heater 26 to vary the duty cycle of the switching of contacts 32, 34 provides the different cooking temperature settings that correspond with the rotational position of the user knob and cam 16. Therefore, a description of such operation is foregone herein in the interest of focusing on the novel and non-obvious advances over such conventional infinite switch operation.

(9) The rotational position of the knob and cam 16 also controls the cooking mode, e.g., simmer or normal temperature control as is also known. However, unlike conventional infinite switch configuration and operation, the embodiment of the present invention illustrated in FIG. 1 includes an auxiliary switching element 38 interposed between the output 40 and load 36. A diode 48 is connected in parallel with the auxiliary switch 38.

(10) The condition of the auxiliary switching element 38, i.e. whether contacts 42, 44 are opened or closed, is controlled by the rotational position of cam 16A via cam follower 46. As illustrated by dashed line connecting cam 16 and cam 16A, in one embodiment of the present invention rotation of the knob and cam 16 by the user also operates to rotate cam 16A. In other embodiments, cam 16 and cam 16A may be embodied as a single cam having multiple cam tracks for cam followers 20, 46, or a single cam track operable to control both cam followers 20, 46. In yet other embodiments, operation of auxiliary switch 38 may be via a push button operable to close contacts 42, 44 upon user activation of a delicate simmer mode via the push button.

(11) In normal cooking modes of operation, the contacts 42, 44 of the auxiliary switch 38 are closed in order to allow control over the power flow to load 36 to be accomplished directly by the opening and closing of contacts 32, 34 by the heater 26 as in a conventional infinite switch. When the contacts 32, 34 are closed, the voltage supplied to the load 36 is the normal full wave supplied between the two phases 12, 14 of the utility power as shown in FIG. 2. This full wave power is supplied to the load 36 until the bimetal element 28 causes the contacts 32, 34 to open at the end of the heating duty cycle period. The percent on-time of such heating cycle is varied via the position of the know and cam 16 as is known in the art to vary the cooking temperature.

(12) Once the user activates the simmer mode of operation, via rotation of the knob and cams 16, 16A in the embodiment shown in FIG. 1, the cam follower 46 causes contacts 42, 44 to open due to the profile of the cam 16A. The length of the reduced radius arc of cam 16A allowing the cam follower 46 to open contacts 42, 44 corresponds to the various selectable temperatures in the simmer mode, and may vary depending on the design of the particular appliance. In other embodiments, the length may extend over only a portion of the simmer mode, preferably over the delicate simmering temperatures at the lower end of the on-time duty cycles available.

(13) When contacts 42, 44 are opened in such a simmer mode of operation, power flow to the load 36 through contacts 32, 34 is subject to operation of diode 48. This diode 48 is normally shorted out by contacts 42, 44 during normal cooking modes, thereby allowing full wave power flow to the load 36 as shown in FIG. 2 discussed above. However, in the simmer modes when contacts 42, 44 are open, only half wave power flow to the load 36 as shown in FIG. 3 is allowed. As the voltage between the two phases 14, 12 goes negative, diode 48 operates to block current flow from one phase 12 to the other phase 14, resulting in half wave power being applied to load 36.

(14) In such an embodiment lower duty cycles can be calibrated, e.g., 1%-4.5%, with the same mechanical switching of contacts 32, 34 as the conventional infinite switch, e.g. 2%-9%. This is because the power to the load 36 is halved via operation of diode 48. Alternatively or additionally, the same duty cycles in terms of power delivered can be held more consistently over time. That is, with half wave power flow to the heating element load 36, a 2% duty cycle power would be the mechanical equivalent to a 4% duty cycle switching with the prior infinite switch. Because of this, a 2% shift over time due to changes in the mechanical tolerance variations would only cause the infinite switch of the embodiment of FIG. 1 to change from 2% to 1% duty cycle power flow, instead of 2% to 0% with the prior infinite switch. In other words, the provision of half wave power during simmer operation allows for calibration at twice the on-time percentage to achieve the same simmer temperature performance, and therefore, a 2% tolerance shift over time continues to allow switching control operation whereas the prior infinite switches stopped switching altogether. In applications where the component drift issues are not significant, then the enhanced lower duty cycle performance of 1% to 4.5% duty cycle allows for a greater precision of adjustment of simmer temperature.

(15) 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.

(16) 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.

(17) 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.