U.S. patent application number 11/232050 was filed with the patent office on 2007-03-22 for cooking system with ventilator and blower.
Invention is credited to John M. Gagas.
Application Number | 20070062513 11/232050 |
Document ID | / |
Family ID | 37882839 |
Filed Date | 2007-03-22 |
United States Patent
Application |
20070062513 |
Kind Code |
A1 |
Gagas; John M. |
March 22, 2007 |
Cooking system with ventilator and blower
Abstract
An indoor or outdoor cooking system with integrated downdraft or
elevating ventilator uses cross-flow or centrifugal blower
technology. The system is controlled by an electronic or mechanical
controller through a touch device, a slide, or knob. These provide
precise control and an efficient way of removal of gases/fumes. A
cook top incorporates the heating elements and a downdraft. The
ventilator's blower assembly has a fan and a filter. The system may
use sensors to detect temperature, fire, effluent, filter change
requirements, fan speed, power, and voltage. The system has
programmable operations and numerous set points.
Inventors: |
Gagas; John M.; (Milwaukee,
WI) |
Correspondence
Address: |
BOYLE FREDRICKSON NEWHOLM STEIN & GRATZ, S.C.
250 E. WISCONSIN AVENUE
SUITE 1030
MILWAUKEE
WI
53202
US
|
Family ID: |
37882839 |
Appl. No.: |
11/232050 |
Filed: |
September 21, 2005 |
Current U.S.
Class: |
126/299D |
Current CPC
Class: |
F24C 15/2021 20130101;
H05B 6/1263 20130101; F24C 15/2042 20130101 |
Class at
Publication: |
126/299.00D |
International
Class: |
F24C 15/20 20060101
F24C015/20 |
Claims
1. An appliance comprising: a cook top having at least one cooking
element; a vent system operably connected to the cook top; and a
cross-flow blower assembly operably connected to the vent
system.
2. The appliance of claim 1, wherein at least one of the cooking
elements is an induction hob assembly.
3. The appliance of claim 1, wherein at least one of a centrifugal
blower motor, squirrel cage wheel, blower housing assembly, large
plenum chamber assembly are replaced with the cross-flow blower
assembly.
4. The appliance of claim 1, wherein the cross-flow blower assembly
further comprises a cross-flow fan, a wheel, and a housing that are
attached below the cooktop and provide direct communication to an
opening in the vent system.
5. The appliance of claim 1, further comprising storage space below
the blower assembly.
6. The appliance of claim 1, wherein the cross-flow blower assembly
further comprises a fan, a variable speed fan motor, an electrical
current regulator such that motor power output can be increased or
decreased to change the air output accordingly as needed, and a
detector for monitoring airflow draw.
7. The appliance of claim 1, wherein the vent system includes at
least one of: an automatic, semi-automatic, or manual controlled
ventilator, and a user interface to set, operate, and adjust the
ventilator.
8. The appliance of claim 6, wherein the fan motor has multiple
selectable or preset speed levels.
9. The appliance of claim 1, wherein a cross-flow blower assembly
further comprises a fan that is used as a power vent for removing
air and mixing air, and for management of moisture; and sensor for
sensing the same.
10. The appliance of claim 1, further including at least one of:
controls for controlling the vent system that are integrated with
the cook top; electronic controls that use: a tactile, membrane,
piezo, capacitance, resistance, induction system, touch panel, or
keypad for selection of operations; controls constructed of glass,
metal or plastic; operating functions made by touching a surface of
the cook top constructed of glass, metal, or plastic; controls
flush, raised, recessed, or remotely installed in any plane or on
any surface of the appliance; and a control remotely controlled by
wired or by wireless electronics and located not on the
appliance.
11. The appliance of claim 1, further including a control display
mounted on a top, front, or side of the vent system or appliance
for easy viewing.
12. The appliance of claim 1, further including an electronic
control housing that is detachable from vent system.
13. The appliance of claim 1, further including a control device
with graphics.
14. The appliance of claim 1, wherein the cook top is a slide-in,
drop-in, or outdoor unit type.
15. The appliance of claim 1, further including at least one
additional cross-flow blower assembly and vent system.
16. The appliance of claim 1, further including at least one of: an
AC or DC powered electronic, mechanical, electromechanical sensor
for detecting at least one of temperature, resistance, and current
to aid in the control of the assembly.
17. The appliance of claim 1, further including at least one of: a
sensor used for detecting and controlling speed for a fan/blower;
an airflow sensor for detecting the flow of air past a filter; a
sensor to scan the surface of the work area for an item placed on
the work area and to control automatic operation of the vent
system; an ultrasonic flow, digital CO2 gas, and NDIR gas sensor
that has the ability to detect backpressure in an exhaust stream
from or as a result of strong winds at a house discharge vent; a
sound-activated system for controlling a vent system; and blower
operations synched with cooking controls.
18. The appliance of claim 1, wherein the vent system is at least
one of: fixed, retractable, and free-standing when used with a
counter, island, wall, or mobile unit.
19. The appliance of claim 1, further including warmer drawer below
the assembly.
20. The appliance of claim 1, further including at least one of: a
display for showing operation, function, speed, blocked filter, or
time; an LED, LCD, Plasma, dot matrix, or vacuum fluorescent
mechanism; and a rotating or popup display.
21. The appliance of claim 1, further including at least one of: a
true timed on/off control; a programmable set point; programmable
set time; programmable set operation; programmable set temperature
for turn on; and programmable filter change requirement based on
air flow.
22. An appliance comprising: at least one cooking element; a
ventilator in communication with the element; a cross-flow blower
in communication with the ventilator; and a heat exchanger in fluid
communication with the blower.
23. A cooking system comprising: a burner; a ventilator operably
communicating with the burner; a blower assembly operably connected
to the ventilator; a filter drawer placed below the ventilator; and
a filter placed at an angle in the drawer.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention pertains to cooking appliances and,
more particularly, to an appliance with a ventilation system having
a fixed or adjustable ventilator and an adjustable blower.
[0003] 2. Discussion of the Related Art
[0004] Many different types of cooking appliances produce smoke,
steam, or other gaseous contamination during use. Often, it is
considered beneficial to utilize some type of ventilation system to
evacuate this air borne contamination, either upward through a
venting hood or downward into a draft flue. In kitchens, most known
venting arrangements take the form of a hood which is fixed above a
cooking surface and which can be selectively activated to evacuate
the contaminated air. Downdraft vent arrangements are also widely
known in the art wherein a cooking surface will incorporate a vent
opening that is positioned between different sections of the
cooking surface or extends along a back of the cooking surface.
These downdraft vents can either be fixed relative to the cooking
surface or can be raised relative to the cooking surface to an
operating position.
[0005] Downdraft blowers are generally multiple speed fans, having
a low speed and a high speed. Blowers are typically controlled by a
mechanical multi-position switch, potentiometer, or rheostat type
control, which set the speed of the fan. For removal of normal
cooking odors, steam, and other effluents and contaminates, low
speed operation of the downdraft blower has been adequate. However,
when using such a cooking system such as a grill, a blower set at
high speed has been better able to withdraw all of the grease laden
air from a kitchen and duct it to the outside environment. In
systems, such as cook tops and grills with optimized proximity
ventilation, cooking gases, vapors and odors are drawn into an
exhaust inlet and are exhausted into the atmosphere. Usually, the
exhaust inlet or vent is located adjacent the cooking surface. The
inlet flow path serially includes a plenum, a blower, an
atmospheric exhaust, and interconnecting ductwork. The flow path to
the atmosphere normally extends through a wall or floor of the room
in which the cooking system is located, but can also be exhausted
into a room if filtered.
[0006] The blower/fan is frequently a generally separate unit from
the rest of the cooking system and is installed prior to the
installation of the unit into a counter top. Some blower systems
are provided with a pair of brackets, which permits the selective
mounting of the blower to the floor or the appliance itself for
discharge either through a wall or through the floor, as required
by the installation. Conventional downdraft venting system
configurations with an exhaust air inlet located at cook top level
work well with electric surface units. However, when used in
combination with gas on glass surface units, the downdraft induced
air flow at the cook top surface tends to interfere with the gas
flame.
[0007] A cooking system using electrical or gas heating for cooking
purposes is normally constructed of a metal housing and a
supporting glass or other cooking surface. The housing normally
contains an electronic or gas package for use in supplying heat to
the element and/or surface and the pot or other container thereon.
This package consists of a group of interconnected components, such
as, coils with wires that are mounted within the housing.
[0008] Because of the heat generated by the package, it is often
necessary to provide some form of cooling for the package. Fans
have been found to be the least expensive and most reliable cooling
solution. The known drawback here, though, has been the sensitivity
of the air flow, or disruption of which causes failure or reduced
energy for operation of the system.
[0009] In order to operate for a prolonged period without the
system breaking down/turning off, it is necessary then to use a fan
that circulates air throughout the interior of the cooking system
housing so as to maintain the proper temperature for the heating
components employed. Failure to keep the element cool results in
loss of power to the cooking product or a complete unit shutdown.
Normally, such a fan or blower is connected into the circuit used
to supply power to the electronic components and, thus, is
automatically turned on each time the cooking element/generator is
turned on. However, to avoid overheating, the fan often remains on
after shutdown of the cooking elements so that heated air within
the cooking system housing can be removed until a proper safe
temperature level is obtained.
[0010] While the use of a fan in this manner is desirable in
preventing heat-caused damage to the electronic components
employed, it is also considered a disadvantage. The use of a fan
has two problems when used for cooling a cook top. First, noise is
often associated with the fan's operation. Too many users find this
noise to be objectionable. Further, the use of a fan alone is
considered a problem because if air flow is blocked, the unit must
be completely shut down for safety reasons. However, a user does
not take into consideration whether or not there is heat buildup
present within a housing, rather only noting that the unit failed
to operate.
[0011] Although it is possible to use other methods to prevent
overheating, e.g., by the use of thermostats and various related
known temperature sensing apparatus for controlling the flow of
current in an electrical circuit, it is known that relying solely
on such expedients is undesirable for any of a variety of reasons,
including effectiveness, cost, and reliability.
[0012] As noted, many conventional cook tops often have integrated
downdraft ventilators. Present designs have long rectangular boxes
extending below the glass or metal cook top as much as 30 inches. A
blower assembly is attached to this box or plenum and extends
therefrom. The plenum does not in some cases provide any sealing to
prevent the drawing of air from the box. Included in the typical
downdraft assembly are: the blower housing assembly, squirrel cage
housing assembly, centrifugal wheel, blower motor assembly, plenum
chamber assembly, and a passage between the cook top and the plenum
chamber for removal of air from the top surface of the appliance.
The box is often of a single-walled or a double-walled construction
if you include the cook top box/housing and has insulating air in
between the plenum and cook top housing. An opening is provided to
the interior of the box for exhausting. The centrifugal type
fan/blower may be housed in the squirrel cage housing assembly with
both attached to the plenum. Alternatively, such a single fan
blower may also be attached to the side of the plenum with air flow
at 90 degrees from the side of the plenum.
[0013] Blowers have been generally designed to draw air downwardly
with the use of a centrifugal type fan, and thus remove
contaminated air from a cook top surface to a box, remove the
interior air from the box, and exhaust it outside or return to the
room. A centrifugal fan creates higher pressures than that of an
axial flow fan. In such conventional systems, the air flow stream
is pulled from the front and sides of the work area to the middle
where the ventilator is. The air stream has to then turn 90 degrees
downwardly, once inside the plenum chamber. The air stream has to
then turn 90 degrees again into a small diameter opening when
compared to the size of the ventilator's plenum chamber. Once the
air stream enters the blower flow, it usually is redirected
downwardly again for exhausting. With all this bending of the air
stream, air is lost. Thus, large amounts of draw/vacuum/suction are
needed to overcome all these losses. With the need for more
draw/vacuum/suction comes a larger fan/blower motor, which
increases costs, noise, size, and weight.
[0014] Present centrifugal fans consist of a wheel with small
blades on the circumference and a shroud to direct and control the
air flow into the center of the wheel and out at the periphery. The
blades move the air by centrifugal force, literally throwing the
air out of the wheel at the periphery, creating a vacuum/suction
inside the wheel. There are two basic design types of wheel blades
in centrifugal blowers--forward curved blades and backward inclined
blades.
[0015] Forward curved wheels are operated at relatively low speeds
and are used to deliver large air volumes against relatively low
static pressures. However, the light construction of the forward
curved blade does not permit this wheel to be operated at speeds
needed to generate high static pressures. Thus, this type is
generally not used in downdraft ventilators.
[0016] The backward inclined blade blower wheel design has blades
that are slanted away from the direction of the wheel travel. The
performance of this wheel is characterized by high efficiency, high
cubic foot per minute (CFM) operation and is usually of rugged
construction making it suitable for high static pressure
applications. The maximum static efficiency for these types is
approximately 75 to 80%. A drawback to this type is that it must be
designed for twice the speed, which increases the cost of the
unit.
[0017] To date, axial flow fans are not used for such cook top
venting as it was believed that they could not provide the static
pressures needed for drawing/vacuum/suction, size, and spacing
requirements. Axial flow fans come in three basic types of fans.
The propeller fan (e.g., the household fan), the tube axial fan,
and vane axial fan (cross-flow or tangential). The first of these
is the most familiar. The propeller fan consists of a propeller
blade and a so-called "aperture" to restrict blowback from the
sides. Without the aperture, the fan is not truly a propeller fan,
since it cannot positively move air from one space to another. The
aperture is usually sheet metal/plastic designed to fit closely
around the periphery of the propeller. The tube axial fan (found in
computers) is literally a propeller fan in a tube. In this case,
the tube replaces the aperture. The tube axial fan generally
increases flow quantity, pressure, and efficiency due to the
reduced air leakage at the blade tips. The vane axial fan
(cross-flow or tangential) is a tube axial fan with the addition of
vanes within the tube to straighten out the air flow. Here, the air
flow changes from helical flow imparted by the propeller into a
more nearly straight line flow and in the process increases the
suction or draws pressure and efficiency while reducing noise. In
general, the propeller fan operates at the lowest pressure. The
tube axial fan is somewhat higher, and the vane axial fan supplies
the highest-pressure output of the three. Vane axial fans are used
when available space for installation is limited, such as that of
computers. Static efficiencies of at least 70 to 75% are achieved
with vane axial fans. The CFM and static performance ranges of the
vane axial fan are similar to that of a centrifugal fan. Horsepower
requirements are also about the same for both designs.
[0018] The present downdraft ventilator designs also present
problems when integrated into a cook top. Because of the low
profile, spilled food and liquids can enter the grate. Removal of
these items is difficult when not captured by the filter. This is
due, in part, to the deep depth of the plenum and the narrow box
size.
[0019] The present design of ventilators is also often large and
bulky. Examples would be downdraft ventilators built into a cabinet
or used on an island counter top. There, space below the unit is
not available for a user to use for storage due to the centrifugal
blower below and the size of the plenum presently used. Large size
also limits the downdraft ventilator from being placed in other
areas or used with other products below the cook top. This also
limits the downdraft ventilator from being used as a freestanding
unit, as a mobile unit, used in a cabinet (e.g., suspended), or in
areas that do not have the ability to support a large structural
frame below.
[0020] The below-referenced U.S. patents disclose embodiments that
were at least, in part, satisfactory for the purposes for which
they were intended. The disclosures of all the below-referenced
prior United States patents in their entireties are hereby
expressly incorporated by reference into the present application
for purposes including, but not limited to, indicating the
background of the present invention and illustrating the state of
the art.
[0021] U.S. Pat. No. 3,859,499 discloses an air flow system for
heat-cleaning ranges in which room air is drawn through air inlets
located along the sides and top of an oven opening. The air passes
through a space between the range's outer casting and the inner
oven cabinet. A blower draws air into the upper air flow passageway
during an oven heat-cleaning cycle. The blower exhausts air to the
atmosphere through a vented splash panel.
[0022] U.S. Pat. No. 6,821,31, entitled "Kitchen air filtration
system" discloses an improved air filtration system for a kitchen
island to cleanse cooking vapors from the air. The system includes
an updraft or downdraft air inlet vent for capturing, either
individually or simultaneously, the vapor-containing air generated
during the cooking process. The captured air is directed through an
exhaust duct to an air filter which removes the cooking vapors from
the air. The filtered air is then discharged back into the kitchen.
The filtered air may also be dehumidified or heated, and a
fragrance may optionally be provided to the filtered air. The air
filtration system can also be used simply as air cleaner for the
kitchen with the option of adding a fragrance to the air.
[0023] U.S. Pat. No. 6,455,818, entitled "Downdraft filter assembly
for a cooking appliance" discloses a filtering system for a
downdraft cooking appliance. A filter assembly is arranged directly
below an air grill leading to a venting plenum. The filter assembly
includes a liner which supports a filter element and is removably
positioned inside the plenum. The filter element can be arranged
inside the liner, attached thereto or insert molded into the liner
material. The liner is preferably suspended from the air grill so
as to be readily removable in unison with the grill for inspection,
cleaning or replacement. In a preferred embodiment, the liner is
formed with opposing, outwardly projecting flanges which slide into
mating channels formed into the underside of the grill. With this
arrangement, exposure of the wall surfaces of the plenum to the
cooking byproducts is minimized, thereby greatly reducing any
necessary cleaning of these surfaces.
[0024] U.S. Pat. No 6,119,680, entitled "Ventilation system for an
appliance" discloses a ventilation system for an appliance, such as
a clothes dryer or a cooking device. The invention includes a
blower unit located remotely from the appliance and connected to
the appliance through an elongated duct. To control the operation
of the blower unit, a transmitter is used to send signals to a
receiver electrically connected to the blower unit. In accordance
with certain preferred embodiments of the invention, radio
frequency, ultrasonic or other similar types of signals are
directed through the duct to the receiver. In accordance with
another preferred embodiment, a power line transmitter is utilized.
A method of remotely controlling the operation of the appliance
ventilation system is also provided.
[0025] However, as the above attempts are lacking, there exists a
need for a state-of-the-art cooking system with an integrated
downdraft or a elevating ventilator using cross-flow or centrifugal
blower technology to accurately control speed, power, voltage,
venting, and noise, reduce weight, cost, and size, and better
remove contaminates. There also exists a need for an accurate
method of controlling the system's operations and a need for the
user to be able to view/see the operations, speeds, set points,
functions, and the contents on the cook top. There is also a need
for a proper vent design so that drawn air does not improperly
remove air at the burner and a need for a system that is easy to
clean and maintain.
[0026] Further, there is a need for controls to be less susceptible
to the environment, a need for a remote control, a need to
accurately apply and control heat output as it is returned to the
room, and a need for a new design that can be used in a variety of
places and spaces.
SUMMARY OF THE INVENTION
[0027] The inventive cooking system preferably has a fixed or an
elevating ventilator integrated into a smooth glass ceramic cook
top for removal of contaminated air. The system may also
incorporate a cross-flow or centrifugal blower system for the
source of air removal device. Further, a cook top with integrated
downdraft or elevating ventilator using cross-flow or centrifugal
blower may be combined with other counter top range items to reduce
the need for an over-the-head (updraft) type ventilator and
increase space below.
[0028] Such a system preferably includes a cook top/grill, built-in
range, or other cooking appliance. It has a single to a plurality
of/inductor heating elements located on a counter, range, or other
surface. However, this inventive system may also use gas or
electric type heating elements found on appliances. The ventilator
preferably includes a base housing or plenum and cross-flow blower
assembly. The base housing is attached to a cook top or other
surface and is preferably permanently fixed. The plenum is
preferably only as deep as a cook top housing member and is
preferably sealed to the glass/metal to prevent leaking of air. The
invention preferably incorporates a keypad and control circuit,
which enables adjustment of the fan speeds and sensors. The control
of the ventilator may be integrated into present controls, located
on or under the cook top, remotely located, or parts of the
keypad/control can be split between the ventilator and other
locations. The controls may include an electronic control board
that may be located on the cook top, or remotely, or parts of the
electronic control board may be split between the cook top and
other locations. The control board also preferably determines that
a stop/obstruction is present by the increase in current, air flow,
voltage, or resistance, and accordingly adjusts or turns off the
power supply.
[0029] In one embodiment, the present invention is preferably a
cook top with integrated downdraft or elevating ventilator using an
electronically controlled cross-flow or centrifugal blower
technology assembly. It preferably includes a cook top housing
assembly, a cross-flow blower assembly, a ventilation system, a
ceramic glass cook top, an opening for the vent or downdraft, and a
filter. The cross-flow blower assembly is composed of a motor item,
a fan wheel with blades, and a blower housing preferably attached
to an air passage in the cook top housing. These items, motor, fan
wheel, housing may be one assembly or may be made so as to be
separate components integrated into a plenum. Seals are provided
for sealing the space between plenum or base housing and walls in
the passage created by the cook top housing. The seal also
preferably makes contact with the vent or grate member to provide
sealing on the cook top. It is also important that the sealing
provide a barrier to the air flow so as not to disrupt the cooling
air to the generator in any way. This provides for better air loss
control and reduces side air removal. This method need not use the
double wall construction used in centrifugal types. In another
embodiment, the plenum may be part of the cook top passage. The
cross-flow blower may be preferably attached to the cook top
housing. This single box design reduces the cost of
manufacturing.
[0030] A cross-flow blower assembly may be used as long as the
surrounding surfaces can take the air movement and not be
interfered with. In one embodiment, air moves down the passage of
the cook top lower housing to the blower assembly from an opening
in the glass ceramic cook top surface. The advantage to using this
method is that the base plenum housing is eliminated and the need
for sealing from the base plenum housing to the cook top member is
eliminated. Note, however, that a centrifugal type blower assembly
may also be used.
[0031] It should be noted that the downdraft ventilator may consist
of multiple cavities or compartments in the same appliance or
multiple fans/blowers and that the invention may be built into/on a
mobile island or cart for use with grilling/cooking equipment. A
mobile unit is preferable so one does not need to have it installed
into/on a cabinet or structural or supporting frame and thus there
is now space below for use by the user.
[0032] Preferably, the construction of the present invention
includes a smooth glass, ceramic, metal, etc. cook top with a
ventilation system that provides air flow for cooling the heating
elements, electronics, and cook top. Because of the invention's
constructions, methods, and designs, one may have nearly limitless
designs, features, appearances, elevations, styles, operations,
sensing, and performances for both fixed and elevating downdrafts.
Further, with the ability to properly seal/isolate the ventilator,
one can have great flexibility in ventilator shapes. Moreover,
there are a number of fans/blowers used. Such fans/blowers come in
many shapes and sizes and may be formed and bent into nearly any
shape. These fans/blowers may be located along/on the cook top's
housing or any other surface. Using such a fan/blower improves air
removal throughout the inside cavity. The use of two or more
fans/blowers can improve on the air removal in the inner cavity and
exhausting. See, e.g., FIG. 4. The use of a variety of electronics
and controls for the blower may also greatly improve on the removal
of contaminated air. Greater control means less flow loss and fan
noise and smaller overall blower size. Preferably, the assembly of
a fan/blower assembly is comprised of a housing, fan, and motor
assembly with bearings to support the fan and motor on the
housing.
[0033] Blower/motor specifications can significantly influence the
performance and reliability of cooking units. First, placing the
blower assembly as close to the items on a cook top location as
possible increases the effectiveness of drawing contaminated air in
and out of the vent system. Second, reducing the number of bends
the air has to flow through and around helps reduce air flow
losses. Also, a cross-flow blower does not need the air stream to
change directions, as does a centrifugal type fan/blower. Further,
using a cross-flow blower increases in effectiveness, and thus
permits the size of the blower/motor to be reduced. Thus, the noise
level is reduced. Long-wheeled cross-flow blowers and tangential
blowers provide other advantages including wide uniform air flow
over the width of the unit without gaps, uniform air delivery for
high capacity geometry that results in a significantly quieter
blower/fan and a smaller profile for the same length of exterior
housing. Good speed control of such blowers may be achieved by
using electronics like resistors, regulating transformers, and
voltage regulators. Other advantages include: the ability to design
for overload protection, no warming of the air as the motor is
situated outside the air flow, longer bearing life, and higher
efficiency. The energy saving from not having to turn on a large
blower motor provides added benefits to the user in the way of cost
saving. Another added benefit is a unit with a lower profile so
that there is more useable room under a range/cook top or in a
cabinet. Finally, the fan may be used for not only ducting heated
air and effluent but also moisture.
[0034] The present invention preferably also includes a control
board and related circuitry to control power/control to the motor,
control to the fan(s)/blower(s), control to an electronic
controller, glass touch pad, or mechanical controls. Controls can
be built with power control to sensors. AC or DC power supplies the
electronic current to the board and other components. As mentioned,
the control board can be located on/in the cook top or remotely. It
can also be divided into more than one board and located at
different locations. The electronic board also can use flex
technology, which permits the board to be or bend into any shape.
There are a number of types of controls that may be connected to
the board. For example, one control may have a real or simulated
mechanical look with electronics below and a knob for turning on
the top. Also, a rotary encoder for high precision sensing and
control or for position detection may be present for control at
different heating levels.
[0035] The present invention may further include a passage in the
cook top housing that provides for a filter. While typically found
in the opening called the "plenum", there are a number of ways to
attach filters including attaching the filter into a recess in
order to lock the filter in place, snapping into or dropping into
place, or using a filter tray.
[0036] A sensor may be used with the filter for the detection of
air flow. Such a sensor improves on the efficiency and required
servicing of the filter. A flow sensor in, on, or behind the filter
area and communication with the electronic control board preferably
detects the movement or reduced movement of air passing by the
sensor. This air movement may have set limits as to when the filter
needs changing. These limits can be adjusted for the type of filter
used, which may be metal mesh, louver, carbon, or a combination of
these types. A different way is to have the electronic control
board set the change out limits automatically based on percentage
of flow blockage.
[0037] Other sensors for air flow may include the simplest and
lowest cost types such as a strain gage on a reed, in which the air
moving across the reed bends the reed causing the strain gage to
send a signal to an electronic control board system. In such a
system, as the air is reduced, the signal changes and the
electronic control board signals the user to change the filter.
Signaling the user may be by sound or by lights or other methods
such as "system not operating" or a combination of signals. Another
low cost method is by magnetics. This would be very similar to the
one above, but would be based on detecting a magnetic gain or loss.
Another sensor type is a differential pressure sensor, which has
one open end on the outside of the filter and one end on the other
side behind the filter. The difference between the sensor openings
can be signaled to the electronic control board, which then can
watch for the changes either up or down. Then when a set point is
reached, the board signals the user for change. A microbridge mass
air flow sensor is another sensor. This sensor operates on the
theory of heat transfer. The other types of possible sensors are:
solid state Hall effect sensors, piezoresistive sensors, calibrated
pressure sensors, transducers, bonded element transducers,
transmitters, and ultrasonic, Doppler, IR, and fiber optic
sensors.
[0038] Additional sensors may be used with the electronic board to
optimize system operation. These include: current sensors to
monitor AC or DC current, adjustable linear, null balance, digital,
and linear current sensors, and magnetoresistive, closed loop
current and digital current sensors, as well as a variety of
others.
[0039] With the present invention, it is also desirable to better
regulate the electrical current to the cross-flow/tangential
fan(s)/blower(s) such that the power output can be increased or
reduced with improved accuracy, and similarly automatically
increasing or decreasing the speed output from the
cross-flow/tangntial fan(s)/blower(s) with greater accuracy.
Determining the needed air flow loading for the inner member cavity
and only supply that amount of power, may be done with electronics.
This method may provide an "energy star" rating and improved energy
use.
[0040] Another aspect of the present invention is to have a nearly
infinitely selectable speed fan adjustment range. This can be done,
for example, by having the user touch down on a glass, resistance
keypad until the speed required is reached. Once the required speed
is reached, the electronic control board may completely cut off
current/power to the blower(s)/fan(s) slowing or stopping the
user's speed adjustments. The keypad may have one or two keypad
locations for operating up or down the speed by the user. Using two
or more locations for each independent operation provides the user
better control. The use of a display to show user the speed level
may assist in finding proper speeds, which then can be programmed
into the electronic control board for repeated operations
later.
[0041] The present invention may also include the ability to supply
a fresh stream of air up the sides or back of the downdraft
ventilator, thus providing a supply of burnable air for a gas cook
top, which has been a problem with present units due to the
blocking by the ventilator. The air is preferably ducted out the
bottom or along the sides or back of a downdraft ventilator tapping
of the vented air, and returns the air at the bottom of the grate
to the cooking area.
[0042] These, and other aspects and objects of the present
invention will be better appreciated and understood when considered
in conjunction with the following description and the accompanying
drawings. It should be understood, however, that the following
description, while indicating preferred embodiments of the present
invention, is given by way of illustration and not of limitation.
Many changes and modifications may be made within the scope of the
present invention without departing from the spirit thereof, and
the invention includes all such modifications. Note the drawings
may not be shown, components of the inventive system are drawn to
scale.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] A clear conception of the advantages and features
constituting the present invention, and of the construction and
operation of typical mechanisms provided with the present
invention, will become more readily apparent by referring to the
exemplary, and therefore non-limiting, embodiments illustrated in
the drawings accompanying and forming a part of this specification,
wherein like reference numerals designate the same elements in the
several views, and in which:
[0044] FIG. 1 illustrates a perspective view of the cooking system
or appliance of the present invention;
[0045] FIG. 2 illustrates a cutaway front view of the appliance of
FIG. 1 along the line 2-2;
[0046] FIG. 3 illustrates a cutaway front view of another
embodiment of the present invention;
[0047] FIG. 4 illustrates a cutaway front view of yet another
embodiment of the present invention;
[0048] FIG. 5 illustrates a perspective view of yet another
embodiment of the present invention;
[0049] FIG. 6 illustrates a cutaway front view of still another
embodiment of the present invention;
[0050] FIGS. 7A-B illustrate enlarged perspective views of various
embodiments of a filter assembly of the present invention;
[0051] FIG. 8 illustrates a top view of controls of yet another
embodiment of the present invention;
[0052] FIGS. 9A-9B illustrate a view of vents of another embodiment
of the present invention;
[0053] FIG. 10 illustrates an enlarged broken away side view of
ventilator and blower housing assemblies of one embodiment of the
present invention;
[0054] FIG. 11 illustrates a perspective view of a blower wheel
assembly of one embodiment of the present invention.
[0055] FIG. 12 is a side view of the wheel assembly of FIG. 11;
[0056] FIG. 13 is a schematic showing air flow through the assembly
of FIG. 11; and
[0057] FIG. 14 is a wiring schematic for electronics of the present
invention.
[0058] In describing the preferred embodiments of the invention
that are illustrated in the drawings, specific terminology will be
resorted to for the sake of clarity. However, it is not intended
that the invention be limited to the specific terms so selected and
it is to be understood that each specific term includes all
technical equivalents that operate in a similar manner to
accomplish a similar purpose. For example, the words "connected,"
"attached," "coupled," and "mounted" and variations thereof herein
are used broadly and encompass direct and indirect connections,
attachments, couplings, and mountings. In addition, the terms
"connected," "coupled," etc. and variations thereof are not
restricted to physical or mechanical connections, couplings, etc.
as all such types of connections should be recognized as being
equivalent by those skilled in the art.
[0059] Further, before any embodiments of the invention are
explained in detail, it is to be understood that the invention is
capable of other embodiments and of being practiced or of being
carried out in various ways. Also, it is to be understood that the
phraseology and terminology used herein is for the purpose of
description and should not be regarded as limiting. For example,
the use of "including," "comprising," "at least one of," or
"having" and variations thereof herein is meant to encompass the
items listed thereafter and equivalents thereof as well as
additional items.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0060] The present invention and the various features and
advantageous details thereof are explained more fully with
reference to the non-limiting embodiments described in detail in
the following description.
1. System Overview
[0061] The appliance of the present invention preferably includes a
cook top with at least one heating element or burner on a cooking
surface, a cook top vent operably connected to the cook top for
removing at least one of air and effluent from the cook top to a
lower cavity, and a blower assembly in communication with the vent.
The appliance may be an outdoor unit, an indoor unit, a mobile
unit, an island unit, a fixed location unit, a drop- or slide-in
cook top, and/or a grill. In such units, the cooking surface is
preferably glass or any of a variety of materials.
[0062] The vent or vent assembly preferably comprises a vent cover
for covering a vent hole. In one embodiment, the vent preferably
includes an elevating downdraft. The vent or ventilator is
preferably operably connected to the cooking surface for drawing
air and effluents therefrom and has an inner cavity and a plenum.
The plenum preferably has walls surrounding a chamber. In other
embodiments, the ventilator folds, slides, or retracts. The vent
may include an actuator-driven venting system having at least one
of: a motorized, electromagnetic, solenoid, and powered venting
control. Such electronic exhausting controls are preferably in
communication with the vent. These controls may be used to, for
example, close a flap or door to the vent when not in use. In one
embodiment, these controls are integrated with those of the burner
and the blower. The downdraft or vent has a shape that may be
rounded, squared, oval, triangular, and rectangular.
[0063] The blower assembly preferably includes at least one of the
following: a system that manages air and effluent from the cook top
and cooling air from the heating element, a regulator for
electrical current to a blower motor such that the power output can
be changed as needed, a tangential fan to circulate air downward, a
cross-flow fan, a centrifugal fan, a fan that can be remotely
located in attached duct work, a fixed speed fan, a variable speed
fan to control air movement, a squirrel cage wheel fan, a fan with
adjustable speeds that may be preset, a fan used as a power vent
for removing air, a fan for management of moisture build up and
controlled by a humidity sensor, a re-circulating system, a
mechanism for sucking air from the appliance top, a fan for
management of heat buildup and controlled by a heat sensor, a large
chamber plenum assembly, and a fan to move air through a heat
exchanger. The blower has an AC or DC motor. The fan may include
blades of straight or skewed design and a long length axial wheel.
Preferably, the appliance's blower operation is synchronized with
the operations of the heating element and its cooling system.
[0064] As mentioned, a controller is preferably present to control
the appliance, e.g., operations such as ventilator movement,
element heating, etc. In one embodiment, the controller is
preferably an electronic controller to control blower speed. Such
an electronic controller includes at least one of: a touch device,
a keypad, a slide, and a knob. The keypad controller may be located
on the cook top, located remotely, split into parts between the top
and another location, or matched to a size, appearance, and
function of another neighboring appliance and the cook top. The
controller includes an electronic control panel having at least one
of a piezo, tactile, membrane, inductive, capacitance, and
resistance device. The panel is constructed from at least one of:
glass, metal, plastic, wood, and composite substrates. The
controller is at least one of: a piezo, capacitance, and resistance
type touch control keypad for use with any size appliance, a
membrane switch, a tactile, resistance, inductive, capacitance
control with decorative overlays, labels, or trim, and a complete
control panel assembly. The controller is preferably installed in a
plane relative to the cooking surface and may be flush, raised,
recessed, and remotely located. The controller may have an
integrated control circuit board. The board may be in at least one
of the following locations: on the cook top, remotely, and split
into several parts between the cook top and other locations and
attached thereto. The circuit board may also include: a
microcontroller, microprocessor control, an IC, a driver, a PC
board, a processor, and a power controller in communication with
the electronic controller.
[0065] In another embodiment, the controller is a remote control
for wireless control of an operation. A device may be provided for
making such a controller at least one of: automatic with no user
interface, semi-automatic with a limited user interface, and
completely manual with the user setting, operating, and adjusting
the system or parts thereof. As such, the controller may also
include a programmable controller to monitor at least one of:
temperature, operations, speed, time, blower efficiency, lighting,
the need for filter change, and air movement.
[0066] In another embodiment, a sound activated control is used to
control at least one operation of the appliance. A computer system
including a full memory and processor may also be used for
connecting the appliance to a whole house system. A display
interface may also be available with the controller to help the
operator with the functions, temperatures, speeds, need for a
filter change, and time. The controller may have a graphic specific
to the design and function of at least one of the blower assembly,
lighting, and the ventilator.
[0067] One or more sensors for the cook top may also be used to
sense various environmental conditions. In one embodiment, a sensor
scans the cook top for an item placed thereon. It may then provide
feedback to the appliance to operate a fan in the blower assembly.
Sensors for the appliance may be also used to detect at least one
of: filter buildup, back pressure, air flow, gas, smoke, heat,
temperature, filter change requirements, speed, power, resistance,
voltage, programmed operations, and set points.
[0068] The appliance may also be equipped with at least one of: an
output display, a rotating display, an LED display, an LCD display,
a sliding panel, a retractable display, a removable display, a
fixed display, an illuminated display that can be adjusted in color
and intensity, a plasma display, a dot matrix display, a vacuum
fluorescent display, and a pop up display. The display is
preferably mounted on the cooking surface or backing for easy
viewing. The display device preferably displays to the operator at
least one of: operations, temperature, functions, range position,
and times.
[0069] The appliance preferably further comprises movable lighting,
for example, on the backing, cook top, or the ventilator for
illuminating a work surface. The lighting can be any device to
illuminate the cook top including a device that is at least one of:
an adjustable light level device, adjustable light position, hidden
lights, exposed lights, a series of lights, a mini fluorescent
tube, mini neon tube, an LED, rope lights under a decorative flange
trim of the ventilator, recessed lighting, direct lighting, and
indirect lighting.
[0070] In one embodiment, the ventilator is adjacent at least two
cavities and has at least two blowers. The second blower preferably
has a speed control independent from a first for moving a different
volume of air away from a second heating element.
[0071] A filter is preferably attached below the vent with the
cavity at an angle and coated with an agent for cleansing air that
passes therethrough.
[0072] The appliance preferably also has a heat exchanger in fluid
communication with the blower and vent for at least one of:
extracting effluents, cooling drawn air to a proper temperature,
and recycling air back. This heat exchanger includes at least one
of: a heat pump, an electronic cooling device, a refrigeration
unit, and a magnetic cooling device. The heat exchanger may be used
in such a way to turn the downdraft into a cooling/heating
ventilator.
[0073] One embodiment of the appliance has a fire suppression
system operably connected to the cook top for controlling fires and
added safety. An IR system may be employed in such a system. The IR
system may be operably connected to the cook top for detecting at
least one of temperature, resistance, heat, fire, distance,
moisture, and steam. The IR system may employ a variety of sensors.
Such sensors may have at least one of an electronic, an
electromechanical, and mechanical component. This system may also
have an electronic touch controller in communication with the
circuit board.
[0074] The appliance may also include other specialized devices,
such as a device for detecting and controlling of speed for the
blower, an air flow sensor for detecting the flow of air past a
filter, a sensor that measures the air flow and provides a signal
to user for filter replacement due to restricted air flow, a beam
or other detector sensor to scan the surface of a work area for an
item placed on the work area and to provide feedback or control
with automatic operation of the ventilator, a means for detecting
gas flow, an ultrasonic sensor, a thermo detection device for the
control of the downdraft, a digital C02 sensor, an NDIR technology
sensor, and a sensor having the ability to detect back pressure
that triggers an increase in fan speed to maintain the proper
volume of extraction.
2. Detailed Description of Preferred Embodiments
[0075] Various embodiments of the present invention are shown in
FIGS. 1-14 which are described in additional detail below.
[0076] FIG. 1 shows one preferred embodiment of an appliance 15 of
the present invention.
[0077] Now referring specifically to FIG. 1, the appliance 15 is
preferably a cooking system that includes a cook top 20 with one or
more heating elements 25 A-D on the cooking surface 28. In one
preferred embodiment, a backing 29 is provided for splash
protection. The appliance 15 and cooking surface 28 are preferably
comprised of a metal, glass, stone, plastic or other materials.
[0078] A vent system or ventilator 30 is operably connected to the
cook top 20 of appliance 15 for removing effluent and hot air from
the cooking surface 28. The ventilator or vent system may consist
of a vent cover 31, which covers a vent hole 32. Below the vent
cover 31 is a lower cavity (not shown) which preferably attaches to
a plenum (not shown). The components of the ventilator are
preferably made from metal, although glass, stone, heat resistant
plastic or other materials maybe used. Because of the flexibility
of the design and the low profile of the blower assembly, the outer
shape of the ventilator can be styled to meet nearly any
requirements.
[0079] Also shown in FIG.1 are various controls 58 on the cook stop
20, which may include slides 50 and knobs 52 to control, e.g., heat
to heating elements 25a-25d and also in another embodiment the up
or down movement of the ventilator 30. On the backing 29, a scanner
82 may be mounted. Also mounted on the backing may be lighting 45,
which preferably includes a light control 96. In one preferred
embodiment, a sensor 90 is also provided. A drawer 26 may be
present below the cook top 20. The drawer 26 may allow access to
storage or a warmer drawer 27.
[0080] FIG. 2 shows a cutaway of the embodiment of FIG. 1 along the
lines 2-2. In FIG. 2, the lower cavity 34 and the plenum 36 are
shown. Inside the cavity 34 and preferably under the cook top 20,
is preferably a blower assembly 40 which may include a fan or
blower 44. The blower may alternatively be located in a plenum
chamber. The fan 44 may have fan blades 78 protruding from a center
portion. Above the fan 44 and below the vent cover 31, is
preferably mounted a filter 74. The filter may be mounted at an
angle to allow for ease of runoff of any grease or other unwanted
materials. In one preferred embodiment, the fan 44 is a cross-flow
blower 114. In the preferred embodiment shown in FIG. 2, ductwork
100 connects the lower cavity 34 with an outside vent. The storage
or other space 27 is below the blower assembly 40. A sensor or
detector 93b is also preferably present for detecting fan air flow
draw efficiency.
[0081] FIG. 3 shows another embodiment to the current invention. In
this embodiment, the vent cover 31 includes a grate which has a
series of vent holes 32. A system for managing air flow 38 is also
provided. In this embodiment, the system for managing air flow 38
includes seals 38a and 38b. Of course, many other components are
possible. A filter assembly 73 is also present. Preferably, a means
for detecting filter buildup 84 is included with the filter
assembly 73. Within the plenum and the lower cavity, is a control
board 98, which includes a micro-controller 70, a processor 102,
and preferably a programmable control 106. On one side of the
plenum is mounted a blower assembly 40. The blower assembly
includes a fan 44, which in this embodiment is a centrifugal flow
fan 95. A regulator 48 for controlling the electric current to the
blower assembly 40 may be connected to a heat sensor 93c. When the
heat sensor 93c detects an increase of heat, the sensor may signal
the regulator to shut off electric current to the blower assembly.
Here, the fan 44 is preferably driven by a variable speed AC motor
79. Centrifugal fans are sometimes referred to as wheel fans
80.
[0082] In FIG. 3, air, shown by arrows A, enters through holes 32
in the grate 31 and travels downwardly into the cavity in the
cooking system appliance 15. The air (arrows A) then travels past
the filter assembly 73 and is drawn toward the fan assembly 40. The
air enters into the fan assembly (arrows AI) and then is exhausted
from the appliance preferably out an exhaust vent (see, e.g.,
arrows AE). Of course, the air entering the vent grate may be laden
with cooking gases, odors, effluents, grease, oils, etc., but the
air exiting (arrows AE) is preferably cleaned air.
[0083] FIG. 4 shows another embodiment of the appliance 15 having a
cook top 20 with at least two assemblies 108a and 108b to provide
and enhance cooling to the heating elements 25 and the cooking
surface 28. These assemblies are preferably provided with a
mechanism for sucking air. In this preferred embodiment, the
mechanism for sucking air preferably includes a first blower
assembly 180a and a second blower assembly 180b. The blower
assemblies include a first fan 182a and a second fan 182b. The fans
are preferably mounted in cavities 184a and 184b.
[0084] Another embodiment of the present invention is shown in FIG.
5. There, the appliance 15 has a cook top 20 that has two cooking
elements 25 and two regular electric heating elements 24. The
heating elements may be electric, gas, or inductive elements or a
combination thereof. As heating elements are well known in the art,
these will not be described in further detail.
[0085] The center of the cooking surface 28 preferably has an
elevating downdraft ventilator 97. The ventilator 97 includes a
plenum 36 and a vent cover 31, which covers a vent hole 32a. This
elevating ventilator 97 can move up and down relative to the
surface 28 to provide maximum ventilation. Also included on the
cooking surface 28 are means for adjusting the ventilator's fan
speed. Preferably such a means includes a keypad 110 having an
output display 130. Also included on the cooking surface may be a
membrane switch 54 which, in this embodiment, preferably controls
the up and down movement of the telescopic ventilator 97. Integral
with the heating element 25, may be a heat sensor 93d to detect and
control heat to the unit. In this embodiment, a remote control unit
62 may be included for remotely controlling the appliance 15. The
remote control unit 62 may be integrated into computer system 86 to
add further appliance integration and control. Such a unit may be
integrated into a whole house system (not shown) which controls
various appliances and household operations.
[0086] FIG. 6 shows yet another embodiment of the current
invention. This embodiment includes a filter assembly 173 which is
contained in the inner cavity 172 of the appliance 115 below the
cook top 121. Below the filter assembly 173 and filter, is
preferably a heat exchanger 120 which provides for cooling of the
effluent and heated air as it passes through the air filter and
down into the inner cavity toward the blower assembly 140. In this
embodiment, the blower assembly preferably includes a cross-flow
blower 214 with a wheel fan.
[0087] FIGS. 7A and 7B show a filter assembly 73. This assembly 73
may be used with an embodiment of the present invention like that
shown in FIG. 6. The filter assembly includes a filter tray 71
which fits into a tray slot 72. The filter tray includes a filter
74 and an air flow sensor 75. The filter tray 71 has a filter tray
handle 77, which may be removed when the filter 74 is ready to be
discarded. The filter assembly preferably forms a filter tray
drawer 78. Such a drawer can slide in and out of the inner cavity
172 of the appliance 115 as best illustrated by FIG. 6.
[0088] The filter or catch 74 is preferably used for removal of
effluents. The filter 74 may use carbon for removing odors,
particulates, greases and oils, and moisture that condensates on
the median. Additional filters may also be included. A metal mesh
filter also may be used as well as a louver type filter. A
combination of these filters with a charcoal element may also be
used in this application. In a preferred embodiment, the filters
are angled to drain fluids off and collect them into a grease trap.
A grease trap or trough is also preferably provided. These troughs
are removable for ease of cleaning. The filter may be set at angle
in the drawer also.
[0089] FIG. 8 shows another embodiment of the present invention. In
this embodiment, a broken-away section of a cook top 20 is shown.
In this embodiment, on the cooking surface 28 is preferably mounted
a series of controls. These controls include touch devices 56 which
are part of preferably a keypad 110. The keypad 110 may be
integrated into a control panel assembly 64 which may include
another touch control panel 68. A display device 91 may also be
present. The display device 91 acts as a display interface 112 to
interface with the user. Also on the cooking surface may be other
controls such as selection switches 92a to control the fan speed,
and 92b to control the height of the elevating ventilator. Graphics
such as a fan 170a and a elevating ventilator 170b are used to
indicate the type of controls. As can be seen at FIG. 8, the
controls can act as on/off switches, high/low switches, up/down
switches, and high/medium/low switches. On the panel may also be an
indicator light to indicate that the surface is hot. Such an
indicator light may be an LED display 140.
[0090] The sheet metal/material construction of the appliance's
back housing 29 may also accommodate a lighting system 45 as
mentioned above. This design allows any type lamp holder to be
installed in a convenient way. For example, in one embodiment, by
twisting a male connector to the female connection, a fixture is
locked in place. The female connection can be designed into the
housing providing a fixed point.
[0091] Alternatively, lighting may come from ventilator and provide
lighting at different angles. Lighting provided may also be on a
bendable, moveable arm, e.g., a snake light system.
[0092] In one preferred embodiment, such as that shown in FIG. 1,
housed within the appliance's frame of metal/plastic or other
material is an opening to provide the viewing of an electronic
display 130. The electronic display 130 preferably rotates and may
also include the control board electronics. The controller is
preferably an electronic board attached by bolts and nuts, but
could be held in place by other methods like adhesive, tape,
connector, etc. The wiring for the control panel preferably is
shielded from being seen and being contaminated by dirt that may
coat the wires.
[0093] As mentioned above and shown in FIG. 1, the appliance 15 of
the present invention preferably has at least, e.g., one sensor 90.
The sensor may form part of a sensor system that includes one or
more of the following: a pot detector system, an IR detector system
for heat, smoke, fire and/or distance, humidity, a gas (e.g.,
hydrocarbons, CO, CO2) detector, a pressure sensor, moisture or
steam sensor, temperature or thermal sensing technology such as
RTDs (resistance temperature detectors), integrated circuit sensors
(IC), thermistors, IR thermometers, bimetallic, and thermocouples.
Other sensors may include: any electronic AC or DC sensor used for
detecting movement, UV reflectance, resistance, flow, item
detection, noise, power or other sensor for the detection and
control of the ventilator blower with electronics. Also, a sensor
may be used for detection and control of speed for both the
fan/blower and the drive mechanism. Sensors for the detection of
the temperature are preferably located on the cooking surface 28,
back housing 29, ventilator 30 or blower assembly 40. Other sensors
are directed for the sensing of the items placed on the cook top or
the range. The sensors are preferably connected to control board 98
(see FIG. 3) via wires or a wireless connection. Finally, an air
flow sensor may be provided to detect the flow of air past the
filter(s) (See, e.g., FIGS. 7A-B, sensor 75). This feature
preferably measures the air flow and indicates to user the need for
filter replacement or cleaning due to restricted air flow.
[0094] Of course, any IR/thermometer that can measure objects that
move, rotate, or vibrate (e.g., web process or any moving process)
may be used in addition to the ones mentioned above. Such IR
sensors are useful as they do not damage or contaminate the surface
of the object of interest and they measure the temperature of the
actual product being used on a cook top or range and not some of
the other parts of the surfaces. Further, the thermal conductivity
of the object being measured such as glass, metal, wood, or even
very thin objects does not present a problem, as with other
sensors. Response time of these sensors is in the millisecond
range, which gives the user more information per time period. Any
other electronic IR sensor used for detecting temperature,
resistance, heat/fire, distance, moisture/steam, or power for
detection and control of the ventilator blower with electronics may
also be used.
[0095] Two types of ventilators may be used with the present
invention, ducted and non-ducted. In a ducted type ventilator,
there is a duct that is used for venting air to the outside. See,
e.g., FIG. 2. This duct can be attached at the top, back, or
directed downward to the floor in a room, or have a chimney cover
the duct at the top.
[0096] In a non-ducted type ventilator, there is no duct that is
used for venting air to the outside. See, e.g., FIGS. 3 and 6. This
non-ducted unit can be vented at the top, side, back, front, and/or
directed downward to the floor in a room.
[0097] As mentioned, a cross-flow fan/blower assembly preferably
provides the drawing force needed to pull contaminated air into the
ventilator. As best shown in FIGS. 11-12, the assembly is
preferably composed of a housing mounted to the appliance. Attached
to the housing is the drive motor. A wheel assembly contains the
bearings, hub, and a wheel of either the skewed or straight bladed
type. A fastener preferably connects the wheel assembly to the
motor.
[0098] Multiple burner specific blowers and ventilators may be used
to divide the cooking surface 28 into zones that provide air flow
control within the zone. See, e.g., FIG. 4. An air curtain may be
created at the perimeter to preferably enclose these zones. Blower
motor speed in the zone may be reduced with the improved efficiency
and thus the noise level may be decreased. This greatly increases
the overall efficiency of venting. Moreover, the energy saved from
not having to turn on and run another large blower motor provides
added benefits to the user in the way of cost saving. An added
benefit is a lower ventilator profile due to the more efficient,
smaller motor(s)/blower(s) assembly. This gives a person more room
for viewing and working near a ventilator, or room for a larger
cabinet below the ventilator to provide more user space. The
fan/blower may also be used for ducting heated air or moisture
out.
[0099] Another aspect of this design is the ability for the fan to
be controlled by a humidity sensor, CO, or CO2 sensor, and/or
hydrocarbon detectors. (See, e.g., FIG. 1, sensor 90). Greater
versatility may be had with the use of electronics and the
different types exhaust elements. These innovations control the
power load for the exhaust vent and only supply that amount of
power needed to effectively operate the ventilator. Electronics or
electromechanical controls may also prevent the spread of fire
through regulating electricity flow, blower speed, and heat.
[0100] As shown in FIGS. 5 and 8, unit 15 may have a panel 64 with,
for example, a display 191 that shows the user, e.g., fan speed
levels. This can be used to assist in finding proper speeds and
heights, which then can be programmed into an electronic control
board for repeated operations later. Further, the panel 64 has the
ability to show to the operator, e.g., types of operations,
functions, filter life/change, and times using electronics and to
accurately control these operations to remove contaminated air.
Such a panel 64 may also be used to control movement and operation
of the ventilator 30. Construction of the electronics includes:
high heat construction design; specialized adhesive construction;
loop resistant circuitry; ESD/EMI/RFI shielding; and LED, LCD,
plasma, dot matrix, vacuum fluorescent display(s). All of these can
improve the control, display, design, look, and operation of the
electronic(s). Electronic touch control panel(s) could use a piezo
touch panel (keypad) for selection of operations by operator. In
some instances, the controls are sufficiently isolated in other
ways to prevent appliance temperatures from damaging the
control.
[0101] As mentioned, the panel 64 may include an electronic touch
controller 68, e.g., a keypad that may be made of glass, metal or
plastic, with selection of the operating function(s) made by
touching the surface of the glass, metal, or plastic. For the
ventilator, a resistance type touch control keypad may be used
whereby touching plastic, metal, or glass at a location, e.g., on
top of the ventilator, causes a change in an electrical signal. The
piezo, capacitance, resistance, inductive and tactile membrane
switches used maybe fitted with decorative overlays, under lays,
labels, trim and completed control panel assemblies. Touch control
key pads/panels may be installed flush, raised, or recessed. It
should be noted that the touch control key pads/panels may be
installed in nearly any plane and on any surface. For example,
touch controls keypads and displays may be placed on the front or
top of the cooking surface 28 to provide the operator with instant
viewing of the operations and functions. A remote control 62 may be
added by wire or by wireless controls, see, e.g., FIG. 5.
[0102] As mentioned, the electronics provided allow for
programmable/selectable set points, programmable/selectable set
times, and programmable/selectable set operations as well as set
times for both on and off or changes in functions, set points,
speed, or functions. The ability to select multiple functions,
operations, and times gives the inventive appliance advantages over
non-electronic controlled units. This programmability/selectability
provides the advantage of being able to enter different functions
or operations into the electronic controls and have the system
respond. Further, an electronic control permits more user
freedom.
[0103] Another aspect of the present invention is a multi-function
display. For example, a clock may be on the electronic(s) display
when not in use or when in use. See, e.g., item 112 in FIG. 8. It
may also be changed to permit other programmable information to be
displayed, such as, messages or computer information. This area may
also have an LED night light included in the electronics such that
the LED would come on when the room is dark. The use of an LED or a
bulb of this type can save energy and space.
[0104] Another aspect of this invention is the ability to have "no
switch" controls. Here, for example, the cook top backing 29 acts
as the switch. For example, a user may touch the trim top surface
in the front, top, or sides and this would operate the ventilator
by moving it and turning on the blower. Alternatively, a user may
touch the ventilator a number of times to move it up or down or to
speed up or slow down the fan. The user may also touch the
ventilator and hold for a longer time to which the blower would
turn off or on. The user may turn a light on in the same
manner.
[0105] The appliance 15 may also be equipped with a sound- or
voice-activated system that in one embodiment lets the user speak
to the appliance and state what controls and operations the user
wants. Sensor 90 may be to detect the sound needed for such
control. This provides the user the ability to operate hands free,
therefore, allowing the users to do something else with their
hands. Alternatively, the appliance can be hooked up to a PC
computer or a whole house computer system for operation and
control.
[0106] Another aspect of this invention is an appliance 15 designed
with a temperature control or cooling element 120. See, e.g., FIG.
6. The element 120 is preferably secured to the inside of cavity
172 or remotely. In this one embodiment, heated air is circulated
through the ventilator 130 and past the element 120 to provide
better heat control to the non-ducted ventilator both inside the
appliance and inside the cooking room. The fan or blower assembly
140 provides air movement inside cavity. This system cools/heats
the exhaust air before delivery of air to the room. Preferably,
such a system is included with a non-ducted unit. These cooling
systems are sometimes referred to as a "heat pump." Thus, such a
heat pump may be used to make the ventilator not only a venting
unit, but a cooling/heating unit. This feature is important, for
example, when larger ventilators are designed to recycle air back
into the room. With the use of larger cook ranges, a large amount
of heat is generated and returning this heated air to the room can
be a big issue for the user. Here, the cooling/heating system is
used for extracting effluents (like steam) and cooling of the drawn
air to a proper temperature for return. The system may also include
a device to select a precise return air temperature. For example,
with the ability to cool and treat the exhaust air, this feature
provides the user the ability to select the temperature of the
returning treated air to the room, e.g. 70 degrees Fahrenheit.
Humidity buildup in the cavity chamber may also be controlled by a
power venting or condensation drainage system. The system may
include an electric chill or a refrigerant such as that found in
freezers, a circulating system to provide removal of heat, or an
electric cooling heat exchanger.
[0107] In accordance with another aspect of this invention, the
ventilator may be controlled by electronics and equipped with an AC
or DC electronic temperature sensor, e.g., sensor 93a, 93b, 93c,
and 93d, located on the ventilator, cook top, or elsewhere such
that the temperature of the ventilator can be detected accurately.
See FIGS. 1-5. Such controls provide control and operation response
to sense temperature on the range or in the ventilator and then
turn the exhausting functions on/off and adjust speed according to
needs. Any electronic sensor used for detecting heat/temperature,
CO, CO2, hydrocarbons, or power, for example, thermal detection
devices may be used to control the exhaust. In one embodiment, the
blower exhaust motors are electronically connected to a
temperature-sensing device and is DC powered in accordance with
requirements for the unit. Here the motor/blower is also protected
in the event of a fire by an automatic turn off. The user may also
select settings or preset settings for the electronic control(s) to
maintain the desired exhaust flow within the vent's chamber. The
sensing device maintains performance in a predetermined desired
range of operating temperature(s) or set point(s). A sensor may
also be mounted on an electronic board or it can be attached by
itself to any wall or location from which detection of the board's
temperature can be made. FIG. 14 shows examples of wiring
schematics for electronics of the present invention.
[0108] RTDs may be used to provide the appliance low cost sensing
over other methods when used with electronics. Even though RTD
sensors tend to be relatively slower in response than
thermocouples, which are used in many ventilators today, RTDs offer
several advantages well know to those of ordinary skill in the
art.
[0109] For example, one method for a sensor circuit uses a RTD
temperature sensitive element to measure temperature from ambient
to elevated temperatures. One of ordinary skill in the art is
familiar with such sensor circuits, so the circuit is not shown.
The information from the sensor circuit can be also displayed
and/or processed for control of the motor, blower, and speeds. All
of the above information can be made on a chip. This chip can be
placed in an ideal area for detection of temperature. This
circuitry preferably provides data/information to the control board
for controlling functions of the ventilator. Alternatively,
distributed temperature may be used to sense temperature at every
point along an SS sheathed fiber and feature a resolution of 0.5
degree C. and a spatial resolution of 1.5 m. The fiber can range up
to 2,000 m and can be coiled at specific points of interest. The
fiber can be sheathed with a nonconductive polymer for intrinsic
applications. This method provides the ability to profile a
range/cook top for detection of temperatures at many points. The
strip may be along the complete front of a ventilator trim at the
edge. Response times are thus reduced and provide the control board
the ability to sense the complete top of a target zone rather than
just one zone. This also provides the manufacturers the ability to
customize the zones placing more points in areas for detection. The
use of electronics and sealed components allow theses systems to be
used outdoors also.
[0110] Next generation fiber optic distributed temperature sensors
(DTS) may be used as part of the present invention to sense
temperature at every point along an SS sheathed fiber. These
feature a resolution of 0.5 degree C. and a spatial resolution of
1.5 m. The fiber may range up to 2,000 m and can be coiled at
specific points of interest. The fiber may be sheathed with a
nonconductive polymer for intrinsic applications. With this system,
many locations for detection are provided. Response times are
shorter and sensing of the complete top of a target zone rather
than the one zone may occur. This also provides the manufacturers
the ability to customize the zones by placing more points in areas
for better detection.
[0111] As mentioned, another aspect of the present invention is to
have nearly infinite fan speed adjustment levels. This can be done,
for example, by having the user touch down on a glass resistance
keypad until the speed required is reached. Once the speed is
reached, the electronic control may reduce or completely cut off
current/power to the blower(s)/fan(s). The keypad may have one or
more keypad location(s) for operating the increase or decrease/on
or off of the speed by the user. For example, three locations for
independent operations can provide the user with better control. A
display may show the user the speed level and may be used to assist
in finding proper speeds, which then can be programmed in to the
electronic control circuit for repeated operations later.
Alternatively, the sensor 93c for controlling the fan 44 may be
connected to fan regulator 48 as shown in FIG. 3.
[0112] The appliance of this invention is designed for outdoor
locations as well as indoor ones. The appliance design has the
ability to weather outdoor temperatures and environment. For
example, the use of electronics for appliance provides better
sealing for these environments. Further, remote electronic controls
62 not only provide convenient remote operations for use outdoors,
but also reduce the effects for some of the environment on the
controls. Further, electronics are not subject to the mechanical
problems of turning in extreme weather conditions. They are also
resistant to other environmental conditions.
[0113] As previously mentioned above, the ventilator of the present
invention is very versatile. For example, it may be built into/on a
mobile island or cart; such as for use with grilling/cooking
equipment. Alternatively, the ventilator 330 itself may be a
separate mobile unit, e.g., a frame that is self-supporting or
free-standing. See, e.g., FIG. 10. Such a mobile ventilator may be,
e.g., mounted on wheels 314 and does not need to be installed into
a cabinet or other unit to add structural support. This embodiment
330 preferably has a combined heat exchanger and filter 340 that is
mounted over the blower 352 and duct 353. A light 379 may also be
included.
[0114] FIG. 5 shows a remote sensing and receiving system which
includes a sensor and/or a remote receiver 107 along with remote
control panel 62 at a different location. Here, the sensor
preferably includes a transducer to sense a physical parameter on
the cook top of a range. The transducer will generate an electrical
signal representative of the physical parameter and apply the data
to a processor. In response, the processor drives a digital
display, which produces visual indications of these parameters. The
processor provides communication between the sensor(s) and the
remote receiver, which drives some operations by the ventilator.
For example, the receiving unit 62 controls the ventilator from
signals for turning on, to adjusting the speed of the blowers. The
sensor(s) and receiver(s) may both have a transmitter and receiver
to enable communication through signals. This would be helpful when
changing set points or detection points.
[0115] In one embodiment, the remote sensing and receiving system
or detecting and display system is configured as a remote keypad.
For example, the keypad apparatus preferably includes a display and
a remote transducer unit having a temperature sensor unit or other
transducer exposed to the cook top/range.
[0116] As discussed, physical parameters measured by remote sensing
and receiving system are not limited to temperature. For example, a
sensor/transducer may be used in extinguisher devices in which the
quality of the air from a range is measured for CO, CO2 or other
gasses for fire fighting. Note: Transducer Technology, Inc offers a
T series carbon monoxide sensor using nano--particulate technology
for sensing or an amperometric electrochemical sensor. In this
embodiment, if a fire develops, the remote sensor and remote
control devices can activate a fire extinguisher. Here, a
microprocessor preferably controls the various circuits associated
with this system. Various other devices may be coupled to such a
microprocessor to control other functions within the appliance.
[0117] In another embodiment, a fire protection system may be
included. See, e.g. FIG. 5, system 105. The fire protection system
105 preferably has a warning device and a built-in fire
extinguisher. The fire detection system preferably also turns off
the blower and other electronics and closes at least one vent
through a control board. This feature prevents the spread of fire
in and around the appliance. Further, critical temperature levels
may be set by the factory so that when the sensors detect these
present levels, the ventilator activates the fire protection
system.
[0118] Another feature of the present invention is preferably the
use of an output device or display 130 located, for example, on a
sliding panel, a rotating panel, or popup panel attached to the
backing 29 of the appliance 15. See FIG. 1. In the rotating display
shown, the display panel or screen is an LCD display 150. Input
buttons 143a, 143b may also be present. This ability to conceal the
display 130 protects it from damage and provides a smooth looking
surface. In one embodiment, this is accomplished by placing an
electronic display on a rotating drum, a rotating L-shaped plate,
or on a triangle-shaped part. Once the operations are complete, the
user or the appliance 15 can rotate the display 130. In one
embodiment, the user can touch the front of the display 130 to
activate movement. Once the electronics sense the pressure on the
display 130, the rotation begins until it reaches the stop point.
In this case, the stop point would be when the unit provides the
smooth surface. The other way the display 130 may move to a closed
position is if the display 130 and the ventilator have been off for
a time. Once that time has been reached, the display 130 returns
back to the closed position. A motor or some other means of
rotating the display 130 may be used to provide movement. Switches,
stepper motors, or magnetism can be used for the location of stop
points.
[0119] In another embodiment, one or more displays may be used to
interface with the operator the functions, temperatures, speeds,
need for a filter change, and time. For example, the controller may
have a graphic specific to the design and function of at least one
of the blower assembly (e.g., a small fan picture), lighting, and
the ventilator (e.g., ventilator graphic) as shown in FIG. 8.
Again, such controls are preferably mounted on at least one of: a
top, face, side, or other surface of the ventilator or cooking
surface for easy viewing and use.
[0120] In the embodiment shown in FIGS. 9A-9B, the cooking system
205 includes a counter top 210, cooking surface 212, and a
ventilator 220. The ventilator 220 is a telescoping system located
at the rear of the cooking surface 212. A vent 223 is provided
preferably in front of the ventilator 220.
[0121] Burners 218 are located on the cooking surface 212. Controls
246, preferably for the cooking surface, are located toward the
front of the cooking surface 212. Controls 278 for the ventilator
220 are preferably located on the top 226 of the ventilator. The
ventilator top 226 fits into an opening 290 when the ventilator is
closed and is flush with the surrounding molding.
[0122] As mentioned, the ventilator preferably includes a
tangential or cross-flow fan/blower that uses an AC or DC drive
motor(s). See, e.g., FIGS. 11-13. The cross-flow blower(s) may use
tangential wheels and skewed fan blades, straight blades or other
blade designs for the moving of air. Alternatively, a long length
axial or centrifugal fan/blower assembly wheel may be used. The fan
may be of a fixed or a variable speed with nearly infinite speed
setting. As mentioned, the blower is preferably located as close to
each of the burners as possible. With two or more blowers,
different size blowers may be used with different cubic feet per
minute ratings (CFM). This provides greater effluent removal where
needed.
[0123] If large burner elements are located at the front of a
range, the invention provides the ability to use a large cross
blower (CFM) near those burners to remove the contaminated air.
Each fan can be used as a power exhaust vent for removing air, or
mixing fresh air with return air, and /or management of
moisture/heat buildup. Fan operations may be controlled by a
sensor, detector, or switch. Such individualized features allow the
ventilator to detect the air flow draw needs for each burner and
also the amount of draw needed. As the blower draws air downward,
it eliminates hot spots or stratified layers of varying
temperatures on a range's cook top. Alternatively, the
fan/blower(s) may be remotely located from the ventilator or built
on/in with ductwork while still providing individual air removal
near a burner. These ducts can be closed off to each location and
opened when selected by a user or system.
[0124] Referring more particularly to FIG. 11, a preferred
embodiment of a blower fan assembly 440 and fan or impeller 444 is
shown. In general, with a crossflow/tangential fan or blower, the
air is drawn in over the entire length of the fan impeller. Inside
the impeller the airflow is diverted and accelerated by the vortex
created by the rotation of the impeller. The air stream then exits
over the entire length of the impeller on the discharge side. At
the narrowest point between the impeller and the vortex creator,
the intake and discharge side of the fan is separated and, together
with the fan rear guide wall directs the airflow
crossflow/tangential (impellers, e.g.) wheels are usually more
efficient when a focused flow of air is required to cool or heat an
immediate space such as the cook top. When used in this manner, the
air does not have to travel long distances, but instead is used in
the immediate surroundings such as in stoves or on a cook top.
[0125] One of the reasons that crossflow/ tangential wheels are
quieter in comparison to a centrifugal-style blower is that for
products with the same CFM rating, the air speed of the tangential
wheel is much slower since the outlet area is much larger than that
of a centrifugal blower. This can be seen as an advantageous
feature, because the large area of discharge of the tangential
blower does not require additional diffusion. Diffusion areas
create losses and decrease efficiency. Reduced noise is a highly
sought after feature for kitchens due to the user using the kitchen
as a central meeting point in a home. Crossflow blowers may be
retrofitted to existing systems after older, less efficient blower
assemblies have been removed.
[0126] Moreover, when compared to double inlet wheels used in a
double blower, tangential impellers will generally provide an equal
or slightly increased CFM with the same motor. The airflow is
tangentially across the inlet area and tangentially out across the
discharge area. The most efficient configuration is when this
90-degree change in direction can be utilized in the design of a
product. The flow principle allows the air intake of the blower to
take place over the whole length of the outer impeller periphery.
The air then flows into the impeller interior where it is reversed
and accelerated by the vortex, which is caused by the impeller
rotation (acceleration due to the turning of the blades). Finally
the air is distributed at the discharge side or bottom and any
where in between over the whole impeller length. In this way, the
air flows through the impeller first from outside to inside and
then from inside to the outside. The impeller is typically a
cylindrical cage of forward curved impeller blades with two or more
supporting discs, i.e., the so-called "wheel". Here the vortex
separates suction side and discharge side at the narrowest line
between impeller and vortex and causes the flow pattern together
with the scroll.
[0127] Ideally, if filters or coils are involved, tangential
blowers are best used in a pull-through rather than a push-through
manner. The inlet air speed is over a larger surface and,
therefore, is lower than the discharge airspeed. This usually
contributes to lowering the static in the system as well.
Crossflow/tangential wheels do best in low-static situations, so it
would be a good idea to try to minimize the static in a system to
best utilize the power of a blower. This can be achieved by
minimizing the changes in direction of airflow within a cook top
down draft system. Using the 90-degree change within the tangential
occurs by positioning the blower where the airflow is required to
make a 90-degree turn. A 180-degree flow of air can be designed
such that the air is drawn in to the cross-flow tangential wheel
and exits by going straight through. Funneling of the discharged
air should be avoided. This is best done by reducing the discharge
closest to the wheel rather than to slowly reduce the discharge
area. For example, having the opening for exhausting at less than
0.45 times the diameter causes problems and having restricted or
tapered flowing out the end results in back pressure and reduced
blower efficiency.
[0128] Thus, housing design is critical in blower performance. As
best shown in FIG. 13, the preferred housing design includes: For
optimum CFM, A=0.60o, B=0.85o, C=0.60o, E=F=0.07o, G=15 deg, and
HIJ should be a straight line. If a smaller outlet is necessary, it
is better to reduce A first to a minimum of 0.45o, then A and B
together rather than tapering the outlet. Air will discharge
following the 15 degree upward. If this is not desirable, for
maximum discharge, the entire housing must be rotated-G should not
be reduced. Reducing A will affect CFM, but not air speed. For
noise control, dimensions E and F are critical, with F being the
most critical. Reducing both E and F will increase CFM and noise
level. When using grills at discharge, the CFM will be directly
reduced by the percent of area covered if the blower maintains the
same wheel speed. For the cook top down draft application when the
motor runs below its maximum speed: when static of any kind is
applied to the system at the discharge, the wheel will speed up to
try and maintain the same CFM up to the maximum speed of the motor.
This is a useful design feature that is used in this application
where static might build with time (as contamination in a filter).
If the initial motor is designed to run below its maximum speed,
this leaves room for the motor to speed up and maintain its
performance.
[0129] The housing 450 used for the crossflow/tangential impeller
wheel 444 has galvanized steel for end plates 452 and two parts to
produce vortex baffle 470 and scroll. Alternatively, aluminum could
be used for less weight as could stainless steel or steel painted.
The impeller used in the down draft appliance is aluminum for
lightweight and thus a lower horsepower motor would be required to
drive the blower. But galvanized steel, stainless steel or steel
painted can be used but require a larger motor 453 to drive these
designs due to the added weight. These heavy weight materials also
provide other benefits such as stronger blades, which can run at
higher speeds, chemical resistance, and better aesthetics. The
blower wheel blades 460 are preferably made of lightweight and
strong materials also. The wheel 444 is mounted in the housing 450
on shafts 465a, b, which are mounted on bearings 469 on one end and
a motor 453 on the other.
[0130] The following formulae represent the preferred optimum
operational design criteria of the blower wheel.
[0131] For specified wheel dimensions, a change in speed will
optimize the system: N new = N old .times. ( CFM new CFM old )
##EQU1## Resulting in: HP new = HP old .times. ( N new N old ) 3
##EQU2## SP new = SP old .times. ( N new N old ) 2 ##EQU2.2##
[0132] If the static pressure is acceptable, wheel length can be
optimized (while other conditions remain constant): L new = L old
.times. ( CFM new CFM old ) ##EQU3## Resulting in: HP new = HP old
.times. ( new old ) ##EQU4##
[0133] If the static pressure is not acceptable, wheel diameter
must be resized using: SP new = SP old .times. ( D new D old ) 2
##EQU5## Resulting in: CFM new = CFM old .times. ( D new D old ) 3
##EQU6## HP new = HP old .times. ( D new D old ) 5 ##EQU6.2##
[0134] Where: [0135] N=Speed [0136] (Revolutions per minute) [0137]
CFM=Volume [0138] (Cubic Feet per minute) [0139] HP=Horsepower
[0140] SP=Static Pressure [0141] (inches of water) [0142] L=Wheel
Length [0143] (inches) [0144] D=Wheel Diameter [0145] (inches)
[0146] The below illustrate examples of preferred embodiments of
the present invention: TABLE-US-00001 Wheel Housing Dimensions
Diameter A B C D E 4'' 6.25'' 6.00'' 2.70'' 2.24'' 1.30'' 4.5''
6.65'' 6.50'' 3.00'' 2.50'' 1.25'' 5'' 7.15'' 7.25'' 3.12'' 3.02''
1.91'' 5.5'' 7.63'' 8.00'' 3.45'' 3.50'' 2.15'' 6'' 8.00'' 8.75''
3.90'' 3.75'' 1.80'' 8'' 10.00'' 11.50'' 5.00'' 5.40'' 3.25''
[0147] TABLE-US-00002 Diameters available (inches) Number of Blades
4'' 29 blades 4.5'' 30 blades 5'' 36 blades 5.5'' 36 blades 6'' 36
blades 8'' 52 blades
[0148] TABLE-US-00003 TABLE 3 CFM for different sized
cross-flow/tangential wheels at zero static pressure and 1625 RPM.
Static Pressure Wheel Sample Wheel Length (in.) (in.) Maximum Dia.
(in.) 10 15 20 25 30 35 40 45 at 1750 rpm 4 350 525 700 875 1050
n/a n/a n/a 0.18 4.5 500 750 1000 1250 1500 1750 n/a n/a 0.23 5 650
1000 1325 1650 2000 2325 2675 n/a 0.45 5.5 900 1350 1775 2200 2650
3100 3550 n/a 0.57 6 1400 1900 2350 2800 3300 3750 4225 0.65 8 3350
4500 5550 6700 7800 8900 1000 1.10
[0149] In sum, the advantages of using a cross-flow/tangential
blower are generally as follows:
[0150] Uniform, extended airflow over large surfaces,
[0151] Space-saving installation due to 90 degrees airflow pattern
or 180 degrees air flow,
[0152] Fan length can be matched to appliance width (note: airflow
conditions remain the same even for wider appliances, i.e., there
is a simplified design and drafting in case of modular
systems),
[0153] Quieter operation due to flow-inducing impeller and housing
design,
[0154] Longer working life due to the robust design and location of
bearings away from the hot air zone,
[0155] Works equally well in any arrangement, e.g., right or left
hand drives,
[0156] Dynamically balanced to minimize noise and vibration,
[0157] High performance with low noise and low electricity
consumption,
[0158] Long, narrow air flow path for very efficient cooling,
and
[0159] Easier to install.
[0160] There are virtually innumerable uses for the present
invention, all of which need not be detailed here. For example, the
cook top disclosed herein may be used in a side-to-side,
back-to-back, or other configuration for serving as part of a
larger, expandable cooking area. Of course, this and all of the
other disclosed embodiments can be practiced without undue
experimentation.
[0161] Although the best mode contemplated by the inventors of
carrying out the present invention is disclosed above, practice of
the present invention is not limited thereto. It will be manifest
that various additions, modifications, and rearrangements of the
features of the present invention may be made without deviating
from the spirit and scope of the underlying inventive concept. In
addition, the individual components need not be fabricated from the
disclosed materials, but could be fabricated from virtually any
suitable materials. For example, construction materials for the
cook top, the downdraft, and blower are at least one of: metal,
glass, stone, a transparent material, tile, plastic, and manmade
material.
[0162] Other features may be added to the conventional cross-flow
blower to further increase the effectiveness, e.g., a heavy duty
double-ball bearing motor, an aluminum impeller, and
self-lubricating sleeve bearings. Further, a tangential fan with
c-frame shade pole motor may be used as it can better withstand hot
air exhaust.
[0163] Moreover, the individual components need not be formed in
the disclosed shapes, or assembled in the disclosed configuration,
but could be provided in virtually any shape, and assembled in
virtually any configuration. Further, although various components
as described herein as physically separate modules, it will be
manifest that they may be integrated into the apparatus with which
they are associated. Furthermore, all the disclosed features of
each disclosed embodiment can be combined with, or substituted for,
the disclosed features of every other disclosed embodiment except
where such features are mutually exclusive.
[0164] It is intended that the appended claims cover all such
additions, modifications and rearrangements. Expedient embodiments
of the present invention are differentiated by the appended
claims.
* * * * *