EXTENSION RACK ASSEMBLY FOR CONSUMER APPLIANCE AND CONSUMER APPLIANCE INCORPORATING SAME

Abstract

An extension rack assembly is mountable within and removable from a consumer appliance side walls. The extension rack assembly is movable between an overlapped position and an extended position. A mechanism is provided for automatically securing the extension rack assembly in the consumer appliance when the extension rack assembly within the side walls is moved from the overlapped position to the extended position and for allowing removal of the extension rack assembly when the extension rack is maintained in the overlapped position and slid from the side walls. The extension rack assembly may also or alternatively be configured to receive a rack in a first orientation having a first height within the consumer appliance and in a second orientation having a second height within the consumer appliance

Description

FIELD OF THE INVENTION

The subject matter disclosed herein relates generally to extension rack assemblies for consumer appliances and relates more particularly to extension rack assemblies with automatic locking mechanisms for consumer appliances.

BACKGROUND OF THE INVENTION

Various types of types of sliding racks have been proposed for consumer appliances such as refrigerators, dishwashers and ovens. The most basic racks are constructed of metal rods (or wire) formed into a rack shape. The racks are slidable into an opening along elements either formed into or attached to the interior walls of the consumer appliance. These racks are of solid, one-piece construction and have no moving parts. Racks are typically slidably removable from an appliance cabinet for cleaning and/or for placement at one of multiple locations within the cabinet. Refrigerator or freezer racks and shelves may thus be attachable at multiple locations depending on consumer preference. Racks within ovens are typically insertable at different heights within the oven to allow for different cooking parameters.

Complimentary shapes such as stops, edges, lips, etc., may be provided on the racks and within the appliance cabinet as safety features to prevent the racks from inadvertently sliding completely out of the cabinet when not desired. This can be especially important for an oven, for example when an oven is heated and heavy items are located on the racks and then slid outward for inspection, manipulation or removal.

Some racks known as extension racks include multiple movable parts. One part of an extension rack is the main rack surface on which an item is placed by a consumer, for example for cooking or storage. At the sides of the extension rack are slides, one part being attachable to the main rack surface and the other part being attachable to the appliance cabinet interior. The slide parts are movable relative to each other, often using ball bearings, to extend the main rack surface out of the cabinet. As above, at times it is desired to slide the main rack surface out partially, and at times it is desired to remove the entire rack from the cabinet, for example for cleaning or repositioning. Therefore, some sort of mechanism is typically included to hold part of the rack slide in the cabinet when desired.

In conventional rack slide assemblies, that mechanism must typically be released by the user, for example by moving a lever or the like on the rack slide assembly, to free the device from the appliance cabinet. This can be a complicated procedure and it may be difficult for a user to find or operate such a mechanism. If the consumer appliance is an oven which is hot, the user must be careful in effecting the release as the rack assembly portions will also be hot. Accordingly, a rack slide assembly providing a secure attachment and ready removal from a consumer appliance would be appreciated.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

According to certain aspects of the disclosure, an extension rack assembly is provided for a consumer appliance, the extension rack assembly including a rack sized for placement within the consumer appliance and two rack slides. Each rack slide includes a first rack slide member attachable to a side edge of the rack and a second rack slide member attachable to a side wall of the consumer appliance. The first rack slide members are slidable relative to the respective second rack slide members between an overlapped position and an extended position. A latching mechanism is attached to at least one of the second rack slide members, each latching mechanism including a lock bar having a locking protrusion movable between a locking position and a sliding position. Each latching mechanism includes a spring member urging the locking protrusion toward the locking position. The first rack slide members locate the locking protrusion in the sliding position when the rack slide members are in the overlapped position. The spring member locates the locking protrusion in the locking position only when the rack slide members are in the extended position. Various options and modifications are possible.

According to other aspects of the disclosure, a consumer appliance includes a cabinet having side walls, a rack sized for placement within the cabinet, and two rack slides. Each rack slide includes a first rack slide member attachable to a side edge of the rack and a second rack slide member attachable to a respective side wall. The first rack slide members are slidable relative to the respective second rack slide members between an overlapped position and an extended position. A latching mechanism is attached to at least one of the second rack slide members, each latching mechanism including a lock bar having a locking protrusion movable between a locking position and a sliding position. Each latching mechanism includes a spring member urging the locking protrusion toward the locking position. The first rack slide members locate the locking protrusion in the sliding position when the rack slide members are in the overlapped position. The spring member locates the locking protrusions in the locking position only when the rack slide members are in the extended position. Again, various options and modifications are possible.

According to certain other aspects of the disclosure, an oven includes an oven cabinet having side walls and an extension rack assembly mountable within and removable from the oven side walls. The extension rack assembly is movable between an overlapped position and an extended position. A mechanism is provided for automatically securing the extension rack assembly in the oven cabinet when the extension rack assembly within the oven side walls is moved from the overlapped position to the extended position and for allowing removal of the extension rack assembly from the oven cabinet when the extension rack is maintained in the overlapped position and slid from the oven side walls. As above, various options and modifications are possible.

According to still other aspects of the disclosure, an extension rack assembly for a consumer appliance includes a rack sized for placement within the consumer appliance and two rack slides. Each rack slide includes a first rack slide member attachable to a side edge of the rack and a second rack slide member attachable to a side wall of the consumer appliance. The first rack slide members are slidable relative to the respective second rack slide members between an overlapped position and an extended position. The first rack slide members are configured to receive the rack in a first orientation having a first height within the consumer appliance and in a second orientation having a second height within the consumer appliance. Again, various options and modifications are possible.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 provides a front view of a cooking appliance with its door closed;

FIG. 2 provides a front view of a portion of the cooking appliance of FIG. 1 with its door opened;

FIG. 3 provides a perspective front, close-up view of a portion of an interior of the cooking appliance as in FIG. 2 with the extension rack assembly in an overlapped position and a locking protrusion in a sliding position;

FIG. 4 provides a perspective front, close-up view of a portion of an interior the cooking appliance as in FIG. 3 with the extension rack assembly moved to an extended position and the locking protrusion in a locking position;

FIG. 5 provides a top view of the extension rack assembly in the overlapped position;

FIG. 6 provides a top view of the extension rack assembly in the extended position;

FIG. 7 provides a close up perspective view of a locking tab mechanism of an extension rack assembly;

FIG. 8 provides a diagrammatical view of the interaction of the locking bar, camming surface and side wall during movement of the extension rack assembly between an extended position and an overlapped position;

FIG. 9 provides a diagrammatical top view of the extension rack assembly showing an optional reversible rack configuration;

FIG. 10 provides an end view as in FIG. 9 with the extension rack assembly in a low position; and

FIG. 11 provides an end view as in FIG. 9 with the extension rack assembly in a high position.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 illustrates a consumer appliance in the form of a cooking appliance, in particular a free standing range 10 including a cabinet 12 that incorporates a generally rectangular cooktop 14. An oven 16 is positioned below cooktop 14 and has a front-opening access door 18. A range backsplash 22 extends upward of a rear edge 24 of cooktop 14 and contains various controls, indicators, etc. 26 for selecting operative features of heating elements for cooktop 14 and oven 16. If desired, the various controls can be integrated into a front or side portion of cooktop 14. A drawer 28 may be provided to for storage or as part of a broiler. The construction and operation of the range, including the controls, oven and cooktop are believed to be within the purview of those in the art without further discussion.

It is contemplated that the present disclosure is applicable to any type of cooking appliance, oven, stove or range, whether free standing, built in, countertop or undercabinet, whether gas, electric, combinations, etc. Also, the present disclosure is applicable to other consumer appliances. Therefore, the rack assemblies disclosed herein could be employed in refrigerated appliances such as refrigerators or freezers, or in dishwashers or other consumer appliances. No limitation on the use of the rack assemblies disclosed herein should be construed by virtue of the examples shown in the Figures using an oven within a range to illustrate aspects of the rack assemblies.

An extension rack assembly 30 includes a rack 32 sized for placement within interior side walls 20 of oven 16. Extension rack assembly 30 includes two rack slides 34. Each rack slide 34 includes a first rack slide member 36 attachable to a side edge 38 of rack 32 and a second rack slide member 40 attachable to one of the side walls 20 (See FIG. 7). Side edge portions 38 may be detachable or permanently attached to first rack slide members 36. As shown in FIGS. 2-8, rack 32 includes a plurality of rods 42 extending between the rack assemblies 30 and welded to the respective first rack slide members 36. However, it should be understood that rack 32 may be removable if desired.

Second rack slide members 40 are connectable in some way, either directly or indirectly, to side walls 20. Thus, as shown, side walls 20 may include a number of channels 44 at different heights for receiving a sub-rack 46 attached to second rack slide members 40. Channels 44 are defined between adjacent ridges 45. Sub rack 46 includes cross portions 48 connecting the two second rack slide members 40 for movement together just as rods 42 of rack 32 connect the two first rack slide members 36 for movement together. Sub-rack 46 also includes mounting portions 50 along both sides of the rack assembly 30 for engaging channels 44 of side walls 20. Mounting portions 50 may include an upturned rear stop 52 and an upturned front stop 54 for interacting with corresponding portions of side walls 20. Rear stop 52 is present as a vertical stop that engages the underside of formed channels 45 when rack 32 is extended and prevents the sub-rack 46 from moving vertically in the rear. Front stop 54 interacts with a bumper 56 disposed in ridge 45 along channel 44 to indicate to a user that rack assembly 30 is fully inserted into the channels on side walls 20.

It should be understood that channels 44, stops 52 and 54, bumpers 56, etc., are not required. Therefore, rack slides 34 could be mounted in other ways, for example on rods extending from side walls instead of within channels 44 formed by ridges 45, with or without stops and bumpers. Also, rack slides 34 could be attached directly to side walls 20. Accordingly, various mounting methods are possible within the scope of the invention, and describing the rack slide members as being attachable to the side walls would incorporate any and all such methods.

The first rack slide members 36 are slidable relative to their respective second rack slide members 40 by virtue of a ball bearing assembly 58 attached between the rack slide members. The first and second rack slide members 36 are 40 are movable between an overlapped position (See FIGS. 3 and 5) and an extended position (See FIGS. 4 and 6) via relative sliding permitted by bearing assembly 58. When rack slide members 36 and 40 slide relative to each other, rack 32 and sub-rack 46 also move relative to each other accordingly. It should be understood that more sliding is permitted than shown in FIGS. 4 and 6, and that rack 2 can therefore move many more inches forward out of oven 16. The orientations in FIGS. 4 and 6 are intended to show the point at which extension rack assembly 30 would become secured to the oven 16, as described below.

It is also possible to use more than two rack slide members (for example three or more). In such case the first rack slide member would be attachable to the rack, the second rack slide member would be attachable to the side walls, and a third rack slide member would be between the first and second rack slide members. In such case two bearing assemblies would be required (between the first and third rack slide members, and between the third and second rack slide members). Similarly, a fourth rack slide member could also be added. In any event, describing the assembly as having first and second rack slide members does not limit the assembly to two such members, and only refers to the members that are positioned as described.

A latching mechanism 60 is attached to each of the second rack slide members 40. Each latching mechanism 60 includes a lock bar 62 pivotally mounted to second rack slide member 40, for example via a plate 64 having extending arms 66, 68 and an axle 70 therethrough. Arms 72 and 74 of lock bar 62 are also connected to axle 70. Lock bar 62 has a locking protrusion 76 movable between a locking position (FIGS. 4 and 6) and a sliding position (FIGS. 3 and 5). Each latching mechanism 60 also includes a spring member 78 urging locking protrusion 76 toward the locking position. The first rack slide members 36 locate the locking protrusions 76 in the sliding position when the rack slide members 36 and 40 are in the overlapped position (FIGS. 3 and 5). Spring members 78 locate locking protrusions 76 in the locking position only when the rack slide members 36 and 40 are in the extended position (FIGS. 4 and 6). Locking protrusions 76 contact stops 80 along side walls 20 when rack assembly 30 is located fully within side walls 20 and the rack slide members 36 and 40 are slid apart. FIGS. 5 and 6 schematically show the positions of stops 56 and 80 that are on the ridge 45 below side rods 50 (as opposed to those that would be on the ridge above and would be contacted by the depicted stop 54 and locking protrusion 76) for clarity of illustration. Camming surfaces 82 on first rack slide members 36 contact a cam follower 84 on lock bar 62 to define the pivot motion that spring member 78 dictates as the lock bar moves to the sliding position. The camming surface 82 causes locking protrusion 76 to not contact stop 80 when the rack slide members 36 and 40 are in the overlapped position and allows the locking protrusion 76.to contact the stop when the rack slide members are moved to the extended position.

In other words, when rack slide members 36 and 40 are first slid together into the side walls 20 (in or eventually into) the overlapped position as in FIG. 5, locking protrusions 76 are in an unlocked position. Accordingly, by sliding rack assembly 30 out of side walls 20 without relative movement between rack slide members 36 and 40, rack assembly 30 can be slid freely from walls 20. This would typically be done by grasping rack assembly 30 by the front so that rack 32 and sub-rack 46 move together as a unit. Thus, rack assembly 30 will slide freely though channels 44 and out of side walls 20.

However, when rack slide members 36 and 40 are located fully within channels 44 and side walls 20, and the rack slide members are slid apart to the extended position as in FIG. 6, camming surface 82 will slide forward and cam follower 84 will pivot under influence of spring member 78, causing locking protrusion 76 to be immediately pivoted outward to the locked position. Locking protrusion 76 thus will be extended so that any pulling transmitted to second rack slide member 40 will be halted by stop 80 contacting locking protrusion 76. Stop 80 should thus be located along channel 44 at a location corresponding to a desired stopping of second rack slide members 40. Typically, that desired location would be just forward of locking protrusion 76 when rack assemblies 30 are properly and fully inserted into channels 44.

It should be understood that only one latching mechanism 60 could be employed on only one side, if desired. Also, it should also be understood that latching mechanism 60 can be attached to second rack slide member(s) 40 directly or indirectly. Therefore, latching mechanism 60 being “attached to” second rack slide member 40 would also include the latching mechanism being attached to something attached to and/or moving along with the second rack slide member, such as sub-rack 46 or any other structure.

Oven side walls 20 are typically constructed of metal with a porcelain-enamel type coating. Accordingly, the contact between sub-rack 46 and channel 44/ridges 45 will create higher frictional forces than are provided by smooth rolling ball bearing assemblies 58. Therefore, when a user pulls on rack 32 with rack assembly 30 fully inserted into channels 44, first rack slide members 36 will move relative to second rack slide members 40 as bearing assemblies 58 provide low friction and sub-racks 46 will stay substantially motionless within channels 44/ridges 45. Camming surfaces 82, which before movement had pushed cam follower surface 84 outward so as to pivot locking protrusions 76 away from side walls 20 by overcoming spring members 78, will slide away from the cam followers allowing the spring members to pivot the lock bars 62. Locking protrusions 76 will then pivot outward to a position where, if second rack slide members 40 were slid along channels 44, stops 80 will contact the locking protrusions, thereby holding the second rack slide member in place.

FIG. 8 shows, from left to right, the pivoting inward of locking protrusion 76 when the rack slide members 36 and 40 are moved from the extended to the overlapped position (for example by pushing in rack 32). From right to left, FIG. 8 shows the pivoting of lock protrusion 76 outward to a locking position that occurs when rack slide assemblies 36 and 40 are slid apart (for example by pulling out rack 32).

Such contact therefore prevents the entire rack assembly 30 from being inadvertently slid out of side walls 20. The extension of lock protrusion 76 happens somewhat automatically as rack 32 is grasped and slid outward, due to differences in frictional characteristics between parts. No lever, button or other release is required to slide rack 32 outward, as with previous designs. Therefore, inadvertent accidents or burns due to complicated removal or sliding procedures are unlikely. By grasping both rack 32 and sub-rack 46, rack assembly comes right out. By grasping only rack 32, lock protrusions 76 spring outward after only slight motion, allowing rack 32 to move forward to the limits of the bearing assemblies 58.

Therefore, the above locking bar 62, spring 78 and camming structure 82, 84 provides a mechanism for automatically securing extension rack assembly 30 within side walls 20 when the extension rack assembly is moved from the overlapped position to the extended position, and for allowing removal of the extension rack assembly from the side walls when the extension rack is maintained in the overlapped position and slid from the side walls.

FIGS. 9-11 show a variation in which rack assembly 130 includes a removable rack 132. Rack 132 is mountable between rack slides 134 as above, with a sub-rack 146, bearing assemblies 158, locking bar 162, camming surface 182, etc. Therefore, the operation of rack assembly with reference to mounting within side walls is the same as above.

However, rack assembly 130 includes receivers 133 (such as u-channels as shown) on first rack slides 136 for receiving rack 132 in two orientations. Rack 132 also includes two side extensions 135 at its edges perpendicular to main rack surface 137. Rack 132 can therefore be mounted at either of two heights relative to rack slides 134. For an oven, that can allow for different baking configurations by changing only the position of rack 132, not the whole rack assembly. Therefore, added adaptability and functionality are provided by such structure.

It should be kept in mind that the above rack assemblies and their various components are not limited to a particular type of oven, or to an oven for that matter. Such assemblies could be used with any type of consumer appliance.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. An extension rack assembly for a consumer appliance, the extension rack assembly comprising:

a rack sized for placement within the consumer appliance;

two rack slides, each rack slide including a first rack slide member attachable to a side edge of the rack and a second rack slide member attachable to a side wall of the consumer appliance, the first rack slide members being slidable relative to the respective second rack slide members between an overlapped position and an extended position; and

a latching mechanism attached to at least one of the second rack slide members, each latching mechanism including a lock bar having a locking protrusion movable between a locking position and a sliding position, each latching mechanism including a spring member urging the locking protrusion toward the locking position, the first rack slide members locating the locking protrusion in the sliding position when the rack slide members are in the overlapped position, the spring member locating the locking protrusion in the locking position only when the rack slide members are in the extended position.

2. The extension rack assembly of claim 1, wherein each first rack slide member includes a camming surface and each lock bar includes a cam follower, the locking protrusion position controlled at least in part by the interaction of the camming surface and the cam follower.

3. The extension rack assembly of claim 2, each camming surface being configured so that movement of the rack slide members from the extended position to the overlapped position automatically moves the locking bar to the sliding position by overcoming the spring member.

4. The extension rack assembly of claim 2, each camming surface being configured so that movement of the rack slide members from the overlapped position to the extended position automatically moves the locking bar to the locking position via the spring member.

5. The extension rack assembly of claim 1, the rack slides being configured to be freely slid from the consumer appliance while in the overlapped position with the locking bar spaced from the oven side walls.

6. The extension rack assembly of claim 5, wherein the rack slides may be freely slid from the consumer appliance while in the overlapped position without releasing an engagement between the locking bar and side walls.

7. The extension rack assembly of claim 1, the rack slides being configured to be fixed within the consumer appliance while in the extended position due to contact between the locking bar and the side walls.

8. The extension rack assembly of claim 1, wherein the first rack slide members are configured to receive the rack in a first orientation having a first height within the consumer appliance and in a second orientation having a second height within the consumer appliance.

9. A consumer appliance comprising:

a cabinet having side walls;

a rack sized for placement within the cabinet;

two rack slides, each rack slide including a first rack slide member attachable to a side edge of the rack and a second rack slide member attachable to a respective side wall, the first rack slide members being slidable relative to the respective second rack slide members between an overlapped position and an extended position; and

a latching mechanism attached to at least one of the second rack slide members, each latching mechanism including a lock bar having a locking protrusion movable between a locking position and a sliding position, each latching mechanism including a spring member urging the locking protrusion toward the locking position, the first rack slide members locating the locking protrusion in the sliding position when the rack slide members are in the overlapped position, the spring member locating the locking protrusion in the locking position only when the rack slide members are in the extended position.

10. The consumer appliance of claim 9, wherein each first rack slide member includes a camming surface and each lock bar includes a cam follower, the locking protrusion position controlled at least in part by the interaction of the camming surface and the cam follower.

11. The consumer appliance of claim 10, each camming surface being configured so that movement of the rack slide members from the extended position to the overlapped position automatically moves the locking bar to the sliding position by overcoming the spring member.

12. The consumer appliance of claim 11, each camming surface being configured so that movement of the rack slide members from the overlapped position to the extended position automatically moves the locking bar to the locking position via the spring member.

13. The consumer appliance of claim 9, the rack slides being configured to be freely slid from the cabinet while in the overlapped position with the locking bar spaced from the side walls.

14. The consumer appliance of claim 9, the rack slides being configured to be fixed within the cabinet while in the extended position due to contact between the locking bar and the side walls.

15. An oven comprising:

a cabinet having side walls;

an extension rack assembly mountable within and removable from the oven side walls, the extension rack assembly movable between an overlapped position and an extended position; and

means for automatically securing the extension rack assembly in the oven cabinet when the extension rack assembly within the oven side walls is moved from the overlapped position to the extended position and for allowing removal of the extension rack assembly from the oven cabinet when the extension rack is maintained in the overlapped position and slid from the oven side walls.

16. The oven of claim 15, wherein the means for automatically securing and allowing removal includes at least one latching mechanism attached to the extension rack assembly for selectively engaging the side walls.

17. The oven of claim 16, wherein the latching mechanism includes a locking bar and a spring member, the spring member urging the locking bar toward a locking position.

18. The oven of claim 17, wherein the extension rack assembly is configured to automatically move the locking bar away from the locking position when the extension rack assembly is in the overlapped position.

19. An extension rack assembly for a consumer appliance, the extension rack assembly comprising:

a rack sized for placement within the consumer appliance;

two rack slides, each rack slide including a first rack slide member attachable to a side edge of the rack and a second rack slide member attachable to a side wall of the consumer appliance, the first rack slide members being slidable relative to the respective second rack slide members between an overlapped position and an extended position, the first rack slide members being configured to receive the rack in a first orientation having a first height within the consumer appliance and in a second orientation having a second height within the consumer appliance.

20. The extension rack assembly of claim 19, wherein each first rack slide member includes a receiver for receiving the rack in either one of two possible orientations.