Cooking Panel Comprising Gas-Fired Burner Units and a Continuous Cooking Surface of Glass Ceramic or a Comparable Material

1. Field of the Invention

The invention relates to a cooking panel whose cooking units are heated with gas burners which are covered by a common or continuous cooking surface, consisting of glass ceramic or similar material.

2. Description of the Prior Art

Gas-fired cooking panels having a continuous cooking surface of glass ceramic or similar material are known. They are disclosed, for example, in the German Pat. Nos. 24 40 701, 27 21 921, 26 33 849 as well as in the French Pat. Nos. 2 058 722 and 2 076 174. The cooking units of these known cooking panels are heated with radiant gas burners according, for example, to the German Pat. Nos. 26 33 849 or with atmospheric burners. Differences between the embodiments according to the aforementioned patents consist, among other things, in the manner of managing the combustion air and the exhaust gas, this being done with auxiliary blowers in some of the devices--that, for instance, according to the German Pat. No. 20 76 174.

The fundamental structure of known cooking appliances of the type described above shall be described below with reference to the example of a cooking panel comprising a continuous cooking surface of glass ceramic heated with radiant gas burners that is equipped with three cooking zones and one warmer zone.

Each cooking zone of this cooking panel has a radiant gas burner allocated to it, the burner consisting of a gas mixing chamber with an externally attached venturi tube with a gas jet and a perforated ceramic plate which upwardly terminates the gas mixing chamber. The German Pat. No. 26 33 849 describes this type of burner. In operation, this ceramic plate is caused to glow by means of small flames that burn at the end of the perforation and functions as a heat radiator. A sheet metal ring, referred to as the exhaust gas ring, is put in place on this burner arrangement as a combustion chamber limitation, the ring being supported on a plurality of springs secured to the combustion chamber and being pressed by the springs against the glass ceramic cooking surface from below via a sealing ring consisting of refractory material. The exhaust gas ring carries a rod expansion switch for temperature limitation of the burner and the required ignition and monitoring electrodes as well as an exhaust gas nozzle. The latter discharges into an exhaust gas channel consisting of sheet metal which eliminates the burner exhaust into the warmer zone or directly out of the cavity. The warmer zone is heated by the exhaust gases of one or more cooking unit burners. It consists of an upwardly open sheet metal trough comprising a sealing ring and connections for the exhaust gas ducts as well as an exhaust stack. It is likewise pressed against the cooking surface by means of springs and conducts the exhaust gases into the open air via a system of baffle plates which serve the purpose of intimately mixing the hot exhaust gases with the cool ambient air.

All three cooking unit burners are completely independent of one another and consist of the above-described main components in addition to further piece parts.

The cooking unit burners are controlled with allocated solenoid valves that are disposed in the cavity space in the course of the gas conduits. A separate, thermally insulated housing is provided for the temperature-sensitive control and monitoring electronics, the housing being attached laterally or to the front of the cooking panel or being externally mounted at some other location.

The various, known cooking panels of the type described above are respectively constructed of similar component parts having equivalent functions and include a number of disadvantages:

The separate manufacture of the numerous, sometimes complex components as piece parts is cost-intensive and the assembly of the cooking panel necessarily requires a great assembly outlay with high assembly cost. The multitude of components promotes susceptibility to malfunction and reduces the service friendliness of these cooking panels. Also disadvantageous are the high weight of these cooking panels as well as the lack of versatility in the selection of the cooking unit diameters and the disposition of the cooking zones in the cooking surface. It is also disadvantageous that the individual burners have large structural heights, wherewith large overall heights of the cooking panels necessarily follow, in turn preventing easy incorporation of these cooking panels in kitchen appliances. A further disadvantage of the known cooking panels with gas firing and a continuous cooking surface is that the exhaust-carrying parts of sheet metal become very hot during operation and thus heat the cavity space surrounding the burner unit, so that electrical lines and auxiliary elements such as, for example, gas control valves that are disposed in the cavity space are exposed to great temperature stresses.

A further disadvantage given the known cooking panels is that the electrical ignition and flame monitoring require complex electronic control devices that are cost-intensive and which, due to their temperature sensitivity can only be disposed in spaces that are well thermally insulated, usually outside of the cavity space.

An object of the invention is therefore a cooking panel for gas firing comprising a continuous cooking surface of glass ceramic or similar material which avoids the described disadvantages, which, in particular, can be manufactured simply and cost-favorably with low assembly outlay, which is operational reliable and service-friendly, is constructed mechanically stable given low overall weight and good thermal insulation, and which, given a low built-in depth, simultaneously guarantees the greatest possible freedom in view of the selection of the cooking zone diameters as well as the disposition of the cooking and warmer zones in the cooking surface.

FIG. 1 is a top plan view of the burner units with the cooking unit removed.

FIG. 2 is a side sectional view of a burner unit with the cooking panel in place.

FIG. 3 is a partial side sectional view of an alternative embodiment of a burner unit.

FIG. 3a is a partial side sectional view for alternative embodiment of a burner unit.

FIG. 4 is a partial side sectional view of a burner unit showing a labyrinthoseal.

FIG. 4a is a partial side sectional view of a burner unit with the labyrinthoseal having an air gap.

FIG. 5 is a partial side sectional view showing an easily maneuvered lever for removing a burner from the cooking panel.

FIG. 5a is an end view of the lever shown in FIG. 5.

FIG. 6 is a side sectional view of an alternative embodiment of the burner unit.

FIG. 7 is a side sectional view of an alternative embodiment of the burner unit.

FIG. 8 is a side sectional view of an alternative embodiment of the burner unit using an atmospheric burner.

FIG. 9 is a side sectional view of a pilot light.

FIG. 9a is a plan view of the pilot light shown in FIG. 9.

FIG. 10 is a plan view of the burner units with the cooking surface removed.

FIG. 11 is a side sectional view of an alternative embodiment of the burner unit.

FIG. 12 is a side sectional view of an alternative embodiment of the burner unit.

FIG. 13 is a schematic diagram showing the controls and burner units.

The main element of the gas-fired cooking panel comprising a continuous cooking surface of glass ceramic or similar material according to the invention is a low-mass component of refractory material, preferably consisting of aluminum silicate fibers with an inorganic binder, in which all burner units as well as one or more warmer zones of the cooking panel are molded with their essential components.

Such a structural part for cooking panels comprising three cooking units that are heated with radiant gas burners and that are equipped with a warmer zone is shown in plan view in FIG. 1; FIG. 2 shows a section along the line II--II in FIG. 1 through the right front cooking unit burner 1 in this low-mass structural part 1 consisting of refractory material.

In the plan view (FIG. 1) onto the structural part 9, one can see three cooking unit burners 1 having circular, perforated ceramic plates or jet plates 6 of which only one-fourth is respectively illustrated. The jet plates 6 separate combustion chambers 2 from gas mixing chambers 3 that are situated therebelow and which are not illustrated in FIG. 1 (see FIG. 2). Exhaust gas ducts 5 lead from the combustion chambers 2 to the center of the cooking panel. A pilot light 10 shared by all cooking unit burners 1 and comprising an ignition and monitoring means 11 is situated in the center and shall be described later.

The exhaust gas ducts 5 conduct the exhaust gases from the center into a warmer zone 7 having an exhaust stack 8 through which the exhaust gases are eliminated from the cooking cavity. Depressions 12 are also molded into the structural part 9, temperature limiters 13, rod expansion switches in this case, being inserted thereinto with precise fit and being capable of being pemanently fixed there. The electrical feeder lines of the temperature limiters 13 as well as other electrical auxiliaries that are not shown in FIG. 1, for instance, the leads of ignition and monitoring electrodes, can expediently be manufactured of solid wires that are co-embedded in the mass of refractory material when the part 9 is molded and thus act as an additional stiffening of the structural part 9 after drying. Further details of the structural part 9 consisting of refractory material proceed from the section in FIG. 2. For the sake of clarity, all parts shown in FIG. 1 that are behind the cooking unit burner 1 such as, for example, the warmer zone 7, are not shown in FIG. 2.

The gas mixing chamber 3 of the burner 1 with a gas mixing means 4 is formed onto the combustion chambers 2 in FIG. 2. The jet plate 6 is supported around on a seat 17 and is glued in this seat 17 with adhesive (not shown), preferably an inorganic, refractory bonding agent. The exhaust gas duct 5 is covered by a separate refractory part 15a comprising a cover. The cover 15a is expediently manufactured of the same material as part 9 and is glued into it. The sealing of the combustion chamber 2 relative to the cooking surface 14 is assumed by a soft seal 16 consisting of aluminum silicate fiber.

All three cooking unit burners of the cooking panel according to the invention are constructed in the same fashion and molded into the structural part 9 with their components such as combustion chamber 2, gas mixing chamber 3, exhaust gas duct 5, gas mixing means 4 together with the warming zone 7 and the exhaust stack 8.

The entire heating means of the cooking panel thus consists of a single, thermally well-insulating structural part having a low overall height, the part 9, that can be economically manufactured with known wet molding techniques for silicate fiber material and can be built into the cooking panel with minimum assembly outlay. Additional adjustment work such as required in the known cooking panels is largely eliminated with precise-fit recesses 12 in part 9 for the temperature limiters 13 and potential, additional recesses (not shown) for the ignition and monitoring unit 11 of the central pilot light 10. There are no restrictions with respect to the placement of the gas mixing units 4 in the structural part 9 so that they can be placed at the respectively most favorable locations in the structural part 9 in order to further reduce the assembly outlay. Additionally, the greatest possible freedom with respect to the selection of the cooking unit diameters and their position in the cooking surface is provided within the framework of the commonly prescribed dimensions of the cooking surface 14.

The gas mixing means 4 (FIG. 2) is described as follows: The conical bore in FIG. 2 cooperates with a gas jet 30 as an injector through which the combustion air is suctioned in. The necessary over-pressure in the gas mixing chamber 3 is achieved by means of the sudden reduction in cross-section at the end of the conical bore down to the cross-section of the mixing chamber 3. The gas is mixed with the combustion air by means of eddy formation at the same time.

The air quantity can be regulated with an air choke plate 32 that is screwed onto a thread 31 of the gas jet 30. Tests have shown that the burners 1 function well with this simple mixer means 4 and that, in particularly, the exhaust gas hygiene according to regulations is assured.

The gas jet 30 and the air choke plate 32 are not integrated into the structural part 9. They are expediently combined in a prefabricated unit for all burners together without the required gas admission conduits and gas control valves.

The structural part 9 can be manufactured of one-piece or, should the molding technology applied require it, can be composed of a plurality of parts. It can, for example, be divided into an upper part and a lower part by means of a parting plane indicted in FIG. 3 with the line E--E, said upper and lower parts being separately manufactured and subsequently glued or mechanically pressed together.

FIGS. 3, 4 and 4a show further embodiments of the cooking cavity according to the invention. Identical positional numbers in these and all further Figures indicate structural parts having the same function or, respectively, indicate identical structural parts. Given the embodiment according to FIG. 3, the covers 15a and the sealing rings 16 (FIG. 2) have been replaced by a common cover plate 15 which covers all exhaust gas conducts 5 (FIG. 3) and from which the openings for the combustion chambers 2 of the cooking unit burners 1 (FIG. 1) and the warmer zone 7 (FIG. 1) are punched. Like the part 9, the cover plate 15 is manufactured of, for example, aluminum silicate fiber material having an inorganic binder. It can be glued to the cooking surface 14. The structural part 9 is executed bipartite in this case and is formed by the upper part 9a and the lower part 9b whose parting plane is indicated with the line E--E in FIG. 3.

The jet plate 6 consisting of a special ceramic material is glued into the seat 17 provided therefor, as shown at the left in FIG. 3. Alternatively, the jet plate 6 is manufactured of silicate fiber material and is molded in one work step with the upper part 9a, as shown at the right in FIG. 3. In contrast to the above-described execution with a glued-in jet plate (FIG. 2) consisting of a special ceramic compound, the jet plate is a component part of the structural part 9 in this case, arising when the parts 9a and 9b are bonded in the plane E--E.

An embodiment wherein the upper part 9a is not bonded to the lower part 9b is shown in FIG. 4. The two parts are equipped with the elements of a labyrinth seal 23 and are pressed tightly against one another with a press means. The remaining parts in FIG. 4 correspond to the illustrations in FIGS. 2 and 3.

For reasons of stability, there is often a demand that the cooking surface 14 be able to move or, respectively sag in the direction toward the jet plate 6 given percussive stresses. In order to produce the necessary play, the labyrinth seals 23 are executed with the air gap having a height of 1.5 mm through 2 mm, as shown in FIG. 4a at 23a.

FIGS. 5 and 5a show a simple and service-friendly apparatus for assembling the complete heating unit which is composed of the structural part 9 (FIG. 2) and the cover plate 15 (FIG. 3). These parts are placed in an auxiliary frame 18 consisting of the parts 9 and 15 against the cooking surface 14 with levers 19, as shown in FIG. 5a. To this end, the levers 19 are rotatably secured to a cooking surface frame 21 with rivets 22, the frame 21 being in turn rigidly connected to the cooking surface 14 via an adhesive 20.

The above-described structural part 9 can also be manufactured of refractory material and sheet metal in a hybrid format such as is shown in FIG. 6. The parts 9a and 15 of refractory material (FIG. 3) which define the combustion chambers 2 and the exhaust gas ducts 5 as well as the warmer zone 7 (FIG. 1) are expediently retained. Instead of the lower part 9b (FIG. 3), the mixing chambers 3 (FIG. 6) comprising an all-around seat 17 into which the jet plates 6 can be glued are now impressed into a common sheet metal trough 9c. If necessary, further depressions for the region of the warming zone 7 (FIG. 1) and the exhaust gas duct regions can be impressed in the sheet metal trough. Additional beads can serve to stiffen the sheet metal trough 9c. The parts 9a and 15a are laid or, respectively, glued into the trough 9c. The mixing chambers 3 are supplied with the gas/air mixture over applied mixing means 4, for example venturi tubes that can partially project into the mixing chambers.

The weight of the cooking cavity can be further reduced in that the common structural part 9 for the cooking unit burners 1 and the warming zone 7 (FIG. 1) is manufactured of expanded aluminum silicate material having a binder. When this material is open-pored, then an additional seal is required in the region of the gas mixing chamber of the structural part 9. As shown in FIG. 7, this seal can be achieved in that a gas mixing chamber is inserted into the structural part 9 as a sheet metal bucket 3a into whose seat 17a the jet plate 6 is glued. The sheet metal bucket 3a is expediently rigidly glued to the structural part 9a. The sheet metal bucket 3a can also be disposed such that it externally surrounds the gas mixing chamber 3 molded into the structural part 9. All further features of the arrangement in FIG. 7 correspond to the features of the embodiments described above.

In the above-cited examples, the cooking unit burners 1 (FIG. 1) are constructed as radiant gas burners or gas jet burners comprising a mixing chamber 3 and the jet plate 6. When the structural part 9 (FIGS. 2 or 3) is modified in accordance with FIG. 8, then atmospheric burners can be utilized for heating the cooking unit. The combustion chamber 2 in FIG. 8 is larger than in the preceeding example and the mixing chamber is eliminated. The burner exhaust of the atmospheric burner 24 proceeds via an annular exhaust gas duct 5 at the upper edge of the combustion chamber 2 that is covered by the cover plate 15 into an exhaust gas duct system that can, for example, be executed in accordance with FIG. 1 and heats the warming zone 7 (FIG. 1). An exhaustor is expediently attached to the exhaust stack 8 (FIG. 1) of the warming zone 7 in a known manner, the exhaustor promoting the exhaust gas flow and seeing to the induced aeration of the combustion chamber 2 in FIG. 8 through the large bottom opening 25. The burner 24 is ignited through the exhaust gas duct 5 via a pilot light in the center of the cooking panel that is provided there in common for all burner units of the cooking panel. Only the trigger tube 10b of this pilotlight is shown in FIG. 8. When the cooking unit burners are individually ignited and monitored, then ignition electrodes 101 and monitoring thermocouples 111 are provided at the respective burner 24 in a known manner instead of the common pilot light. These parts are indicated with broken lines in FIG. 8.

The operating reliability of the cooking panels having radiant gas burners is significantly improved when a gas safety switch that is protected in a known manner with a thermocouple is disposed in front of the solenoid valves that are required for the control of the calorific output of the cooking unit. It is advantageous that the monitoring circuit comprising thermocouple and gas safety switch works without auxiliary energy and completely independent of the control circuit comprising the solenoid valves and offers additional safety in case of failure of the solenoid valve. Expediently and cost-favorably, a common pilot light 10 with monitoring thermocouple 11 is provided, as shown schematically in FIG. 1, this actuating a common gas safety switch for all burner units 1 which is inserted in the main gas line of the cooking panel.

FIG. 9 shows a suitable pilot light, for example for the ignition and monitoring of three burner units. Ignition tubes 10b having fine bores or slots 10e disposed behind one another on a line are attached to the gas port block 10a which is equipped with fine bores 10h and a jet 10i for the monitoring flame. The ends of the ignition tubes 10b are designed as a jet 10f. This system is supplied with gas via the gas jet 10d, whereby the required combustion air is sucked in through the bores 10g in the lower part of the gas port block. The gas port block 10a, the gas jet 10d and the ignition electrode 11a as well as the monitoring thermocouple 11 are secured in common on or, respectively, in the console 10c.

When the gas/air mixture flows into the burner, it emerges at the fine bores 10h and 10e as well as at the pilot light jet 10i and the end jets 10f of the ignition tube. A flame border that ignites the gas/air mixture at the jets 10f is formed during ignition both around the gas port block 10a as well as along the ignition tube 10b. Pilot lights can thus burn into the combustion chambers of the cooking unit burners or, respectively, a gas/air mixture emerging from them is ignited.

An auxiliary gas flow is diverted from the gas mixing chambers of the cooking unit burners 1 (FIG. 10) over separate feeder lines or respectively, the illustrated bores 27 whose diameters are greater than the jet orifices of the jet plate 6 and is conducted through the webs 26 which bound ignition channels 26a in the exhaust gas ducts 5 to the ignition gas port block 10a and is ignited there, so that gas/air mixture flowing from the jet plate 6 is in turn ignited by means of flashback via the already ignited auxiliary gas flow.

The ignition of the gas mixture proceeding from the burner (FIG. 9) through the channels 26a can advantageously ensue by means of a catalytically acting ignition surface which is disposed in the center of the exhaust gas ducts 5 instead of the pilot light and which is heated indirectly either with gas or electrically. A thermocouple is provided for monitoring ignition, this monitoring the temperature of the ignition surface.

When a separate pilot light is employed with an appertaining gas safety switch for each burner unit, then the pilot lights can be disposed as shown in FIG. 11. Openings are provided in the structural parts 9a and 9c such that the pilot light 20 which forms a unit with the ignition electrode 28 projects to the edge of the combustion chamber 2 so that the pilot flame can heat the monitoring thermocouple 11a. It is advantageous given this arrangement that the pilot flame of the burner 29 burns right above the burner jet plate 6, wherewith the gas/air mixture of the main burner is ignited immediately upon actuation of the cooking unit switch.

FIG. 12 shows a cooking unit burner 1 comprising the combustion chamber 2 and the exhaust gas duct 5 which are both formed into the structural part 9 of refractory material and comprising the gas mixing chamber 3 and the gas admission 54. The gas mixing chamber is covered by the jet plate 6. The cumbustion chamber 2 is terminated by the cooking surface 14.

The jet plate 6 and the housing or the gas mixing chamber 3 comprise an opening 38a in the proximity of the exhaust gas channel for the pilot flame 41 of the pilot light 110 attached below the opening 38a. A ceramic tube 38 in the opening 38a is bonded gas-tight to the jet plate 6 and to the housing of the gas mixing chamber 3 so that no gas/air mixture of the cooking unit burner 1 proceeds from its mixing chamber 3 into the combustion chamber 2.

The pilot flame 41 now burns perpendicular to the flow of exhaust gas from the cooking unit burner 1 and is no longer unfavorably influenced by said flow, even during ignition and extinguishing processes. In particular, the pilot flame 41 is kept from going out due to pressure surges in the combustion chamber 2 with this pilot burner arrangement.

As a further embodiment according to FIG. 12, flow element 43 is attached above the opening 38a and below the cooking surface 14, said flow element preventing the tip of the pilot flame 41 from topically overheating the cooking surface 14. The flow element 43 can, for example, consist of a heat-resistant wire wound into a flat spiral and, given transparent cooking surfaces, simultaneously serves as a luminous display for the presence of the pilot flame. As known from incandscent hoods, it can, for example, be coated with a mixture of thorium and ceroxide in order to improve the luminous spot and/or can consist of or be coated with, for example, platinum which catalytically promotes the ignition of the air/gas mixture in the combustion chamber 2 of the cooking unit burner 1.

The manner of functioning of the cooking unit burner 1, particularly its ignition and ignition supervision, is seen in the schematic diagram of the cooking panel comprising two cooking unit burners shown in FIG. 13.

The gas safety switches 46 are combined in a block, this being indicated in FIG. 13 by means of a broken line around the parts 46. The manual actuation of the gas safety switches 46 and an electrical change-over switch 47a are mechanically coupled to one another and to a manual key 47. This mechanical coupling is shown in FIG. 13 by means of the dot-dash line. Further, the double lines marked in black and white identify the gas-carrying conduits in FIG. 13. A pilot burner unit 110a consisting of a pilot burner 110 with ignition electrode 44 and thermocouple 45 is allocated to each cooking unit burner 1, as are an electromagnetic control valve 50 and an energy regulator 49. The gas safety switches 46 and the control valves 50 are combined into a structural unit. The ignition electrodes 44 are supplied by the high voltage means 48. A switch 49a which is coupled to the corresponding energy regulator 49 is inserted in the control circuit of the thermocouples 45. With the assistance of an electrically heated bimetallic switch, the energy regulators 49 generate a chronological clocking of the supply stream of the control valves 50 and thus control the temperature of the cooking unit via the selectable on-time of the cooking unit burner 1 in a known manner. The D.C. voltage required for the control valves 50 is generated with the rectifiers 52. A rod limit switch (not shown) which is disposed in the combustion chamber 2 of the cooking unit burner 1 interrupts the coil current of the control valves 50 when the temperature of the cooking unit exceeds the maximum allowable value.

In order to light one of the two cooking unit burners 1, its energy regulator 49 is switched on and, thus, the contact 19a in the thermocouple circuit is also closed. The allocated control valve 50 opens simultaneously. The control valve 50 is thereby switched currentless by the changover switch 47a and inhibits the gas feed to the cooking unit burner 1 for the duration of the ignition operation of the pilot burner 110. At the same time, the change over switch 47a switches the high voltage means 48 on and the spark ignition 44 of the pilot burner 110 is placed in operation. Both pilot burners are supplied with gas via the gas safety switches 46 opened at the same time by the manual key 47 and ignited.

When the hand key is released after a few seconds have elapsed, the changover switch 47a switches the high voltage means 48 and, thus, the ignition spark off. At the same time, this switch re-engages the power supply to the energy regulator 49 and the control valve 50 of the previously switched-on cooking unit burner 1 is opened. When the corresponding thermocouple of the pilot burner 110 of this cooking unit burner 1 is hot enough, the allocated gas safety switch 46 remains open because the thermocouple circuit is closed with the switch 49a and, thus, the valve plate of the gas safety switch is retained in the "open" position by its current coil. In contrast thereto, the pilot burner 110 of the cooking unit that has not been turned on is extinguished when the manual key 47 is released because its thermocouple cirucit is interrupted by the switch 49a in the energy regulator 49 of this cooking unit burner.

The pilot burner 110 of the cooking unit that has been turned on remains in operation independently of the allocated energy regulator 49 and rod temperature limit switch until the cooking unit is turned off at the energy regulator 49. When this is the case, both the control valve 50 as well as the current coil of the gas safety switch 46 become currentless and both valves close.

If the pilot burner 110 of the engaged cooking unit goes out for any reason during operation, the gas safety switch closes after the expiration of a safety interval and blocks the gas feed to both the pilot burner 110 as well as to the cooking unit burner 1. The cooking unit can then be re-engaged only in the manner described above by means of actuating the manual key 47.

When one of the two cooking unit burners 1 is already on and the second is to be turned on, then the described ignition operation is similarly repeated. The cooking unit burner 1 that has already been turned on is thereby extinguished for the duration of the ignition operation, whereas its pilot burner remains on. When the manual key 47 is released, the second pilot burner also remains on and both cooking unit burners light via the corresponding pilot flames.

The principle presented with reference to the preceeding example can be analogously employed in all gas equipment having a plurality of burner locations.

As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceeding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.