Toaster assembly and method for toasting bread products

• US 6,205,910 B1
• Filed: 04/14/2000
• Issued: 03/27/2001
• Est. Priority Date: 04/16/1999
• Status: Expired due to Fees

• Current Assignee: Star Manufacturing International Incorporated (Middleby Corporation)
• Original Assignee: Star Manufacturing International Incorporated (Middleby Corporation)
• Inventors: Vaughn, Thomas Daro
• Primary Examiner(s): Simone, Timothy F.
• Application Number:
  US09/549,774
• Time in Patent Office: 347 Days
• Field of Search: 993/26--33, 993/39, 993/40, 993/85--93, 994/00, 994/01, 994/44--50, 994/82, 994/83, 219/521, 219/492, 219/494, 219/497
• US Class Current: 99/326
• CPC Class Codes: A47J 37/08 Bread-toasters

Abstract

A toaster/heater assembly for toasting and heating food products has a housing containing a frame, and a heating chamber having a toaster/heater ensemble which heats two compartments of the chamber. The ensemble has a middle unit and two side units, each of which are divided into two insulating boards having side edges with nibs separated by notches. A pair of lower terminals are spaced from each other and connected to ends of a heating element. For the side units, the heating element winds from a terminal around the nibs and notches of one board section to then cross to the other board section to likewise wind, so that almost all of the strands of the element face a heating compartment. The middle unit heating element winds through the notches and nibs and crosses to the other board section and likewise winds about it so that heat radiates from both of its sides to two different compartments. The boards have food guides, such as rods, extending from mounts about the top and bottom of the boards to space the food products from the heating elements. Lugs extend from the bottom mounts to fit in corresponding frame openings. Lugs extend from the sides of the mount plate into corresponding frame fittings. The units can be handled by grasping the food guides. The frame has an activating switch aligned with part of a carriage for the units to be activated by the carriage part upon descending.

Claims

1. A toaster/heater assembly for toasting and heating food products, comprising:

(a) a housing;

(b) a frame within the housing;

(c) a toaster/heater unit mounted in association with a frame, the toaster/heater unit comprising a board of insulating material having a bottom and a top, and a first side and a second side;

(d) the toaster/heater unit comprising a heating element mounted in association with the board for radiating heat toward food products placed within the housing;

the heating element having first and second ends;

(e) the toaster/heater unit comprising a food guide associated with the element board, the food guide having a first end and a second end, means for mounting the first end of the guide in association with the board and means for mounting the second end of the guide in association with the board, the guide being shaped to project outwardly from its mounting in association with the board to be spaced from the surface of the board and spaced from the heating element to help prevent bread or other food placed within the frame from contacting the heating element while allowing radiant heat emitted from the heating element to pass around it to strike against food products placed in the frame.

2. The toaster/heater assembly of claim 1 wherein the guide comprises a rod, with the first end of the rod mounted in association with the board near the top of the board, and the second end of the rod mounted in association with the board near the bottom of the board.

3. The toaster/heater assembly of claim 1 wherein the food guide comprises a pair of rods joined together by a bite section, each rod having an end, means for mounting the bite section to the board, and means for mounting the ends of the rod to the board.

4. The toaster/heater assembly of claim 3 wherein the bite section is mounted near either the top or the bottom of the board, and the rod ends are mounted to the other of the top or the bottom of the board.

5. The toaster/heater assembly of claim 2 further comprising an upper support plate mounted toward the top of the board, and a lower support plate mounted toward the bottom of the board, and wherein the first end of the rod is mounted to the upper support plate and the second end of the rod is mounted to the lower support plate.

6. The toaster/heater assembly of claim 3 further comprising an upper support plate mounted toward the top of the board, and a lower support plate mounted toward the bottom of the board, and means for mounting the bite section of the food guide to one of the first or second support plates, and means for mounting the rod ends to the other of the upper or lower support plate.

7. The toaster/heater assembly of claims 5 or 6, wherein the bottom support plate has a mounting plug that extends downwardly therefrom, and further has a first depending leg located and spaced from said plug to one side of the plug, and a second depending leg located and spaced from the plug to the other side of said plug;

the frame having a platform with a deck section, the deck section having a hole sized to receive the plate plug, the platform deck also having a first kerf sized to receive the first plate leg, and having a second kerf sized to receive the second plate leg, so that the interaction between the plug and legs with the deck helps to stabilize the mounting of the board relative to the deck.

8. The toaster/heater assembly of claim 5 or 6, wherein the upper support plate has outer ends with a lug projecting from each outer end, the frame comprising a pair of partition walls, each wall having a slit sized to receive its corresponding projecting lug to help hold the board in a fixed position relative to the frame.

9. The toaster/heater assembly of claim 8 wherein the projecting lugs extend through their corresponding slits, and a part of each lug that extends beyond the slit is bent to one side to better retain the position of the upper plate relative to the partition walls.

10. The toaster/heater assembly of claim 1 comprising a first upper support plate and a second upper support plate, each of which is mounted toward the top of the board, the first upper support plate being mounted to the first side of the board, and the second support plate being mounted to the second side of the board opposite the first side of the board, the outer ends of the first and second support plate each having a projecting lug, the frame comprising a pair of partition walls, each wall having a slit sized to receive each projecting lug, the lugs from each end of the first and second support plates being bent away from each other at a point past the slit to help retain the position of the support plates and board relative to the frame.

11. The toaster/heater assembly of claim 1 further comprising a first terminal mounted to a side of the board near the bottom of the board, the first end of the heating element being an electrical connection with the first terminal, the first terminal being mounted to the board at a first point and at a second point, so that the mounting at the two points resists pivoting of the terminal relative to the board.

12. The toaster/heater unit of claim 11 further comprising a second electrical terminal, the second terminal being mounted to the board at a point laterally spaced along the board from the first terminal to be separate from the first terminal, the terminal being mounted to the board at a first point and at a second point to resist pivoting of the first terminal relative to the board, the second end of the heating element being in electrical connection with the second terminal.

13. The toaster/heater assembly of claim 12 wherein the frame has a platform with a deck section, the deck section having a first hole and a second hole, each of the first and second terminals having a portion that extends beneath the board so that the said portion of the first terminal extends through the first hole to extend beneath the platform deck, and the said portion of the second terminal extends through the second hole to extend beneath the platform deck.

14. The toaster/heater assembly of claim 12 wherein the first terminal is secured to the board by an upper securing member and a lower securing member spaced from one another, and wherein the second terminal is secured to the board by an upper securing member and a lower securing member which are spaced from one another, and wherein the first end of the element is electrically connected at the upper securing member of the first terminal, and wherein the second end of the heating element is connected to the upper securing member of the second terminal.

15. The toaster/heater assembly of claim 6 wherein the upper support plate has an angle-shape including an upper flange shoulder that projects outwardly from the board, the flange having a recess, the bite section of the rod being mounted to the upper support plate at a location beneath the recess.

16. The toaster/heater assembly of claim 1 wherein the board has first and second edges, and the first and second board sides each have surfaces, the first board edge has a series of notches with nibs formed between the notches, and the second board edge has a series of notches with nibs formed between the notches, and wherein the heating element winds about the board in a pattern to extend along the surface of the first board side to pass through the first one of said notches to wrap about a nib to extend along the surface of the second side of the board to thence pass through a second notch to pass along the surface of the first side of the board.

17. The toaster/heater assembly of claim 16 further comprising a first electrical terminal and a second electrical terminal, each of which is mounted to the board, and wherein the first end of the first heating element is in electrical connection with the first terminal and extends therefrom to wind through notches and around nibs along the first longitudinal board edge and winds through notches and about nibs along the second longitudinal edge to wrap about the board and thence extend so that the second end of the heating element is in electrical connection with the first terminal, wherein the heating element extends in such pattern to be substantially on the surface of the first side of the board and insubstantially on the surface of the second side of the board, so that almost all of the heat radiated by the heating element radiates outwardly from the surface of the first board side.

19. The toaster/heater assembly of claim 17 further comprising a first electrical terminal and a second electrical terminal, each of which is mounted to the board, and wherein the first end of the first heating element is in electrical connection with the first terminal and extends therefrom to wind through notches and around nibs along the first longitudinal board edge and winds through notches and about nibs along the second longitudinal edge to wrap about the board and thence extend so that the second end of the heating element is in electrical connection with the first terminal, wherein the heating element extends in such pattern to be substantially on the surface of the first side of the board and insubstantially on the surface of the second side of the board, so that almost all of the heat radiated by the heating element radiates outwardly from the surface of the first board side.

18. A toaster/heater assembly for toasting and heating food products, comprising:

(a) a housing;

(b) a frame within the housing;

(c) a toaster/heater unit mounted in association with a frame, the toaster/heater unit comprising a board of insulating material having a bottom and a top, and a first side and a second side, wherein the board has first and second edges, and the first and second board sides each have surfaces, the first board edge has a series of notches with nibs formed between the notches, and the second board edge has a series of notches with nibs formed between the notches;

(d) a heating element mounted in association with the board for radiating heat toward food products placed within the housing;

the heating element having first and second ends, wherein the heating element winds about the board in a pattern to extend along the surface of the first board side to pass through the first one of said notches to wrap about a nib to extend along the surface of the second side of the board to thence pass through a second notch to pass along the surface of the first side of the board.

20. A toaster/heater assembly for toasting and heating food products, comprising:

(a) a housing;

(b) a frame within the housing;

(c) a toaster/heater unit mounted in association with the frame, the toaster/heater unit comprising a board of insulating material, the board having first and second longitudinal edges, a bottom and a top, a first side with a substantially flat first surface, and second side with a substantially flat second surface, the board having a plurality of holes extending through the board from the first side to the second side, the holes being aligned generally vertically and located between the longitudinal edges of the board, the plurality of holes comprising an uppermost hole and a bottom hole;

(d) a heating element having first and second ends, the heating element extending in a pattern to wind from a first point on the first edge thence along the surface of the first board side, thence through a first hole, thence along the surface of the second board side, thence through a second hole above the first hole to the first board side and thence extending along the surface of the first board side to a second point on the first edge which second point is above the first point on the first edge, thence once again to pass along the surface of the first board side to pass through the second hole, thence to pass along the surface of the second board side to pass through a third hole to the first board side, thence along the surface of the first board side to a third point on the first edge which third point is above the second point on the edge, thence again along the surface of the first board side to repeat the aforesaid pattern until the heating element extends to its uppermost point on the first board edge.

21. The toaster assembly of claim 20 wherein the heating element extends from its uppermost point on the first board side to then pass along the surface of the first board side to a first point on the second board edge, thence the element extends along the surface of the first board side to pass through the uppermost hole, thence to extend along the first board side to a second point on the second board edge, and thence to extend along the surface of the first board side through a hole, thence to extend along the surface of the second board side to pass through a hole located beneath the previous hole, thence to extend along the surface of the first board side to a third point on the second edge of the board.

22. The toaster assembly of claim 21 wherein the heating element repeats the aforesaid pattern of extending from the second edge of the board through the plurality of holes until it passes through the bottom hole, and thence extends to a point on the second board edge.

23. The toaster assembly of claim 22 wherein the toaster/heater unit has a first electrical terminal and a second electrical terminal, the first terminal being mounted to the board, and the second terminal being separate from the first terminal and mounted to the board to be laterally spaced from the first terminal.

24. The toaster assembly of claim 23 wherein the first end of the heating element is connected to the first terminal and the second end of the heating element is connected to the second terminal, so that electricity can flow from the first terminal through the heating element to the second terminal so that the heating element emits radiant heat.

25. A toaster/heater assembly for toasting and heating food products, comprising:

(a) a housing;

(b) a frame within the housing;

(c) a toaster/heater ensemble, the ensemble comprising a middle toaster/heater unit comprising a board of insulating material, having a bottom and a top, and a first side and a second side, with a heating element mounted with the board so that the element passes generally equally along the first side of the board and along the second side of the board;

the ensemble further comprising a pair of side toaster/heater units, each side unit comprising a board of insulating material having a bottom and a top, and a first side and a second side, and each side unit having a heating element mounted with the board, with almost all of the heating element extending alongside the first board side and little of the heating element extending along the second board side;

the two side units being mounted to the sides of the middle unit so that the first side of the first side unit faces a side of the board of the middle unit, and the first side of the second side unit faces the other side of the middle unit.

26. The toaster/heater assembly of claim 25 comprising a plurality of ensembles, the ensembles being arranged relative to the housing and to the frame so that one of the side units of the outermost ensemble has its second side facing the frame and facing the housing, and a second side unit of a second ensemble has its second side facing the frame and facing the housing.

27. A toaster/heater assembly for toasting and heating food products, comprising:

(a) a housing;

(b) a frame within the housing;

(c) a pair of toaster/heater units mounted in association with the frame, the toaster/heater units each comprising a board of insulating material having a bottom and a top, and a first side and a second side, each unit having a heating element mounted in association with the board for radiating heat at least from one of the sides of each of the boards, with a toaster/heater compartment formed therebetween;

(d) a food support assembly comprising a carriage, the food support assembly being moveably mounted relative to the housing and to the frame, and shaped to hold food within the compartment and move food downwardly into the compartment and upwardly out of the compartment, the carriage comprising a member having a lower substantially flat surface;

(e) an electrical switch mounted in association with the frame, the switch having an activating member moveable to place the switch in an “

on”

or “

off”

position, with electrical circuitry to energize the heating element in the “

on”

position and to de-energize the heating element in the “

off”

position, the carriage moveable in a vertical direction so that it moves towards the switch activator positioned beneath the carriage so that its substantially flat surface engages the activator to place the switch in the “

on”

position to cause the heating elements to radiate heat, and the carriage moveable upwardly away from the switch activator to disengage the activator to place the switch in the “

off”

position to de-energize the heating elements.

28. The toaster/heater assembly of claim 27 wherein the member comprises a plate, the plate having a flange with a lower substantially flat surface for engaging the switch activator.

29. The toaster/heater assembly of claim 27 further comprising an assembly to engage the carriage to hold it against the switch activator to place the switch in the “

on”

position, and to disengage from the switch activator, comprising a claw member, means for pivotally mounting the claw to the frame;

the claw having an initial position and means for biasing the claw to its initial position, the claw having an upper surface that has a curved portion and extends at an angle of about 30°

to 60°

relative to the horizontal component of the housing, the claw having a talon whose upper surface forms part of the upper surface of the claw, the talon having an underside;

the carriage having a projecting member so that when the carriage is moved downwardly, the projecting member engages the upper claw surface to pivot the claw from its initial position so that the projecting member passes beneath the talon underside, to allow the claw to be biased to its initial position with the talon underside overlying the projecting member to hold the carriage in fixed position with the carriage member'"'"'s substantially flat lower surface engaged with the switch activator to maintain the switch in the “

on”

position.

30. The assembly of claim 29 wherein the angle of the claw upper surface is about 40°

relative to the housing.

31. The assembly of claim 29 wherein the underside of the talon is substantially flat.