Shell structure for a heating appliance, and method of manufacturing heating appliance including same

An assembly for a heating appliance, comprising:

• a shell for a heating appliance comprising first and second side panels and front and rear end panels, the front end panel having first and second sub panels and each sub panel having a vertical edge, the vertical edges of the first and second sub panels being spaced apart to form an opening, and each sub panel including an aperture extending to the corresponding vertical edge;
• a first side heating element attached on the inside of the first side panel and including a terminal extending through the aperture in the first sub panel, the first side heating element operable responsive to a power signal being applied on the terminal to generate heat;
• a second side heating element attached on the inside of the second side panel and including a terminal extending through the aperture in the second sub panel, the second side heating element operable responsive to a power signal being applied on the terminal to generate heat;
• and
• a center heating element attached to the rear end panel between the first and second side heat elements, the center heating element including a terminal extending through an aperture in the rear panel and operable responsive to a power signal being applied on the terminal to generate heat.

A heating appliance, comprising:

• a shell having first and second side panels and first and second end panels, and the first end panel having first and second sub panels, each sub panel having a vertical edge and the vertical edges of the first and second sub panels being spaced apart to form an opening between the vertical edges, the first end panel allowing the insertion of components through the opening during assembly of the heating appliance;
• a first heating element attached on the inside of the first side panel and a second heating element attached on the inside of the second side panel, each heating element including at least one terminal adapted to receive a power signal and operable responsive to the power signal being applied to generate heat;
• and
• an electronic circuit coupled to the terminals of the heating elements, the electronic circuit operable to apply the power signals to the heating elements during a heating cycle of the appliance and to remove the power signal to terminate the heating cycle.

A method of manufacturing an assembly for a toaster, comprising:

• providing a shell having first and second side panels, a rear end panel, and a front end panel, the front end panel having an opening;
• inserting a first outer heating element through the opening;
• attaching the first outer heating element to the first side panel;
• inserting a second outer heating element through the opening;
• attaching the second outer heating element to the second side panel;
• inserting a center heating element through the opening;
• and
• attaching the center heating element to the rear end panel.

A method of manufacturing an assembly for a toaster, comprising:

• providing a shell having first and second side panels and first and second end panels, the first end panel having an opening;
• inserting a first outer heating element through the opening and attaching the first outer heating element to the first side panel;
• inserting a second outer heating element through the opening and attaching the second outer heating element to the second side panel;
• inserting a first outer bread guard through the opening and positioning the first outer bread guard adjacent the first outer heating element;
• inserting a second outer bread guard through the opening and positioning the second outer bread guard adjacent the second outer heating element;
• inserting a center heating element through the opening and attaching the center heating element to the second end panel;
• attaching a bottom bracket to the first end panel and thereby securing the outer bread guards to the shell;
• attaching a carriage support bracket to the first end panel to cover the opening;
• and
• inserting first and second center bread guards adjacent respective sides of the center heating element, the center bread guards being inserted through the top of the shell;
• and
• inserting first and second bread trays adjacent the first and second after bread guards, respectively.