Abstract:
A refrigerator includes French-style doors and a rotating mullion. The rotating mullion is mounted to one of the French-style doors through first and second hinge members. Each of the first and second hinge members include first and second hinge elements having corresponding cam members. The cam members include multiple lobes and extend about hinge pins that define an axis of rotation for the mullion. The multiple lobes actually define first and second detent positions for the rotating mullion. A spring biases the first cam member against the second cam member so that the rotating mullion is positively maintained in either the first or second position. The mullion is formed from mating halves, each including a portion of an integrally formed pin element. The pin element travels within a guide element to automatically rotate the mullion between the first and second positions during use.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention pertains to the art of refrigerators and, more particularly, to a refrigerator including first and second French-style doors, as well as a rotating mullion bar that enables independent operation of each of the first and second French-style doors.  
         [0003]     2. Discussion of the Prior Art  
         [0004]     In general, refrigerators having French-style doors are known. Typically, French-style doors are used in side-by-side configurations to seal fresh food and freezer compartments. With the growing popularity of bottom mount refrigerators, manufacturers are now finding it desirable to provide French-style doors for the upper fresh food compartment.  
         [0005]     French-style doors are desirable for a number of reasons, foremost among them is weight reduction. By design, French-style doors divide an opening in half such that each French door is approximately half the weight of a conventional door. In addition, with the increased number of storage zones being employed on refrigerator doors, the use of French-style doors enhances the arrangement for storing, as well as the accessibility to a wide variety of objects. Accordingly, when used in conjunction with a fresh food compartment, the size and strength of support structure, generally required in side-by-side applications, can be reduced substantially. However, despite all of the desirable features, there exists a drawback with French-style doors in that a mullion bar, which in side-by-side configurations divides the fresh food and freezer compartments, hinders taking goods in and out of the fresh food compartment. While the mullion is not required to “divide” the compartments, French-style doors require a central sealing surface.  
         [0006]     A stationary mullion bar fixed to the refrigerator will limit the size and shape of goods capable of being placed in the compartment, as well as the accessibility to the goods. Toward that end, manufactures have devised two solutions to confront this issue. One solution is to mount a stationary mullion on one of the two French-style doors. With this arrangement, the door with the mullion is closed first, then the second door is closed against the mullion. While effective, this design necessitates a specific order of opening and closing the French-style doors and, if not followed, could lead to the door with the mullion bar being left ajar which would allow the cool air within the compartment to leak out.  
         [0007]     The second solution offered to date by refrigerator manufacturers utilizes a rotating or pivoting mullion that alleviates the problems associated with the stationary mullion discussed above. Like the stationary mullion, the rotating mullion is carried by one of the two French-style doors. Typically, the mullion is caused to pivot when the door is opened or closed, with the mullion pivoting about hinge elements that allow the mullion to travel between first and second positions. Most designs include a locking mechanism, either in the form of a magnetic retaining element or a separate, spring biased, lock. In any event, the locking mechanism retains the mullion in the second position when the door is open, yet releases as the door is closed to allow the mullion to rotate into the first position. While the known retaining and locking mechanisms are functional, they necessarily require additional parts and manufacturing steps which add to the cost and complexity of the overall design.  
         [0008]     Based on the above, there still exists a need in the art for a refrigerator having French-style doors and a rotating mullion. More specifically, there exists a need in the art for a rotating mullion that integrates a locking mechanism within a hinge to reduce the number of component parts, as well as the complexity of manufacturing.  
       SUMMARY OF THE INVENTION  
       [0009]     The present invention is directed to a refrigerator having French-style doors and a rotating mullion bar. In general, the refrigerator includes a cabinet shell having first and second refrigerated compartments each having a respective opening. Preferably, the French-style doors are provided to selectively seal the opening of the first refrigerated compartment. More preferably, the French-style doors are each provided with a gasket to maintain a seal between the doors and the cabinet shell.  
         [0010]     In accordance with the most preferred form of the invention, the French-style doors constitute first and second door members. A rotating mullion is mounted to one of the first and second door members to provide a central sealing surface between the first and second door members. Most preferably, the rotating mullion is mounted to first and second hinge members which include first and second hinge elements. More specifically, the first hinge element is mounted to one of the French-style doors and the second hinge element is secured to the rotating mullion. In addition, the first hinge element includes a first cam member and a hinge pin, while the second hinge element includes a corresponding second cam member and is rotatably mounted to the hinge pin. The first and second cam members each include multiple lobes that are adapted to nest one within the other. The multiple lobes define first and second operating positions for the rotating mullion. Actually, a spring biases the first and second cams together through the hinge pin. With this arrangement, the rotating mullion can be selectively retained in each of the first and second operating positions.  
         [0011]     In further accordance with the most preferred form of the invention, the rotating mullion includes a guide pin member. The guide pin member extends from a top portion of the mullion and rides within a guide element. As the guide pin member travels within the guide element, the rotating mullion moves between the first and second operating positions. Preferably, the rotating mullion includes first and second mating halves each defining a portion of the guide pin member extending therefrom. More preferably, a respective portion of the guide pin member is integrally formed on each of the mating halves. Finally, the rotating mullion is provided with a heating arrangement which, during operation of the refrigeration system, prevents frost and condensation from forming on the rotating mullion.  
         [0012]     Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of a preferred embodiment when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is an upper right perspective view of a bottom mount refrigerator having French-style doors and a rotating mullion constructed in accordance with the present invention;  
         [0014]      FIG. 2  is a front elevational view of the refrigerator of  FIG. 1 ;  
         [0015]      FIG. 3  is a perspective view of a door liner employed in connection with the present invention;  
         [0016]      FIG. 4  is a cross-sectional view of a sealing gasket employed with the door liner of  FIG. 3 ;  
         [0017]      FIG. 5  is a partially exploded plan view of the door liner and rotating mullion in accordance with the present invention;  
         [0018]      FIG. 6  is a partially exploded, perspective view of one refrigerator door, the rotating mullion, and hinge elements of the invention;  
         [0019]      FIG. 7  is a top view of an end portion of the rotating mullion of  FIG. 5  positioned within a guide element;  
         [0020]      FIG. 8  is a top view of the rotating mullion and French-style doors depicted in a closed position;  
         [0021]      FIG. 9  is a top view of the rotating mullion of  FIG. 7  moving from the closed position in  FIG. 8  to an open position;  
         [0022]      FIG. 10  is a top view of the rotating mullion and French-style doors of  FIG. 9  showing the mullion continuing to travel within the guide element; and  
         [0023]      FIG. 11  is a top view of the rotating mullion and French-style doors of  FIG. 9  depicting the mullion disengaging from the guide element upon further opening of the door.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0024]     With initial reference to  FIGS. 1 and 2 , a bottom-mount refrigerator constructed in accordance with the present invention is generally indicated at  2 . Refrigerator  2  is shown to include a cabinet shell  4  having a top wall  6 , bottom wall  7 , opposing side walls  8  and  9  and a rear wall  10  which combine to form first and second compartments  12  and  14 . In the embodiment shown, first or fresh food compartment  12  includes a liner having a top portion  16 , a bottom portion  17 , opposing side wall portions  18  and  19  and a rear wall portion  20 . In addition, a guide element  22 , which will be detailed more fully below, is arranged on top portion  16 . If desired, a second guide element  23  could be provided on bottom portion  17 .  
         [0025]     Refrigerator  2  is provided with an upper door assembly  26  which, in accordance with the preferred form of the invention, is constituted by French-style doors including first and second door members  28  and  29 . First and second door members  28  and  29  are provided with respective handles  32  and  33  to enable a consumer to operate door members  28  and  29  providing access to fresh food compartment  12 . Actually, first and second door members  28  and  29  pivot about upper and lower hinges  35  and  36 ,  37  and  38  respectively. As detailed more fully below, first and second doors  28  and  29  are adapted to selectively seal against upper front face portion  40  and lower front face portion  41  to prevent cold air from escaping first or fresh food compartment  12 . Actually, first and second door members  28  and  29  also seal against side portions of cabinet  4  (not separately labeled). Finally, a lower or freezer door  45  is provided to enable access to the second or freezer compartment  14 . In the embodiment shown, refrigerator  2  is a bottom mount configuration with lower freezer door  45  being adapted to slide in and out of cabinet  4  to provide access to frozen goods located within second compartment  14 .  
         [0026]     Reference will now be made to  FIG. 3  in describing the preferred structure of a liner portion for door member  29 . Actually, except as identified below, the structure of each door member  28  and  29  is identical. Therefore, a detailed description of door member  29  will be made and it is to be understood that door member  28  has commensurate structure. As shown, a liner  54  is depicted as having an outwardly projecting top portion  56 , bottom portion  57 , opposing side portions  58  and  59  and a rear portion  60  which collectively define a storage cavity  62 . In a manner known in the art, storage cavity  62  is provided with a plurality of shelf support elements, one of which is indicated at  65  on side portion  58 . However, it should be understood that a corresponding plurality of shelf support elements (not shown) are provided on opposing side portion  59 . In any event, shelf support elements  65  are adapted to receive a variety of shelf members, i.e. adjustable shelves, bins, storage units and the like, for retaining goods such as butter, soda and the like on door member  29 . Liner  43  is also provided with a sealing surface  68  having a flexible gasket  71  (see  FIGS. 1 and 4 ) which is used in providing an air-tight seal for fresh food compartment  12  when door member  29  is closed. The liner for door member  28  is identically constructed to that described above.  
         [0027]     As indicated above, gaskets  71  are provided on door members  28  and  29  in order to establish an air tight seal about fresh food compartment  12  when door members  28  and  29  are closed. Referring to  FIG. 4 , each gasket  71  preferably includes a first or inner portion  86  interconnected with a second or outer portion  88 . As shown, inner portion  86  includes a pliable, main body portion  91  which defines a plurality of cavities. More specifically, main body portion  91  defines a primary cavity  94 , as well as a plurality of secondary cavities  96 - 98 . In addition, inner portion  86  is provided with a first leg member  100  and a second leg member  101 . First leg member  100  has an end  102  which, in combination with first leg member  100 , forms a decorative skirt that covers an edge portion (not separately labeled) of door liner  54  and sealing surface  68  of respective ones of first and second door members  28  and  29 .  
         [0028]     In a manner similar to that described for inner portion  86 , outer portion  88  includes a pliable, main body portion  106  which shares a common wall with main body portion  91 . Main body portion  106  defines a primary cavity  109  and a plurality of secondary cavities  112  and  113 . Actually, secondary insulation cavity  113  has provided therein a magnet  116  which is adapted to draw gasket  71  against front face portions  40  and  41  of cabinet shell  4 . Additionally, outer portion  88  is provided with a second leg member  120  having a first end  122  extending to a second end or flap  123  defining a sealing surface for gasket  71 . In accordance with the invention, a respective flap  123  is provided at the upper and lower inner corners of gasket  71  for both doors  28  and  29  as clearly shown in  FIG. 1 . When doors  28  and  29  are closed, respective flaps  123  overlap so as to reduce a flow of air from refrigerator  2  and thus limit or slow heat transfer. Finally, a projecting member  130  extends from inner portion  86  and serves to interconnect gasket  71  with sealing surface  68  of a respective one of first and second door members  28  and  29 . In the embodiment shown, projecting member  130  includes a flared end  132  having an arrow-like cross section and is provided with first and second engagement surfaces  134  and  135 . Actually, a plurality of projecting members  130  are provided along the length of gasket  71 , with each projecting member  130  being adapted to be pressed into a respective opening or receiver (not shown) formed in liner  54  to fixedly position gasket  71  upon sealing surface  68 .  
         [0029]     The above-described structure has been presented for the sake of completeness and to enable a better understanding of the present invention which is particularly directed to incorporating a rotating/pivoting mullion assembly, generally indicated at  145  in  FIGS. 5 and 6 , in refrigerator  2 . As shown, mullion assembly  145  includes a mullion bar  148  having first and second mullion bar members  153  and  154 , which are preferably molded of plastic, and a trim piece  156  which is made of metal to enable magnet  116  of gasket  71  to seal against trim piece  156 . In the most preferred form of the present invention, first mullion bar member  153  includes a first end  160 , a second end  162 , and an interconnecting transverse web portion  164 . First end  160  is provided with a guide pin portion  166 , the details of which will be discussed more fully below. Additionally, first mullion bar member  153  is provided with a plurality of mounting lugs  168 - 171 , and a wire channel  175  that enables passage of an electrical conductor from door  28  to a heating element  177 . In accordance with the invention, heating element  177  is positioned between first mullion bar member  153  and trim piece  156 . Heating element  177  prevents condensation from forming on mullion  153  and trim piece  156 . Also, while heating element  188  is depicted as an electrical activator unit, a yoder tube would also be acceptable. First mullion bar  153  also includes a plurality of trim piece mounting slots, one of which is indicated at  176 . Trim piece mounting slots  176  are sized to snap-fittingly receive a corresponding plurality of mounting projections  178  extending from trim piece  156 .  
         [0030]     In further accordance with the most preferred form of the present invention, second mullion bar member  154  is provided with a first end  184  having a guide pin portion  186 , a second end  187 , and an interconnecting transverse web portion  188 . As perhaps best seen in  FIG. 7 , pin portions  166  and  186  combine to define a guide pin  190  which, as will be discussed more fully below, travels within upper guide element  22  mounted within fresh food compartment  12 . Although not included in this preferred embodiment, it should be noted that a second guide pin  191  (see  FIG. 2 ), similar to guide pin member  190 , could be provided at second ends  162  and  187  of mullion bar  148 . Second mullion bar member  154  includes a plurality of fastener receiving apertures  194 - 196  which, in the embodiment shown, are shaped to receive a hexagonal nut of a type known in the art. With this arrangement, a plurality of mechanical fasteners (not shown) can be inserted through the plurality of mounting lugs  168 - 171  to engage with nuts (also not shown) received within fastener receiving members  193 - 196  to join first and second mullion bar members  153  and  154  to form mullion bar  148 . Of course, other connection arrangements, such as integral snap-connectors or glue, could also be employed. Finally, positioned between first and second mullion bar members  153  and  154  is an insulation strip  199 . Preferably, insulating strip  199  is formed from EPS insulation, however other forms of insulation, such as blown foam, are also considered acceptable. In any event, insulation strip  199  is positioned to slow cold air conduction through mullion bar  148  and reduce sweating.  
         [0031]     Referring to  FIGS. 5 and 6 , mullion bar assembly  145  further includes first and second hinge members  206  and  207  which pivotally secure mullion bar  148  to door member  28 . Since the structure of each hinge member  206  and  207  is identical, a detailed description of hinge member  206  will be made and it is to be understood that hinge member  207  has commensurate structure. Hinge member  206  includes a first hinge element  210  having a base portion  212  interconnected with a first, multi-lobed cam member  214 . In the embodiment shown, a hinge pin  216  projects through first multi-lobed cam member  214  and is spaced from first multi-lobed cam member  214  by an interior cavity  217 . In accordance with the most preferred form of the invention, first hinge element  210  is secured to first door member  28  by sliding base portion  212  upon a dovetail clip  219  (also see  FIG. 7 ) secured to a side portion  58  of first door member  28 .  
         [0032]     As further shown in  FIGS. 5 and 6 , hinge member  206  includes a second hinge element  222  which includes a second, multi-lobed cam member  226  and a mounting flange  229  adapted to interconnect with first mullion bar portion  153 . Second hinge element  222  further includes a cylindrical base portion  231  adapted to be received in interior cavity  217  of first hinge element  210 . Actually, second hinge element  222  includes a central bore  233  through which extends hinge pin  216  that enables first and second multi-lobed cam members  214  and  226  to nest one within the other. Finally, hinge member  206  incorporates a spring  236 , preferably a coil spring, positioned above second hinge element  222  which is adapted to provide a biasing force holding second hinge element  222  against first hinge element  210  as will be further discussed below. At this point, it is only important to note that second hinge element  222  is mounted in hinge mounting recess  240  established between first and second bar portions  153  and  154 , with mounting flange  229  preventing relative rotation between second hinge element  222  and mullion bar  148  while second hinge element  222  can vertically shift or translate relative to first flange element  210  within hinge mounting recess  240 .  
         [0033]     In further accordance with the most preferred form of the present invention, mullion assembly  145  includes a cover  244  having a base member  245  interconnected with a pivot member  246  through a conduit or sleeve  248  ( FIG. 5 ). With this construction, either a control wire (not shown) can extend within first door member  28  and interconnect with heating element  177  to heat mullion bar  148  so as to prevent condensation build-up on mullion bar  148  and first and second door members  28  and  29 . In addition, base member  245  is provided with a plurality of bumpers  250  that dampen the impact of mullion bar  148  on side portion  58  of liner  54  when door  28  is opened.  
         [0034]     Having described a preferred structure of the rotating mullion bar of the present invention, reference will now be made to  FIGS. 7-11 , which have been presented without gasket  71  for clarity of the drawings, in describing a preferred method of operation. With initial reference to  FIG. 7 , mullion bar  148  is adapted to rotate about first and second hinge members  206  and  207 , as well as pivot member  246  of wire cover  244 . Toward that end, guide pin  190  travels through a guide path  260  provided in guide element  22  when door member  28  is opened or closed. As shown, guide path  260  includes a first sloping portion  262  extending to a substantially straight segment  264  followed by a curved portion  266  and terminating in an in-turned portion or projection  267 . As further shown in  FIG. 7 , guide pin  190  is provided with a first cam surface  280  which is adapted to engage guide path  260  when door member  28  is closed and a second cam surface  285  which is adapted to engage projection  267  when door member  28  is opened. With this arrangement, it should be understood that door member  28  could be opened irrespective of the position of door member  29 .  
         [0035]     In any event, when door member  28  is in a closed position as shown in  FIGS. 7 and 8 , second cam surface  285  of guide pin  190  rests against projection  267  of guide element  22 . With initial movement of door member  28  to the position shown in  FIG. 9 , guide pin  190  is forced against projection  267  causing mullion bar  148  to gradually begin to rotate relative to door member  28 . As door member  28  continues to open as shown in  FIG. 10 , second cam surface  285  of guide pin  190  begins to travel along projection  267  causing mullion bar  148  to further rotate relative to door member  28 . As guide pin  190  continues further along its outward path as represented in  FIG. 11 , multi-lobed cam member  226  rotates and raises upward relative to multi-lobed cam member  214 . As multi-lobed cam members  214  and  226  reach a high point, coil spring  236  is compressed, creating a spring force in mullion bar  148 . With this particular construction, once guide element  22   190  reaches the end of second cam surface  285 , mullion bar  148  snaps or is biased against side portion of door member  28  causing mullion bar  148  to reach an end point as represented in  FIG. 1 . In the most preferred embodiment of the invention, mullion bar  148  rotates approximately 110° between these two positions. Mullion bar  148  will remain in this position until door member  28  is closed causing first cam surface  280  to travel along guide path  260  so as to rotate mullion bar  148  to the sealed position shown in  FIG. 8 . With this construction, door member  28  can be opened and closed without having to operate door member  29 , while still enabling gasket  71  of door member  29  to seal against mullion bar  148 . In this manner, the likelihood that a door will be left ajar is reduced.  
         [0036]     Although described with reference to a preferred embodiment of the present invention, it should be readily apparent of one of ordinary skill in the art that various changes and/or modifications can be made to the invention without departing from the spirit thereof. For instance, rotating mullion bar  148  could be mounted to either one of the French-style doors  28 ,  29 . In addition, while the hinges for the rotating mullion are described as being mounted to the door with dovetail arrangements, a variety of other fastening means could be employed. In general, the invention is only intended to be limited to the scope of the following claims.