Abstract:
A resinous plastic breaker strip for a built-in refrigerator/freezer provides a substantially seamless front face therefor. The breaker strip includes a front portion defining a front face and a rearwardly extending sidewall portion fitted to the liner. A number of spacers partially secure a liner to a rigid frame that extends around the door openings. In-situ formed urethane foam provides the remainder of the rigidity and strength to the cabinet. The breaker strip front portion is spaced forwardly of the frame member. An elongated magnet is disposed between the breaker strip and the frame to magnetically attract the door gasket magnet. In a preferred embodiment an odd number of alternating magnet poles are aligned with the axis of elongation of the magnets and the poles of the stationary cabinet magnet are opposite those of the door gasket magnet. The seamless breaker strip provides a non-metallic door sealing surface which reduces heat transfer and condensation on the outer front face of the cabinet.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to refrigerator cabinets, and more particularly, to an improved cabinet wall structure to provide a seamless front face for a refrigerator cabinet. 
     2. Description of Background Art 
     Conventional refrigerators include an outer shell and an inner liner, with a breaker strip disposed therebetween to act as a heat-break. Typically, the outer shell includes a forward marginal edge which turns inwardly to act as a flange for magnetic attraction to the magnetic door gasket with the breaker strip being secured within a rolled portion of the flange. If a refrigerator door is in an opened position, a seam is apparent where the breaker strip meets the outer shell. Such an arrangement is shown in Palmer U.S. Pat. No. 2,789,720. The seam may be undesirable from an appearance standpoint. 
     The outer shell of known refrigerator cabinets is typically of steel or sheet metal construction. The front marginal edge therefore provides a metallic surface on which a magnetic door gasket seals against. Accordingly, a seamless front face may be achieved by further extending inwardly the front marginal edge of the outer shell. Such a construction is shown in Kesling U.S. Pat. No. 3,078,003. 
     The use of the outer shell to provide a seamless front face aggravates a condition known known as &#34;sweating.&#34; When a portion of the outer shell extends internally to the refrigerator cabinet, condensation is more likely to build up on this front face. Therefore, it is necessary to utilize &#34;anti-sweat&#34; heating elements disposed rearwardly of the front face to minimize such condensation. These heating elements increase the cost of the refrigerator both from a manufacturing standpoint and an operational standpoint. With the high cost of energy, it is desirable to minimize the necessity of such heaters. 
     The present invention overcomes the above problems of prior refrigerator cabinets, in a novel and simple manner. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, a refrigeration apparatus cabinet is provided with a breaker strip which provides a seamless front face for the cabinet. 
     Broadly, there is disclosed herein a novel breaker strip for a refrigeration apparatus cabinet which extends between a front edge portion of an outer wall and an inner liner. The breaker strip includes a front portion defining a front face of the cabinet, disposed forwardly of the front edge portion of the outer wall. The breaker strip also includes a rearwardly extending inner turned portion which is secured to the liner to provide a seamless front face for the cabinet. 
     The refrigeration apparatus includes an outer shell having top, bottom and first and second side outer walls. Each said outer wall defines a front edge portion. A liner fits within the outer shell and is spaced from each of the outer walls. A frame structure is provided around the front periphery of the cabinet to add rigidity thereto. The frame is spot welded to the outer walls. A plurality of spacers which, in the preferred embodiment are made of resinous plastic material, are provided to loosely receive a channel portion of the liner to help maintain the liner in spaced relation with the frame, and thus the outer walls. The breaker strip is made of resinous plastic and extends between the outer wall and the liner around all four above-mentioned walls. The breaker strip includes a front portion disposed forwardly of the front edge portion of the outer wall defining a seamless front face for the cabinet. The front portion of the breaker strip is spaced from the frame to prevent moisture condensation on the metal frame. The breaker strip also includes a rearwardly extending inner turned portion which is loosely secured tothe liner. The spacers and the breaker strip retain the liner in spaced relationship to the outer shell during an in-situ foam insulating process, which takes place with the cabinet front facing upwardly. After the insulating process the cabinet is fixedly secured by the spacers tying the liner to the frame and by the foam adhering to the liner and the rearwardly extending portion of the breaker strip. 
     An elongated magnet extends around the periphery of the cabinet in a space between the breaker strip front portion and the frame to attach the door gasket magnet. 
     In one embodiment, the magnet is attached to the frame and a pair of rearwardly extending hook members engage a pair of ribs in the magnet to secure the breaker strip to the frame. In a preferred embodiment, the elongated cabinet-mounted magnet and door magnet each have an odd number of alternating poles extending the full length of the magnet. The poles on one magnet are opposite the poles of the other magnet. In this structure, it is not possible to install a magnet backward which would have the effect of attempting to align like poles. 
     The liner is coupled to the frame with a plurality of plastic spacers. The spacers are screwed or riveted to the frame and are loosely fitted into a turned portion at a front edge of the liner. In-situ insulation foam fills the space between the liner and the outer shell and provides rigidity to the structure by adhering to the shell, frame and liner. 
     In a refrigerator/freezer having a freezer and a fresh food compartment, a pair of liners are disposed within the outer walls of the cabinet. An additional breaker strip portion is provided to extend between inner front edges of each of the two liners. This additional breaker strip portion includes a front portion defining a front face of a divider wall of said cabinet, and first and second rearwardly extending inner turned portions secured to the freezer compartment liner and a fresh food compartment liner, respectively. 
     Further features and advantages of the invention will readily be apparent from the specification and from the drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front elevation of a refrigerator/freezer having a breaker strip embodying the invention; 
     FIG. 2 is a sectional view taken along lines 2--2 of FIG. 1; 
     FIG. 3 is a partial sectional view taken, with the doors removed, along lines 3--3 of FIG. 1; and 
     FIG. 4 is a sectional view similar to that of FIG. 2, or a modified form of the invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, a refrigeration apparatus, such as a refrigerator/freezer, 10 includes a breaker strip according to the present invention. The invention is shown utilized with a built-in side-by-side refrigerator/freezer; however, other types of refrigeration apparatus may be used in conjunction with the breaker strip of the present invention, as will be obvious to those skilled in the art. 
     The refrigerator/freezer 10 includes a cabinet 12 provided with an insulating separator or divider wall, (not shown) defining a below-freezing, or freezer compartment 14 and a fresh food, or above-freezing compartment 16. A freezer door 18 and a fresh food door 20 are provided for selective access to the freezer and fresh food compartments 14, 16, respectively. 
     The cabinet 12 includes first and second sidewalls 24, 26, a bottom wall 28 which is part of a base assembly (not shown) and a top wall 30 defining an outer shell. 
     A portion of the cabinet 12 along the first outer sidewall 24 embodying a breaker strip 22 of the invention is illustrated in greater detail in FIG. 2. Although not shown, the cabinet construction along the second sidewall 26 and the top and bottom walls 26, 28 are similar to that shown in FIG. 2 as will be obvious to those skilled in the art. 
     A channel frame 35 provides a support structure for the cabinet 12. The channel frame 35 includes a front portion 36, a rearwardly turned side portion 37, substantially parallel to the sidewall 24, an inwardly extending central portion 38 and a rearwardly turned flange portion 39 in a substantially parallel plane to the plane of the side portion 37. The frame 35 is of steel construction. A front edge portion 40 of the first outer wall 24 is secured by, for example, spot welding it to the side portion 37 of the frame 35. The frame 36 extends up the full extent of the first outer wall 24. An elongated trapezoid-shaped magnet 41 having an odd number of alternating poles is secured to the front portion 36 of the frame 35 with, for example, screws or rivets 42. Alternatively, an appropriate adhesive could be utilized to secure the magnet 41 to the frame 35. The magnet 41 includes first and second ribs 44, 46 in its opposite sidewalls. 
     An inner liner 48 is disposed within and spaced from each wall 24, 26, 28, 30 and 34 of the shell. A front portion 50 of the liner 48 comprises a turned end channel portion 52. A plurality of molded plastic spacers 56 are disposed between the flange portion 39 of the frame 35 and the liner 48. The spacer is preferably made of resinous plastic material. The spacers 56 includes a central portion angularly disposed between the outer wall 24 and the liner 48, having apertures 58 formed therein. Spacer 56 also includes a first forwardly extending wall 60 and a second forwardly extending wall 62. Apertures are provided in the first forwardly extending wall 60 so that the spacer 56 may be secured to the flange portion 39 of the frame 35 utilizing screws 64 or any other suitable securing devices. The second forwardly extending wall 62 of the spacer 56 is loosely received within the channel portion 52 of the liner 48 to partially maintain the liner 48 in spaced relation with the outer wall 24. 
     The breaker strip 22 extends between the front edge portion 40 of the outer wall 24 and the front portion 50 of the liner 48. The breaker strip 22 is extruded and is made of a resinous plastic, and includes a front portion 66 defining a front face 68. The front portion 66 is spaced outwardly from the portion 36 at the frame 35 to prevent moisture condensation on the frame 35. A pair of oppositely facing hook members 70, 72 extend rearwardly from the front portion 66. Each said hook member 70, 72 includes a locking ridge 74, 76, respectively. When the breaker strip is positioned with the hook members 70, 72 disposed forwardly at the magnet 41 and a force is applied to the breaker strip 22, the ridges 74, 76 engage the ribs 44, 46, respectively of the magnet 41 to retain the breaker strip 22 thereon and thereby secure the breaker strip 22 to the frame 35. 
     The breaker strip 22 includes a rearwardly extending inner turned portion 78 including a bifurcated end portion 80 loosely and resiliently embracing the front turned edge portion 50 of the liner 48. The bifurcated end portion 80 includes a finger portion 81. The breaker strip 22 also includes a rearwardly extending outer turned portion 82 having a distal portion 83 disposed forwardly of the front edge portion 40 of the outer wall 24. The front face 68 of the breaker strip 22 is similarly disposed forwardly of the front edge portion 40 of the outer wall 24 and to the front edge 50 of the liner 48 providing a seamless front face for the cabinet 12. 
     The spacers 56, frame 35 and breaker strip 22 retain the liner 48 in spaced relation to the outer wall 24 during an in-situ foam insulating process which takes place with the cabinet 12 facing upwardly. 
     The foam also passes through the apertures 58 of the spacers 56 to fill the area between the breaker strip 22, the frame 35 and the spacers 56. After the insulating process the cabinet 12 is fixedly secured by the spacers 56 tying the liner 48 to the frame 35, and by the foam 84 adhering to the liner 48 and the fingers 81 of the breaker strip 22. A seal 86 of, for example, closed cell foam, is disposed between the front portion 66 of the breaker strip 22 and the front portion 36 of the frame 35 to serve as a foam stop. 
     If necessary, heating elements (not shown) may be disposed in the space 88 defined by the front portion 66, the outer turned portion 82 and the hook member 70 of the breaker strip 22 and the front portion 36 of the frame 35 to prevent condensation from building up along the front face 68 of the breaker strip 22. 
     The door 18 includes a rubber gasket 90 having an elongate magnet 92 disposed therein. The magnet 92 has an odd number of poles of alternating polarity, opposite the poles at the other magnet 41. By using magnets of opposite polarity it is not possible to install a magnet backward which would have the effect of attempting to align like poles. When the door 18 is in a closed position, the magnets 92 and 41 are attracted to one another causing the gasket 90 to seat firmly against the front face 68 of the breaker strip 22 preventing air from flowing between the freezer compartment 14 and the outside. 
     As previously discussed, the refrigerator/freezer 10 is a built-in unit. Such a unit may have cabinetry built around it so that its outer walls are not exposed. Alternatively, a decorative end piece 94 of, for example, stainless steel or aluminum, is secured by any known means to the outer wall 24. An insert 96 is secured to the end piece 94. The insert 96 may be of wood or laminate construction designed to match existing cabinetry. 
     In a refrigerator/freezer unit, an additional inner resinous plastic breaker strip portion 100 is provided for the divider wall between the freezer compartment 14 and the refrigerator compartment 16. Each said compartment 14, 16 includes a liner of similar shape. The breaker strip 100 is illustrated in FIG. 3. 
     The freezer compartment liner 48 includes an innermost front edge channel portion 102 similar to the front edge channel portion 52 previously discussed with reference to FIG. 2. Similarly, a liner 104 for the fresh food compartment 16 is in juxtaposed relation with the freezer liner 48 and includes an inner front edge channel portion 106. A channel frame portion 108 having forwardly extending sidewalls 110, 112 and outwardly extending front walls 114, 116 extend between the frame sections (not shown) for the top and bottom walls 28, 30. First and second elongated trapezoidal magnets 118, 120 are secured with, for example, screws 122 to the front portions 114, 116, respectively of the channel frame 108. 
     The breaker strip 100 extends between the two liners 48, 104 and includes a front portion 124 defining a front face of the divider wall disposed forwardly of the channel frame 108. A pair of hook members 126, 128 each having ridges 130, 132, respectively, extend rearwardly from the front portion of the breaker strip 100. The breaker strip 100 further includes first and second rearwardly extending turned portions 134, 136, each including a bifurcated end 138, 140, respectively, loosely and resiliently embracing each of the channel edge portions 102, 106 of the liners 48, 104. A spacer 156 of resinous plastic is T-shaped and includes forwardly extending turned portions 158 and 160 at each end of the T, which are loosely secured to the liner channel edges 102 and 106, respectively, to maintain the liners in spaced relation. A snap connector 162 at the lower leg of the T locks into an aperture in the channel frame 108 to also partially retain the liners in spaced relation. Each of the rearwardly extending turned portions 134, 136 includes an inwardly extending ridge 142, 144, respectively. The ridges 130, 142 coact with the magnet 118, while the ridges 132, 144 coact with the magnet 120 to retain the breaker strip 100 in association with the channel frame 108 to define a seamless front face for the divider wall at the cabinet 12. During the in-situ foaming process, previously discussed, the foam 84 fills the space between the lines 48 and 104 and the breaker strip portion 100. 
     A breaker strip 22&#39; for an alternate embodiment of the present invention is illustrated in FIG. 4 wherein primed reference numerals correspond to elements previously discussed with reference to FIG. 2. An elongated magnet 42&#39; is of rectangular shape and is secured by, for example, an adhesive 42&#39; to the front portion 36&#39; of the metal frame 35&#39;. The breaker strip 22&#39; is made of a thermoformed plastic, and includes a front portion 66&#39; defining a front face 68&#39;. The front portion 66&#39; is spaced outwardly from the front portion 36&#39; of the frame 35&#39;. The breaker strip front portion 66&#39; is secured, for example, by a layer of adhesive 148 to the magnet 41&#39; to secure the breaker strip 22&#39; with respect to the frame 35&#39;. 
     An angle member 150 of, for example, stainless steel includes a front portion 152 overlying a portion of the breaker strip front portion 68&#39;. A side portion 154 of the angle member 150 is secured, for example, by screws 156 to the rearwardly turned side portion 37&#39; of the channel frame 35&#39;. 
     In all other respects the refrigerator cabinet construction including the breaker strip 22&#39; is similar to that previously discussed with reference to FIG. 2. By utilizing the breaker strip 22&#39; it is possible to thermoform the breaker strip 22&#39; in a single piece construction to cover the entire front face periphery of the cabinet, and divider wall to provide seamless strips where each of the respect top, bottom, divider and side walls are joined together. 
     Thus, the invention broadly comprehends a breaker strip for a refrigerator cabinet which provides an aesthetically pleasing one-piece trim which acts as a non-metallic door sealing surface which minimizes heat transfer and condensation. 
     The foregoing disclosure of the preferred embodiment is illustrative of the broad inventive concepts comprehended by the invention.