Abstract:
A method of assembling a gas supply device within an appliance cabinet is disclosed. The method comprises bending a tube assembly prior to installation in the appliance, attaching a fitting to the first end of the tube, attaching the fitting of the first end of the tube to a burner assembly, attaching a second fitting having a non-circular portion to the second end of the tube, attaching a mounting bracket with a non-circular profile to the non-circular portion of the second fitting in a fixed condition to prevent rotation of the body with respect to the bracket, and mounting the tube assembly in the appliance cabinet.

Description:
This Application is a Division of Ser. No. 09/020,017 filed Feb. 6, 1998, U.S. Pat. No. 6,030,003. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention generally relates to a gas supply assembly for an appliance powered by natural gas. The invention also provides a method of assembling the appliance. 
     Many domestic appliances are powered, at least in part, by natural gas. This necessitates that the appliance be provided with a gas supply assembly for connecting the appliance to an external gas supply line and for feeding the incoming natural gas to a burner assembly. 
     Various improvements of gas supply assemblies have been made through the years. These improvements include the use of a double-bead fitting such as found in U.S. Pat. Nos. 4,871,199 issued Oct. 3, 1989 and 5,573,285 issued Nov. 12, 1996, which are each incorporated herein by reference. Another improvement is the use of a stake joint to join a gas carrying tube with a fitting component. Examples of stake joints are found in U.S. Pat. Nos. 3,930,298 issued Jan. 6, 1976, 3,977,710 issued Aug. 31, 1976 and 4,126,929 issued Nov. 28, 1978, each of which are incorporated herein by reference. Double-bead fittings and stake joints have helped to reduce the number of parts required by the appliance, and reduced the number of steps required to assemble the appliance. 
     Despite these improvements, however, there exists a need in the art of appliance manufacturing to further improve the gas supply assembly and the method of assembling the appliances. It has been found that during installation, excessive torque is often placed on parts comprising the gas supply assembly. This excessive torque commonly results in fractured parts or separated joints which would allow the leakage of natural gas. Obviously, this condition is unacceptable and must be corrected before completing the assembly process. Repairing or replacing damaged parts, however, increases both the total cost and assembly time of the appliances. 
     In addition, the installation process of a gas supply assembly into the appliance is lengthy and difficult. A number of factors contribute to this problem. These factors include the lack of space within the appliance to manipulate parts and tools, the difficulty in positioning the gas supply assembly around other appliance subsystems, and the difficulty in holding one end of gas supply assembly while securing the other. These difficulties also increase the total cost of the appliance. 
     The present invention overcomes at least some of the above-noted disadvantages of the related art by providing a gas supply assembly for an appliance that makes the assembling process easier and faster while minimizing the number of damaged parts. This is accomplished by providing a preshaped gas supply assembly that has interlocking components to support and prevent the rotation of the assembly during installation. The gas supply assembly can be attached to a burner assembly outside of the appliance where manipulation of the parts is simple. The gas supply assembly is constructed of lightweight parts that assist in reducing the overall weight and shipping cost of the appliance. 
     BRIEF SUMMARY OF THE INVENTION 
     According to the present invention, a gas supply assembly for an appliance includes a tube with a first end and a second end. The tube is preshaped to fit around appliance subsystems, thus enhancing the installation of the gas supply assembly in the appliance. The first end is provided with a first fitting and the second end is provided with a second fitting, the second fitting having a second fitting shape. The assembly also has a mounting bracket defining a bracket opening for receiving the second fitting. The bracket opening has a shape complementary to that of the second fitting shape so that the mounting bracket and the second fitting cooperate to substantially prohibit rotation of the tube. 
     The present invention also provides a method of assembling an appliance having a cabinet. A tube assembly includes a preformed tube shaped to fit around objects in the cabinet, first fitting at a first end of the tube and a second fitting at a second end of the tube. The tube assembly is attached to a burner assembly using the first fitting. The tube assembly and the attached burner assembly are then inserted into the cabinet so that a first portion of the second fitting extends through an opening defined by the cabinet. The burner assembly is then secured within the cabinet. 
     The present invention also provides a method of assembling a gas supply device. A tube, having a first end and a second end, is bent into a shape which enhances installation of the device in an appliance. A first fitting is attached to the first end of the tube. A second fitting, defining a second fitting shape, is attached to the second end of the tube. A mounting bracket is provided for attaching the device to a cabinet. The mounting bracket defines a bracket opening for receiving the second fitting. The bracket opening has a shape complementary to that of the second fitting shape. The mounting bracket is placed on the second fitting so that the second fitting shape and the bracket opening shape cooperate to substantially prohibit rotation of the tube relative to the second fitting. The cabinet is provided with a receptor for receiving the mounting bracket and preventing rotation of the mounting bracket. Therefore, rotation of the device as a whole is prevented to avoid damage to the device. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
     These and further features of the present invention will be apparent with reference to the following description and drawings, wherein: 
     FIG. 1 is a partial cross sectional view of a gas supply assembly according to the present invention; 
     FIG. 2 is a partial cross sectional view of the gas supply assembly of FIG. 1 rotated 90 degrees; 
     FIG. 3 is a cross sectional view along the line  3 — 3  in FIG. 2; 
     FIG. 4 is a cross sectional view along the line  4 — 4  in FIG. 3; and 
     FIG. 5 is a cross sectional view along the line  5 — 5  in FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the detailed description which follows, identical components have been given the same reference numerals, and, in order to clearly and concisely illustrate present invention, certain features may be shown in somewhat schematic form. 
     Referring to FIGS. 1 and 2, the present invention provides a gas supply assembly  10  for a gas powered appliance. The illustrated appliance is a clothes dryer, but other types of gas powered appliances are within the scope of the present invention. The gas supply assembly  10  connects a burner assembly  11  that consumes natural gas to an external gas supply line  13 . The burner assembly  11  includes a tube manifold  12  and other components such as a gas valve, a gas burner, an igniter and a burner mounting bracket  15 . 
     The appliance includes a cabinet  17  having at least one cabinet wall  14 . The cabinet wall  14  is provided with an opening  16  (FIG. 3) and, as will be discussed in greater detail below, a part of the gas supply assembly  10  extends through the cabinet opening  16  (FIG.  3 ). 
     The gas supply assembly  10  includes a tube assembly  18  and a mounting bracket  52 . The tube assembly includes a tube  20 , a first or burner fitting  24  and a second or inlet fitting  30 . The tube assembly  18  parts are preferably made of lightweight nonferrous material, such as aluminum, but can be any other suitable material such as steel. Such a tube  20  is resilient, but is also easily bent into a desired shape and is flexible so that it will yield slightly during installation. This makes manipulation of the gas supply assembly  10  relatively effortless when the components are positioned and secured in the appliance. The tube  20  is fabricated with a series of bends  33 ,  34 , and  35  in predetermined locations and with predetermined angles. The bends  33 ,  34  and  35  are provided to allow the gas supply assembly  10  to extend through the interior of the appliance from the gas supply line  13  to the burner assembly  11 . Some bends  33 ,  34  and  35  may also be required to guide the tube around other components in the appliance. While the illustrated tube has  3  bends, other quantities, locations, and/or angles may be necessary for other appliances. 
     The tube  20  has a first end  22  provided with the burner fitting  24 . The burner fitting  24  is preferably a double-bead fitting, but can be other suitable types of fittings. U.S. Pat. Nos. 4,871,199 issued Oct. 3, 1989 and 5,573,285 issued Nov. 12, 1996 both disclose double-bead type fittings and are incorporated herein by reference. The burner fitting  24  engages the burner assembly  11  via the tube manifold  12 , as best shown in FIG.  2 . 
     The tube  20  has a second end  28  provided with the inlet fitting  30 . The inlet fitting  30  is also made out of lightweight nonferrous material, such as aluminum, but can be any other suitable material. This type of material makes the inlet fitting  30  easy to machine and manufacture, resulting in an economical product. The inlet fitting  30  is preferably joined to the tube  20  using a stake joint  32  (FIG.  3 ), but can be joined by any suitable joint. Examples of stake joints  32  are disclosed in U.S. Pat. Nos. 3,930,298 issued Jan. 6, 1976, 3,977,710 issued Aug. 31, 1976 and 4,126,929 issued Nov. 28, 1978, all of which are incorporated herein by reference. 
     Referring to FIG. 3, the inlet fitting  30  is shown in cross section. The inlet fitting  30  is provided with a body portion  36 . The body portion  36  is preferably shaped so that it may be grasped by a wrench. For example, a hex-shaped body portion  36  will suffice. The inlet fitting  30  has a front  40  at one end and a back  42  at the other end. Extending from the front  40  is a first threaded portion  44  and a second threaded portion  46 . The first threaded portion  44  is sized for connection to the gas supply line  13  (FIG.  1 ). 
     The inlet fitting  30  defines a passageway  50  extending from the front  40  to the back  42 . The tube  20 , which is preferably joined to the back of the inlet fitting  30 , communicates with the passageway  50  so that natural gas may flow from the gas supply line, through the inlet fitting  30 , through the tube  20 , to the burner assembly  11 . As one skilled in the art will appreciate, the tube  20  may alternatively be joined to a side of the inlet fitting  30  and communicate with a passageway  50  originating in the front  40  of the inlet fitting  30 , turning in the inlet fitting  30  and terminating in the side of the inlet fitting  30  where the tube  20  is connected to the inlet fitting  30 . 
     With reference to FIGS. 3 and 4, the mounting bracket  52  defines a bracket opening  54 . The bracket opening  54  is sized and shaped to receive the inlet fitting  30  so that the mounting bracket  52  cooperates with a complimentary inlet fitting shape  56 . In this manner, the mounting bracket  52  and the inlet fitting  30  cooperate so as to minimize rotation of the tube  20 . The interaction between the mounting bracket  52  and the inlet fitting  30  also serves to support the tube  20  within the appliance. The inlet fitting shape  56  is preferably defined by the outer surface of the second threaded portion  46 , but may be defined by the body portion  36  or the first threaded portion  44  with equivalent results. Once received by the mounting bracket  52 , the inlet fitting  30  is secured to the mounting bracket  52 . In the preferred embodiment, this is accomplished by threadably engaging a nut  60  on the second threaded portion  46 . The mounting bracket  52  is provided with a recess  62  in the area around the bracket opening  54 . The recess  62  accommodates the nut  60  allowing the mounting bracket  52  to be secured flush with the cabinet wall  14 . 
     In order to be secured to the cabinet wall  14 , the mounting bracket  52  and the cabinet wall  14  are provided with at least one screw hole. A screw  64 , or equivalently a bolt and nut combination, is used in conjunction with the screw hole to secure the mounting bracket  52  to the cabinet wall  14  (FIGS.  2  and  4 ). For enhanced aligning and securing capability, the mounting bracket  52  may be provided with projections  66 , preferably in the form of ridges along edges of the mounting bracket  52 . To receive the projections  66 , the cabinet wall  14  is provided with receptors  68 . The receptors  68  are preferably in the form of slots for receiving the ridges. The projections  66  and receptors  68  cooperate to align the mounting bracket  52  and help to retain the mounting bracket  52  in position. With the use of projections  66  and receptors  68 , the use of screws  64  to secure the mounting bracket  52  becomes optional. This is because the resiliency of the components, namely the tube  20  and the inlet fitting  30 , will hold the mounting bracket  52  in place once the burner assembly is secured within the appliance. One skilled in the art will appreciate that receptors  68  may be integrally formed with the cabinet wall  14  or on a separate receptor plate (not shown) that is secured to the cabinet wall. 
     An appliance incorporating the gas supply assembly  10  according to the present invention may be assembled in an easy and time efficient manner. Two alternative assembly methods are contemplated. 
     The first assembly method begins with attaching the tube assembly  18  to the burner assembly  11  by securing the burner fitting  24  to the burner manifold  12 . This step is preferably performed outside the appliance cabinet  17  where the parts are easily manipulated. Then, the mounting bracket  52  is placed on the inlet fitting  30  so that the inlet fitting shape  56  is in cooperation with the bracket opening  54 . The mounting bracket  52  is then secured to the inlet fitting  30  using the nut  60 . Next, the tube assembly  18 , with the attached burner assembly  11  and mounting bracket  52 , is inserted into the cabinet  17  so that the first threaded portion  44  extends through the cabinet opening  16  and the burner mounting bracket  15  is adjacent a receiving point  72 . Once the components are inserted and positioned in the appliance, the burner assembly  11  is secured within the appliance by attaching the burner mounting bracket  15  to the receiving point with screws  74  or the like. Finally, the mounting bracket  52  is secured to the cabinet wall  14  with the screw(s)  64  or aligning the projections  66  to be received by the receptors  68 , or both. It should be noted that the projections  66  and the receptors  68  may already be aligned as a result of the inserting and positioning procedure. It should also be noted that the order of many of the steps may be changed. For example, the mounting bracket  52  may be secured to the inlet fitting  30  before the burner assembly  11  is secured to the tube assembly  18 . 
     The second assembly method also begins with attaching the tube assembly  18  to the burner assembly  11  by securing the burner fitting  24  to the burner manifold  12 . This step is preferably performed outside the appliance cabinet  17  where the parts are easily manipulated. Next, the mounting bracket  52  is secured to the cabinet wall  14  using the screw(s)  64  so that the bracket opening  54  is aligned with and adjacent the cabinet opening  16 . At this point, the projections  66  should be engaged in the receptors  68 , if the embodiment using the projections  66  and receptors  68  is selected. It should be noted that the step of attaching the tube assembly  18  to the burner assembly  11  and the step of securing the mounting bracket  52  may be conducted in an opposite order with equivalent results. Next, the tube assembly  18 , with the attached burner assembly  11 , is inserted into the cabinet  17  so that the first threaded portion  44  extends through the cabinet opening  16 , the inlet fitting shape  56  is in cooperation with the bracket opening  54 , and the burner mounting bracket is adjacent the receiving point  72 . Once the components are inserted and positioned in the appliance, the burner assembly is secured within the appliance by attaching the burner mounting bracket  15  to the receiving point with screws  74  or the like. Finally, the mounting bracket  52  is secured to the inlet fitting  30  by passing the nut  60  over the first threaded portion  44  and through the cabinet opening  16 , then by threadably engaging the nut  60  on the second threaded portion  46 . Should this assembly method embodiment be employed, the cabinet opening  16  must be large enough to accommodate the nut  60  and a tool to tighten the but  60 . One skilled in the art will appreciate that the order of many of the foregoing steps may be changed with equivalent results. 
     For a number of reasons, both of these methods greatly assist in making the assembly of the appliance easy and economical. A major reason is that the components are assembled in locations where working on the parts is simple. For example, the tube assembly  18  is attached to the burner assembly  11  outside the appliance cabinet  17  rather than inside the cabinet  17  where space is limited and manipulation of the parts and tools is difficult. Another reason is that before the inlet fitting  30  and mounting bracket  52 , and the mounting bracket  52  and cabinet wall  14 , are permanently secured, they all lock together with cooperating shapes as to support and prevent rotation of the tube assembly while the burner assembly  11  is being secured. Once the burner assembly  11  is secured, the remaining parts may be secured with little effort. Another reason is that the selection of the tube  20  material adds flexibility to the gas supply assembly  18 . This allows for the easy manipulation of the components during the positioning and securing of the burner assembly  11  and inlet fitting  30 /mounting bracket  52  combination. 
     Although particular embodiments of the invention have been described in detail, it is understood that the invention is not limited correspondingly in scope, but includes all changes and modifications coming within the spirit and terms of the claims appended hereto.