Abstract:
A refrigerator door includes a handle that is secured to the door utilizing connectors at first and second ends of the handle. The connectors do not have exposed screws, thereby improving the appearance of the refrigerator door.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Refrigerators typically include one or more doors having handles that are attached to the doors. The doors may be attached by screws or other types of fasteners. However, known door attachment arrangements may suffer from various drawbacks. 
       SUMMARY OF THE INVENTION 
       [0002]    One aspect of the present invention is a method of assembling a handle to a refrigerator door. The method includes providing a refrigerator door having a liner and a front sheet that is spaced from the liner to define an interior space. The door includes an outwardly facing edge surface extending transversely from the front sheet. The edge surface has a first opening. The edge surface may be formed in a door cap, and the edge surface may face upwardly. The front sheet has an inner surface facing the interior space, and an oppositely facing outer surface. The outer surface may comprise an upright outer surface of the refrigerator door. The front sheet includes second and third openings through the front sheet. The method includes providing a locking member having first and second connectors. The first connector may comprise a threaded opening, and the second connector may comprise a channel or bore that extends and connects to the threaded opening. The method includes positioning the locking member in the interior space with the first connector in registry with the first opening, and the second connector in registry with the second opening. The locking member may be adhesively secured to the inner surface of the front sheet. The method further includes providing a handle having first and second opposite ends. The first end has a first insert portion, and the second end has a second insert portion. The first insert portion of the handle is inserted into the third opening in the front sheet, and the second insert portion is inserted into the second opening in the front sheet, and the second insert portion engages the second connector of the locking member. A fastener is inserted through the first opening in the edge surface, and the fastener engages the first connector of the locking member and the second insert portion of the handle to thereby secure the second insert portion of the handle to the locking member to retain the handle in an installed position on the refrigerator door. The locking member may include a protrusion that is positioned in the first opening to align the first connector with the first opening. The interior space of the refrigerator door may be filled with foam insulation that at least partially encapsulates the locking member. 
         [0003]    These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]      FIG. 1  is a partially fragmentary side elevational view of a refrigerator and refrigerator door showing a door handle according to one aspect of the present invention; 
           [0005]      FIG. 2  is a partially fragmentary enlarged view of the upper end of the door handle of  FIG. 1  showing attachment thereof to the refrigerator door; 
           [0006]      FIG. 3  is a partially fragmentary isometric view of the upper end of the handle of  FIGS. 1 and 2 ; 
           [0007]      FIG. 4  is an exploded view of the upper end of the door handle, locking member, and locking screw; 
           [0008]      FIG. 5  is a partially fragmentary, enlarged view of a lower portion of the handle of  FIG. 1  showing the attachment of the lower end of the handle to the refrigerator door; 
           [0009]      FIG. 6  is an enlarged view of another embodiment in which the door includes a housing and a reinforcing plate at the lower end of the handle; 
           [0010]      FIG. 7  is an isometric view of the locking member; 
           [0011]      FIG. 8  is a partially fragmentary view of the locking member taken along the line VII-VII;  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
         [0013]    With reference to  FIG. 1 , a refrigerator  1  according to one aspect of the present invention includes an insulated cabinet  2  having one or more openings  4  on a front side  6  of the cabinet  2 . A door  8  is movably mounted to the cabinet  2  by one or more hinges  10  whereby the door  8  rotates about a vertical axis relative to the cabinet  2  to selectively close off the openings  4 . A gasket  12  attached to the refrigerator door  8  extends around the opening  4  when door  8  is in a closed position to seal the opening  4 . 
         [0014]    A door handle  20  is secured to the refrigerator door  8  utilizing an attachment configuration/method that does not result in screws that are visible to a user. Handle  20  includes an elongated main portion  22 , a first or lower end  24 , and a second or upper end  26 . First or lower end  24  of handle  20  has a first insertion portion or protrusion  14 , and the second or upper end  26  includes a second insertion portion or protrusion  16 . 
         [0015]    With further reference to  FIGS. 2-4 , upper end  24  of handle  20  includes an end surface  28  that contacts an outer surface  30  of a front side  32  of door  8 . Front or outer surface  30  of door  8  may be formed by a front sheet of material  34  of door  8 . Door  8  may include an inner member such as liner  36  that is spaced apart from front sheet  34  to form an interior space or cavity  38  that may be filled with foam  40  during the assembly process as described in more detail below. The front sheet  34  may comprise polymer or metal, and the inner liner  36  preferably comprises a polymer material. A top cap  42  extends along the upper edge  44  of door  8 , and includes an outwardly and upwardly facing surface  46  that extends transversely relative to the front side  32  of door  8  and outer surface  30  of door  8 . Top cap  42  includes an opening  48  that receives a threaded fastener such as set screw  50  having a hex socket  51 . As discussed in more detail below, a locking member  52  is disposed inside door  8 , and includes threaded opening  72  that receives set screw  50 . Locking member  52  also has a front surface  54  that may be adhesively secured to an inner surface  56  of front sheet  34  of door  8  when assembled. 
         [0016]    With reference to  FIG. 3 , the second protrusion  16  includes a base portion  58  that extends from end surface  28 , and first, second, and third conical surface portions  60 ,  62 , and  64 , respectively. The conical surface portions  62  and  64  define a recess or annular groove  66  that is engaged by end  68  of set screw  50  when the handle  20  is assembled to the refrigerator door  8 . End  68  of set screw  50  preferably comprises a flat, oval, cup, or dog end (not conical), and opening  48  may be configured/positioned such that end  68  of set screw  50  only contacts conical surface  64 , thereby generating a force pulling surface  28  of handle  20  into contact with outer surface  30  of door  8 . Surface  64  is preferably at an angle θ ( FIG. 4 ) of about 45-70 degrees relative to centerline “C” of protrusion  16 . However it will be understood that the present invention is not limited to any specific angle. Also, it will be understood that the protrusion  16  may have a square or rectangular cross sectional shape, and surfaces  60 ,  62 , and  64  may be flat. Thus, the present invention is not limited to the specific configuration shown in  FIG. 3 . 
         [0017]    With further reference to  FIGS. 7 and 8 , locking member  52  includes a bore or opening  70 , and a threaded opening  72  that extends transverse to the opening or bore  70  and intersects therewith. When assembled, protrusion  16  of handle  20  is inserted into opening  70 , and screw  50  is inserted into threaded opening  72 . The screw  50  is tightened to thereby engage the end  68  of screw  50  with the sloped surface  64  of recess or groove  66  of protrusion  16 . Screw  50  may engage surfaces  62  and  64  ( FIG. 4 ), only surface  62 , or only surface  64 . 
         [0018]    Locking member  52  includes protrusions  74  that are received in an opening  76  in front sheet  34  of door  8  when locking member  52  is assembled with the front sheet  34 . The protrusions  74  ensure that the opening  70  of locking member  52  is aligned with opening  76  in front sheet  34 . The locking member  52  preferably includes a pair of arms or flaps  78  that extend outwardly and inwardly from opposite sides  80 A and  80 B of locking member  52 . The flaps or arms  72  are encapsulated or embedded in foam  40  to thereby hold the locking member  52  in place within interior space or cavity  38  of door  8 . 
         [0019]    With reference to  FIG. 5 , first insertion portion or protrusion  14  at lower end  24  of handle  20  is generally in the form of a hook, and includes a base portion  82  that extends transversely from an end surface  84  of handle  20 . The protrusion  14  further includes a central portion  86  that extends generally downwardly, parallel to the front side  32  of door  8 . An end portion  88  of protrusion  14  includes a surface  90  that faces inner surface  56  of front sheet  34  when handle  20  is installed on door  8 . When assembled, the surface  90  may abut or contact inner surface  56 . Alternatively, the surface  90  of handle  20  may be spaced inwardly from inner surface  56  of front sheet  34  to define a gap. 
         [0020]    With reference to  FIG. 6 , a housing  96  and reinforcing plate  98  may be secured to inner surface  56  of front sheet  34  by adhesive or the like prior to injecting foam  40  into interior space or cavity  38 . Reinforcing plate  98  is preferably made of a rigid material (e.g. steel or other metal), to ensure that end surface  90  of protrusion  14  of handle  20  does not cause front sheet  34  to deform outwardly. Housing  96  may be made of polymer or other suitable material, and is generally box-shaped to seal off foam  40  during injection of liquid foam  40  prior to curing to thereby prevent the foam  40  from escaping through opening  18  in sheet  34  and to ensure that foam  40  does not fill space  100  in a manner that could otherwise interfere with insertion of end portion  14  of handle  20 . 
         [0021]    Referring again to  FIG. 1 , during assembly of door  8  the locking member  52  is adhered to inner surface  56  of front sheet  32 . The protrusions  74  of locking member  52  ( FIG. 7 ) are positioned in opening  76  in front sheet  34 . Adhesive material is utilized to adhesively bond the locking member  52  to the front sheet  34 . The front sheet  34  and inner liner  36  are then connected to one another utilizing known techniques, and door top cap  42  is also attached to the front sheet  34  and liner  36  utilizing adhesives or other suitable techniques. A rod or the like (not shown) may then be inserted through opening  48  in top cap  42 , with an end of the rod extending downwardly into threaded opening  72  of locking member  52 . The rod may be removed after foam  40  ( FIG. 2 ) is foamed in place to form a bore/opening that receives set screw to. Alternatively, the set screw  50  may be inserted through opening  48  in top cap  42 , and the set screw  50  may be threadably engaged with threaded opening  72  of locking member  52 . 
         [0022]    Polyurethane foam  40  ( FIG. 2 ) or other suitable material is then injected into the interior space or cavity  38  of door  8 . The foam  40  surrounds and encapsulates the locking member  52 , and the foam  40  secures the locking member  52  in place upon curing of the foam  40 . As discussed above, the foam  40  preferably encapsulates the flaps or arms  78  to retain the locking member  52  in place. The screw  50  can then be at least partially removed to permit insertion of protrusion  16  of handle  20  into the opening  70  of locking member  52 . 
         [0023]    To connect the handle  20  to door  8 , the protrusion  14  at lower end  24  of handle  20  is first inserted into opening  18  (see also  FIG. 5 ) with the handle  20  in an outwardly rotated position designated “ 20 A” in  FIG. 1 . The handle  20  is then rotated upwardly and inwardly as designated by the arrow “A,” and the protrusion  16  at upper end  26  of handle  20  is inserted into opening or bore  70  in locking member  52 . The set screw  50  is then tightened, thereby causing end  68  of set screw  50  to engage surface  64  of recess or groove  66  of protrusion  16 , thereby securely interconnecting the upper end  26  of handle  20  to the refrigerator door  8 . 
         [0024]    Because screw  50  is positioned along the upper edge  44  of door  8 , the screw  50  is not visible by a user. The screw  50  is preferably disposed in a recess  92  ( FIG. 2 ) that is lower than upper surface  94  of top cap  42 , thereby ensuring that the screw  50  is hidden. 
         [0025]    The handle  20  may be assembled to the refrigerator door during assembly of refrigerator  1  at a factory or other such production facility. Alternatively, the handle  20  may be initially disconnected from the door  8 , and the handle  20  may be assembled to the door  8  after shipping the refrigerator  1  to a retailer. Still further, the handle  20  may be installed to door  8  at the time the refrigerator is installed in a house, building, or other such facility. 
         [0026]    It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.