Door assembly for an appliance

An appliance including a chassis having a top, a bottom, a left and right side opposite one another other and connecting the top and the bottom, and a back opposite an opening. The chassis defines a cavity with an opening for accessing the cavity. A door assembly joined to the chassis includes a door for closing access to the opening and a first and second door lift sub-assemblies. The door lift sub-assemblies are configured to move with the door in a first direction and a second direction different than the first direction. At least one stabilizing device operatively connects the first and second door lift sub-assemblies to synchronize movement of the first and second door lift sub-assemblies in the first direction.

BACKGROUND OF THE INVENTION

This invention relates generally to an appliance, and more particularly, to a vertical lift door assembly for an appliance.

A known appliance typically includes a door for closing access to a cavity. The known appliance door is hinged along one of the edges and swings to an open position. The door therefore requires enough clear space at the front to allow for the door to open and for an operator to easily utilize the appliance. Objects in front of the appliance often interfere with the opening of the door for full access to the appliance or with an operator's positioning around the opening.

BRIEF DESCRIPTION OF THE INVENTION

As described herein, the embodiments of the invention overcome one or more of the above or other disadvantages known in the art.

In an embodiment of the invention, an appliance includes a chassis having a top, a bottom, a left and right side opposite one another other and connecting the top and the bottom, and a back opposite an opening. The chassis defines a cavity with an opening for accessing the cavity. A door assembly joined to the chassis includes a door for closing access to the opening and a first and second door lift sub-assemblies. The door lift sub-assemblies are configured to move with the door in a first direction and a second direction different than the first direction. At least one stabilizing device operatively connects the first and second door lift sub-assemblies to synchronize movement of the first and second door lift sub-assemblies in the first direction.

In another embodiment, a method of accessing a cavity of an appliance includes extending a door from a first closed position to a second extended position by moving the door along a first and second horizontal slide, the first and second horizontal slide synchronized to move in unison, and lifting the door from the second extended position to a third open position by moving the door along a first and second vertical slide.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the invention are described below, with reference to the figures. Throughout the figures, like reference numbers indicate the same or similar components. References to preferred embodiments are for illustration and understanding, and should not be taken as limiting.

FIG. 1illustrates an exemplary appliance100with a door102in a closed position.FIG. 2illustrates appliance100with door102in an open position. In the illustrated embodiment, appliance100is an oven, such as an over the range microwave oven, and the various components and embodiments will be described in terms of oven100. However, it is contemplated that the various components and embodiments are applicable not only to over the range microwave ovens that are installed above a cooking apparatus, such as a gas range (not shown), but to other forms of appliances as well, such as, but not limited to, free standing microwave ovens, ranges, front loading laundry washers and dryers, dish washers, refrigerators, freezers, and the like. Therefore, oven100is provided by way of illustration rather than limitation.

Turning toFIGS. 1 and 2, oven100includes a main body or chassis112defining a cavity114therein. Chassis112supports a housing116surrounding cavity114. A front edge118of chassis112surrounds an opening120that provides access to cavity114. Door102closes access to opening120and cavity114. Cavity114is surrounded by a plurality of sidewalls (not labeled), and the sidewalls are made of heat insulation material. Each of the sidewalls includes an inner porcelain coating thereon for resisting a high temperature.

In the exemplary embodiment, oven100includes at least one heating module such as, for example, an RF generation system (e.g., a magnetron), an upper heater module, and/or a lower heater module for cooking and/or heating items placed in cavity114. Upper and/or lower heater module includes radiant heating elements such as a ceramic heater or a halogen-cooking lamp. Upper and/or lower heater module may also include a sheath heater. Upper and/or lower heater module may include a conventional bake element, broil element, or a convection-heating element. A convection fan may be provided for blowing air over heating elements and into cavity114.

The specific heating elements and RF generation system can vary from embodiment to embodiment, and the elements and system described above are exemplary only. For example, upper heater module can include any combination of heaters including combinations of halogen lamps, ceramic lamps, and/or sheath heaters. Similarly, lower heater module can include any combination of heaters including combinations of halogen lamps, ceramic lamps, and/or sheath heaters. In addition, the heaters can all be one type of heater. The specific ratings and number of lamps and/or heaters utilized in upper heater module and lower heater module can vary from embodiment to embodiment. Generally, the combination of lamps, heaters, and RF generation system is selected to provide the desired cooking characteristics for speed cooking, microwave, and convection/bake modes.

In the exemplary embodiment, oven100includes a top126, a bottom128, a front130, a rear132, a first left side134and a second right side136. Additionally, in the exemplary embodiment, door102includes a door top138, a door bottom140, a first door side142and a second door side144. Door top138, door bottom140, first door side142and second door side144have a similar orientation as top126, bottom128, first left side134and second right side136, respectively. Opening120faces front130and door102is positioned along front130. A vent124is positioned along front130proximate top126. A control panel146is positioned along first left side134. Control panel146and vent124are substantially flush, and in plane with, door102when door102is in the closed position. In the exemplary embodiment, door102is slidably coupled to oven100such that door102moves along front130generally vertically upward from the closed position illustrated inFIG. 1to the open position illustrated inFIG. 2. Alternatively, door102moves generally vertically downward.

During operation, when door102is in the first closed position, door102is moved horizontally outward, such as in the direction of arrow A, for a selected distance. The distance is selected such that door102will clear any obstructions vertically above door102, such as, for example, vent124or cabinets. Once extended horizontally, door102is lifted vertically upward, such as in the direction of arrow B, to the third open position illustrated inFIG. 2. When opened, a user may access cavity114. To close door102, door102is pulled vertically downward, such as in the direction of arrow C to a lowermost position, and then door is pushed horizontally inward toward cavity114, such as in the direction of arrow D to the closed position illustrated inFIG. 1.

FIG. 3illustrates a cross-sectional view of oven100showing door102in a second extended position. In the second extended position, door102has been moved horizontally away from cavity114(shown in phantom inFIG. 3is the door102in the first closed position) in order to clear a portion of oven or other obstructions as door102is opened vertically upward. As illustrated inFIG. 3, chassis112includes a front frame portion150extending along front130and a cavity portion152defining cavity114. Housing116is coupled to, and supported by, front frame portion150.

In the exemplary embodiment, oven100includes a door assembly154joined to chassis112. Door assembly154includes a first door lift sub-assembly156and a second door lift sub-assembly158. First door lift sub-assembly156is coupled to cavity portion152of chassis112proximate first left side134of oven100. Second door lift sub-assembly158is coupled to cavity portion152of chassis112proximate second right side136of oven100. Each of first and second door lift sub-assemblies156and158are coupled to door102. In the exemplary embodiment, first and second door lift sub-assemblies156and158are coupled to door102proximate door bottom140(shown inFIGS. 1 and 2). A portion of first door lift sub-assembly156extends through, and are movable within, a first slot160in front frame portion150and a portion of second door lift sub-assembly158extends through, and are movable within, a second slot162in front frame portion150. Slots160and162provide access to door102from inside housing116and chassis112. As such, the hardware of first and second door lift sub-assemblies156and158may be substantially enclosed and hidden from view from outside oven100.

In the exemplary embodiment, first door lift sub-assembly156includes a first vertical slide170and a first horizontal slide172. First vertical slide170is oriented to have more of a vertical direction of movement than a horizontal direction of movement, and first vertical slide170is configured to move door102in a substantially vertical direction. First horizontal slide172is oriented to have more of a horizontal direction of movement than a vertical direction of movement, and first horizontal slide172is configured to move door102in a substantially horizontal direction. In one exemplary embodiment, slides170and172operate independently from one another and singly such that only one of slides170and172are operated at a time; however, the slides170and172may co-operate to provide a diagonal motion of the door. In the exemplary embodiment, door102is mounted to first horizontal slide172. In an alternative embodiment, door102is mounted to a connecting device or bracket (not shown) that is coupled to first horizontal slide172.

First vertical slide170includes a fixed member174and a movable or sliding member176. First horizontal slide includes a fixed member178and a movable or sliding member180. In the exemplary embodiment, first vertical slide fixed member174is fixedly mounted to chassis112proximate to door102, and first vertical slide movable member176is slidably coupled to fixed member174. Movable member176is movable between a lifted position, generally toward a top portion of fixed member174, and a lower or resting position, generally toward a bottom portion of fixed member174. First horizontal slide fixed member178is fixedly mounted to first vertical slide movable member176, and first horizontal slide movable member180is slidably coupled to fixed member178. Movable member180is movable between an extended position, generally toward a front portion of fixed member178such as in the direction of door102, and a retracted position, generally toward a rear portion of fixed member178such as away from door102.

In the exemplary embodiment, second door lift sub-assembly158includes a second vertical slide182and a second horizontal slide184. Second vertical slide182is oriented to have more of a vertical direction of movement than a horizontal direction of movement, and second vertical slide182is configured to move door102in a substantially vertical direction. Second horizontal slide184is oriented to have more of a horizontal direction of movement than a vertical direction of movement, and second horizontal slide184is configured to move door102in a substantially horizontal direction. In the exemplary embodiment, slides182and184operate independently from one another and such that only one of slides182and184are operated at a time. In the exemplary embodiment, door102is mounted to second horizontal slide184. In an alternative embodiment, door102is mounted to a connecting device (not shown) that is coupled to second horizontal slide184.

Second vertical slide182includes a fixed member186and a movable or sliding member188. Second horizontal slide184includes a fixed member190and a movable or sliding member192. In the exemplary embodiment, second vertical slide fixed member186is fixedly mounted to chassis112, and second vertical slide movable member188is slidably coupled to fixed member186. Movable member188is movable between a lifted position, generally toward a top portion of fixed member186, and a reset or resting position, generally toward a bottom portion of fixed member186. Second horizontal slide fixed member190is fixedly mounted to second vertical slide movable member188, and second horizontal slide movable member192is slidably coupled to fixed member190. Movable member192is movable between an extended position, generally toward a front portion of fixed member190such as in the direction of door102, and a retracted position, generally toward a rear portion of fixed member190such as away from door102.

FIG. 4illustrates a portion of oven100with housing116removed for clarity and showing door assembly154. First door lift sub-assembly156is mounted to chassis112proximate first left side134of oven100and second door lift sub-assembly158is mounted to chassis112proximate second right side136of oven. The description ofFIG. 4will be described with reference to the features and operation of first door lift sub-assembly156with the understanding that second door lift sub-assembly158includes similar features and operates in a similar manner.

In the illustrated embodiment, vertical slide fixed member174is coupled to chassis112. Vertical slide movable member176is slidable in a vertical direction along fixed member174, such as in the direction of arrow E. Notably, movable member176slides upward as door102is opened and movable member176slides downward as door102is closed. In an alternative embodiment, door102opens downward; in which case, movable member176slides downward as door102is opened and upward as door102is closed.

Horizontal slide fixed member178is mounted to vertical slide movable member176. As such, horizontal slide172is simultaneously movable in a vertical direction with vertical slide movable member176. In the exemplary embodiment, horizontal slide172is oriented orthogonally with respect to vertical slide170. Horizontal slide movable member180is slidable in a horizontal direction along fixed member178, such as in the direction of arrow F. As indicated above, a portion of horizontal slide172extends through first slot160. In the exemplary embodiment, horizontal slide movable member180extends through slot160. In the illustrated embodiment, slot160is elongated in the vertical direction and extends parallel to vertical slide170. As such, as door102is either opened or closed, horizontal slide172is moved vertically within slot160.

An exemplary opening operation of door102is described below with reference toFIGS. 5-7. However, it is contemplated that other opening operations are applicable to door102.FIG. 5illustrates door102and door assembly154in a retracted and closed position.FIG. 6illustrates door102and door assembly154in an extended and closed position, in that door still restricts access to cavity114(shown inFIG. 3) even though door is not sealed or immediately adjacent front frame portion150of chassis112(shown partially in phantom).FIG. 7illustrates door102and door assembly154in an open position wherein cavity114is accessible. Thus, the opened and closed positions refer to a vertical position of door102with respect to front frame portion150and the extended and retracted positions refer to a horizontal position of door102with respect to front frame portion150.

Turning toFIG. 5, in the retracted and closed position, door102is substantially aligned with and adjacent front frame portion150of chassis112and closes access to cavity114. In the exemplary embodiment, oven100includes an interlock for locking door102in the retracted and closed position. The interlock is used to ensure that door102remains closed during operation of oven100, and the operation of oven stops when door is no longer in the retracted position, such as when a user opens door102. In one embodiment, the interlock may be a latch.

In the retracted position, horizontal slide movable member180is in a rearward position such that a rearward end210of moveable member180is positioned proximate a rearward end212of horizontal fixed member178. In the one embodiment, a roller element214is coupled to movable member180. Roller element214rotates to ease movement of door102between the retracted position and the extended position. In the one embodiment, a ledge216(shown in phantom inFIGS. 5 and 6) extends inward from front frame portion150. Ledge216is positioned adjacent slot160. Roller element214engages ledge216and is guided by ledge216as door102is moved between the retracted and extended positions. In the retracted position, roller element214engages ledge216to resist vertical movement of door102. In the one embodiment, ledge216is substantially horizontal.

During operation, door102is pulled generally horizontally outward from cavity114, such as in the direction of arrow G, to the extended position, which is illustrated inFIG. 6. As door102is moved to the extended position, roller element214is guided along ledge216. Additionally, horizontal movable member180is guided by rail portions218of horizontal fixed member178. Rail portions218retain movable member180in channels. Alternatively, rail portions218are provided on movable member180and receive fixed member178in the channels created by rail portions218.

In the extended and closed position, rearward end210of moveable member180is positioned remote with respect to rearward end212of horizontal fixed member178. Additionally, an upward end220of vertical moveable member176is positioned remote with respect to an upward end222of vertical fixed member174. In the exemplary embodiment, horizontal slide172includes a stop (not shown) to limit how far movable member180can move with respect to fixed member178. As such, door102cannot be pulled completely out of door lift sub-assembly156. As door102is moved vertically between the closed and open positions, roller engages front frame portion150and guides door102along front frame portion150in a substantially vertical direction.

During operation, door102is lifted generally vertically upward, such as in the direction of arrow H, to the open position, which is illustrated inFIG. 7. In one embodiment, as door102is moved to the open position, roller element214is guided along front fame portion150. Additionally, rail portions224of vertical fixed member174guide vertical movable member176. Rail portions224retain movable member176in channels. Alternatively, rail portions224are provided on movable member176and receive fixed member174in the channels created by rail portions224.

In the extended and open position, upward end220of moveable member176is positioned proximate upward end222of vertical fixed member174. In the exemplary embodiment, vertical slide170includes a stop (not shown) to limit how far movable member176can move with respect to fixed member174. As such, door102cannot be lifted completely out of door lift sub-assembly156. In the extended position, door102is lifted to a position wherein cavity114is accessible and access to cavity114is generally unobstructed.

In an alternative embodiment, door102is moveable in a substantially arcuate path as door102is opened and closed. For example, door102may include both a horizontal and a vertical component as door is opened from the closed position. As such, both of slides170and172are operated simultaneously. Front frame portion150may include an arcuately shaped ledge, similar to ledge216, for guiding door102along the predetermined path of travel as door102is opened. In another alternative embodiment, door102is movable from the extended and closed position in a generally downward direction to the open position.

FIG. 8illustrates an alternative door assembly250. Door assembly250is similar to door assembly154, and like components are identified with like reference numerals. In contrast to door assembly154, horizontal slide172of door assembly250is oriented in a non-orthogonal orientation with respect to vertical slide170. In the illustrated embodiment, vertical slide170is mounted substantially vertically within oven100(shown inFIG. 1) and horizontal slide172is inclined at a predetermined angle252from a perpendicular orientation of vertical slide170. Horizontal slide172is partially upwardly sloped such that door102is lifted slightly from the retracted position to the extended position. In alternative embodiments, horizontal slide172is partially downwardly sloped or vertical slide170is angled from a vertical orientation. In one embodiment, angling of horizontal slide172facilitates reducing or correcting roll, pitch and/or yaw of door102with respect to front frame portion150.

FIG. 9illustrates another alternative embodiment of door assembly260. Door assembly260is similar to door assembly154, and like components are identified with like reference numerals. In contrast to door assembly154, door assembly260includes multiple horizontal slides172. Multiple horizontal slides172provide stability to door102and facilitates reducing or correcting roll, pitch and/or yaw of door102with respect to front frame portion150.

Fixed members178of horizontal slides172are mounted to chassis112. Fixed member174of vertical slide170is coupled to movable members180of horizontal slides172. A connecting member262is coupled to movable member176of vertical slide170, and door102is coupled to connecting member262. During operation, door102is pulled outward from the retracted position. As door102is moved outward, vertical slide170is moved generally toward front frame portion150. Once in the extended position, door102is moved vertically upward from the closed position to the open position. As door102is moved vertically, vertical slide movable member176is moved vertically upward along vertical slide fixed member174.

FIG. 10illustrates a further alternative door assembly270, showing side views of each of first and second door lift sub-assemblies156and158and a pulley system272extending there between. Door assembly270is similar to door assembly154, and like components are identified with like reference numerals. In contrast to door assembly154, door assembly270includes pulley system272. Pulley system272includes a continuous rope or cable274extending between a first side276and a second side278. Cable274is joined to first horizontal slide172and second horizontal slide184to aide in moving first horizontal slide172and second horizontal slide184along first vertical slide170and second vertical slide182, respectively. Cable274is joined such that each of horizontal slides172and184are movable simultaneously either upward or downward, depending on if door102is opening or closing. Although the figures show a specific embodiment, it is to be understood that the synchronization system is not limited to the use of the cable and pulley.

In another exemplary embodiment, door102is rotatably coupled to horizontal slide movable members180and188. As such, top138of door102may be rotated generally away from cavity114for cleaning door102. In an alternative embodiment, door102is removably coupled to horizontal slide movable members180and188. As such, door102may be removed for cleaning door102.

In another embodiment, as shown inFIGS. 11 and 12, a guide bracket300and roller302may be used to control the motion of travel of the door during opening and closing. Guide bracket300has a slot304in which roller302travels. Slot304contains a substantially horizontal portion310and a substantially vertical portion312. A transition portion314connects the horizontal310and vertical312portions. Roller302is operatively connected to horizontal slide member180. Roller302is in position306when door102is in a closed position. During opening of the door102roller302moves along the horizontal portion310(configured to constrain or limit vertical motion) of slot304until reaching transition portion314then moves up vertical portion312(configured to constrain or limit horizontal motion) until reaching point308when door102is fully open. The transition portion314of slot304may be abrupt so as to not allow horizontal and vertical motion of the door to occur at the same time. Transition portion314may not be abrupt and consist of a sloped area where horizontal and vertical motion occurs simultaneously. Alternatively the transition portion314may be rounded to permit smooth travel and transition from the horizontal to the vertical direction. The arc may have one uniform radius or may consist of a varying radius. Although the figures show examples of a particular embodiment, it is to be understood that different guide elements, other than the bracket and roller, can be used.

In an embodiment, guide300is operatively connected to side434of chassis112and a second guide301is connected to side436of chassis112. First and second guides300,301are mirror images of the other. Since each side of door102is synchronized to operate cooperatively and thus only one of first or second guides300,301is required. Therefore, reference will be made to first guide300, however, all features are equivalent on guide301.

In an embodiment a stabilizing device is incorporated with and operatively connects the first156and second158door lift sub-assemblies.

As shown inFIGS. 11-15a horizontal stabilizing member400is disposed under the chassis112. The horizontal stabilizing member traverses the width of the chassis112and is operatively connected to the chassis112by at least one horizontal slide410and412. In an embodiment, a third410and fourth412horizontal slides operatively connect horizontal stabilizing member400to the bottom430of chassis112proximate to sides434and436respectively. The horizontal stabilizing member400has vertical slots402,403at either end for mating connection with the substantially vertical tabs405,406of the sliding members180,188of the first and second horizontal slides of the first156and second158door lift sub-assemblies. Horizontal stabilizing member400is confined in movement except in a direction along an axis parallel with horizontal slides410and412. This restriction of movement coordinates the movement of slides180,188so neither may move independently of the other, thus preventing door102from rotating about a vertical axis and becoming disoriented during operation.

As shown in the embodiment illustrated inFIGS. 16,17and18, door assembly154,156includes a counter-balance sub-assembly200to facilitate aiding a user in lifting door102to the open position and to provide resistance to door102closing prematurely or too quickly. For example, in the exemplary embodiment, counter-balance sub-assembly200includes a spring member202, such as, but not limited to, a roll-up type or a spiral-type constant torsion spring, coupled to either horizontal slide172or vertical slide movable member176. Spring member202provides a upward pulling force on horizontal slide172or vertical slide movable member176to aide in opening door102. Spring member202is positioned to provide a tension on door102throughout the range of motion of door102. In the exemplary embodiment, the length of spring member202is substantially longer than the distance of travel of door102to minimize the change in force over the range of motion of door102and provide a constant tension force on door102. However, use of a varying diameter pulley201reduces the change in spring tension during the range of motion. The spring force is selected to counter the weight of the door and should be great enough to maintain the door in the third open position without the user holding the door.

In an alternate embodiment the spring is selected to raise the door with no assistance from a user. This will prevent the door closing prematurely and allow a user to remove and replace objects in the cavity without the user having to hold the door or maintain an upward force on the door.

In another alternative embodiment, a motor to lift door102replaces counter-balance sub-assembly200. A switch on control panel146may operate the motor. In one embodiment, the motor includes a drive screw to drive the vertical slide170up and down. Alternatively, the motor winds or unwinds a coil or spool of material to raise or lower door102. The motor may operate at a constant speed or may operate at a variable speed. In another alternative embodiment, counter-balance sub-assembly200includes a counterbalance weight that is movable to aid in the opening and closing of door102.

A door assembly for an appliance is thus provided in a cost effective and reliable manner. The door assembly includes horizontal slides and vertical slides. An appliance door is coupled to the slides such that the door may be opened by pulling the door away from a cavity of the appliance then lifting the door to an open position. By providing a vertical lift door, the door may be opened in a different manner than a hinged door typically used with appliances. The vertical lift door needs less clearance to open the door, than other types of doors.