Method of making an appliance door

A method of making an appliance door includes inserting a door pan into a fixture having first and second forming molds, which are pressed together. An inner door liner is placed over the door pan and secured thereto to form a base door. A mold cavity is formed between the door pan and the inner door liner. An insulative material is injected into the mold cavity defined by the space between the door pan and the inner door liner. A removable decorative exterior skin is extended over the base door. A support frame and a plurality of utility lines are provided. An insulative material contacts the support frame. A base door is formed by an inner door liner secured to the insulative material and the support frame.

BACKGROUND OF THE PRESENT INVENTION

The present invention generally relates to a method of making an appliance door, and more specifically, to a method of making an appliance door that can be used on a variety of refrigerator constructions. New refrigerator designs are incorporating flexible design concepts allowing the consumer to select different features. Some of the features include, for example, module components. These and other modules operate using utilities in the form of electrical power, data signals, and fluids in either liquid or gaseous form, or the like.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a method of making an appliance door includes inserting a door pan into a fixture having first and second forming molds. An inner door liner is placed over the door pan. The first and second forming molds are pressed together. A mold cavity is formed between the door pan and the inner door liner. An insulative material is injected into the mold cavity defined by the space between the door pan and the inner door liner. The inner door liner is secured to the door pan to form a base door. A removable decorative exterior skin is extended over the base door.

In another aspect of the present invention, a method of making an appliance door includes inserting a film into a fixture having first and second forming molds. An inner door liner is placed over the film. The first and second forming molds are pressed together. A mold cavity is formed between the film and the inner door liner. An insulative material is injected into the mold cavity defined by the space between the film and the inner door liner. The inner door liner is secured with the frame to form a base door. A removable decorative exterior skin is extended over the base door.

In yet another aspect of the present invention, a method of making an appliance door includes inserting a support frame into a fixture having first and second forming molds. Utility lines are inserted into the fixture. The first and second forming molds are pressed together. An insulative material is injected between the first and second forming molds in contact with the support frame. The injected insulative material is set to form a base door. An inner door liner is secured over the base door. A removable decorative exterior skin is extended over the base door.

These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

DETAILED DESCRIPTION OF EMBODIMENTS

FIGS. 1A-1Cgenerally illustrate a method of making an appliance door10(FIG. 12). An inner door liner12is placed over the door pan14a. First and second forming molds16,18of a fixture are pressed together. A cavity20is formed between the door pan14aand the inner door liner12. An insulative material22is injected into the cavity20defined by the space between the door pan14aand the inner door liner12. The inner door liner12is secured to the door pan14ato form a base door24and a perimeter gasket40is affixed thereto. A decorative exterior skin26(FIG. 2) is extended over the base door24.

The reference numeral10generally designates an appliance door and is intended to cover each variation of constructing a door as disclosed herein and equivalents thereof, including doors10a,10b,10c,10d, and10e.

Referring now toFIGS. 2-3, the inner door liner12may include any of a number of configurations. The illustrated embodiment ofFIGS. 2 and 3includes a projection30in the inner door liner12for receiving a storage unit or module such as an ice machine32. The projection30projects into an interior side34of the inner door liner12, but opens to an exterior side36(FIG. 2). Multiple shelves33are disposed below the projection30and are adapted to support food goods or feature modules disposed thereon. It is contemplated that the inner door liner12is formed from any of a number of materials, including high impact polystyrene, ABS, and polyethylene. The ice machine32extends into the projection30in the inner door liner12and includes conduits38that are disposed between the insulative material22and the door pan14a. Alternatively, the conduits38may extend into channels formed in the insulative material22. The conduits38are designed to receive utility lines including electrical lines and water lines. A gasket40extends around a periphery of the inner door liner12and is held against a perimeter flange integral to the door pan14a. The door pan14ais adhesively bonded by the insulative material22to inner door liner12to form the base door24. The decorative outer skin26is then secured over the base door24adjacent to the door pan14ato form the appliance door10a. The door pan14aprovides structural support to the appliance door10a.

Referring again toFIGS. 2 and 3, an aperture49is made in the insulative material22during the foaming process or made after the insulative material22has set and hardened. The aperture49is designed to accommodate a wide variety of modules and devices and may be formed during door construction in a multitude of ways. Specifically, the aperture49may be cut out after the base door24is formed, or after the complete door10is constructed. Alternatively, the aperture49may be made using a block that creates a void in the door during the injection of foam material22into the cavity20. The block is later removed to create the aperture49. A decorative exterior skin26may then be assembled over the pan14ato provide aesthetic variation for door10ain terms of shape, color, finish, or material type. The decorative exterior skin26, as illustrated, includes a face wall26a, as well as a plurality of perpheral sidewalk26b,26c,26d,26e.

Referring now to the embodiment illustrated inFIGS. 4 and 5, another manner of assembling an appliance door10bincludes inserting the inner door liner12and gasket40in the first and second forming molds16,18(FIGS. 1A-1C) which are subsequently pressed together. The insulative material22, which is polyurethane or a similar material, is then inserted into the cavity20formed by the first and second forming molds16,18. A release agent or film51bis placed against the mold surface of the second forming mold. The film51bmay be of polyethylene or similar material. The film51bcan also be used as a moisture barrier that inhibits moisture from entering the insulative material22. A frame14bhaving a tubular construction (FIGS. 4 and 5) is then placed in abutting contact with the insulative material22, and the inner door liner12and gasket40are secured with the inner door liner12by the door flange44. A component, such as the ice machine32is placed in the appliance door10bin operable connection with the inner door liner12and is accessible from the outside of the appliance door10b. The tubular outer frame14badds rigidity to the appliance door10band is fastened or welded at each corner50, as shown inFIG. 4A. Cross members52are positioned at predetermined points in the frame14b, to add additional strength, as needed. The cross members52may be welded or mechanically fastened to the frame14bat positions that do not interfere with components that may be installed in the door10b. If the film51bor release agent is present on both sides of the insulative material22, the inner door liner12may be secured to the frame14bby mechanical fasteners.

Alternatively, as shown in the embodiment illustrated inFIGS. 6 and 7, an appliance door10cmay use a stair-step frame14chaving a three-dimensional stair-step design instead of the tubular construction of frame14b. The stair-step frame14cis formed from a single metal blank and stamped or folded on a break press, for example, then cut and bent into typically a rectangular shape and the adjoining ends fastened mechanically or by tack weld to provide a unitary frame14c(FIG. 6A). It is contemplated that the stair-step design could have a variety of constructions with varying dimensions, depending on the required rigidity, weight, and versatility desired.

Referring now to the embodiment illustrated inFIGS. 8 and 9, yet another manner of assembling the appliance door10dincludes inserting a frame14dinto the mold cavity20. The frame14dmay include molded plastic, metal, or other material, and may be in various forms, including H-beam, I-beam, U-channel, or other configurations. In addition, the frame14dmay include utility lines38and mounting hardware adapted to connect with components that may exist in the appliance door10d. The frame14dis either encased in or bonded to the insulative material22in the mold cavity20. After the insulative material22cures around the frame14dand is connected or bonded to the inner door liner12and gasket40, a component, such as the ice machine32shown is installed in the frame14dand connected with utility lines38to form the base door24. A decorative exterior skin26may then be assembled over the base door24to provide aesthetic variation in shape, color, finish, or type of material for door10d.

Referring now to the embodiment illustrated inFIGS. 10 and 11, yet another manner of assembling an appliance door10eincludes inserting a release agent or film51eagainst the mold surface of the second forming mold18(FIGS. 1A-1C). The first and second forming molds16,18are then closed and insulative material22is inserted into the cavity20. The insulative material22conforms to the shape of the inner door liner12. The inner door liner12and insulative material22are then withdrawn from the mold as a single frameless unit. The film51emay be polyethylene or similar material. The film51ecan also be used as a moisture barrier. A component, such as the ice machine32shown, is inserted into the aperture49in the insulative material22. The utility lines38may be encased in the insulative material22, or may extend through channels39formed to receive the utility lines38. The exterior skin26, gasket40, and door flange44are then press-fitted or otherwise fastened together about the periphery of the appliance door10e. The insulative material22, when assembled with the inner liner12, decorative exterior skin26and flange44, provides the structural rigidity for the appliance door10e.

It is contemplated that pockets could be made in the insulative material22to accommodate removable insulation panels, such as those disclosed in U.S. patent application Ser. No. 12/466,398, entitled “VACUUM INSULATION PANELS APPLIED TO OR AS A FEATURE MODULE,” filed on May 15, 2009, the entire disclosure of which is hereby incorporated by reference, or storage compartments, such as those disclosed in U.S. patent application Ser. No. 12/402,608, entitled “PLENUM ON FRONT OF REFRIGERATOR/FREEZER DOOR,” filed on Mar. 12, 2009, the entire disclosure of which is hereby incorporated herein by reference, as well as removable modules or components, etc., such as those disclosed in U.S. patent application Ser. No. 12/402,559, entitled “VACUUM FOOD PRESERVATION SYSTEM,” filed on Mar. 12, 2009; U.S. patent application Ser. No. 12/402,747, entitled “CHILLING AND THAWING MODULAR APPLIANCE SYSTEM,” filed on Mar. 12, 2009; and U.S. patent application Ser. No. 12/402,731, entitled “MODULAR DOOR MOUNTED CLIMATE CONTROLLED MEDICINE COMPARTMENT,” filed on Mar. 12, 2009, the entire disclosures of which are hereby incorporated herein by reference. The decorative exterior skin26may then be assembled over the base door24to provide aesthetic variation in shape, color, finish, or type of material for door10e.

FIGS. 12-17illustrate one embodiment of the assembled appliance door10. The appliance door10includes first and second brackets53,55(FIG. 12) that are designed to secure a handle (not shown) to the door10. Tabs56are also disposed along the door edge for connection of a trim piece (not shown). The interior of the door10has the shelves33disposed at the bottom of the door10, however, it is contemplated the shelves33and any components (such as the ice machine32) could be arranged in various manners or styles, as desired by the end user. Pin receivers57are designed to receive pivot pins about which the door10can rotate between open and closed positions after installation.

The appliance door10discussed above is designed for use with a variety of decorative skins26. Accordingly, it is contemplated that a single base door24may be used across a breadth of appliances or models with the decorative outer skin26being the only changed item. The decorative outer skin26may have a variety of constructions and is adapted to receive a variety of components. In addition, the base door24may be connected with, for example, the decorative outer skin26by press-fitting, and later have the decorative outer skin26removed and have a different decorative outer skin26secured over the base door24by end caps64that extend over the top and bottom edges66,68of the inner door liner12to hold the exterior skin26in place, as discussed in further detail below.

Referring now toFIGS. 18-21, in each of the aforementioned embodiments, it is conceivable that the exterior skin26may be press-fitted to the inner door liner12, such as shown inFIGS. 18 and 19, or may be wrapped around side edges60of the inner door liner12as shown inFIGS. 20 and 21. End walls62of the exterior skin26cover the side edges60and abut the inner door liner12. In the event that the exterior skin26is wrapped around side edges60of the inner door liner12, then end caps64are situated over top and bottom edges66,68of the inner door liner12to hold the exterior skin26in place. The decorative outer skin26can also be permanently bonded adhesively or by other mechanical means such as clips or screws.