Appliance cabinet and method of assembling same

An appliance cabinet, such as a laundry treating appliance cabinet, having a chassis and a cover removably mounted to the chassis, and a labyrinth coupler connecting the cover and the chassis, wherein the coupler is physically configured to define a path requiring a specific sequence of movements between the cover and the chassis to couple or uncouple the cover from the chassis.

BACKGROUND OF THE INVENTION

Laundry treating appliances, such as a washing machine or a clothes dryer, may include an outer cabinet, including a chassis or lower housing and a cover or top panel coupled to the lower housing. A cycle of operation of the laundry treating appliance, such as during a load imbalance condition, may cause vibrations and/or displacement of the cabinet. Due to the vibration/displacement, the top panel may move relative to the lower housing and/or may become dislodged from the lower housing.

SUMMARY OF THE INVENTION

The invention relates to an appliance cabinet and a method for assembling the same, the cabinet having a chassis defining an open top, a cover removably mounted to the chassis to close the open top, and a coupler connecting the cover and the chassis. The coupler includes a first structural element on the chassis and a second structural element on the cover, wherein the first and second structural elements are physically configured to define a path requiring a specific sequence of relative movements between the cover and chassis to couple or uncouple the cover from the chassis.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention relates to a cabinet for an appliance, such as a laundry treating appliance. In particular, one embodiment of the invention relates to a cabinet structure having an improved coupling between a lower housing and a top panel on the lower housing.

FIG. 1illustrates one embodiment of a laundry treating appliance10having a cabinet12according to one embodiment of the invention. As illustrated, the laundry treating appliance is a vertical-axis washing machine; however, the laundry treating appliance10may be any appliance which includes a cabinet structure, non-limiting examples of which include a horizontal-axis washing machine; a horizontal or vertical axis clothes dryer; a combination washing machine and clothes dryer; a tumbling or stationary refreshing/revitalizing machine; an extractor; a non-aqueous washing apparatus; and a revitalizing machine. As used herein, the term “vertical-axis” washing machine refers to a washing machine having a rotatable drum that rotates about a generally vertical axis relative to a surface that supports the washing machine. However, the rotational axis need not be perfectly vertical to the surface. The drum may rotate about an axis inclined relative to the vertical axis, with fifteen degrees of inclination being one example of the inclination. Similar to the vertical axis washing machine, the term “horizontal-axis” washing machine refers to a washing machine having a rotatable drum that rotates about a generally horizontal axis relative to a surface that supports the washing machine. The drum may rotate about the axis inclined relative to the horizontal axis, with fifteen degrees of inclination being one example of the inclination. The laundry treating appliance10described herein shares many features of a traditional automatic washing machine, which will not be described in detail except as necessary for a complete understanding of the invention. It is also understood that the cabinet12is applicable to appliances other than laundry treating appliances. For purposes of description related to the figures, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented inFIG. 1from the perspective behind the laundry treating appliance10, which defines the rear of the laundry treating appliance10.

As illustrated inFIG. 1, the cabinet12may include a chassis in the form of a lower housing14having a front panel16, a rear panel18, and a pair of side panels20. The front, rear, and side panels16,18,20may each be formed as separate pieces, or may be formed as one or more continuous pieces. For example, the rear panel18may be separate, while the front and side panels16,20may be continuous with each other. The panels16-20may be mounted to a frame (not shown). It is noted that the terms “chassis” and “lower housing” as used herein may include just a frame on which outer panels are attached, or the entire cabinet, with or without an underlying frame. A cover in the form of a top panel24may be supported on an upper portion of the lower housing14, above the front, rear, and side panels16,18,20. A lid (not shown for clarity) may be hingedly coupled to the top panel24for selectively closing an opening in the top panel24through which interior components of the laundry treating appliance, such as a drum and treating chamber, may be accessed.

The lower housing14and top panel24may include a coupling structure that prevents unintentional movement of the top panel24relative to the lower housing14. Specifically, the coupling structure includes one or more structural elements on the lower housing14that interact with one or more cooperating structural elements on the top panel24. The cooperating structural elements are physically configured to curb or obstruct movement by preventing the top panel24from being dislodged from the lower housing14during operation, even in an unbalanced load condition within the laundry treating appliance10, unless the top panel24undergoes a specific sequence of movements along a path defined by the cooperating structural elements. The sequence of movements may be designed to be tortuous or labyrinthine, so that the top panel24must be deliberately moved through the sequence dictated by the coupling structure in order to remove the top panel24from the lower housing. As such, the coupling structure may be considered to be a labyrinth coupler. Throughout the sequence of movements, the first and second structural elements may selectively engage each other in different combinations; as used herein, the term “engage” and variations thereof includes any contact, abutment, or other interaction between the first and second structural elements.

FIG. 2is a rear view of the laundry treating appliance10fromFIG. 1. At least one hinge illustrated as a hinge bracket28, which may form a portion of the coupling structure, couples the top panel24to the lower housing14; as illustrated, the laundry treating appliance10includes two spaced hinge brackets28. The hinge bracket28comprises a lower portion30coupled to the rear panel18of the lower housing14and an upper portion32coupled to the top panel24and joined to the lower portion30by a living hinge34. The hinge bracket28permits the top panel24to move with respect to the lower housing14, while still remaining attached to the lower housing14.

FIG. 3is a perspective view of a portion of the laundry treating appliance10, with the top panel24removed to show interior components. A bracket36, only a portion of which is visible inFIG. 1, may be coupled to the lower housing14along an upper front of the lower housing14and at least partially along the upper sides of the lower housing14, such that the bracket36spans the corner junctions between the front panel16and the side panels20. As illustrated, the bracket36may include multiple features related to the coupling structure. A first guide38may be provided along a front side of the bracket36, and may include a recess40open to a front side of the lower housing14and a guide tab42adjacent the recess. A second guide44may be provided along a lateral side of the bracket36, and may include a generally flat and L-shaped tab having an upwardly-projecting stem portion46and a rearwardly-projecting arm portion48. A third guide50may be provided along a rear side of the bracket36, and may be similar in shape to the second guide48, but may be oriented perpendicularly to the second guide48. The third guide50may include an upwardly-projecting stem portion52and a laterally-projecting arm portion54.

The portion of the bracket36not shown is generally a minor image of the portion shown inFIG. 3, and has many of the same structural elements arranged for cooperative registry with the structural elements of the top panel24to provide support and movement-curbing functionality to the assembled cabinet12. The bracket36may further be contoured, and configured with other embossments, openings, slots, depressions, rails, flanges and the like, for support of the bracket36on the lower housing14and the top panel24on the bracket36.

While multiple guides are provided in the illustrated embodiment, fewer guides may be provided for the coupling structure. In an alternate embodiment, only one of the second or third guides44,50may be provided in addition to the first guide38. Further, while the features of coupling structure on the lower housing14are shown as being formed on the bracket36, it is also within the scope of the invention for the features of the coupling structure on the lower housing14to be formed on any of the front, rear, and side panels16,18,20or the frame (not shown).

FIG. 4is a bottom perspective view of a portion of the top panel24. The top panel24includes an upper wall56connected to a peripheral side wall58, and having an inwardly projecting bottom wall60connected to a lower end of the peripheral side wall58. In the perspective shown inFIG. 4, a front side62and a lateral side64of the peripheral side wall58are visible. As illustrated, the bottom wall60includes multiple features related to the coupling structure. A front tab66may be formed in the bottom wall60along the front side62of the peripheral side wall58by a relief area68, and may be generally horizontally-oriented and rearwardly-projecting. A slot70may be formed in the bottom wall60adjacent the lateral side64of the peripheral side wall58, and may be an elongated enclosed opening formed in the bottom wall60. A lateral tab72may be formed in the bottom wall60along the lateral side64of the peripheral side wall58by a recess forming a relief area74, and may be generally horizontally-oriented and inwardly-projecting.

The portion of the top panel24not shown is generally a minor image of the portion shown inFIG. 4, and has many of the same structural elements arranged for cooperative registry with the structural elements of the bracket36to provide support and movement-curbing functionality to the assembled cabinet12. The top panel24may further be contoured, and configured with embossments, openings, slots, depressions, rails, flanges, and the like, for support of the top panel24on the lower housing14and bracket36.

FIGS. 5A-6Eillustrate the relative position of the coupling structure during movement of the top panel24along the path dictated by the coupling structure in order to at least partially uncouple the top panel24from the lower housing14. In general, the specific sequence of relative movements between the top panel24and lower housing14to couple or uncouple the top panel24from the lower housing14includes a first linear movement along a first axis, a second linear movement along a second axis that is non-coaxial with the first axis, and a third movement interposed between the first and second movements along a third axis that intersects the first and second axes. As such, the third movement is a shifting-type movement. Optionally, the sequence can include a fourth movement along a fourth axis after the second linear movement.

More specifically, as illustrated herein, the sequence of movements to remove the top panel24include, with respect to the lower housing14, moving the top panel laterally forward (corresponding to the first linear movement), lifting at least the front portion of the top panel24upwardly a first time (corresponding to the third movement), moving the top panel laterally rearwardly (corresponding to the second linear movement), and lifting at least the front portion of the top panel24upwardly a second time (corresponding to the fourth movement). Throughout the sequence of movements, the top panel24may remain at least partially coupled to the lower housing14by the hinge brackets28. In this sequence, the first and second linear movements are opposing and are vertically offset. Further, the first and second linear movements may be sliding-type movements. The third and fourth movements may be pivoting movements due to the hinge brackets28, and may have both a vertical component and a horizontal component.

FIG. 5Ashows the front portion of the coupling structure with the top panel24in a fully coupled position. As illustrated, in the fully coupled position, the top panel24may be generally aligned with the lower housing14. The front tab66(not visible) cooperates with the recess40of the first guide38, such that the front tab66may be at least partially received within the recess40and the guide tab42overlies the bottom wall60. The second guide44cooperates with the slot70, such that the stem portion46projects through the slot70. The third guide50cooperates with the lateral tab72, such that the arm portion54projects over the relief area74. The front tab66within the first guide38limits the rearward movement of the top panel24with respect to the lower housing14.

FIG. 5Bshows the front portion of the coupling structure with the top panel24in a first intermediate position. As illustrated, in the first intermediate position, the top panel24may be translated laterally in a forward direction with respect to the lower housing14. The second guide44remains in the slot70, with the stem portion46moved forwardly in the slot70and the arm portion48now overlying the bottom wall60. The stem portion52of the third guide50is also translated forward, with the arm portion54projecting over the lateral tab72. The front tab66may be removed from the recess40of the first guide38and the guide tab42does not overly the bottom wall60of the top panel24. To move from the coupled position shown inFIG. 5Ato the first intermediate position, the top panel24may be pulled or otherwise moved in a forward direction. Movement to the first intermediate position may also include some upward movement, i.e. a vertical component. The second guide44within the slot70limits the forward movement of the top panel24.

FIG. 5Cshows the front portion of the coupling structure with the top panel24in a second intermediate position. As illustrated, in the second intermediate position, at least the front portion of the top panel24may be translated vertically in an upward direction with respect to the lower housing14. The front tab66may be cleared from the recess40of the first guide38and the guide tab42may be cleared from the bottom wall60of the top panel24, such that the first guide38is no longer coupled to the top panel24. The arm portions48,54of the second and third guides44,50remain overlying the bottom wall60, but now abut the bottom wall60. To move from the first intermediate position shown inFIG. 5Bto the second intermediate position, at least the front portion of the top panel24may be lifted or otherwise moved in an upward direction. The second and third guides44,50abutting the bottom wall60limit the upward movement of the top panel24.

FIG. 5Dshows the front portion of the coupling structure with the top panel24in a third intermediate position. As illustrated, in the third intermediate position, the top panel24may be translated laterally in a rearward direction with respect to the lower housing14. The top panel24remains uncoupled from the first guide38. The second guide44remains in the slot70, but the arm portion48projects over the slot70and not over the bottom wall60of the top panel24. The arm portion54of the third guide50projects over the relief area74. To move from the second intermediate position shown inFIG. 5Cto the third intermediate position, the top panel24may be pushed or otherwise moved in a rearward direction. Movement to the third intermediate position may also include some downward movement, which would include a vertical component. The second guide44within the slot70limits the rearward movement of the top panel24.

FIG. 5Eshows the front portion of the coupling structure in a partially uncoupled position. As illustrated, in the partially uncoupled position, at least the front portion of the top panel24may be translated vertically in an upward direction with respect to the lower housing14. The top panel24may be uncoupled from all three guides38,44,50. To move from the third intermediate position shown inFIG. 5Eto the partially uncoupled position, at least the front portion of the top panel24may be lifted or otherwise moved in an upward direction. While not visible inFIG. 5E, the top panel24remains coupled to the lower panel14by the hinge brackets28.

FIG. 6Ashows the rear portion of the coupling structure with the top panel24in a fully coupled position. As illustrated, in the fully coupled position, the top panel24may be generally aligned with the lower housing14and the hinge bracket28may attach the top panel24to the lower housing14. The lower portion30of the hinge bracket28comprises a generally flat hinge plate76having a flange78at a lower end thereof. The lower portion30may be fixedly coupled to the rear panel18of the lower housing14by a first fastener80, with a slot82in the rear panel18receiving the flange78and the hinge plate76adjacent the rear panel18. The upper portion32also comprises a generally flat hinge plate84having an angled portion86joined to the upper end of the hinge plate84by a curved portion88. A stop90may be provided near the terminal end of the angled portion86. The upper portion32may be coupled to the top panel24by a second fastener (not shown), with a slot94in the peripheral side wall58of the top panel24receiving the angled portion86.

FIG. 6Bshows the rear portion of the coupling structure with the top panel24in the first intermediate position. As illustrated, in the first intermediate position, the top panel24may be translated laterally in a forward direction with respect to the hinge bracket28. Movement to the first intermediate position may also include some upward movement, which would include a vertical component. The angled portion86guides the movement of the top panel24. The stop90may limit the forward movement of the top panel24with respect to the hinge bracket28.

FIG. 6Cshows the rear portion of the coupling structure with the top panel24in the second intermediate position. As illustrated, in the second intermediate position, the top panel24may be pivoted in an upward direction with respect to the hinge bracket28.

FIG. 6Dshows the rear portion of the coupling structure with the top panel24in the third intermediate position. As illustrated, in the third intermediate position, the top panel24may be translated laterally in a rearward direction with respect to the hinge bracket28. Movement to the third intermediate position may also include some downward movement, which would include a vertical component. The angled portion86guides the movement of the top panel24.

FIG. 6Eshows the rear portion of the coupling structure in the partially uncoupled position. As illustrated, in the partially uncoupled position, the top panel24may be pivoted in an upward direction with respect to the hinge bracket28to a greater angle than for the second or third intermediate positions.

WhileFIGS. 5A-6Eillustrate the relative position of the coupling structure during movement of the top panel24along the path dictated by the coupling structure in order to at least partially uncouple the top panel24from the lower housing14, it is understood that the same sequence of movements in reverse will serve as a method to assemble the top panel24and the lower housing14.