Abstract:
A connection assembly snap-interlocking first and second components is initiated with a first tab member provided on a first leg of the first component extending into a slot formed at an inner portion of the second component. The connection is then completed upon relatively rotating the first and second components about an axis defined by the first tab member, with a terminal bent portion of the first tab member engaging with the second component, another portion of the first tab member abutting a biasing arm extending from the second component, and a terminal portion of a second tab member, which extends from an outer edge portion of the second component, being snap-received and retained in an opening formed in a second leg of the first component.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention pertains to the art of connections and, more particularly, to a connection assembly for snap-connecting two components. The snap connection assembly has particular application in interlocking certain appliance components, such as cosmetic end caps to structural posts for a cooking appliance control panel. 
         [0003]    2. Description of the Related Art 
         [0004]    Certainly, there exist an abundance of different connection assemblies in the art. In particular, mechanical fasteners are commonly employed to interconnect a wide range of components. Obviously, utilizing mechanical fasteners requires more parts and, although mechanical fasteners can be produced economically, the use of mechanical fasteners can add to the cost of the overall assembly. Perhaps more importantly, the use of mechanical fasteners can add to the complexity and overall assembly time. Although this may not be a significant factor for many products, one can readily image the additional, cumulative assembly time and cost associated with utilizing mechanical fasteners, such as screws, in interconnecting certain components of a product which is mass produced at a manufacturing plant. 
         [0005]    With this in mind, some consideration can be given to utilizing other known connection arrangements to avoid, or at least minimize, the need for supplemental mechanical fasteners. Welding, gluing and other similar connection variations are seen to have similar deficiencies in connection with increased elements, cost and assembly time. Still, there are other connections, such as snap or twist-type connections, which can be employed to advantageously avoid the number of parts, as well as reduce assembly time. Unfortunately, these types of connections are generally not very robust and, as such, have not been relied upon to securely interlock multiple components. In addition, snap-type connections are typically relegated for use with interconnecting plastic components which readily provide for necessary component flexure in making the connection. 
         [0006]    With the above in mind, it would be beneficial to provide a snap-connection which can be effectively used to interlock components in a robust fashion. More particularly, there is seen to be a need in the art for a snap-type connection particularly for use to securely interlock metal components, or a combination of plastic and metal components. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention is directed to a connection assembly which enables snap-interlocking of first and second components which can be formed from various materials, particularly metal and plastic. In accordance with the invention, the first component includes first and second angled legs, a first tab member projecting from the first leg and an opening extending into the second leg, and the second component includes at least one leg or body portion provided with an opening adapted to receive the first tab member of the first component and a second tab member including a terminal portion sized to be received in the opening in the second leg of the first component. A biasing arm provided on the second component comes into engagement with the first tab member prior to the second tab member reaching the opening. With this arrangement, the first and second components can be snap-interlocked by initially positioning the first tab member provided on the first leg of the first component into the opening formed in the second component. Thereafter, the components can be relatively rotated, causing the biasing arm to engage the first tab member. Upon further relative rotation, the terminal portion of the second tab member is snap-received into the opening in the first component, while another portion of the second tab member abuts the second leg of the first component. The biasing arm formed in the second component and abutting the tab member of the first component provides a biasing force tending to counter rotate the components relative to each other, thereby stabilizing the interconnected components. 
         [0008]    The connection assembly of the invention has a wide range of uses, while finding particular use in attaching cosmetic or trim components to appliances during a manufacturing process in order to substantially reduce or eliminate the need for mechanical fasteners, while significantly reducing the overall assembly time. Still, additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of preferred embodiments when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is an upper right perspective view of a cooking appliance incorporating control panel end-caps connected in accordance with the present invention; 
           [0010]      FIG. 2  is an exploded perspective view of an end cap and support post incorporated in the cooking appliance of  FIG. 1  and designed to be interlocked in accordance with the connection assembly of the invention; 
           [0011]      FIG. 3A  is an enlarged exploded view of portions of first and second metal components designed to be connected in accordance with the present invention; 
           [0012]      FIG. 3B  shows the enlarged component portions of  FIG. 3A  in a partially assembled state; 
           [0013]      FIG. 3C  shows the enlarged component portions of  FIG. 3A  in a fully assembled state; 
           [0014]      FIG. 3D  shows an opposing side view of the fully assembled arrangement of  FIG. 3C ; 
           [0015]      FIG. 4A  shows an outer side view of the end cap and support post fully assembled in accordance with the invention; 
           [0016]      FIG. 4B  shows an inner side view of the fully assembled end cap and support post of  FIG. 4A ; 
           [0017]      FIG. 5A  is an enlarged exploded view of portions of metal and plastic components designed to be connected in accordance with the present invention; 
           [0018]      FIG. 5B  shows the enlarged component portions of  FIG. 5A  in a partially assembled state; 
           [0019]      FIG. 5C  shows the enlarged component portions of  FIG. 5A  in a fully assembled state; and 
           [0020]      FIG. 5D  shows an opposing side view of the fully assembled arrangement of  FIG. 5C . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    At this early point, it should be pointed out that the connection assembly of the invention can be used to robustly interlock a wide range of components in various fields. However, one particularly advantageous use of the invention is considered to be interlocking cosmetic or trim components to support or structural components in appliances. With this in mind, initial reference will be made to  FIG. 1  in fully describing the connection assembly of the present invention utilized to interlock multiple components of a cooking appliance generally indicated at  2 . As shown, cooking appliance  2  takes the form of a free-standing gas range. Range  2  includes a cabinet  4  having a front panel portion  5 , opposing side panel portions  6 , a bottom portion  7 , a range top  8 , and a main back panel  9 . Certainly, range top  8  can take on various forms. In the embodiment shown, range top  8  is provided with five gas burner elements  11 - 15 , i.e., four outer quadrant gas burner elements  11 - 14  and a central gas burner element  15 , which are covered by left and right, mirror image burner grates  17  and  18 . 
         [0022]    In the embodiment illustrated, cabinet  4  further includes a front control surface  20 . Preferably, control surface  20  supports a plurality of control knobs  21 - 25  for regulating the activation/de-activation of gas burners  11 - 15  respectively. Furthermore, cabinet  4  includes an upstanding control panel  30  arranged at an upper rear portion  31  of cabinet  4 . In the embodiment shown, control panel  30  includes a central control and display unit, generally indicated at  35 , for use in establishing a desired heating operation to be performed within an oven  40  of range  2 . For this purpose, central control and display unit  35  is employed for conveying information and verifying input/operational parameters to a user. At the same time, oven  40  includes an oven cavity  45  and a door  50  which can be pivoted by means of a handle  53  to access oven cavity  45 . As illustrated, door  50  includes a window  55  for viewing the contents of oven cavity  45  when door  50  is closed. Finally, arranged below door  50  and extending across cabinet  4  is a lower face panel  58 . 
         [0023]    Again, as indicated above, the above structure is known in the art and has been described for the sake of completeness in connection with presenting a preferred embodiment for the connection assembly of the present invention. To this end, it should be noted that cabinet  4  has associated therewith internal rear support structure, such as generally indicated at  65  in connection with the right rear portion of range  2 . Similarly, corresponding support structure (not shown) is provided at the left rear portion of range  2 . As will become more fully evident below, each support structure  65  is employed in mounting control panel  30 . However, particularly important with respect to the present invention is the manner in which each of a pair of metal, cosmetic end caps  70  and  71  provided at rear side regions of cabinet  4  is snap-connected to a respective support structure  65 . In particular, it is the cooperating configuration of support structure  65  and end caps  70  and  71  which enables each end cap  70 ,  71  to be snap-connected to a respective support structure  65  in an extremely secure and robust manner, without a requirement for any additional mechanical fasteners, that is of concern to the present invention as will now be described in detail. 
         [0024]    As shown in  FIG. 2 , support structure  65  represents a first component to which a second component, represented by end cap  70 , is configured to be snap-connected. As depicted, support structure  65  includes a corner post  80  having a first leg  84  and a second leg  86 . In the embodiment shown, support structure  65  is formed of sheet metal, with second leg  86  being bent at a substantially perpendicular angle relative to first leg  84  such that a vertex portion  88  is defined there between. Extending from second leg  86 , at a position remote from first leg  84 , is an offset leg  90  which leads to an upper bracket portion  93  and a lower bracket portion  94 . Upper bracket portion  93  is shown to include an uppermost section  98  and a bent flange section  99 . A pair of holes  101  and  102  are provided in uppermost section  98  and bent flange section  99  respectively. Lower bracket portion  94  includes a lowermost section  106  leading to an intermediate section  107  having extending therefrom an ear mount  110  provided with a hole  111 . Also provided in lowermost section  106  is a hole  114 . In connection with the overall invention, the particular configuration and construction of upper and lower bracket portions  93  and  94  are not significant to the invention. Instead, it is simply important to note at this point that a particularly preferred embodiment of the connection assembly is for use in the mounting of control panel  30 . Therefore, the particular construction of upper and lower bracket portions  93  and  94  are configured based on the structure of range top  8  and control panel  30  which extend between and are mounted to the corresponding side corner posts  80  through respective regions of bracket portions  93  and  94 . 
         [0025]    More importantly, as the connection assembly of the present invention can be utilized in a wide range of fields, it is the construction and arrangement of first and second legs  84  and  86  which is of more interest to the invention. As shown, first leg  84  includes a first inner portion  124  leading to a first outer portion  125 . In a similar manner, second leg  86  includes a second inner portion  128  leading to a second outer portion  129 . It is from second outer portion  129  that upper and lower bracket portions  93  and  94  extend, with all the structure being shown to be formed from bending a single piece of sheet metal. As depicted, first and second legs  84  and  86  are provided with a pair of spaced openings  134  and  135 . As each opening  134 ,  135  is identically constructed, a detailed description will be made regarding opening  134  and it is to be understood that opening  135  has corresponding structure. As illustrated, opening  134  preferably extends through vertex portion  88  and is defined by upper, lower and side edges  140 - 143 . In this manner, opening  134  extends partially into first leg  84 , as well as partially into second leg  86 . However, as will become more fully evident below, it is the extension of opening  134  into second leg  86  which is particularly important in accordance with the invention. 
         [0026]    Also shown spaced from openings  134  and  135  are a pair of distortion reducing reliefs  145  and  146 . Although reliefs  145  and  146  can take various forms, each is shown to take the form of a U-shaped slot  148  having spaced slot portions  149  and  150  joined by a cross slot section  151 . An arm  152 , which stems from part of first leg  84 , aids in defining U-shaped slot  148  and includes an aperture (not separately labeled) which is adapted to receive a screw (not shown) used to attach back panel  9  to corner post  80 . For the sake of completeness, corner post  80  is also shown to include spaced dimpled zones  153  and  154  which add rigidity to the angle between first and second legs  84  and  86 . More important in connection with the present invention is the inclusion of first and second tab members  156  and  157  projecting from first outer portion  125 . Although tab members  156  and  157  can be vertically aligned with or vertically spaced from openings  134  and  135 , the tab members  156  and  157  are certainly horizontally or laterally spaced from openings  134  and  135  based on the orientation as illustrated in this figure. 
         [0027]    As indicated above, the connection assembly of the present invention is being described with reference to the exemplary arrangement of mounting end caps  70  and  71  to cabinet  4  of range  2 .  FIG. 2  also shows end cap  70  which essentially constitutes a cover member for the terminal ends of control panel  30 . In this sense, end cap  70  represents a cosmetic or trim piece for range  2 . In any case, end cap  70  is shown to include a first body portion  164  that represents a rear side of end cap  70 . First body portion  164  is established by an inner portion  166  and an outer portion  167 . End cap  70  also includes a second body portion or face  170 , as well as an in-turned peripheral edge  174 . In the exemplary embodiment shown, in-turned peripheral edge  174  is provided with a tab  177  having an opening  179  at a bottom thereof. 
         [0028]    Projecting from outer portion  167  of first body portion  164  is a pair of spaced second tab members  185  and  186 . As with openings  134  and  135 , each of second tab members  185  and  186  are identically constructed such that the construction of second tab member  185  will now be described in detail and it is to be understood that second tab member  186  has identical structure. As shown, second tab member  185  includes a first tab portion  188  extending directly from outer portion  167  of first body portion  164 , a second tab portion  189  extending at an angle from the first tab portion  188 , and a terminal tab portion  190  projecting from the second tab portion  189 . In the most preferred embodiment shown, first tab portion  188  projects at an acute angle relative to first body portion  164  and away from second body portion  170 . Second tab portion  189  is angled relative to first tab portion  188  so as to extend substantially parallel to first body portion  164 . Terminal tab portion  190  essentially constitutes a reduced length section of second tab portion  189  so as to also extend substantially parallel to first body portion  164 . As will be more fully evident below, each second tab member  185 ,  186  is adapted to cooperate with a respective opening  134 ,  135  such that second tab members  185  and  186  are spaced along first body portion  164  a distance corresponding to the spacing between openings  134  and  135  along corner post  80 . In essence, these tab and opening combinations constitute portions of a respective connection assembly such that the spaced pairs represent parts of two connection assemblies constructed in accordance with the present invention. 
         [0029]    As also shown in  FIG. 2 , provided along first body portion  164  within inner portion  166  is a pair of spaced openings  194  and  195 . Again, openings  194  and  195  are commensurately constructed such that a detail reference will now be made to the preferred configuration of opening  194  and it is to be understood that opening  195  is correspondingly formed. As shown, opening  194  includes a first longitudinally extending slot portion  197  and a second longitudinally extending slot portion  198 . Second longitudinally extending slot portion  198  opens into first longitudinally extending slot portion  197  but is shorter than first longitudinally extending slot portion  197  such that a pair of spaced lands  201  and  202  are established at inner portion  166  of first body portion  164 . In the most preferred embodiment shown, first longitudinally extending slot portion  197  is also provided with a pair of spaced cut-out extensions  205  and  206  between which extends a biasing arm  208 , which can be linear or arcuate in shape. Although not shown in  FIG. 2  based on the perspective taken, arm  208  of this embodiment actually curves into end cap  70  and includes a terminal end portion (not shown) which extends substantially parallel to second body portion  170 . 
         [0030]    Reference will now be made to  FIGS. 3A-3D  in describing the manner in which two components, here end cap  70  and corner post  80 , are interlocked in accordance with the present invention. Initially, first and second legs  84  and  86  are arranged spaced from first body portion  164  and second body portion  170  as shown in  FIG. 3A . Upon initial interconnection, first body portion  164  is angled and arranged spaced from first leg  84  such that first tab member  156  can be inserted within first longitudinally extending slot portion  197  of opening  194 . To this end, it should be noted that each first tab member includes a first tab portion  213  and a second tab portion  214 . First tab portion  213  projects at an angle from first leg  84  and away from second leg  86 . First tab portion  213  leads to second tab portion  214 , which is angled relative to first tab portion  213  and preferably extends substantially parallel to first leg  84  in a different, offset plane. As illustrated, first tab portion  213  preferably extends at an obtuse angle from first leg  84 , while second terminal tab portion  214  extends at an acute angle from first tab portion  213 . With this arrangement, first tab portion  213  projects through opening  197  and, as first body portion is rotated in a manner indicated in  FIG. 3B , second tab portion  214  abuts lands  201  and  202 . At the same time, terminal tab portion  190  of second tab member  185  reaches opening  134 . At this point, first body portion  164  is slightly spaced from first leg  84  and first tab portion  213  abuts biasing arm  208 . However, continued rotation of first body portion  164  causes flexure of both first tab member  156  and second leg  86 , thereby allowing terminal tab portion  190  to snap into opening  134  as illustrated in  FIG. 3C . To further enhance the flexure of second leg  86 , flex-enhancing reliefs, such as that indicated in the form of slots or slits  220  and  221  in  FIG. 2  for opening  134 , could also be provided. Once terminal tab portion  190  is snapped into position, first body portion  164  is securely fixed to corner post  80 . This overall interconnection is further illustrated in  FIG. 3D  which shows an opposing side view of the fully assembled arrangement of  FIG. 3C . 
         [0031]    As previously indicated, the snap connection assembly of the present invention can be utilized to interlock a wide range of components. In particular, it is essentially required that the first component have relatively angled legs and be formed with a tab member corresponding to first tab member  156  and an associated opening  134 , while the second component include at least a corresponding first body portion having a tab member corresponding to the second tab member  185  and an opening corresponding to opening  194 . Although the connection assembly can be utilized in a wide range of fields, it is considered particularly advantageous in connection with securing trim or cosmetic pieces onto appliances during the manufacture thereof. Along these lines, the connection assembly has particular applicability to securing end caps  70  and  71  to corner posts  80  of range  2 . Although various other connection arrangements can be utilized, employing the present invention enables end caps  70  and  71  to be easily, fixedly snap-secured in place with a minimal number of connection assemblies and without worry of the need for cost and assembly time associated with additional mechanical fasteners. As illustrated in connection with  FIG. 2 , two identically constructed connection assemblies are provided along the length of one side of end cap  70  to establish the desired connection. To further support a free end (not separated labeled) of each end cap  70 ,  71 , opening  179  of tab  177  can cooperate with additional structure (not shown) provided for cabinet  4  to finalize the overall assembly, such as through another snap connection, a friction fit or a mechanical fastener extending through opening  179 . At this point, it should be realized that additional fastening structure could also be provided, such as a similar tab at an upper end of the end cap  70 ,  71  to directly fasten the end cap  70 ,  71  to control panel  30 . However, given the robustness of the snap connection assembly of the invention, this additional fastening arrangement is actually not needed for the end cap  70 ,  71 , but could be beneficial to further support control panel  30 . In any case, it should be readily apparent that end caps  70  and  71  can be quickly snap-fit to the respective corner posts  80  in a minimal amount of time along an assembly line by utilizing the connection assembly of the present invention.  FIGS. 4A and 4B  represents side views illustrating the fully attached arrangement of end cap  70  to corner post  80 . This actual assembly of end cap  70  to corner post  80  can be performed either before or after control panel  30  is secured across range  2  through the use of mechanical fasteners provided in connection with upper and lower bracket portions  93  and  94 . Certainly, although two connection assembly points are referenced for use in securing end caps  70  and  71  to each corner post  80 , the overall number of connection assemblies would be correspondingly varied depending upon the length of the parts employed. Therefore, for interconnecting first and second components which are quite small, only a single connection assembly as illustrated in  FIGS. 3A-3D  would be necessary. Depending upon the robustness of the connection desired and the overall length of the components, additional spaced connection assemblies, such as the two spaced connection assemblies indicated in  FIGS. 2 ,  4 A and  4 B, could be employed. 
         [0032]    In addition to the above, it should be understood that the connection assembly of the present invention need not be limited for use between metal components. Instead, each of the first and second components could be formed of plastic and assembled in a manner similar to that shown in  FIGS. 3A-3D . However, since the robustness of the overall interconnection relies to some extent on the stiffness of the overall components, a different design is preferable when utilizing plastic in forming one or more of the components. To this end, reference will now be made to  FIGS. 5A-5D  which illustrates the connection assembly of the present invention used to snap-interlock a plastic second component  227  to the first component referenced with respect to corner post  80 . Therefore, the first component in this embodiment is made of metal, while second component  227  is preferably made of plastic. As clearly shown with initial reference to  FIG. 5A , second component  227  includes a first body portion  230  having an inner portion  232  and an outer portion  233 . In addition, second component  227  includes a second body portion or a face  236  which extends at an angle from first body portion  230  in a manner directly corresponding to the arrangement between first leg  84  and second leg  86  described above. However, unlike the first embodiment described above, first body portion  230  of second component  227  is provided with a second tab member  240  having first and second tab sections  243  and  244  which are interconnected by a connecting tab section  245 . Stemming from connecting tab section  245  is a flexible arm  248  that is formed with a terminal catch  251 . Catch  251  has a tapered or beveled end portion  254 , as well as a ledge  258  spaced from tapered end portion  254 . Also provided in first body portion  230  is an opening  262  that takes the form of a longitudinally extending slot  262  which defines an upper land  264 . Projecting into opening  262  from a side opposite land  264  is a biasing arm  265 . 
         [0033]    As shown in  FIG. 5B , initial assembly includes the insertion of first tab member  156  into opening  262  such that terminal tab portion  158  extends over land  264 . Continued rotation of first body portion  230  causes arm  265  to abut against first tab portion  157  prior to catch  251  reaching opening  134 . At this point, forced rotation of second component  227  causes flexure of the components as tapered end portion  254  rides against second leg  86  and catch  251  projects into opening  134  such that ledge  258  comes into engagement with side edge  142 . At this point, due to the interaction between arm  165  and first tab member  157 , as well as the interengagement of terminal tab portion  158  with land  264 , flexible arm  248  is biased in a direction away from first leg  84 , thereby maintaining a robust interlocking arrangement between catch  251  and second leg  86  at opening  134 . 
         [0034]    As with the embodiment described above, the embodiment of  FIGS. 5A-5D  can be utilized in relation to securing a wide range of components. Certainly, it should be readily apparent that in each of these embodiments, the second body portion or face  170 ,  236  can take various forms without altering the overall connection assembly. That is, there are no tabs or cut-outs provided in either second body portions but instead each portion provides a smooth, aesthetically pleasing surface which is particularly advantageous in connection with the preferred embodiment wherein the invention is utilized for securing trim or cosmetic pieces. In any case, although the embodiments described above utilize second components which only include body portions that are angled at substantially 90° from one another, it should be readily apparent that the second body portion  170 ,  236  can extend from the first body portion  164 ,  230  in a wide range of fashions without negatively affecting the interlocking arrangement of the connection assembly. With this in mind, although described with respect to preferred embodiments of the invention, it should be readily understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. Again, it should be realized that the connection assembly of the invention can be utilized with a wide range of components made from varying materials and used in numerous fields. In general, the invention is only intended to be limited by the scope of the following claims.