Abstract:
A spill-resistant appliance may be constructed to prevent spilled liquids from entering a control housing and contacting electronics with the use of a first sealant preferably formed out of santoprene and a second sealant preferably formed out of a very high bond, double-sided foam tape. The first sealant and the second sealant may be used in various areas of the control housing that contains electronics for operating the appliance. The first and second sealants may also be used to help attach the control housing to other components of the appliance.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority from U.S. Provisional Patent Application Ser. No. 61/755,144, filed on Jan. 22, 2013, the entirety of which is expressly incorporated by reference herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    Spill protection is often sought for appliances used in both the kitchen and outdoors. This invention relates to preventing liquids from entering the internals of such appliances. 
         [0004]    2. Discussion of the Related Art 
         [0005]    Warming drawers are well known in the prior art. U.S. Patent No. D608,144 discloses a warming drawer wherein the controls are exposed on the drawer front. During use, it is possible for liquid spills above the drawer to drip onto the controls and potentially interfere with proper operation. 
         [0006]    Another example of a warming drawer is disclosed in U.S. Pat. No. 6,849,835. As shown in  FIG. 1 , control knobs are exposed on an outer surface of the housing. Just as described above, water spills during use of the warming drawer may introduce moisture to the control area and potentially seep into the electronics within the appliance. 
         [0007]    What is needed, therefore, is a way to spill-proof appliances, such as warming drawers, making them resistant to entry of liquids such as water. What is also needed is to prevent liquids from seeping past controls and reaching delicate electronics within the appliance. Furthermore, it is also needed to prevent intrusion of liquids into appliances through any openings such as control housing seams, knob openings, indicator lights, and power switches, thus ensuring proper operation. 
       SUMMARY AND OBJECTS OF THE INVENTION 
       [0008]    A spill-resistant appliance is hereby disclosed comprising a chassis. The chassis forms a box with a front portion. A plurality of openings is included on the front portion and may hold various components such as control knobs, switches, lights, and other similar items. The chassis includes sides and a cavity configured to receive an extendable member that may extend from and retract into the cavity. 
         [0009]    A control housing holds a plurality of controls which may include circuit boards, wiring, and other electronic devices. The control housing attaches to the front portion and sides of the chassis with removable fasteners. Either manual or electronic controls may be inserted into the plurality of openings on the front portion of the chassis and communicate via wired communication or even wirelessly with the plurality of controls in the control housing. 
         [0010]    in order to protect the controls within the control housing from liquid such as water spills, a first sealant may be included on each of the openings on the front portion of the chassis. The first sealant may include o-rings, rings, or flexible boots made from any material such as rubber or poly vinyl chloride. The first sealant forms a liquid-tight seal between the plurality of manual controls and the front portion of the chassis for preventing liquid from entering the control housing through the plurality of openings. 
         [0011]    A second sealant may also be included between the control housing and the parts of the chassis in contact with the control housing such as the front portion and sides. The second sealant may include a gasket material such as santoprene, silicone, paper, poly vinyl chloride, adhesive bonding tape, or any other gasket, and forms a liquid-tight seal on any seam created during manufacturing of the control housing and between the control housing and the chassis. Preferably, when adhesive bonding tape is used, very high bond “VHB” tape may be used such as VHB double-sided foam tape produced by 3M. An added benefit to VHB tape is it that it works as both a sealant and for securing parts together. 
         [0012]    The first sealant may include at least one control knob shaped to interlock with a ring in an opening on the front portion of the chassis. The ring mates with both the opening and the knob to form a liquid-tight seal, preventing liquid from entering the opening. The ring may be made of any material but is preferably a rubber or poly vinyl chloride material. The knob and the ring preferably move relative to one another with the ring statically fixed on the front portion of the appliance. Alternatively, the ring may be attached to the knob and moves with the knob as it is turned. 
         [0013]    Inside the control housing, the plurality of controls is stored and controls all the functions of the appliance. The controls inside the control housing may include electronic circuit boards, wiring, or any other electronic devices. Additionally, the controls may include at least one indicator light and the first sealant may also include an o-ring, or gasket, secured on the indicator light. In order to properly locate and supply sufficient force to hold the o-ring in place, a clip may be provided that attaches to the indicator light and presses the o-ring against the front portion of the chassis or the control housing, preventing liquid from entering the respective opening. 
         [0014]    The plurality of manual controls may also include a switch with a flexible boot between the switch and the front portion of the chassis forming a liquid-tight seal and preventing water from entering the respective opening. 
         [0015]    In the event that any liquid should enter the any openings on the front portion of the chassis, the second sealant may also include an adhesive bonding tape, sealant strips, gasket strips, or gasket forms that attach to the front portion of the chassis at an inclined angle to deflect liquids away from the control housing. 
         [0016]    When manufacturing the control housing, a box-like shape may be preferential. When making the edges of the box, seams may be used that include openings into the interior of the box. Flaps or flanges made with right angles may be used to cover the respective seams and prevent liquid from entering the control housing. Additionally, the first or second sealant may he used to further prevent water from entering the control housing at the seams. 
         [0017]    After the appliance is constructed, or ever partially constructed, the effectiveness of the first and second sealants, and any other liquid-proofing elements, may be tested. The testing may include pouring a significant amount of liquid, for example, at least 500 milliliters of a tap water or a water spray, on the control housing and determining the effectiveness of preventing the tap water from entering the control housing with the use of the first and second sealant and also the right angle flanges. 
         [0018]    These and other aspects and objects of the present invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    A clear conception of the advantages and features constituting the present invention and of the construction and operation of typical mechanisms provided with the present invention will become more readily apparent by referring to the exemplary, and therefore non-limiting, embodiments illustrated in the drawings accompanying and forming a part of this specification, wherein like reference numerals designate the same elements in the several views, and in which: 
           [0020]      FIG. 1  illustrates a partially exploded perspective view of a spill-resistant appliance according to one embodiment of the present invention; 
           [0021]      FIG. 2  illustrates an exploded view of the spill-resistant appliance according to  FIG. 1 ; 
           [0022]      FIG. 3  illustrates a perspective side view of the spill-resistant appliance according to  FIG. 1 ; 
           [0023]      FIG. 4  illustrates a partial side view of the spill-resistant appliance according to  FIG. 1 ; 
           [0024]      FIG. 5  illustrates a partial front view of the spill-resistant appliance according to  FIG. 1 ; 
           [0025]      FIG. 6  illustrates a partial perspective view of the spill-resistant appliance according to  FIG. 1 ; 
           [0026]      FIG. 7  illustrates a partial perspective view of the spill-resistant appliance according to  FIG. 1 ; 
           [0027]      FIG. 8  illustrates a partial perspective view of the spill-resistant appliance according to  FIG. 1 ; 
           [0028]      FIG. 9  illustrates a partial cross-sectional view of knob inserted in a front portion of the spill-resistant appliance according to  FIG. 1 ; 
           [0029]      FIG. 10  illustrates a partial front view of the spill-resistant appliance according to  FIG. 1 ; 
           [0030]      FIG. 11  illustrates a partial perspective view of the spill-resistant appliance according to  FIG. 1 ; 
           [0031]      FIG. 12  illustrates a side view of an indicator light inserted in a simulated front portion of a partial front view of the spill-resistant appliance, partially assembled, according to  FIG. 1 ; and 
           [0032]      FIG. 13  illustrates a partial cross-sectional view of a switch inserted in a front portion of the spill-resistant appliance according to  FIG. 1 . 
       
    
    
       [0033]    In describing the preferred embodiment of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the words “connected”, “attached”, or terms similar thereto are often used. They are not limited to direct connection but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art. 
       DETAILED DESCRIPTION OF EMBODIMENTS 
       [0034]    The present invention and the various features and advantageous details thereof are explained more fully with reference to the nonlimiting embodiments described in detail in the following description. 
         [0035]    Beginning with  FIG. 1 , an appliance  22  is shown in a partially exploded, perspective view. The appliance  22  includes a chassis  24  and a drawer  36 . The drawer  36  may be inserted into the chassis  24  and extended from the chassis  24  by gliding along a pair of rails  34 . The chassis  24  is preferably formed in the shape of a box  25  with sides  28  and a front portion  26 . A cavity  30  forms the interior of the box  25  and receives the drawer  36 . A gasket  37  may be used to seal the cavity  30  when the drawer  36  is in the retracted position and inside the cavity. 
         [0036]    In order to control the function of the appliance  22 , a plurality of manual controls is included on the front portion  26  of the chassis  24 . The manual controls may include a touch screen LCD, pushbuttons, capacitive touch buttons, or any other manual input devices. The manual controls may also include electronic controls. Preferably, the controls include a knob  40 , a switch  48 , and an indicator light  46 . The knob  40  is preferably configured to allow rotary adjustment to modify the operation of the appliance  22 . The switch  48  is preferably a rocker switch for turning the appliance  22  on and off. The indicator light  46  may indicate whether the appliance  22  is on or off or may signal malfunctions as well. 
         [0037]    Various electronic components that communicate with the knob  40 , switch  48 , and indicator light  46  may be included in a control housing  72  that is attached to the chassis  24  along one of the sides  28  and the front portion  26  of the box  25 . A power cord  68  may also extend from the interior of the control housing  22  to the exterior of the control housing  22 . 
         [0038]    In order to prevent liquid spills that may occur in the vicinity of the appliance  22  from damaging the controls, various sealants may be used to protect the contents inside the control housing  72 . For example, a first sealant  56  may be included along the joint where the control housing  72  meets the box  25 . The first sealant  56  may be any type of sealant that may be formed into a gasket-like material. Gasket-like materials include paper, cork, silicone, fibrous material, neoprene, but, preferably, santoprene is used. The first sealant  56  may be cut into various shapes to form premade gaskets that are attached at various points of the chassis  24 . Any potential spots where liquid may enter the control housing may be sealed with the first sealant  56  to form a watertight. leak-proof joint  57 . The first sealant  56  is particularly advantageous to seal the joints where two objects are joined together. The joint  57  between the control housing  22  and the box  25 , for example, benefit from the use of the first sealant along the joint  57  and helps keep liquids out of the control housing  72 . 
         [0039]    Now turning to  FIG. 2 , a fully exploded view of the chassis  24  is shown. The box  25  is shown separated from the front portion  26 ; however, a second front portion  27  is still attached to the box  25  and can be seen extending from a side  28  of the box  25 . The second front portion  27  is attached to the front portion  26  with the use of the second sealant  60  placed at various intervals along the second front portion  27 . Preferably, strips of the second sealant  60  are placed at an angle oriented with a downward slope such that the portion of the second sealant  60  closer to the cavity  30  of the box  25  is in a higher position than the portion of the second sealant  60  on the opposing side of the cavity  30 . Positioning the second sealant  60  with slope helps funnel any liquid that might fall between the front portion  26  and the second front portion  27  away from the box  25  and also away from the control housing  72 . Preferably, the second sealant  60  is a foam adhesive tape with adhesive on both sides of the tape. One particular example of such a tape is very high bond, “VIM” tape commonly made by 3M. The second sealant  60  may be trimmed either manually with scissors or automatically with a press to form the desired shapes necessary for the application. The second sealant  60  helps prevent liquid penetration into the control housing  72  and may be used in any location where liquid may enter the control housing  72  or any other area where liquid is undesirable. The second sealant  60  also functions as an adhesive to hold together various components. The first sealant  56  is also shown above the box  25  and is in position for ceiling the seam of joint  57  between the control housing  72  and the box  25 , as described in reference to  FIG. 1 . The first sealant  56  may also be used in any location where liquid may enter the control housing  72  or any other area where liquid is undesirable. 
         [0040]    The control housing  72  is also shown separated from the side  28  of the box  25 . Multiple fasteners  64  are shown that are used to attach the control housing  72  to the box  25  and also to the second front portion  27 . Various components such as electronics  76  and sensor  78  are protected inside the control housing  72 . Insulation  74  may also be used to shield the components inside the control housing  72  from heat that is generated inside the cavity  30  when the appliance  22  is in operation. Additional items such as wiring  70  may also be included inside the control housing  72 . A power cord  68  supplies power to the various components inside the control housing  72  and is passed through a hole  77  on the control housing  72 . A grommet  80  on the power cord  68  seals the hole  77  and prevents any liquid from entering the control housing  72  through the hole  77 . 
         [0041]    The knob  40 , switch  48 , and indicator light  46  are shown separated from the front portion  26  exposing their respective openings  32 . In order to seal the opening  32  of the knob  40 , a ring  42  is inserted into the opening  32  of the knob  40 . While the ring  42  may be made out of any material, preferably a deformable material such as polyvinyl chloride is used to seal the opening  32 . The knob  40  is shaped to surround the ring and act as a double barrier against liquid entering the respective opening  32 . In order to seal the opening  32  of the indicator light  46  an O-ring  44  is inserted around the indicator light  46  on the part of the indicator light  46  that is passed through the front portion  26 . A clip  45  is also inserted on the part of the indicator light  46  passed through the front portion  26  after the O-ring  44  is attached and helps press the O-ring  44  up against the front portion  26  and seal the respective opening  32  from liquid entry. To seal the opening  32  of the switch  48 , a boot  50  (shown in  FIG. 14 ) is used to surround the switch  48 . Alternatively, the switch  48  may be waterproof without the use of boot  50 . 
         [0042]      FIG. 3  shows the appliance  22  with the drawer  36  in the extended position. The control housing  72  is also shown attached to the box  25  of the chassis  24 . As explained above, the first sealant  56  is placed along the joint  57  between the control housing  72  and the box  25 . The first sealant  56  is also used in the joints  57  between the control housing  72  and the front portion  26 . The power cord  68  is also shown extending from the control housing  72  and the grommet  66  can be seen preventing liquid from entering the hole  77 . While the first sealant  56  is shown in the various joints  57 , the second sealant  60  may also be used in any of these locations in addition to the first sealant  56 , or as a replacement of the first sealant  56 . 
         [0043]    Moving on to  FIG. 4 , the box  25  of the chassis  24  is shown with the control housing  72  removed. The front portion  26  is shown attached to the second front portion  27  with the second sealant  60  between them. The first sealant  56  is also shown applied to the side of the second front portion  27 . The wiring  70 , electronics  76 , and the indicator light  46  are all shown extending from the front portion  26  and the second front portion  27 . Insulation  74  may be seen against the box  25  to help insulate against heat generated when the appliance  22  is in operation. The control housing  72  covers all these elements with the use of the first sealant  56  and the second sealant  60  preventing liquids from contacting these devices. 
         [0044]    Transitioning to  FIG. 5 , the second front portion  27  is shown attached to the box  25  of the chassis  24 . As described with reference to  FIG. 2 , the second sealant  60  may be placed in various positions along the second front portion  27 . The second sealant  60  works to help secure the second front portion  27  to the front portion  26  and to prevent liquid from entering the control housing  72  (not shown). The second sealant  60  may be placed on the second front portion  27  with a downwardly angle to deflects any liquid that may run along the face of the second front portion  27  away from the chassis  24 . 
         [0045]      FIG. 6  shows the rear side of the second front portion  27  while it is attached to the front portion  26 . A strip of the second sealant  60  may be placed on the front portion  26  above the second from portion  27  to help prevent liquids from flowing between the front portion  26  and the second front portion  27 . A strip of first sealant  56  is also shown along the top of the box  25  to prevent liquid from entering the control housing  72  once it is in place. 
         [0046]    The control housing  72  is shown in  FIG. 7  detached from the box  25 . A flange  54  forms a right angle along an edge of the control housing  72  and provides a wider area for sealing the control housing  22  against the front portion  26  (not shown).  FIG. 8  also shows the control housing  72  with an open seam  52 . Preferably, the seam  52  is closed with a flange  54  forming a right angle around the seam  52  and sealing the seam  52 , thus preventing the entry of liquids. Any other means of sealing the seam  52  may also be used including, but not limited to, welding, adhesives, or forming a similar seam in another fashion. As long as the seam  52  is water tight, any sealing means may be used. 
         [0047]      FIG. 9  shows a cross-sectional view of the knob  40  inserted in an opening  32  of the front portion  26  and the second front portion  27 . The ring  42  is shown sealing the opening  32  and preventing liquids from entering. The shape of the knob  40  includes a lip  41  that surrounds the ring  42  and offers added protection against the entry of liquids. Alternatively, the knob  40  may be attached to the ring  42  with either an adhesive or integrally molded as one piece, allowing the knob  40  and ring  42  to move in unison as the knob  40  is adjusted. 
         [0048]    Similarly,  FIG. 10  shows the ring  42  inserted in the opening  32  for the knob  40  (removed in this view). As previously disclosed, the ring  42  is formed out of any material commonly used for forming grommets such as rubber or polyvinyl chloride.  FIG. 11  shows the knob  40  inserted into the opening  32  and surrounding the ring  42  with a lip  41 . 
         [0049]    Transitioning now to  FIG. 12 , the indicator light  46  is shown inserted into a simulated opening  32  in a front portion  26 . The O-ring  44  is shown around a portion of the body of the indicator light  46  that is passed through the front portion  26 . An additional O-ring  44  may also be included on the opposite side of the front portion  26  for added protection from liquids. A clip  45  is positioned on the indicator light  46  and may be pushed up against the front portion  26  to move the O-ring  44  against the front portion  26  and retain pressure against the O-ring  44 . This effectively seals the opening  32  that the indicator light  46  is inserted into against any liquid entry. 
         [0050]      FIG. 13  shows a cross-sectional view of the switch  48  while it is inserted through an opening  32  in the front portion  26  and the second front portion  27 . A boot  50  attaches under a lip  49  of the switch to deflect any liquids away from the opening  32  on the front portion  26 . As described above, the boot  50  is formed out of any deformable serial such as rubber or polyvinyl chloride. The boot  50  is flexible and deformable to allow a user to operate the switch  48  while encapsulating the switch  48  from any liquids. 
         [0051]    The individual components called out herein need not be fabricated from the disclosed materials, but could be fabricated from virtually any suitable materials. Moreover, the individual components need not be formed in the disclosed shapes, or assembled in the disclosed configuration, but could be provided in virtually any shape, and assembled in virtually any configuration. Further, although the components described herein are often described as physically separate modules, it will be manifest that they may be integrated into the apparatus with which it is associated. Finally, all the disclosed features of each disclosed embodiment can be combined with, or substituted for, the disclosed features of every other disclosed embodiment except where such features are mutually exclusive. 
         [0052]    As can be seen, it is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but includes modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.