Abstract:
A washer door or lid as defined by a tempered glass panel bordered by an open frame-like encapsulation of one-piece injection molded polymeric/copolymeric synthetic plastic material. The latter material is preferably acrylonitrile/styrene/acrylate polymer blended with mica glass beads at a ratio of substantially 70%-30% to 90%-10% by weight, but preferably 80%-20% by weight. Further specifics of the washer lid include a relatively thick inner periphery of the encapsulation which securely grips and reinforces an outer peripheral edge of the tempered glass panel, a rigid outer peripheral skirt, an indiscrete handle, a reinforced hand corder for a switch actuator and opposite rear corners carrying hinges for securing the washer lid to an associated washer opening.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a divisional of application of U.S. patent application Ser. No. 10/671,660 filed on Sep. 29, 2003 and now U.S. Pat. No. 7,032,350 B2; which is a divisional of U.S. patent application Ser. No. 09/878,947 filed on Jun. 13, 2001 and now U.S. Pat. No. 6,665,984. 

   BACKGROUND OF THE INVENTION 
   The invention is directed to a door or lid which is normally hinged to a washer opening to define a top-loading or a front-loading washer. Conventionally such doors or lids have been made of metal with or without a glass panel through which the interior of the washer can be viewed. 
   DESCRIPTION OF THE RELATED ART 
   U.S. Pat. No. 4,695,420 granted on Sep. 22, 1987 and assigned to Caterpillar, Inc. makes reference to the desirability of injection molding plastic articles having a variety of complex shapes and sizes including panels and doors of vehicles or equipment enclosures, such as cab doors. Such cab doors were originally manufactured by utilizing a flat rigid frame fabricated from metal to which is unitized a window in what is termed a costly and time-consuming operation. The window or glazing is floated in a soft gasket channel isolated from the frame to reduce shock-loads and thermal stresses induced by varying coefficients of thermal expansion between the metal frame and the glazing/glass panel. It is believed that the process just described is workable because the window panes in all cases are sheets of transparent plastic material, such as polycarbonate and acrylic with the preferred material being a polycarbonate having a silicone hard coat applied thereto to make the polycarbonate glazing or window pane more scratch-resistant. The silicone hard coat on the peripheral edge is removed by sanding or grinding to assure good bonding between the eventually molded frame and the polycarbonate glazing. 
   With the advent of excellent molding qualities of modem plastic materials, an effort was made to form a door by first manufacturing a pre-shaped pane of transparent glass and subsequently integrally molding the latter into a door frame as the window thereof. Following this process, the window pane was distorted and wavy and the door frame had a tendency to warp. However, by utilizing a high modulus plastic material, such as polyurethane and a shrink-reducing filler material, undesired high temperature rise from exothermic reaction was moderated, particularly when a catalyst was added in sufficient amounts to control the weight of the reaction and the heat evolution. Also, by heating the glass and forming the frame by reaction injection molding, both the frame and the glass window pane thermally contract similarly absent window pane buckle and with bonding of the edges of the glass window pane to the frame. 
   Glass and specifically tempered glass have heretofore never been provided with an injection molded polymeric/copolymeric frame to form a door or lid, and particularly a washer lid. However, injection-molding polymeric/copolymeric material as an encapsulation or border to form a shelf is well known, as is evidenced by U.S. Pat. No. 5,273,354 granted on Dec. 28, 1993; U.S. Pat. No. 5,362,145 granted on Nov. 8, 1994; U.S. Pat. No. 5,403,084 granted on Apr. 4, 1995; U.S. Pat. No. 5,429,433 granted on Jul. 4, 1995; U.S. Pat. No. 5,441,338 granted on Aug. 15, 1995; U.S. Pat. No. 5,454,638 granted on Oct. 3, 1995; U.S. Pat. No. 5,540,493 granted on Jul. 30, 1996 and U.S. Pat. No. 5,735,589 granted on Apr. 7, 1998. 
   Other patents dealing with glass to which material is injection molded normally include windshields to which a gasket is molded and/or cured in situ so as to encapsulate a marginal peripheral edge of the windshield. Typical of such window assemblies and methods of forming the same are found in such patents as U.S. Pat. No. 4,778,366 granted on Oct. 18, 1998; U.S. Pat. No. 4,688,752 granted on Aug. 25, 1987 and U.S. Pat. No. 4,732,553 granted on Mar. 22, 1988. 
   Other patents which were located during the search of the instant invention include U.S. Pat. No. 4,543,283 granted on Sep. 22, 1987; U.S. Pat. No. 3,843,982 granted on Oct. 29, 1974; U.S. Pat. No. 6,146,574, granted on Nov. 14, 2000 and U.S. Pat. No. 4,336,301 granted on Jun. 22, 1982. 
   SUMMARY OF THE INVENTION 
   The present invention is specifically directed to a door or lid for a washer, but contrary to the door of U.S. Pat. No. 4,695,420, the transparent panel is constructed from tempered glass and an open frame-like encapsulation is preferably a polymeric/copolymeric synthetic plastic material in the form of acrylonitrile/styrene/acrylate polymer blended with mica glass beads at a ratio of substantially 70%-30% to 90%-10% by weight, but preferably 80%-20% by weight. The latter specifics of the blended material which is injection molded to form the open frame-like encapsulation achieves a much lower shrink ratio and elasticity, as compared to polypropylene which is normally used in the injection molding of a tempered glass substrate to form a shelf (not a door). Since tempered glass or a similar glass substrate has virtually a zero coefficient of expansion, the same obviously will not expand or contract in relationship to the expansion or contraction of conventional polymeric/copolymeric material, such as polypropylene. Consequently, typical “weld lines” created in the injection molded open frame-like encapsulation or border tend to fracture, particularly as such parts experience temperatures varying between −30° F. to +104° F. However, through the utilization of the specific blended materials latter defined at the ratios stated, such fracture has been essentially eliminated and the washer door or lid of the present invention achieves unexpected longevity, absent deterioration, and aesthetic characteristics at competitive prices, particularly at higher price-ranged washers. 
   The aesthetics of the washer lid are also enhanced by designing the exterior of the frame-like encapsulation which is exposed to the consumer as a relatively smooth, unbroken surface except as might otherwise be desired by a washer manufacturer who might specify a recess in the outer surface for reception of a decal, label or the like carrying trademark or other information. The interior of the washer lid which is less susceptible to scrutiny because of it being opened essentially only when the washer is being loaded or unloaded is engineered to include structural characteristics necessary for optimum functionality of the washer lid including, for example, an internally stepped relatively thick inner periphery of the frame-like encapsulation which securely grips and reinforces the peripheral edge of the tempered glass panel, an outboard depending peripheral skirt achieving exterior peripheral rigidity of the frame-like encapsulation, an indiscrete handle portion along an underside of a front wall of the encapsulation which is essentially unobservable when the washer lid is closed, a reinforced corner for a switch actuator, and opposite rear comers rigidly supporting hinges which are utilized to hinge the washer lid to an associated washer opening for movement between open and closed positions thereof. 
   With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a fragmentary top perspective view, and illustrates a washer with a washer lid or door of the present invention hinged thereto in its closed position. 
       FIG. 2  is a fragmentary perspective view of the washer of  FIG. 1 , and illustrates the washer lid in its open position. 
       FIG. 3  is a bottom plan view of the washer lid or door, and illustrates a tempered glass panel bonded by an open frame-like encapsulation formed of one-piece injection molded polymeric/copolymeric plastic material. 
       FIG. 4  is a fragmentary cross sectional view through a corner portion of two identical rear comers of the washer lid, and illustrates a generally L-shaped hinge defined by a mounting portion and a pintle portion with the former being fastened to a depending peripheral skirt of the frame-like encapsulation and the pintle portion passing through a slot of the depending peripheral skirt. 
       FIG. 5  is an exterior fragmentary side elevational view of the hinge of  FIG. 4 , and illustrates the details thereof. 
       FIG. 6  is an interior fragmentary side elevational view of the hinge of  FIG. 4 . 
       FIG. 7  is a fragmentary bottom plan view of a forward corner of the frame-like encapsulation, and illustrates a switch actuator seated upon reinforcing ribs projecting from a top panel of the frame-like encapsulation and being secured to the peripheral skirt by fasteners. 
       FIG. 8  is an outside fragmentary side elevational view of the forward corner illustrated in  FIG. 7 , and illustrates details of the switch actuator. 
       FIG. 9  is a fragmentary cross sectional view of the peripheral skirt of the corner of  FIG. 7 , and illustrates further details of the switch actuator. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   A washer  10  is illustrated in  FIGS. 1 and 2  of the drawings and includes a conventional washer body  11  having an interior tub or chamber  12  including an upper frame  13  to which is hinged a novel washer lid or door  20  of the present invention. The upper frame  13  defines an upstanding inner peripheral wall  14  ( FIGS. 2 and 4 ) at opposite rear comers (unnumbered) which the upper frame  13  is provided with openings  15  ( FIG. 4 ) for hinging the washer lid  20  thereto in a manner to be described more fully hereinafter. 
   A conventional agitator (not shown) is mounted in the tub or chamber  12  and reciprocates arcuately in a conventional fashion. A conventional safety switch or “ON”/“OFF” switch  18  ( FIG. 2 ) is carried by and beneath an apertured horizontal frame portion  16  of the upper frame  13  of the washer  10 , and is switched “on” and “off” by the washer lid  20  in a manner to be described more fully hereinafter. 
   The washer lid or door  20  includes a tempered glass panel  21  of a predetermined peripheral configuration defined by a substantially continuous peripheral edge  22 . The glass panel  21  further includes opposite inner and outer surfaces  23 ,  24 , respectively, bridged by the peripheral edge  22 . A peripheral portion  25  of the glass panel  21  is defined by the peripheral edge  22  and immediately adjacent surface portions of the opposite inner and outer surfaces  23 ,  24 , respectively. 
   An open frame-like encapsulation or border  30  is formed as a one-piece of injection molded polymeric/copolymeric synthetic plastic material. The polymeric/copolymeric synthetic plastic material is preferably acrylonitrile-styrene-acrylate polymer blended with mica glass beads at a ratio of substantially 70%-90% of the polymer and substantially 30%-10% of the mica glass beads, respectively, by weight. The preferable range by weight of the blend is substantially 80% of the polymer to substantially 20% of the mica glass beads. The latter ranges of the polymer and the mica glass beads achieve an extremely low shrink ratio and elasticity, as compared to polypropylene. As the injection molded blended polymer of the open frame-like encapsulation  30  cools, its virtually minimal shrink ratio parallels the almost zero coefficient of expansion of the tempered glass panel  21 . Consequently, weld lines of the injection molded frame-like encapsulation  30  will not fracture, particularly when subject to temperature anywhere between −30° F. to 140° F. 
   The open frame-like encapsulation  30  includes an outer peripheral portion  31  and an inner peripheral portion  32  with the inner peripheral portion  32  entirely encapsulating the glass panel outer peripheral portion  25  including the peripheral edge  22  and immediately adjacent surface portions of the opposite inner and outer surfaces  23 ,  24 , respectively. The frame-like encapsulation  30  further includes an inner or lower surface  34  and an outer or upper surface  35  defining therebetween the overall inner and outer surface configurations of the frame-like encapsulation  30  and the wall thickness thereof. The frame-like encapsulation inner surface  35  is stepped ( FIG. 2 ) at the frame-like inner peripheral portion  32  and defines thereat a relatively thicker wall thickness than the wall thickness at the outer peripheral portion  31 . However, the outer surface  34  has a configuration which is substantially continuous and unstepped which presents an aesthetic appearance to the washer lid  20  when in the closed position ( FIG. 1 ), and all remaining injection-molded characteristics are formed along the inner surface  35  and are hidden from view ( FIG. 1 ) except, of course, when the washer lid  20  is opened ( FIG. 2 ). 
   The outer peripheral portion  31  of the washer lid  20  is defined as continuously downward depending peripheral wall or skirt which is smooth and unbroken except along a front edge (unnumbered) of the frame-like encapsulation  30 . At the front edge ( FIGS. 1-3 ) of the frame-like encapsulation  30  a curved wall portion  38  ( FIGS. 2 and 3 ) of the depending skirt  31  is recessed inwardly and opens concavely outwardly to define a handgrip recess  40  in association with an overlying ledge or lip  39  of the frame-like encapsulation  30 . In order to open the washer lid  20 , a person merely inserts one or more fingers within the handgrip area  40  ( FIG. 1 ) and lifts upwardly against the ledge  39  to pivot the washer lid  20  from the position shown in  FIG. 1  to the position shown in  FIG. 2 . 
   The frame-like encapsulation  30  also includes substantially identical corner portions  50 ,  50  ( FIGS. 1 and 4 ) defined by the peripheral skirt  31  with a radius (unnumbered) of each corner portion  50  including an elongated curved slot or opening  52  ( FIGS. 4 and 5 ). Two bosses  53 ,  54  project inwardly of the peripheral skirt  31  and each includes a respective bore  55 ,  56 . Hinge means in the form of a hinge pin  60  is associated with each corner portion  50  and is of a generally L-shaped configuration defined by a pintle portion  61  connected by a radius portion  62  to a mounting portion  63  which includes respective flattened recessed portions  64 ,  65  seated upon and receiving therein the bosses  53 ,  54 , respectively. Threaded fasteners  64 ′,  65 ′ are fed through bores (unnumbered) of the bosses  53 ,  54  and are threaded into threaded openings (unnumbered) of the flattened portions  64 ,  65 , respectively, of the mounting portion  63  of each hinge  60  thereby rigidly attaching each of the hinges  60  to the peripheral skirt  31  adjacent an associated one of the rear corner portions  50 . The pintle portions  61  of the hinge pins  60  lie in coaxial relationship to each other and project in opposite directions. Each pintle portion  61  is fitted in one of the openings  15  ( FIG. 4 ) of the inner peripheral wall  14  of the upper frame  13  of the washer body  11  to thereby permit pivoting movement of the washer lid  20  between the positions shown in  FIGS. 1 and 2  of the drawings. 
   At the corner portion  50  adjacent the hand recess  40  ( FIGS. 3 ,  7 ,  8  and  9 ), a one-piece molded switch-actuator mechanism  69  defined by a mounting block  70  having a switch actuator leg  71  rests upon four substantially parallel relatively spaced reinforcing ribs  72  which project downwardly from the inner surface  34  of the frame-like encapsulation  30 . The peripheral skirt  31  in the area of the ribs  72  includes two bores  74  through which pass fasteners  75  which are threaded into the mounting block  70  to rigidly secure the same in the manner illustrated in  FIGS. 7 through 9  of the drawings. The leg  71  of the switch-actuating mechanism  69  is aligned with the safety “ON”/“OFF” switch  18  to close the latter when the washer lid  20  is closed ( FIG. 1 ) and open the latter when the washer lid  20  is open ( FIG. 2 ) to respectively start and stop the washer agitator (not shown) in a conventional manner. 
   A substantially inwardly directed flange  85  is located at each of the front corners  50 ,  50  of the washer lid  20  in spaced relationship to the inner surface  34  ( FIGS. 3 ,  7  and  9 ). The flange  85  illustrated at the upper left hand corner  50  of  FIG. 3  includes an opening  86  carrying a rubber or similar flexible stop (not shown) which contacts and rests upon the horizontal frame portion  16  of the upper frame  13  of the washer body  11  when the washer lid  20  is in the closed position thereof ( FIG. 1 ). The leg  71  of the switch-actuating mechanism  69  passes through and is radially supported by the opening  86  of the flange  85  ( FIGS. 7 and 9 ). 
   As is most readily apparent from  FIG. 1  of the drawings, the washer lid  20  presents an extremely aesthetic appearance to the overall washer  10  due to the relatively smooth and unbroken upper/outer surface  35  of the encapsulation  30 . Even in the open position ( FIG. 2 ) of the washer lid  20 , the interior of the washer lid  20  is relatively aesthetic in appearance since the hinges  60 ,  60  are unobtrusive, as is the design and location of the switch block  69  which is partially hidden by the flange  85  ( FIG. 7 ). However, most important is the fact that, even though the panel  21  is constructed from glass, the specific blend of the polymer and the mica glass beads from which the frame-like encapsulation  30  is injection molded achieves an intimate bond between the components, absent fracture or weakening of the encapsulation  30  due to the similarities between the low shrink ratios and elasticities of these materials. Since the tempered glass panel  21  has almost a zero coefficient of expansion, there will obviously not be any material of the expansion or contraction of the same relative to the injected polymeric/copolymeric material of the encapsulation  30  at temperatures ranging between −30° F. to −140° F., temperatures which heretofore would cause injection molded polypropylene to fracture. Hence, a strong, durable and aesthetic acceptable washer lid  20  is achieved by the present invention, though usage is as other than a washer lid is well within the breadth of the present disclosure. 
   Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus without departing from the spirit and scope of the invention, as defined by the appended claims.