Abstract:
A mullion is attached to a cabinet shell of a refrigerator through the use of a retainer that includes a laterally extending portion positioned between primary and secondary flanges of the cabinet shell, and a longitudinally extending portion that is interengaged with additional flange structure defined by the mullion. Clips formed on the retainer engage wall portions formed by the mullion flange structure to secure the retainer to the mullion. A tab formed on the retainer engages a keyhole formed in the secondary flange of the cabinet shell, thereby aiding in securing the retainer to the cabinet and preventing the mullion from undesirably shifting in either a horizontal or vertical manner.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention generally relates to a refrigerated cabinet and, more specifically, to the mounting of a mullion extending along a partition between two compartments of a refrigerator cabinet. 
   2. Discussion of the Prior Art 
   A conventional refrigerator cabinet is defined by insulated freezer and fresh food compartments which are disposed in either a side-by-side or a vertically spaced configuration. Generally, integrally molded fresh food and freezer liners are used for defining interior storage compartments of the cabinet. More specifically, the conventional refrigerator cabinet is typically defined by an outer shell that is formed from sheet metal to which is attached, at a front face portion thereof, a mullion that partitions the shell into two section. Each of the fresh food and freezer liners are inserted into a respective cabinet section before being mated with return flange portions of both the cabinet shell and the mullion.  FIG. 1  illustrates, in a cross-sectional view, a typical prior art side-by-side refrigerator cabinet front flange design and the manner in which a mullion is typically attached thereto. As shown in  FIG. 1 , the side-by-side refrigerator cabinet includes an outer metal shell  3 ′ having a top panel portion that is bent, typically through a roll-forming process, so as to define a front face primary flange  47 ′. The cabinet shell  3 ′ returns sharply back behind the primary flange  47 ′ and is again roll-formed to create secondary flange  61 ′ that is spaced from the primary flange  47 ′ by a cavity. 
   A mullion  11 ′ is provided at an upper end portion thereof with a slight bend so that it may abut against the primary flange  47 ′, while the terminal end extends within the cavity defined between the primary and secondary flanges  47 ′ and  61 ′. As clearly shown in  FIG. 1 , the primary flange  47 ′ supports the mullion  11 ′ in one direction, i.e., it limits movement of the mullion  11 ′ in a direction away from the secondary flange  61 ′. A yoder tube (not shown) is often positioned between the upper terminal end of the mullion  11 ′ and the secondary flange  61 ′ in order to prevent the mullion  11 ′ from moving in a direction away from the primary flange  47 ′. Of course, as is known in the art, the yoder tube is designed to run along the mullion  11 ′ and provides an inexpensive and efficient heat transfer arrangement whereby the heat of condensation of the hot refrigeration gases is used to prevent condensation of moisture adjacent the front door openings of the freezer and fresh food compartments. 
   There are several problems associated with this prior art configuration. For instance, unless additional attachment steps are taken, the only member preventing the mullion  11 ′ from moving away from the primary flange  47 ′ is the arrangement of the yoder tube between the mullion  11 ′ and the secondary flange  61 ′. Often the yoder tube cannot sufficiently retain the mullion  11 ′ in the desired position and the mullion  11 ′ moves away from the primary flange  47 ′ such that a non-flush assembly is created between the parts. In addition, unless extreme tolerances are maintained, there is nothing to stop the mullion  11 ′ from sliding downward along the primary flange  47 ′ to create a gap between the terminal edge of the primary flange  47 ′ and the bent portion of the mullion  11 ′. There is also nothing that prevents the mullion  11 ′ from shifting sideways within the gap between primary flange  47 ′ and secondary flange  61 ′, at least until liners are inserted into cabinet shell  3 ′. Not only is such a poorly fitted part unsightly, but it can create problems when the refrigerator cabinet is insulated in the wall spaces between the liners and the outer shell  3 ′. More specifically, once the mullion  11 ′, yoder tube and cabinet liners are in place, foamed insulation is injected between the cabinet shell  3 ′ and the liners and the insulation will tend to leak during the foaming process if there is any vertical gap between the cabinet shell  3 ′ and mullion  11 ′, the mullion  11 ′ shifts sideways or the mullion  11 ′ shifts in the direction of secondary flange  61 ′. 
   Based on the above, there exists a need in the art for an improved arrangement for attaching a mullion to the return flange portion of a refrigerator cabinet shell. More specifically, there exists a need for an retainer arrangement which will securely hold the mullion in place, while providing for a flush connection between the cabinet shell and the mullion, in order to prevent horizontal or vertical shifting of the mullion and reduce or eliminate foam leakage during the cabinet foaming process. 
   SUMMARY OF THE INVENTION 
   The present invention is directed an improved mullion retainer for interconnecting the outer shell of a refrigerator cabinet and a refrigerator mullion. The refrigerator includes at least one liner positioned within the cabinet shell in order to define laterally spaced fresh food and freezer compartments separated by a fore-to-aft extending divider wall, with a mullion provided at the front of the divider wall. The outer cabinet shell includes a return flange configuration defining a front facing primary flange and a secondary flange, with the primary and secondary flanges being separated by a cavity or gap. 
   The mullion retainer of the present invention is formed with two longitudinally extending legs that mate with return flange portions of the mullion. The retainer further includes a laterally extending portion adapted to be received in the cavity between the primary and secondary flanges of the cabinet shell, and a tab that cooperates with a keyhole notch in the secondary flange. The tab helps secure the retainer to the cabinet shell, and prevents both horizontal and vertical movement of the mullion with respect to the cabinet. 
   Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of a preferred embodiment when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a partial, cross-sectional view of a mullion to cabinet shell connection utilized in a prior art refrigerator design; 
       FIG. 2  is a front plan view of a side-by-side refrigerator, shown with upper portions of the doors of the fresh food and freezer compartments being cut-away to reveal the mullion and mullion retainer of the present invention; 
       FIG. 3  is a partial, rear exploded view of the cabinet shell return flange, mullion and mullion retainer of the side-by-side refrigerator of  FIG. 2 ; 
       FIG. 4  is a cross-section side view of the mullion retainer of  FIG. 3 ; 
       FIG. 5  is a rear perspective view of the assembled mullion retaining arrangement of  FIG. 3 ; and 
       FIG. 6  is a cross-sectional side view of the assembled mullion retaining arrangement of  FIG. 5 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   With initial reference to  FIG. 2 , a preferred embodiment of the mullion retainer arrangement of the present invention is shown for use in a side-by-side refrigerator cabinet  1 . In a manner known in the art, cabinet  1  has an outer shell  3  that includes a top panel  7 , a pair of opposed side panels  8  and  9  and a rear panel (not shown). A vertically extending partition in the form of a mullion  11  is provided adjacent the front of cabinet  1  and aids in dividing the interior of cabinet  1  into a freezer compartment  13  and a fresh food compartment  15 . As shown, freezer compartment  13  is provided with a door  17  that is hinged at the outer edge of cabinet  1  for swinging movement about a vertical pivot axis and fresh food compartment  15  is likewise provided with a similar door  19  that is also hinged along an opposed edge of cabinet  1  for swinging movement about a vertical pivot axis. The freezer and fresh food compartments  13  and  15  are defined by a pair of spaced liners  20  and  21  that are mounted within cabinet  1 . As the general construction and mounting of doors  17  and  19 , as well as liners  20  and  21 , are known in the art and are not considered part of the present invention, they will not be further discussed herein. Instead, the present invention is directed to the manner in which mullion  11  is interconnected to cabinet shell  1  through the use of a mullion retainer  24 , the construction and manner of use of which will be detailed more fully below. 
     FIG. 3  will now be referenced in describing the preferred construction of cabinet  1  and mullion  11  which facilitates their interconnection through mullion retainer  24 . Top panel  7  of outer shell  3  is bent to form flange structure  26  which defines a front facing primary flange  28 , a return flange  29  and a secondary flange  30 . Secondary flange  30  includes a main portion  32  and a lip portion  34  extending substantially perpendicularly from main portion  32 . A keyhole cut-out  36  is formed in the secondary flange  30  and extends across main portion  32  and lip portion  34 . The space between primary and secondary flanges  28  and  30  defines a gap  38 . 
   Preferably, mullion  11  is formed of steel to include a planar body portion  40  and reverse flange structure generally indicated at  42  and  44 . Reversing flange structures  42  and  44  have oppositely directed configurations and include wall portions  46  and  48  extending substantially parallel to planar body portion  40 , and wall extensions  50  and  52  projecting substantially perpendicularly to planar body portion  40 . With this construction, reversing flange structures  42  and  44  define a pair of elongated slots or channels  54  and  56 , with slots  54  and  56  being adapted to receive flange portions (not shown) of fresh food liners  20  and  21 , respectively. Of course, this interconnection between mullion  11  and liners  20  and  21  occurs after mullion  11  is attached to cabinet  1 . Mullion  11  also includes a lip  58  extending from planar body portion  40  such that a rearwardly facing surface  60  and a front facing surface  62  of lip  58  are slightly offset from planar body portion  40  towards reversing flange structures  42  and  44 . 
   Reference will now be made to  FIG. 3  in describing the preferred construction of mullion retainer  24 . Mullion retainer  24  includes two longitudinally extending members or legs  76  and  77  that generally extend in a first axial direction. Longitudinally extending members  76  and  77  include respective retaining clips  82  and  83 . Longitudinally extending members  76  and  77  are integrally formed with a laterally extending portion  86  that extends transverse to the first axial direction. Mullion retainer  24  also includes flanges  88  and  89  that extend along sections of both portion  86  and longitudinally extending members  76  and  77 , mainly for structural integrity and positioning purposes. Extending in the first axial direction and offset from body section  86  is a finger member  94 . Finger member  94  includes a sloping portion  96  that leads to an upstanding portion  98 . Bent rim portions  100  and  101  are formed by the transition of planar body section  86  to sloping portion  96 . Additionally, as clearly shown in  FIGS. 3 and 4 , a small punched-out tab  104  extends substantially perpendicularly from planar body section  86 , below finger member  94 . 
   The manner is which mullion retainer  24  interconnects flange structure  26  and mullion  11  will now be discussed. Elongated slots  54  and  56  of mullion  11  are sized to spaciously receive longitudinally extending members  76  and  77  of retainer  24 . As depicted in  FIG. 5 , when longitudinally extending members  76  and  77  are inserted into slots  54  and  56 , clips  82  and  83  extend over wall portions  46  and  48  of mullion  11 , respectively. In this manner, wall portions  46  and  48  are sandwiched between clips  82 ,  83  and longitudinally extending members  76 ,  77  such that mullion  11  is secured to retainer  24 . 
   After securing retainer  24  to mullion  11 , tab  104  of retainer  24  is aligned with keyhole  36  in return flange  26 . Next, laterally extending portion  86  of retainer  24  and lip  58  of mullion  11  are inserted into gap  38  between return and secondary flanges  29  and  30 , while tab  104  is received within keyhole  36 . The engagement of front facing surface  62  of lip  58  with return flange  29  results in a smooth outer appearance at the transition between mullion  11  and return flange  26 . 
   As depicted in  FIG. 6 , the structure of retainer  24 , including offset finger member  94  and the structure of offset lip  58  of mullion  11 , provides a snug fit for the retainer  24 /mullion  11  assembly within gap  38 . Likewise, tab  104  is sized to fit snuggly in the upper part (not separately labeled) of keyhole  36 . With this construction, mullion retainer  24  accurately positions mullion  11  with respect to outer shell  3 , while preventing any relative horizontal or vertical movement between the mullion  11  and the outer shell  3 . Furthermore, by reducing the potential for any gaps between outer shell  3  and mullion  11  through the use of mullion retainer  24 , the present invention effectively eliminates any foam leakage in this overall region during insulation of refrigerator cabinet  1 . More specifically, by maintaining conforming surfaces between flange structure  26 , mullion retainer  24  and mullion  11 , when the zone between outer shell  3  and the fresh food and freezer liners  20  and  21  is injected with insulation during a cabinet forming process, leakage of insulation material in this area of the refrigerator cabinet  1  is prevented. 
   Although described with reference to a preferred embodiment 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. For instance, the relative length of longitudinally extending members  76  and  77  and laterally extending portion  86  can vary from that shown in the drawings without departing from the spirit of the invention. In addition, although the invention has been described with reference to side-by-side refrigerator cabinet  1 , the invention could also be employed in connecting a mullion for other types of refrigerators, including top and bottom-mount styles. In general, the invention is only intended to be limited by the scope of the following claims.