Abstract:
A method of forming a passageway in an insulated door of a refrigerator includes the steps of forming a conduit by inserting a mandrel in the space between a door liner and outer skin, filling the space with foam insulation, and removing the mandrel. In one embodiment, the mandrel is encased with a polymeric skin prior to the inserting step, such that, when the mandrel is removed, the skin remains at the boundary of the passageway so formed. In another embodiment, the method includes mounting fluid and/or electrical conduits to an inside surface of the door liner and subsequently injecting the foam insulation to surround the conduits. In yet another embodiment, fluid and/or electrical conduits are mounted to an outer surface of the door liner. A cover is then positioned over the conduits.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a division of application Ser. No. 12/402,644 filed Mar. 12, 2009, entitled R EFRIGERATOR WITH  M ODULE  R ECEIVING  C ONDUITS , now U.S. Pat. No. 8,117,865, which claims priority under 35 U.S.C. §119(e) and the benefit of U.S. Provisional Application No. 61/035,775 entitled R EFRIGERATOR  W ITH  S PACE  M ANAGEMENT  M ODULES , filed on Mar. 12, 2008, the entire disclosures of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to a refrigerator and specifically a method of forming passageways in a foam insulated refrigerator door for receiving conduits including utilities for supplying electrical power or fluids to plug-in modules at one or more locations. 
     Currently designed refrigerators may include adjustable shelves and some optional accessories, such as ice makers and water dispensers, which can be part of the original equipment of the refrigerator or, in some cases, added on to specific modules premanufactured to accommodate such additional components. A refrigerator typically will have shelving in the door which can be adjustable but otherwise has very little ability to change the configuration of the refrigerator shelving either in the cabinet of the refrigerator or in the door. There exists a need, therefore, for a refrigerator which can accommodate new accessories in modular form at owner selected locations within a refrigerator and particularly in its door. In order to accommodate such flexibility, it would be desirable to provide a refrigerator having a modular architecture to provide specialized functions, new features, and flexibility to the consumer in selecting desired features. 
     SUMMARY OF THE INVENTION 
     In order to accommodate these desirable goals, a refrigerator door is manufactured with a method to form passageways to receive a conduit carrying utilities for the operation of different modules. The conduit includes one or more access ports with connectors at selected locations or adjustable locations in the refrigerator door for the easy installation of such modules. 
     The present invention includes a method of forming a passageway in an insulated door of a refrigerator comprising the steps of forming a conduit by inserting a mandrel in the space between a door liner and outer skin, filling the space with foam insulation, and removing the mandrel to leave a passageway for defining or receiving a conduit. In one embodiment, the mandrel is encased with a polymeric skin prior to the inserting step, such that, when the mandrel is removed, the skin remains at the boundary of the passageway so formed. In a refrigerator with such construction, a cabinet has a hinged access door and a conduit mounted in the door for carrying at least one of an electrical conductor and a fluid transmission tube positioned within the conduit. At least one connector is positioned at a selectable location along the conduit and coupled to at least one of an electrical conductor and a fluid transmission tube. A module requiring at least one of electricity and a fluid for its operation is mounted to the door at a selected location in one embodiment and includes a module connector for mating with the connector for receiving the necessary utilities for operation of the module. 
     In another embodiment, the method includes mounting fluid and/or electrical conduits to an inside surface of the door liner and subsequently injecting the foam insulation to surround the conduits. 
     In yet another embodiment, fluid and/or electrical conduits are mounted to an outer surface of the door liner. A cover is then positioned over the conduit. In each embodiment, one or a plurality of modules are provided for mounting to or within the door wherein at least one module requires at least one of electricity and a fluid from the conduit for its operation and wherein at least one of the modules includes a module connector for mating with at least one connector of the conduit when the module is mounted to the door at a selected location. At least one module includes a conduit and a second connector for coupling to a second module to supply one of electricity and fluid to or through the second module. 
     Such a modular construction allows the efficient manufacture of a consumer upgradable refrigerator with interchangeable modules which can easily be removed for service or replacement with a different module having newer features. These and other features, objects and advantages of the present invention will become apparent upon reading the following description thereof together with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view, partly broken away, of a refrigerator embodying the present invention; 
         FIG. 2  is a fragmentary perspective view of a refrigerator door, such as shown in the refrigerator of  FIG. 1 , showing one step of its manufacturing process; 
         FIG. 3  is a fragmentary perspective view of the door shown in  FIG. 2 , shown during a second step of its manufacturing process; 
         FIG. 4  is a perspective view of the door shown in  FIGS. 2 and 3 , shown during a third step of its manufacturing process; 
         FIG. 5  is a fragmentary perspective view of the door shown during a subsequent step of the door manufacturing process; 
         FIG. 6  is a fragmentary perspective view of an alternative embodiment of the invention in which a conduit is positioned within a door, such as shown in  FIGS. 2-5 ; 
         FIG. 7  is a fragmentary perspective view of an alternative embodiment in which a conduit is positioned on the inner liner of a door; 
         FIG. 8  is a fragmentary perspective view, partly exploded, of a refrigerator embodying the present invention, in which a plurality of modules are shown together with a plurality of connectors on the refrigerator door; 
         FIG. 9  is a fragmentary perspective view, partly exploded, of a refrigerator door with an alternative embodiment of a connection port for a module coupled to the door for receiving utilities; 
         FIG. 10  is a fragmentary perspective view of an alternative embodiment of connection ports in a door showing a plurality of connecting ports and connectors for multiple modules; 
         FIG. 11  is a fragmentary perspective view of a quick disconnect connector which can be employed in any of the embodiments of the present invention for supplying two different fluids between a module and a refrigerator door; 
         FIG. 12  is a fragmentary perspective view of a quick disconnect coupling for supplying a single fluid between a module and the refrigerator door; 
         FIG. 13  is a fragmentary perspective view of a quick disconnect electrical coupling which can be used in the system of the present invention; 
         FIG. 14  is a fragmentary perspective view of a refrigerator door showing an alternative embodiment of the present invention wherein a conduit is centered inside the liner of the door; 
         FIG. 15  is an enlarged fragmentary cross-sectional view, taken along section line XV-XV, of the construction of  FIG. 14 ; 
         FIG. 16  is a perspective view of a door, partly broken away, showing an alternative mounting of a conduit; 
         FIG. 17  is an enlarged vertical cross-sectional view, taken along section line XVII-XVII of  FIG. 16 ; 
         FIG. 18  is a horizontal cross-sectional view of an alternative embodiment of the mounting of a conduit in a refrigerator door; 
         FIG. 19  is perspective view of a refrigerator door showing a conduit with multiple connectors and an accordion-type cover for exposing one or more connectors for use in coupling a module thereto; 
         FIG. 20  is an enlarged section of area XX of the door shown in  FIG. 19 ; 
         FIG. 21  is a perspective view of a refrigerator door including a sliding connector coupled to a conduit for providing variable positioning of a connector for a module; 
         FIG. 22  is an enlarged perspective view of the area XXII shown in  FIG. 21 ; 
         FIG. 23  is a perspective view of a refrigerator door showing an alternative embodiment of an electrical connector for a module in which a spring-loaded slideable connector is mounted within a track of the conduit for providing electrical power for modules which can be placed at various locations within the refrigerator door; 
         FIG. 24  is an enlarged fragmentary perspective view of the structure shown in the encircled area XXIV in  FIG. 23 ; 
         FIG. 25  is a perspective view of a refrigerator door showing an alternative arrangement for supplying multiple connecting areas for attaching modules to a refrigerator door; 
         FIG. 26  is a cross-sectional view taken along section line XXVI-XXVI in  FIG. 25 ; 
         FIG. 27  is a perspective view of a refrigerator door showing interconnected modules; 
         FIG. 28  is an enlarged fragmentary perspective view showing the details of the interconnection of the modules to one another; and 
         FIG. 29  is an exploded perspective view of the modules shown in  FIGS. 27 and 28 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring initially to  FIG. 1 , there is shown a refrigerator  10  embodying the present invention. The refrigerator shown is illustrative only, it being understood that the refrigerator could be a single door, multiple door, left and right door, or any typical refrigerator design in terms of the refrigerator itself. Refrigerator  10  includes a refrigerated cabinet  12  which includes a freezer compartment with a closure door  14 . The refrigerated cabinet  12  is enclosed by a door  18  which embodies the present invention. Door  18  is coupled to cabinet  12  by upper and lower hinge plates  20  and  30 , respectively. A conduit  22  in door  18  receives a bundle of utilities  24  which extend from cabinet  12  within the door  18 , as explained in greater detail below. The door includes access ports with connectors for coupling one or more modules requiring utilities for their operation and which can be mounted to the liner  26  of the door to provide flexibility for the homeowner in selecting desired modules for their particular convenience. The door  18  includes a typical magnetic seal  28  around the periphery thereof and is pivotally mounted at its upper end by pivot plate  20  and hollow pivot pin  22  serving as a conduit for the utilities  24 . Plate  30  also includes a pivot pin  32  to pivotally mount door  18  at its lower end. 
     The modules are inserted into liner  26  and are mechanically coupled to the door by conventional coupling members within the side walls  23  of the door. Some modules, such as an ice maker or a water dispenser, require some form of utility, such as electrical operating power, a chilling fluid, a warming fluid, or water for dispensing. Such modules are also described in copending patent application Ser. No. 12/343,682 entitled M ODIFIED  A TMOSPHERE FOR  F OOD  P RESERVATION  filed on Dec. 24, 2008, (Publication No. 2009/0229278) and U.S. Pat. No. 8,020,360 entitled D EVICE AND  M ETHOD TO  P RODUCE A  M ODIFIED  A TMOSPHERE FOR  F OOD  P RESERVATION , the disclosures of which are incorporated herein by reference. 
     Common to each of the following described embodiments of the invention is a conduit which extends into the door and which, in one embodiment, is integrally formed in the door as an open passageway by the process illustrated in  FIGS. 2-5 . As seen in  FIG. 2 , a door  18  is shown with the inner liner  26  typically of a molded polymeric material and an outer skin  27  coupled thereto. The space  29  between the outer skin and liner  26  is open and a mandrel  31 , such as a tubular member, is inserted in a polyethylene sleeve  33  and positioned within the space  29  at a desired location which may vary from door to door. 
     In the embodiment shown in  FIG. 3 , the sleeve  33  and mandrel  31  are positioned in the corner of the door, and the door is then foamed with an insulative foam  35 , as seen in  FIG. 4 . Subsequently, the mandrel  31  is removed, as shown by arrow A in  FIG. 4 , leaving a cylindrical passageway defining a conduit  40  extending vertically substantially the height of door  18 . The conduit  40  may be the passageway formed as shown in  FIG. 4  or may be lined with a cylindrical tube or sleeve  42  ( FIG. 5 ) for receiving a bundle of utility supplying electrical conductors or fluid tubes for electrical and fluid transmission from either the top of the door, as seen in  FIG. 1 , or at the bottom of the door. Utility conduits typically fit within a sleeve  42  which extends through an aperture  45  in end cap  44  positioned over the ends of the door  18  to complete the door construction. It is understood that a lower end cap is likewise employed. Not all doors will include end caps, and, in such event, other pathways for providing the utilities will be employed. 
     Also, instead of foaming a conduit or passageway utilizing mandrel  31 , a tubular conduit, such as  48  ( FIG. 6 ), can be secured to the inner surface  21  of liner  26  by a suitable bonding adhesive and coupled to utilities again through an aperture  45  in an end cap, such as  44  (not shown in  FIG. 6 ). Thus, instead of forming a conduit directly in the foam insulation of the refrigerator door, a physical tubular conduit can be placed either within the door ( FIG. 6 ) or on the liner  26 , as illustrated in  FIG. 7 . 
     In  FIG. 7 , a tubular member  48  can also define a conduit  40  for the electrical and fluid utilities supplied to the door  18 . In this embodiment, the utilities are supplied through an aperture  45  in end cap  44 , as in the previous embodiment, but, instead of extending directly into a sleeve  42  as shown in  FIG. 5 , they are coupled by right angle connectors through the liner and into an external conduit  48  located in the corner of one of the walls  23  of liner  26 . A cover  25  typically is employed to enclose the utilities carrying conduit  48 . Conduit  48  in the various embodiments extends substantially the length of the height of door  18  to make the electrical conductors and fluid tubes available as needed for modules to be placed in the doors and coupled to the utilities as described in the figures below. 
     Referring now to  FIG. 8 , there is shown a refrigerator door  50 . Door  50  can be manufactured as described in connection with  FIGS. 2-7  to include an internal or external conduit which leads to mounting ports  52  at spaced locations within the interior  26  of the refrigerator door. Each port  52  includes a connector  54  which is coupled to the utilities  24  which include, for example, electrical conductors and fluid conductors, for supplying utilities to one or more of a plurality of modules  60  requiring electricity, a cooling fluid, water, a heated fluid, or the like, for providing the module with operating utilities. Each of the modules  60  likewise include a connector  56  which mates with connectors  54  when the module is inserted within the refrigerator door. Although four connectors are shown in  FIG. 8  with a pair of modules  60 , one or more of the connectors and modules may be employed. Thus, the system shown in  FIG. 8  can accommodate from one to four powered modules. Ports  52  include not only quick disconnect connectors (as described below with reference to  FIGS. 11-13 ) coupled to the conduit  40  and utilities contained therein but also mounting brackets  55  mounted on the inside of the door walls  23  and correspondingly interengaging mechanical mounting brackets  57  on the sides of the modules  60 , such that the modules can be plugged into the ports  52  and make simultaneous mechanical connection with door  50  as well as electrical an fluid connection through mating connectors  54 ,  56  to the supply conduit  40 . 
     Another arrangement for supplying a module, such as module  60 , in a door  50  is shown in  FIG. 9  in which the conduit  40  extending through the interior of door  50  manufactured in the manner previously described terminates in a trough  58  with a snap-on cover plate  62 , such that the utilities, such as a ribbon electrical connector  64  and quick disconnect fluid connectors  66  can be tucked within the trough  58  when not employed and covered by plate  62 . When a module, such as module  60  which mates with connectors  64  and  66 , respectively, is installed within the port  52  as described in connection with  FIG. 8 , the cover plate  62  is removed and the connections made between the mating connectors and the module  60  is mounted to the port through the mechanical brackets  55  and  57 . Openings or troughs  58  provide access to one or more discreet locations within the interior of the refrigerator door. 
     As seen in  FIG. 10 , a pair of vertically spaced connectors, such as connector  64 , are placed in troughs  58  with the cover plate  62  covering the connectors when not in use. When modules, such as module  60 , are installed one or more of the connectors  64  can be extended for coupling to supply operating electrical power or fluids to the module being installed. Not all modules will require utilities and, in such cases, snap-on cover  62  can remain in place when a module does not need operating utilities for its use. 
     The type of connectors employed for coupling a module to the refrigerator door connectors, such as  54 ,  56  and  64 ,  66  shown in  FIGS. 8-10 , are shown in  FIGS. 11-13 . In  FIG. 11 , there is shown a dual fluid quick disconnect connector  70  which includes a female connector  72  which has nipples  71  which couple to a pair of fluid conduits  73  and  74 , such as water, coolant fluid for refrigeration, or the like. When disconnected from male connector  76 , ball valves seal the gas or liquid in tubes  73 ,  74  from escaping connector  72  which is mounted to the refrigerator door. A male connector  76  is mounted to a module and couples to the female connector  72  when a module is installed. Connector  76  includes fluid sealing O-rings  77  and  78  for the concentric passageways for the two different fluids, which are coupled by connector  70  from the refrigerator door conduits  73  and  74  to the modular conduits  79  and  80  which attach to nipples  81  and  83  of male connector  76 . 
       FIG. 12  is a perspective view of a single fluid interconnection  85  which includes a pair of fittings  86  and  87  with a quick disconnect coupling therebetween. Fitting  86  includes a nipple  88  coupled to fluid conduit  90  extending from the refrigerator door while fitting  87  includes a nipple  89  coupled to conduit  91  associated with a module. Again, when disconnected, connector  86  is sealed. Not all connectors need to include seals and other types of commercially available connectors, such as available from John Guest International Ltd., can be employed. 
       FIG. 13  shows a typical electrical quick disconnect coupling  100  which includes a female section  102  with a pair of conductors  103  and  104  which are coupled to a module to be inserted in the refrigerator door. The coupling also includes a male section  106  for the pair of conductors  107  and  108 , which couple to the refrigerator door supply conduit  40  as described in the previous embodiments. The same type of connectors or other similar commercially available connectors can be used for the quick coupling and decoupling of a module to the conduits mating connectors of the refrigerator doors in each of the embodiments. 
       FIGS. 14 and 15  show yet another embodiment of a refrigerator door  110  embodying the present invention and which includes a liner  26  and first and second conduits  40  and  140 . The first conduit  40  is positioned in the insulated space between liner  26  and skin  27  and positions a connector, such as  53 , at a location on the liner surface of door  110  such that a second conduit  140  with utility wires and tubes contained therein can later be mounted to the door  110 . Conduit  140  will have a connector, such as  54 , which mates with connector  53  and supplies a plurality of spaced connectors  54  along conduit  140  for receiving modules, such as module  112 . Thus, the two conduit system allows a first conduit with a single connector to be manufactured in all refrigerator doors and then, as desired, the customer or retailer can retrofit the door by mounting a snap-in second conduit which mates with the first conduit and provides utilities at various locations to optional modules. The conduit  140  includes a plurality of connectors  54 , such as in the embodiment shown in  FIG. 8 , which may include both types of connectors  70 ,  85 , and  100  as described in the previous drawing figures to supply modules, such as module  112 , at selected vertically spaced locations operating utilities for the module  112 . The utility wires and tubes can extend through an aperture  45  in the upper edge of the door at the pivot point and into conduit  40  in a conventional manner. 
       FIG. 15  is a vertical cross-sectional view of the positioning of the conduits  40  and  140  and utility conduits  90 ,  107 , and  108 , for example, as in the previous embodiment, within conduits  40  and  140 . A decorative shroud  114  ( FIG. 15 ) with openings at spaced-apart locations, as seen in  FIG. 14 , to expose connectors  54  may be employed to cover conduit  140 . As in the previous embodiments, the sides  23  of the refrigerator door include conventional mounting brackets  55  for receiving modules, such as module  112 . 
     In the embodiment shown in  FIGS. 16 and 17 , a conduit  40  is formed in a recess  117  in the back wall of liner  26  of door  120  to conceal the conduit and provide additional space for the modules  112  inserted therein. These modules, like the remaining modules, include mechanical coupling brackets  57  which engage brackets  55  in the refrigerator door for securing the modules mechanically to the refrigerator. The modules  112  also include connectors  56  which mate with connectors  54  in the refrigerator door for supplying utilities from the conduit  40  to the modules. 
     In addition to the door construction shown in  FIGS. 14-17 , a conduit  40  can be embedded as shown in the horizontal cross section of  FIG. 18 , which represents the molding of the conduit  40  in the center insulated area of the liner in a process similar to that shown in  FIGS. 2-5 , except the positioning of the conduit is centered in the liner  26  to mate with a module, such as module  112 , positioned therein and coupled to the door utilizing coupling brackets  55  and  57  in the door and module, respectively. 
       FIGS. 19 and 20  show an alternative embodiment of the invention in which a refrigerator door  125 , including a liner  26 , has the conduit  40  formed in a rectangular channel on the surface of the liner facing the cabinet of the refrigerator. The conduit includes a plurality of spaced-apart connectors  150  at various locations which are selectively covered by an accordion or foldable cover  152  and  154 , as best seen in  FIG. 20 . The movable covers  152 ,  154  selectively expose connectors  150  such that a module, such as modules  60 ,  112 , and  118 ) can be inserted therein and receive the utilities necessary for operation of the modules. Door  125  includes the usual coupling mechanism, as does the module, for coupling the module mechanically to the door as well as electrically and fluidly to the connectors  150 . 
     Another embodiment of the invention is shown in  FIGS. 21 and 22  in which a conduit  40  is again mounted to the liner  26  of door  130  and includes utilities which are coiled in a slacked condition represented by dashed lines  160  in the figures. The utilities extend from aperture  45  in door  130  through the insulation into the channel-like conduit  40 . Conduit  40  includes, in this particular embodiment, a guide slot  161  ( FIG. 22 ) and guide tab  162  on a carrier  164  which includes connectors  166  and  168  for receiving the utilities through coiled or slack conductors and tubes  160 . Thus, the adjustable positioning of carrier  164  allows a module to be positioned substantially anywhere along the vertical height of door  130  by moving carrier  164  to a desired location, which can be selected by the owner of the refrigerator. 
     In the embodiment shown in  FIGS. 23 and 24 , the door  135  allows similar flexibility, however, it employs an electrical only movable connector  170  which comprises a push-spring contact in a track  172  having electrical conductors  173  and  174  on opposite sides, similar to a track for used for track lighting. By compressing the opposite sides of connector  170 , the socket can be moved upwardly and downwardly to the desired adjusted position. In the embodiment shown, two such connectors  170  are shown, although additional connectors can be mounted within the track  172 , if desired, to accommodate more than two modules at infinitely adjustable positions. 
     Another embodiment of the invention is shown in  FIGS. 25 and 26  in which a refrigerator door  138  includes horizontally extending conduits  40 ,  40 ′,  40 ″, and  40 ′″ which are vertically spaced and molded into the liner  26 , as shown in  FIG. 26 , to include utility tubes and conductors, such as  73 ,  74 ,  90 , and  107 ,  108 , respectively, as shown in connection with the connector diagrams of  FIGS. 11-13 . At horizontally spaced locations along conduits  40 - 40 ′″, there are provided connectors, such as  175 , which, like the remaining connectors in the other embodiments, contain quick disconnect couplings, such as shown in  FIGS. 11-13 , for plugging a module, such as module  60 ,  112 , and  118 , into the conduits for receiving utilities extending through aperture  45  in the top of door  138 . By providing horizontally spaced connectors  175 , the module connector can be located at the left, center, or right edge of the module as desired, which provides more flexibility for positioning a module within the door  138 . 
     In addition to providing conduits within the refrigerator door itself, it is possible to utilize modules as the structure for extending utilities throughout the inside of a refrigerator door, as seen in  FIGS. 27-29 . In these figures, there is shown a refrigerator door  145  which receives utilities through an aperture  45  in the upper or lower corner of the door in a conventional manner. The utilities, however, extend through an elbow  180  ( FIG. 28 ) from the liner  26  into a first module  182  by means of a quick disconnect coupling  184 . Module  182  is coupled to the liner by standard coupling brackets  185 , which communicate with brackets  55  in the inner edges  23  of the door, as seen in  FIG. 29 . 
     Module  182  may utilize the utilities such as fluid or electricity provided through elbow  180  and connector  182  or merely pass the utilities through to a second module  186  spaced below module  182  and coupled thereto by means of a second quick disconnect coupling  188 . Module  186  also can be coupled to a lower module  190  through a quick disconnect coupling  188  to receive operating power and fluids therefrom. Modules  182 ,  186 , and  190  may be powered by utilities through the conduits or, in the case of modules  182  and  186 , it may not require the utilities but act as a passageway for the module  190 . In this instance, it is not necessary to mold the conduit within the refrigerator door but only provide a coupling at elbow  180  such that the modules can be coupled thereto and positioned within the refrigerator door. 
     Thus, with the present invention, a great deal of flexibility of the options available to the consumer and offered by a retailer is possible. As new modules become available, the fluids, such as coolant liquids, cooled air, inert gases, heated air, electrical power and binary data, can be supplied utilizing the system of this invention. It will become apparent to those skilled in the art that various modifications to the preferred embodiments of the invention as described herein can be made without departing from the spirit or scope of the invention as defined by the appended claims.