Abstract:
A dishwasher door hinge assembly and spring linkage device is disclosed that enables the spring linkage to be removed from the hinge while the door remains attached to the hinge assembly and to the appliance. This provides in-situ removal of the door from the appliance without requiring the unit to be removed from the cabinet. Both the hinge and the spring linkage have geometry that allow for separation while the appliance remains mounted in final installed state (in-situ).

Description:
FIELD OF THE INVENTION 
       [0001]    The subject matter of the present invention relates generally to a device for servicing dishwasher appliances and more specifically to a device for in-situ removal of the door from an installed dishwasher. 
       BACKGROUND OF THE INVENTION 
       [0002]    Typically, removal of a dishwasher door requires the hinge arms to disconnect from the door while the hinges stay connected to the tub and spring system. To maintain proper door stiffness in relation to the hinge arms, the hinge arms must stay connected to the door during removal of the door. This requires removal of the entire dishwasher from the cabinet in order to access the spring linkage and remove the door. Removal of the entire dishwasher from the cabinet is undesirable because of e.g., the additional labor involved with removing and reinstalling the appliance in the cabinet and accidental damage to cabinets and floors. 
         [0003]    One-piece hinge designs can lower material and labor cost in manufacturing and provide a more robust door hinge system over previous two-piece designs. However, certain one-piece hinges still require removal of the dishwashing appliance from the cabinet in order to remove the dishwasher door. 
         [0004]    Accordingly, a need arises for an in-situ door removal device for dishwashing appliances that allows removal of the dishwasher door without requiring removal of the dishwasher from the cabinet. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0005]    A dishwasher door hinge assembly and a spring linkage is disclosed that enables the spring linkage to be removed from the hinge while the door remains attached to the hinge system and to the appliance. This allows for in-situ removal of the door from the appliance without requiring the appliance to be removed from the cabinet, giving the benefit of reducing the time required to service the unit. Both the hinge and the spring linkage system have geometry that allow for their separation while the appliance remains mounted in final installed state—such characteristics being referred to herein as in-situ door removal. 
         [0006]    In an exemplary dishwashing appliance embodiment, a cabinet defines a wash chamber for the receipt of articles for washing, the cabinet including a pair of opposing side walls, a top wall, and a rear wall. A tub is disposed inside the cabinet configured with a front opening for receipt of a door hinged at its bottom. The door has a pair of one-piece hinges disposed proximate the opposing side walls, each hinge defining a top edge, bottom edge, hinge distal end, and hinge proximal end, the hinge proximal end being removably coupled to the door, the hinge distal end defining an arched cutout extending upward from the bottom edge and terminating near the hinge distal end. Each hinge has a spring linkage including a clevis removably coupled to the cutout, the clevis defining a clevis proximal end and a clevis distal end, the clevis further including a pair of legs positioned on opposing sides of the hinge and extending from the clevis distal end towards the clevis proximal end. A clevis connecting pin is disposed between the pair of legs at the clevis distal end, each clevis leg further including at least one tool bore for complementary receipt of a linkage removal tool. 
         [0007]    In another exemplary embodiment, a dishwashing appliance door hinge assembly is disclosed having a pair of one-piece hinges supported near the bottom of a dishwasher door, each hinge defining a top edge, bottom edge, hinge distal end, and hinge proximal end, the hinge proximal end removably coupled to the door, the hinge distal end defining an arched cutout extending upward from the bottom edge and terminating near the hinge distal end. The assembly also has at least one spring linkage, each spring linkage is attached to one of the hinges. Each spring linkage has a clevis removably coupled to the cutout, the clevis defining a clevis proximal end and a clevis distal end. The clevis has a pair of legs positioned on opposing sides of the hinge and extending from the clevis distal end towards the clevis proximal end. A clevis connecting pin is disposed between the pair of legs at the clevis distal end, each clevis leg having at least one tool bore configured for complementary receipt of a linkage removal tool. 
         [0008]    These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: 
           [0010]      FIG. 1  provides a front view of an exemplary embodiment of a dishwashing appliance as may be used with the present invention. 
           [0011]      FIG. 2  is a cross-sectional view of the exemplary embodiment of a dishwashing appliance shown in  FIG. 1  and hinge. 
           [0012]      FIG. 3  is a side view of an exemplary spring linkage and one-piece hinge installed on a dishwasher frame. 
           [0013]      FIG. 4  is a side view of the exemplary hinge and clevis connection. 
           [0014]      FIG. 5  is a top view of the exemplary clevis. 
           [0015]      FIG. 6  is a perspective of a dishwasher door showing exemplary hinges of the present invention. 
           [0016]      FIG. 7  is a perspective of the exemplary hinge mounted to a dishwasher door. 
           [0017]      FIG. 8  is a close-up side view of various features of the exemplary hinge and clevis connection of the present invention. 
           [0018]      FIG. 9  is a side view of an exemplary hinge of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
         [0020]      FIGS. 1 and 2  depict an exemplary domestic dishwasher  100  that may be configured in accordance with aspects of the present disclosure. Lateral direction L, transverse direction T, and vertical direction V are shown in the figures. For the particular embodiment of  FIGS. 1 and 2 , the dishwasher  100  includes a cabinet  102  having a tub  104  therein that defines a wash chamber  106 . The tub  104  includes a front opening (not shown) and a door  120  hinged at its bottom  122  for movement between a normally closed vertical position (shown in  FIGS. 1 and 2 ), wherein the wash chamber  106  is sealed shut for washing operations, and a horizontal open position for loading and unloading of articles from the dishwasher. Latch  156  is used to lock and unlock door  120  for access to wash chamber  106 . The cabinet  102  includes a pair of opposing side walls  128 , a top wall  127 , and a rear wall  129 . A tub  104  is disposed inside the cabinet  102  and configured with a front opening for receipt of a door  120  hinged at its bottom  122 . 
         [0021]    Upper and lower guide rails  124 ,  126  are mounted on tub side walls  128  and accommodate roller-equipped rack assemblies  130  and  132 . Each of the rack assemblies  130 ,  132  is fabricated into lattice structures including a plurality of elongated members  134  (for clarity of illustration, not all elongated members making up assemblies  130  and  132  are shown in  FIG. 2 ). Each rack  130 ,  132  is adapted for movement between an extended loading position (not shown), in which the rack is substantially positioned outside the wash chamber  106 , and a retracted position (shown in  FIGS. 1 and 2 ), in which the rack is located inside the wash chamber  106 . This rack movement is facilitated by rollers  135  and  139 , for example, mounted onto racks  130  and  132 , respectively. A silverware basket (not shown) may be removably attached to rack assembly  132  for placement of silverware, utensils, and the like, that are otherwise too small to be accommodated by the racks  130 ,  132 . 
         [0022]    The dishwasher  100  further includes a lower spray-arm assembly  144  that is rotatably mounted within a lower region  146  of the wash chamber  106  and above a tub sump portion  142  so as to rotate in relatively close proximity to rack assembly  132 . A mid-level spray-arm assembly  148  is located in an upper region of the wash chamber  106  and may be located in close proximity to upper rack  130 . Additionally, an upper spray assembly  150  may be located above the upper rack  130 . Although a spray assembly  150  is shown, an upper spray arm assembly may be used as well. Other fluid emitting devices for cleaning articles may be used at the lower, middle, and/or upper positions as well. 
         [0023]    The lower and mid-level spray-arm assemblies  144 ,  148  and the upper spray assembly  150  are in fluid communication with a pump  154  and a main supply conduit  152  for circulating fluids (e.g., wash or rinse) in the tub  104 . The main supply conduit  152  is served by a recirculation pump  154  positioned in a machinery compartment  140  located below the tub sump portion  142  (i.e., bottom wall) of the tub  104 , as generally recognized in the art. Pump  154  receives fluid from sump  142  to provide a flow to the main supply conduit  152 . A heating element  170  can be used to provide heat during e.g., a drying cycle. 
         [0024]    Each spray-arm assembly  144 ,  148  includes an arrangement of discharge ports or orifices for directing washing fluid received from pump  154  onto dishes or other articles located in rack assemblies  130  and  132 . The arrangement of the discharge ports in spray-arm assemblies  144 ,  148  provides a rotational force by virtue of washing fluid flowing through the discharge ports. The resultant rotation of the spray-arm assemblies  144 ,  148  and the operation of spray assembly  150  using fluid from pump  154  provides coverage of dishes and other dishwasher contents with a washing spray. Other configurations of spray assemblies may be used as well. 
         [0025]    The middle spray-arm assembly  148  is releasably connected with fluid supply conduit  152  by way of a diverter  200  as further described herein. Specifically, as rack  130  is moved in and out of chamber  106 , fluid supply conduit  112  releasably connects or disconnects from diverter  200 . Other configurations may also be used. 
         [0026]    The dishwasher  100  is further equipped with a controller  137  to regulate operation of the dishwasher  100 . The controller may include one or more memory devices and one or more microprocessors, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with a cleaning cycle. The memory may represent random access memory such as DRAM or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. 
         [0027]    The controller  137  may be positioned in a variety of locations throughout dishwasher  100 . In the illustrated embodiment, the controller  137  may be located within a control panel area  121  of door  120  as shown in  FIGS. 1 and 2 . In such an embodiment, input/output (“I/O”) signals may be routed between the control system and various operational components of dishwasher  100  along wiring harnesses that may be routed through the bottom  122  of door  120 . Typically, the controller  137  includes a user interface panel/controls  136  through which a user may select various operational features and modes and monitor progress of the dishwasher  100 . In one embodiment, the user interface  136  may represent a general purpose I/O (“GPIO”) device or functional block. In one embodiment, the user interface  136  may include input components, such as one or more of a variety of electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. The user interface  136  may include a display component, such as a digital or analog display device designed to provide operational feedback to a user. The user interface  136  may be in communication with the controller  137  via one or more signal lines or shared communication busses. 
         [0028]    It should be appreciated that the invention is not limited to any particular style, model, or configuration of dishwasher. The exemplary embodiment depicted in  FIGS. 1 and 2  is for illustrative purposes only. For example, different locations may be provided for user interface  136 , different configurations may be provided for racks  130 ,  132 , different spray devices and spray arm assemblies may be used, and other differences may be applied as well. 
         [0029]      FIGS. 3, 4, and 5  show the door  120  with a pair of one-piece hinges  300  disposed proximate the opposing side walls  128  of cabinet  102 . Each hinge  300  defines a top edge  302 , bottom edge  304 , hinge distal end  306 , and hinge proximal end  308 . The hinge proximal end  308  is removably coupled to the door  120 . 
         [0030]    The hinge distal end  306  is spaced apart along transverse direction T from hinge proximal end  308 . The hinge distal end  306  defines an arched cutout  310  extending vertically upward from the bottom edge  304  and terminating near the hinge distal end  306 . As shown in  FIG. 9 , for this exemplary embodiment, arched cutout  310  is defined by an edge  369  that includes a first section  371  at an angle α from transverse direction T, an adjacent second section  373  forming a flattened top apex  373  that is parallel to transverse direction T, an adjacent third section  375 , and an adjacent curved or arcuate section  377  into which a pin  328  can be removably received. These sections provide a hook-like shape for cutout  310 . A pin rention lip  340  projects upwardly along vertical direction V and is positioned adjacent to arcuate section  377 . In one exemplary embodiment, angle α may be e.g., in a range including 30 to 60 degrees and, in another exemplary embodiment, about 45 degrees. In one exemplary embodiment, angle θ may be e.g., in a range including 90 to 180 degrees and, in another exemplary embodiment, about 135 degrees. 
         [0031]    Appliance  100  includes at least one spring linkage, shown as a pair of spring assemblies or spring linkages  312 , positioned on each side  128  of cabinet  102 . Only one side is shown in  FIGS. 3, 4, 5, 7, and 8 —it being understood the construction of each side is substantially similar. On each side of appliance  100 , the spring linkage  312  has a clevis  320  removably coupled to the cutout  310  of the hinge  300 . 
         [0032]    For each side, the spring linkage  312  includes a cable  332  coupled to the clevis proximal end  322  using a conical cable mount  336 . The conical cable mount  336  provides a hole of decreasing diameter to secure an end of cable  332 . Spring linkage  312  includes a spring  314  removably coupled to a leg  342  of the dishwasher frame  342 . A cable eyelet  343  is mounted to the cable  332  and coupled to the spring  314 . Spring  314  applies tension to the cable  332 , which in turn pulls on hinge  300  using clevis  320 . 
         [0033]      FIGS. 4 and 5  show the clevis  320  defining a clevis proximal end  322  and a clevis distal end  324 . A pair of clevis legs  326  are positioned on opposing sides of the hinge  300  and form a slot  337  for receipt of hinge  300 . Clevis legs  326  are positioned at clevis distal end  324  and extend from clevis distal end  324  towards the clevis proximal end  322 . Each leg  326  of the clevis  300  has a rib  334  formed into the leg  326  for additional strength and to help guide a spring linkage removal tool (not shown) into position. For this exemplary embodiment, clevis  300  is symmetrical about rib  334 . 
         [0034]    A clevis connecting pin  328  ( FIG. 5 ) is disposed between the pair of legs  326  at the clevis distal end  324  and within slot  337 . Each clevis leg  326  has at least one tool bore  330  for complementary receipt of a linkage removal tool. For this exemplary embodiment, each clevis leg  326  includes a pair of tool bores  330  positioned in an opposing manner about rib  334  so as to provide a total of four tool bores  330 . 
         [0035]    Referring to  FIGS. 6 and 7 , on each door lateral side  114 , door  120  includes a channel  520  into which hinge  300  is positioned and removably attached to door  120 . Door  120  includes at least one retaining clip  512  for removably coupling the hinge  300  to the channel  520 . The door  120  has at least one mounting anchor  510  in the door lateral sides  114  for aligning and maintaining the hinge  300  in position. The hinge  300  has at least one anchor slot  514  for complementary receipt of the at least one mounting anchor  510 . 
         [0036]      FIG. 8  shows the hinge  300  with a pin retention lip  340  projecting towards the second section  373  for retaining the clevis connection pin  328  in an engaged position while the door  120  is opened and closed. The arched cutout  310  is oriented with the entrance on the bottom edge  304 . The arched cutout  310  extends from the bottom edge  304  of the hinge  300  to enable servicing from below without removing the dishwasher from the installed position (in-situ). A linkage removal tool (not shown) gains access to the clevis  320  from the front of the dishwasher after removal of the dishwasher toekick panel. 
         [0037]    Specific features of the arched cutout  310 , as shown in  FIG. 8 , enable front access in-situ removal of the spring linkage  312  from the door hinges  300  thereby allowing in-situ removal of the door. An enlarged entrance  350  at the bottom edge  304  of the hinge  300 , a linear second section  373  positioned near the top edge  302 , and a hinge retention lip  340  allow sufficient space for the clevis connecting pin  328  to easily travel in and out of the arched cutout  310  while also retaining the clevis  320  engaged with the hinge  300  during opening and closing of the door  120 . 
         [0038]    For this exemplary embodiment, the arched cutout  310  is formed such that the clevis connecting pin  328  moves in three linked travel paths for engagement and disengagement with the hinge  300 . The first path  370  starts at the enlarged entrance  350  and extends upward in the first angle α direction toward the rear wall  129 . The second path  372  extends in a generally traverse direction sufficient distance such that the clevis connecting pin  328  clears the pin retention lip  340 . The third path  374  extends downward along second angle θ direction toward the rear wall  129 . These linked travel paths provide serviceable geometry to retain the clevis pin  328  connection with the hinge  300  during normal door  120  operation while also allowing a linkage removal tool (not shown) to disengage the clevis  320  from the hinge  300  for in-situ door  120  removal. As shown, these three paths are at non-zero angles to each other. 
         [0039]    This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.