Abstract:
An improved refrigerator door is provided with a metal outer panel and upper and lower plastic end caps installed on top and bottom edges of the door. The caps include grooves to receive flanges on the edges of the panel, thereby mounting the caps to the panel. The caps include plugs for receipt in a vertical channel in the panel. A bushing is snap fit into the upper cap without the use of hardware fasteners. Electric wires and a water line extend downwardly through the bushing to an ice and water dispenser in the door.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a continuation application of U.S. patent application Ser. No. 11/140,099 filed May 27, 2005, which application is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     Refrigerator doors typically are formed with a metal outer panel and a plastic inner liner, with insulation between the panel and the liner. In the manufacturing process, the outer panel is formed from a flat sheet of metal, with the sequential steps of bending, welding, and painting. It is desirable to buy pre-painted steel, so as to eliminate the costly painting step in the manufacturing process. 
     The prior art refrigerator door manufacturing process also must accommodate variations in the formation of the outer metal panel. For example, while it is desirable to use the same tooling to manufacture the door panels, stainless steel and cold rolled steel have different bending characteristics, which require different tooling. Typically, the edges of the door panel are bent twice to form an edge at 90 degrees to the body of the panel, and an inwardly extending 90 degree lip, forming a channel between the panel body and the lip. Such dual bends increases the complexity of the door manufacturing process and increases the material variations which must be accommodated. 
     Accordingly, a primary objective of the present invention is the provision of an improved refrigerator door. 
     Another objective of the present invention is the provision of a refrigerator door having a metal outer panel, an inner liner, and a plastic end cap. 
     Still another objective of the present invention is the provision of plastic end caps for use on flat and contoured or curved refrigerator doors. 
     Yet another objective of the present invention is the provision of a plastic end cap for refrigerator doors which can accommodate material variations in the steel outer panel of the door. 
     A further objective of the present invention is the provision of a plastic end cap having a ratcheting feature to provide a mating fit with the outer metal panel of a refrigerator door. 
     Another objective of the present invention is the provision of an improved bushing which is quickly and easily mounted in the end of a refrigerator door into which the door pivot pin extends and through which wires and water lines may extend for an ice and water dispenser in the door. 
     Still another objective of the present invention is the provision of a wire and water line bushing in a refrigerator door which snap fits into the edge of the door without the use of hardware fasteners. 
     A further objective of the present invention is the provision of an improved refrigerator door which is economical to manufacture and durable in use. 
     These and other objectives will become apparent from the following description of the invention. 
     BRIEF SUMMARY OF THE INVENTION 
     A refrigerator door is provided with a metal outer panel having opposite side edges defining a door width and opposite top and bottom edges. The panel may be flat or curved across the width. Plastic caps are mounted to the metal panel along the top and bottom edges, and extending across the width of the panel. The caps include a groove adapted to receive an inwardly turned flange on the panel edge. The caps include a ratcheting member to provide a mating fit with the panel, regardless of material or manufacturing variations in the metal panel. The caps mount to the edge of the panel without hardware fasteners. 
     A hollow or tubular bushing is also mounted in a hole in the top plastic cap, such that electrical wires and/or water lines can extend downwardly through the bushing to an ice and water dispenser in the door. The bushing snap fits into the top cap without the use of hardware fasteners. The bushing includes a flange and the top cap includes a slot for receiving the flange to retain the bushing in the top cap. A tube may be mounted from the lower end of the bushing to house the wires and water line. 
     The bottom cap includes a hole for introduction of insulation foam into the door. Vents are provided in the bottom cap for air expulsion during the foaming process. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a refrigerator having contoured doors for the fresh food and freezer compartments. 
         FIG. 2  is a perspective view of a refrigerator having flat doors for the fresh food and freezer compartments. 
         FIG. 3  is a perspective view of the inside of the left hand door of the refrigerator of  FIG. 1 . 
         FIG. 4  is a view similar to  FIG. 3  showing the metal door panel and the top and bottom end caps, but with the liner removed for clarity. 
         FIG. 5A  is a rear perspective view of the right contoured door panel. 
         FIG. 5B  is a top plan view of the contoured door panel of  FIG. 5A . 
         FIGS. 6A-6G  are views of the top end cap for left hand contoured door, including, respectively, a perspective view, a top plan view, a front elevation view, a bottom plan view, and rear elevation view, and views from each end of the end cap. 
         FIGS. 7A-7G  are views showing the bottom end cap for the left hand contoured door, arranged similarly to  FIGS. 6A-6G . 
         FIGS. 8A-8G  are views of the top end cap for the left hand flat door of  FIG. 2 , arranged similarly to  FIGS. 6A-6G . 
         FIG. 9  is a rear perspective exploded view of a flat door and upper end cap. 
         FIG. 10A  is a partial rear perspective view of the top edge of the flat door panel with the upper end cap prior to engagement between the end cap and the door panel. 
         FIG. 10B  is a view similar to  FIG. 10A  showing the flat upper end cap engaged in the flat door panel having a maximum width. 
         FIG. 10C  is a view similar to  FIG. 10B  wherein the flat door panel has a minimum width. 
         FIG. 10D  is a partial rear perspective view of the flat door panel with the upper end cap installed therein. 
         FIG. 11  is a perspective view of the inside of the contoured freezer door of  FIG. 1 . 
         FIG. 12  is a view similar to  FIG. 9  showing the contoured freezer door panel and end caps, with the liner removed for clarity. 
         FIG. 13  is a top plan view of the contoured freezer door panel of  FIG. 10 . 
         FIGS. 14A-14G  are views of the top end cap for the contoured freezer door, arranged similarly to  FIGS. 6A-6G . 
         FIGS. 15A-15G  are views of the bottom end cap for the contoured freezer door, arranged similarly to  FIGS. 6A-6G . 
         FIGS. 16A-16C  are views of the bushing of the present invention used in the top end caps, including a perspective view, a top plan view, and a side elevation view, respectively. 
         FIG. 17  is a front elevation view of a left hand contoured door panel. 
         FIG. 18  is a sectional view taken along lines  18 - 18  showing the bushing mounted in the contoured door panel. 
         FIG. 19  is a sectional view taken along lines  19 - 19  of  FIG. 18 . 
         FIG. 20  is a sectional view showing the beginning step of the installation of the bushing into the top end cap. 
         FIG. 21  is a sectional view showing the bushing installed in the top end cap. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIGS. 1 and 2  show two embodiments of a refrigerator having an upper fresh food compartment and a lower freezer compartment. In  FIG. 1 , the refrigerator  10  includes a pair of French doors  12 ,  13  for the fresh food compartment and a freezer door  14 . The doors  12 ,  13 ,  14  are contoured across the width of each door, so that the front of the refrigerator  10  is slightly curved.  FIG. 2  shows a refrigerator  16  with French doors  18 ,  19  for the fresh food compartment and a freezer door  20  for the freezer compartment. The doors  18 ,  19  and  20  have a flat profile, so that the front of the refrigerator  16  is flat. 
       FIGS. 3 and 4  shows the left hand fresh food door  12  of the refrigerator  10 . The door  12  includes an ice and water dispenser  22 . The structure of the door  12  includes an outer metallic panel  24 , an upper end cap  26 , a lower end cap  28 , and an interior liner  30 . It is understood that the right hand door  13  is constructed similarly to the left hand door  12 , with the exception of the ice and water dispenser  22  and the ice chute  32  in the liner  30 . The doors  18 ,  19  of the refrigerator  16  have substantially the same structure and components as the doors  12 ,  13 , with the only significant different being the curved contour of the doors  12 ,  13  as opposed to the flat profile of the doors  18 ,  19 . 
     The present invention is directed, in part, to the end caps used at the top and bottom of each of the doors  12 ,  13 ,  14 ,  18 ,  19  and  20 . The upper and lower end caps preferably are molded pieces which fit onto the respective doors, without the use of fastening hardware, as described in more detail below. The door caps for the right hand doors  13 ,  19  are mirror images of the caps for the left hand doors  12 ,  18 . 
       FIGS. 6A-6G  show various views of the upper end cap  26  used in the left hand contoured door  12 . The end cap  26  includes a front edge  34  with a horizontally disposed channel  36  formed therein. The cap  26  has a recess  37  adjacent the rear edge which forms a handle or finger grip for opening the door  12 . The upper cap  26  has a left or hinge end with a vertical channel  38  formed therein. The right or trailing end of the upper cap  26  has a rearwardly extending, horizontally disposed channel  40 . The channels  36 ,  38 , and  40  are adapted to receive bent edges  42 ,  44  and  46  of the metal panel  24 , as seen in  FIGS. 4 and 5 . 
     The right end of the upper left cap  26  also includes a resilient tab  48  adapted to engage an inwardly turned lip  50  on the door panel  24 . The end of the tab  48  includes teeth or ribs  52  which ratchet over the lip  50  to provide mechanical retention of the cap  26  with the panel  24 , and to accommodate manufacturing variances in the panel  24 . 
       FIGS. 7A-7G  show the lower end cap  28  for the left hand contoured door  12 . The lower cap  28  includes a front edge  54  with the horizontally disposed channel  56 , a left end with a rearwardly extending, horizontally disposed channel  58 , and a right end with a rearwardly extending, horizontally disposed channel  60 . The channels  56 ,  58 ,  60  are adapted to receive inwardly turned, horizontally disposed edges (not shown) at the bottom of the panel  24 . 
     The lower end cap  28  includes tabs  49  on each end, similar to tab  48  of the upper end cap  26 , with teeth  51  on the ends of the tabs  49 . The tabs  49  engage inwardly turned lips (not shown) on the bottom edge of the door  12 , with the teeth  51  ratcheting for positive engagement with the lips, so as to accommodate manufacturing variances in bending the lips on the edge of the door  12 . 
     After the upper and lower end caps  26 ,  28  are mounted on the metal panel  24 , the liner  30  is attached, using conventional means. Then, insulative foam is added between the panel  24  and the liner  30 . The foam is supplied through a hole  62  in the lower cap  28 . The lower cap  28  also includes air vent slots  64 , to allow air to escape during the foaming process. The cured foam adheres the panel  24 , end caps  26 ,  28 , and liner  30  together. 
     Each door  12 ,  13  is mounted to the refrigerator  10  by a pin extending into the outer and lower corners of the doors  12 ,  13 . The lower pin (not shown) extends upwardly into a bushing which fits through a hex opening  66  in the lower end cap  28 . The upper pin (not shown) extends downwardly into a bushing  68  mounted in the upper end cap  26 . The bushing  68  is shown in  FIGS. 16-21 . The bushing  68  includes a central tube  70 , an inwardly extending tab  72 , a rearwardly extending tab  74 , and a shoulder  76 . 
       FIGS. 20 and 21  show how the bushing  68  is mounted in the upper cap  26 . The outer end of the upper cap  26  includes an opening  78  through which the tab  72  on the bushing  68  is upwardly inserted, as seen in  FIG. 15 . The bushing  68  is then rotated until the tab  74  contacts the bottom surface of the end cap  26 , and the shoulder  76  engages the matable geometry within the opening  78  of the end cap  26 . The bushing  68 , in contact with the inner side of door panel flange  73  locates and fastens the panel  24  front and rearwardly by compressably engaging the flange  73  between the tab  74  and the adjacent flange  75  of the end cap  26 . The bushing  68  in contact with the inner surface of a notched side flange  77  locates and compressably engages the region of the door panel  24  between the end cap flange  79  and the adjacent flange of tab  74 . The tab  72  includes a downwardly extending finger or clip  80  which extends through a slot  82  in the end cap  26  for overlapping retentive engagement with a flange  84  on the bottom of the end cap  26 , so as to lock the bushing  68  onto the end cap  26 . 
     The upper end of the bushing tube  70  is adapted to receive a pin (not shown) extending downwardly from the upper door hinge assembly  86  of the refrigerator  10 . For the left hand door  12 , with an ice and water dispenser  22 , the tube  70  of the bushing  68  is also adapted to receive electrical wires and the water line which extend downwardly through the door  12  for connection to the ice and water dispenser  22 . The lower end of the tube  70  may include a step down portion  88  over which an elongated tube (not shown) may be fit for housing the dispenser wires and water line in the door  12 . 
     The upper and lower end caps for the flat profile doors  18 ,  19  of the refrigerator  16  shown in  FIG. 2  are substantially similar to the upper and lower end caps  26 ,  28  used on the contoured doors  12 ,  13 , except that the front edge is flat, rather than contoured. The upper cap  92  for the left flat door  18  is shown in  FIGS. 8A-8G , and mounts onto a flat door panel  90 , shown in  FIG. 9 . The flat cap  92  includes a straight front edge  94 , with a horizontally disposed channel  96  extending along the front edge  94 . A horizontal channel  98  is provided along the right or trailing end of the flat cap  92 , opposite the left or hinge end of the cap  92 . The channels  96 ,  98  in the cap  92  are adapted to receive inwardly turned lips  91 ,  93  on the flat door panel  90 . 
     The flat upper cap  92  also does not have the flexible ratcheting fingers  48  of the contoured upper cap  26 . Rather, the trailing end of the cap  92  has a plug  95  adapted to be received within the channel  97  formed on the trailing edge of the flat door panel  90 .  FIG. 10A  shows the end cap  92  positioned adjacent the channel  97 , but not yet engaged with the channel  97 . The upper end cap  92  is adapted to slide laterally relative to the door panel  90  until the plug  95  is received within the channel  97  of the door panel  90 . Then, the hinge or left end of the cap  92  is rotated forwardly so that the channel  96  is received onto the panel lip  91 . Thus, the upper end cap  92  can accommodate door panels  90  having varying widths. For example,  FIG. 10B  shows a door panel  90  having a maximum width such that the plug  95  of the cap  92  only extends partially into the panel channel  97 . In comparison,  FIG. 10C  shows a door panel having a minimum width, such that the plug of the cap  92  is fully received within the channel  97  of the flat panel  90 . As further shown in  FIG. 10C , the cap  92  includes a tab  99  adapted to overlay the inwardly turned lip  101  of the door panel  90 . 
     The upper flat cap  92  is adapted to receive the bushing  68  in the same manner as previously described with respect to the contoured upper cap  26 . The flat upper cap  92  includes a hole  100  through which the tab  72  of the bushing  68  extend, and a slot  102  through which the finger  80  of the bushing  68  extends downwardly. 
     The right hand upper cap (not shown) is a mirror image of the left hand upper cap  92 . The lower caps for the flat doors  19  are substantially similar to the lower cap  28 , except for the flat front edge of the cap for the flat doors, and a contoured front edge of the caps for the contoured doors. 
     The inside of the freezer door  14  is shown in more detail in  FIGS. 11 and 12 . The freezer door  14  includes an outer metallic panel  110 , and upper cap  112 , a lower cap  114 , and an inner molded liner  116 . The caps  112 ,  114  are preferably molded plastic and mount onto the freezer panel  110 . 
     More particularly, the freezer panel  110  includes horizontally disposed inwardly turned front lip  118  and inwardly turned side lips  121 ,  123 , as seen in  FIG. 13 . The upper freezer cap is shown in  FIGS. 14A-14G . The cap  112  includes a front edge  124  with the channel  126  extending there along, and opposite side channels  128 ,  130 . The channels  126 ,  128  and  130  are adapted to mechanically receive the panel lips  118 ,  121 ,  123 , respectively, to mount the upper cap  112  onto the freezer panel  110 . The upper cap  112  also includes resilient fingers  132  with ratchet teeth  134  on the ends thereof, similar to the tab  48  with teeth  52  on the upper cap  26  for the fresh food door  12 . The tabs  132  with teeth  134  on each end of the upper freezer cap  112  are adapted to ratchet over the J-shaped lips  120 ,  122  of the freezer panel  110  to mount the cap  112  to the panel  110 , while accommodating manufacturing variances in the panel  110 . 
     The lower freezer cap  114  is shown in  FIGS. 15A through 15G  mounts in the same manner as the upper freezer cap  112 . The lower freezer cap  114  includes a front edge  136  with a channel  138  extending there along. Side channels  140 ,  142  are provided in each end of the lower cap  114 . The channels  138 ,  140  and  142  are adapted to receive inwardly turned lips (not shown) on the lower edge of the freezer door  14  to mechanically mount the cap  114  to the panel  110 . 
     After the upper and lower caps  112 ,  114  are mounted on the panel  110 , the liner  116  is mounted to the panel  110  in a conventional manner. Insulative foam is then supplied to the interior of the door  14  through a hole  144  in the lower cap  114 . Vent slots  146  are provided in the lower cap  114  so as to expel air from between the panel  110  and the liner  116  during the foaming process. The cured foam adheres the panel  110 , upper cap  112 , lower cap  114 , and liner  116  together. 
     It is understood that the contour and flat door panels may be welded and then painted, or more preferably, be pre-painted without welding. In pre-painted door panels, end caps are preferably used at both the top and bottom. On welded, post-painted door panels, use of the end caps may be limited to the tops of the doors, so as to hide the hinges. 
     The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives.