Abstract:
A handle assembly includes a handle body including a handle body having at least one attachment portion proximate a respective end of the handle body, wherein the at least one attachment portion is configured to engage a door panel. At least one latch member is coupled to a respective one of the at least one attachment portion, and the at least one latch member is configured to attach the at least one attachment portion to the door panel. At least one protective member is coupled to a respective one of the at least one attachment portion. The at least one protective member facilitates reducing damage to the door panel during installation of the handle assembly to the door panel.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates generally to home appliances, and more particularly, to methods and apparatus for assembling a handle assembly with a home appliance. 
     Known home appliances, such as refrigerators, generally include a housing defining at least one compartment for storage of food items, and at least one door for accessing the compartment. A handle is typically coupled to an exterior surface of the door for accessing the compartments. In at least some known appliances, fasteners are used to fasten the handle to the door by extending the fasteners through the door from the inside of the door. This known type of construction is a reliable method of coupling handles to the door. However, in at least some known appliances, this type of mounting method is not feasible or is undesirable. For example, in home appliances utilizing a foam in place construction for the door, the fasteners typically do not extend through the inside portion of the door. Additionally, it may be undesirable to a consumer if the fasteners are visible from either side of the door. Moreover, the mounting method of extending fasteners through the door typically provides a gap between the handle and the door after assembly which may be visible to the consumer. 
     As a result, at least some known appliances have been developed which utilize sliding ramp components coupled to an exterior of the door, wherein the handle is vertically mounted to the ramp components using a sliding motion. However, during the process of engaging the ramp components, the sliding motion can cause marring and/or scratching, especially on a high gloss door. This marring or scratching is visible by the consumer and highly undesirable. Moreover, these known appliances utilizing the ramp components for mounting the handle typically require a large pull in force to fully mount the handle to the door, and to minimize the gap between the handle and the door. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one aspect, a handle assembly is provided. The handle assembly includes a handle body including a handle body having at least one attachment portion proximate a respective end of the handle body, wherein the at least one attachment portion is configured to engage a door panel. At least one latch member is coupled to a respective one of the at least one attachment portion, and the at least one latch member is configured to attach the at least one attachment portion to the door panel. At least one protective member is coupled to a respective one of the at least one attachment portion. The at least one protective member facilitates reducing damage to the door panel during installation of the handle assembly to the door panel. 
     In another aspect, a home appliance is provided. The home appliance includes a housing defining at least one compartment therein, at least one door for accessing the compartment, and a door handle assembly coupled to the door. The door handle assembly includes a handle body having a first attachment portion for attaching a first end of the handle body to the door, and a second attachment portion for attaching an opposing second end of the handle body to the door. The door handle assembly further includes a first latch member coupled to the first attachment portion, and a second latch member coupled to the second attachment portion, wherein the latch members are configured to engage the door for securing the handle body to the door. The door handle assembly also includes a first protective member coupled to the first attachment portion, and a second protective member coupled to the second attachment portion, wherein the protective members facilitate reducing damage to the door during installation of the handle assembly to the door. 
     In still another aspect, a method of assembling an appliance is provided, wherein the appliance includes a door having at least one mounting flange extending from an exterior surface of the door, and a door handle assembly having at least one latch member and at least one mounting surface. The method includes securely coupling the at least one latch member to the door handle assembly, and coupling a protective member to each mounting surface of the door handle assembly. The method also includes engaging the at least one latch member with the at least one mounting flange of the door such that only the protective members contact the exterior surface of the door during installation of the door handle assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a refrigerator including an exemplary door handle assembly attached thereto; 
         FIG. 2  is an exploded perspective view of the door handle assembly shown in  FIG. 1  and mounting portions of a door of the refrigerator; and 
         FIG. 3  is a front elevational view of a mounting portion of the door assembled with a latch member of the handle assembly shown in  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a perspective view of a refrigerator  10  including an exemplary door handle assembly  11 . Refrigerator  10  generally includes a housing  12  defining a fresh food compartment  14  and a freezer compartment  16 . A fresh food door  18  is rotatably hinged to an edge of housing  12  for accessing fresh food compartment  14 . A freezer door  20  is arranged for accessing freezer compartment  16 . Handle assembly  11  is coupled to fresh food door  18  for opening operation. It is recognized, however, that the benefits of the present invention may be achieved in refrigerators having other configurations, such as a side by side configuration, or other home appliances, such as conventional ovens, microwave ovens, dishwashers, and the like. Consequently, the description set forth herein is for illustrative purposes only and is not intended to limit the invention. 
       FIG. 2  is an exploded perspective view of door handle assembly  11  and mounting portions or fastening members  24  extending from refrigerator door  18 . In the exemplary embodiment, door handle assembly  11  includes a handle body  26 , a first latch member  28 , a second latch member  30 , a first protective member  32 , and a second protective member  34 . A plurality of fasteners  36  are utilized to couple latch members  28  and  30  to handle body  26 . 
     In the exemplary embodiment, handle body  26  includes a grip portion  38  extending substantially along a longitudinal axis  40  between a first, or upper, attachment portion  42  and a second, or lower, attachment portion  44 . Attachment portions  42  and  44  facilitate attaching respective first and second ends of handle body  26  to an exterior surface of fresh food door  18 . In an alternative embodiment, handle assembly  11  includes a single attachment portion for attaching to door  18 . 
     In the exemplary embodiment, each attachment portion  42  and  44  includes a mounting surface  50  and an exterior edge  52  for interfacing with door  18 . The interface defined by mounting surface  50  and exterior edge  52  is substantially planar and extends substantially perpendicularly to longitudinal axis  40 . Mounting surface  50  provides a flat area to mount protective members  32  and  34 . In the exemplary embodiment, mounting surfaces  50  are provided at an upper edge of upper attachment portion  42  and at a lower edge of lower attachment portion  44 . In an alternative embodiment, mounting surfaces  50  are provided at both upper and lower edges of each attachment portion  42  and  44 . Additionally, a recess  54  is defined within each attachment portion  42  and  44  for receiving latch members  28  and  30 . Each recess  54  is accessed through an opening  56  defined by exterior edge  52 . 
     Latch members  28  and  30  each include a body  58  extending between attachment arms  60 . In the exemplary embodiment, latch members  28  and  30  are fabricated from a metal material. Body  58  includes a ramp opening  62  for mating with mounting portions  24  extending from door  18 . In the exemplary embodiment, ramp opening  62  has a bulbous shape including a first, or head, portion  64  that is wider than a second, or neck, portion  66 . In one embodiment, second portion  66  is tapered such that, as the edges of ramp opening  62  engage mounting portions  24 , latch member  28  or  30  is retained by mounting portion  24  in a friction fit. Moreover, attachment arms  60  are folded over to define a clip. Attachment arms  60  mate with attachment portions  42  and  44  within recesses  54 . Each attachment arm  60  includes a mounting hole  68  for receiving a fastener  36  and for securing latch member  28  or  30  within recess  54 . 
     In the exemplary embodiment, protective members  32  and  34  are fabricated from a low friction film, such as a poly-tetra-fluoro-ethylene material. In the exemplary embodiment, protective members  32  and  34  have a thickness ranged from between approximately 0.003 inches to 0.008 inches. As such, once handle assembly  11  is installed, there is no perceptible gap between edges  52  of attachment portions  42  and  44  and the exterior surface of door  18 . 
     Protective members  32  and  34  are coupled to respective mounting surfaces  50  to reduce, or substantially eliminate contact between handle body  26  and the exterior surface of fresh food door  18 . Specifically, protective members  32  and  34  are coupled to mounting surfaces  50  of attachment portions  42  and  44  to facilitate reducing damage, such as damage from marring or scraping of the exterior surface of fresh food door  18  during installation and/or removal of handle body  26 . In one embodiment, protective members  32  and  34  include an adhesive applied to one surface thereof. Protective members  32  and  34  are coupled to mounting surfaces  50  using adhesive. In an alternative embodiment, protective members  32  and  34  are additionally secured along edges  52  of attachment portions  42  and  44  to reduce damage caused by edges contacting the exterior of door  18 . 
     In the exemplary embodiment, mounting portions  24  each include a mounting flange  70  extending outward from the exterior of refrigerator door  18  and defining a notch or ramp section  72  for retaining latch members  28  or  30  therein. Mounting portions  24  are coupled to refrigerator door  18  in a known manner. In one embodiment, mounting portions  24  are mounted to door  18  by a threaded portion (not shown). Ramp sections  72  are oriented to engage with ramp openings  62  of respective latch members  28  and  30 . Specifically, during assembly, ramp openings  62  slidably engage ramp sections  72  to secure handle assembly  11  to door  18 . 
     During assembly, latch members  28  and  30  are positioned within recess  54  of respective attachment portions  42  and  44 . Fasteners  36  are inserted into mounting holes  68  of attachment arms  60  to secure latch members  28  and  30  to attachment portions  42  and  44 . Next, protective members  32  and  34  are coupled to mounting surface  50  in a predetermined location to facilitate substantially eliminating damage to door  18  during assembly. In one embodiment, protective members  32  and  34  are coupled to mounting surface  50  using an adhesive applied to, for example, mounting surface  50  or protective members  32  and  34 . Finally, handle assembly  11  is coupled to door  18  by coupling latch members  28  and  30  to mounting portions  24 . Specifically, ramp openings  62  are placed over ramp sections  72  and handle assembly  11  is slid along door  18  to engage ramp sections  72 . More specifically, as handle assembly  11  is slid along door  18 , ramp section  72  becomes fully seated within neck portion  66  of opening  62  and handle assembly  11  is secured to refrigerator door  18 . 
     Moreover, as explained above, protective members  32  and  34  are positioned to contact the exterior surface of door  18 . As such, contact between attachment portions  42  and  44  and door  18  is substantially eliminated. Additionally, because protective members  32  and  34  are fabricated from a low friction film, protective members  32  and  34  facilitate reducing the force required to fully couple handle assembly  11  to door  18 . 
       FIG. 3  is a front elevational view of mounting portion  24  assembled with latch member  28  of handle assembly  11 . As illustrated in  FIG. 3 , latch member  28  is securely coupled to attachment portion  42  using fastener  36 . During assembly, ramp opening  62  is positioned over mounting flange  70  such that ramp section  72  is aligned within neck portion  66  of opening  62 . As handle assembly  11  (shown in  FIGS. 1 and 2 ) is moved substantially vertically downward, such as in the direction of arrow A, ramp section  72  becomes fully seated within neck portion  66  and handle assembly  11  is secured to refrigerator door  18  (shown in  FIGS. 1 and 2 ). Moreover,  FIG. 3  illustrates an exemplary position of protective member  32  with respect to attachment portion  42 . Specifically, protective member  32  is positioned along an upper edge of attachment portion  42 . 
     The above described handle assembly is cost-effective and highly-reliable. The assembly includes handle attachment portions having latch members for engaging mounting portions of a refrigerator door. Specifically, the latch portions are slidably coupled to the mounting portions. In the exemplary embodiment, the handle assembly also includes protective members, such as low friction films, that may be applied to the attachment portions in predetermined locations. The protective members substantially eliminate damage to the door during installation of the handle assembly by providing a thin layer between the components. As such, scratching and marring of the door due to installation and removal of the handle assembly is reduced. Moreover, by placing the protective members only in predetermined locations, the handle assembly is fabricated in a cost effective manner. Additionally, because the protective members include a low friction film, the handle assembly is installed quickly and easily compared to conventional handle assemblies. 
     While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.