Patent Publication Number: US-8118947-B2

Title: Sealing device for a dishwasher, and associated apparatus and method

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to dishwashers and, more particularly, to a sealing device for a dishwasher, and associated apparatus and method. 
     2. Description of Related Art 
     A dishwasher generally includes a tub having a forward-facing vertical opening, wherein a door is engaged with the tub so as to be pivotable about the lower end of the tub and to close the tub opening during the washing process. The tub is only partially filled with wash water during the washing process. In such instances, the limited amount of water is re-circulated by a circulation pump through the wash arms of the dishwasher and over the dishware to clean the dishware within the tub. However, because of the manner in which the wash water is re-circulated, the wash water may splash onto or otherwise contact many components within the tub, including any seals configured to retain the water within the tub. As such, there may be opportunities for water leaks to occur. For example, the tub may include a “tub dam” about the lower end of the tub opening to provide a “dam” for containing a particular level of the wash water within the tub. Leakage may sometimes occur by the wash water flowing over the “dam” as evidenced by a leak on the floor in front of the dishwasher unit. In another example, the wash water re-circulated through the wash arms may splash against or otherwise flow toward the seal between the front opening of the tub and the closed door, thereby providing further opportunity for leakage. 
     Thus, there exists a need for an apparatus and method to prevent water from escaping/leaking from a dishwasher, so as to reduce the risk of water damage due to such leaks and to reduce or minimize service calls that result therefrom. Such a method and apparatus should be relatively simple, readily implemented, cost effective, and capable of being retrofitted to existing dishwasher units. 
     BRIEF SUMMARY OF THE INVENTION 
     The above and other needs are met by the present invention which, in one embodiment, provides a sealing device for a dishwasher. Such a sealing device comprises at least one flange member, with each flange member being adapted to interact with at least one of a gasket member, a tub portion, and a door member. Each flange member is configured to extend along at least one of the opposing sides of a front opening of the tub portion. Each flange member is cantilevered with respect to the at least one of the gasket member, the tub portion, and the door member, so as to extend between each opposing side of the front opening of the tub portion and the door member, upon closing thereof, so as to separate the tub portion from the seal and to deflect washing fluid within the tub portion away from the gasket member forming the seal between the door member and the tub portion. 
     Another aspect of the present invention provides a dishwasher comprising a tub portion defining a front opening for receiving dishware therethrough, the front opening having opposing sides. A door member is pivotably engaged at the lower end of the tub portion for selectively allowing access to the tub portion through the front opening. A gasket member is configured to be received in operable engagement with one of the tub portion and the door member along the opposing sides of the front opening. The gasket member is configured to interact with the other of the tub portion and the door member to form a seal therebetween when the door member is pivoted to a closed position with respect to the front opening. The dishwasher further comprises at least one flange member, with each flange member being configured to interact with at least one of the gasket member, the tub portion about the opposing sides, and the door member about the opposing sides. Each flange member is configured to extend along at least one opposing side of the front opening of the tub portion. Each flange member is cantilevered with respect to the at least one of the gasket member, the tub portion about the opposing sides, and the door member about the opposing sides, so as to extend between each opposing side of the front opening of the tub portion and the door member, upon closing thereof, so as to separate the tub portion from the seal and to deflect washing fluid within the tub portion away from the gasket member forming the seal between the door member and the tub portion. 
     Yet another aspect of the present invention comprises a method of sealing a dishwasher appliance, wherein the dishwasher appliance includes a tub portion defining a front opening therethrough into the tub portion. The dishwasher appliance further includes a door member pivotably engaged with a lower end of the tub portion for selectively allowing access to the tub portion. At least one of the door member and the tub portion is adapted to receive a gasket member in operable engagement therewith about the front opening, with the gasket member extending along opposing sides of one of the door member and the tub portion, about the front opening of the tub portion, and being adapted to interact with the other of the door member and the tub portion to form a seal therebetween. Such a method comprises operably engaging a flange member with at least one of the gasket member, the tub portion about the opposing sides, and the door member about the opposing sides so as to extend between each opposing side of the front opening of the tub portion and the door member, upon closing thereof, such that the flange member separates the tub portion from the seal and deflects washing fluid within the tub portion away from the gasket member forming the seal between the door member and the tub portion. 
     Embodiments of the present invention thus provide significant advantages as disclosed herein in further detail. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
       Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale and which do not necessarily illustrate actual geometries, and wherein: 
         FIGS. 1 and 2  schematically illustrate perspective views of a prior art apparatus adapted to be implemented within a dishwasher appliance; 
         FIGS. 3 and 4  schematically illustrate cross-sectional perspective views of the prior art apparatus of  FIG. 1  implemented within a dishwasher appliance; 
         FIG. 5  schematically illustrates a cross-sectional perspective view of a dishwasher appliance implementing a deflector member according to one embodiment of the present invention; 
         FIG. 6  schematically illustrates a perspective view of a tub portion of a dishwasher appliance implementing a deflector member according to one embodiment of the present invention; 
         FIG. 7  schematically illustrates a cross-sectional plan view of a dishwasher appliance implementing a deflector member according to one embodiment of the present invention; 
         FIG. 8  illustrates a perspective view of a deflector member adapted for implementation into a dishwasher appliance, according to one embodiment of the present invention; 
         FIG. 9  illustrates a plan view of the deflector member of  FIG. 8 , according to one embodiment of the present invention; 
         FIG. 10  illustrates a plan view of a deflector member adapted for implementation into a dishwasher appliance, according to another embodiment of the present invention; 
         FIG. 11  schematically illustrates a perspective view of a tub portion of a dishwasher appliance implementing the deflector member of  FIG. 10 , according to one embodiment of the present invention; and 
         FIG. 12  schematically illustrates a cross-sectional plan view of a of a dishwasher appliance implementing the deflector member of  FIG. 10 , according to one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. 
     As shown in  FIGS. 3-7  and  12 - 13 , a dishwasher appliance typically includes a door  10  pivotable about the lower end of a tub  20 , adjacent to a substantially vertical front opening defined by the tub  20 , wherein a user may selectively pivot the door  10  between a substantially vertical “closed” position (in which the door  10  covers the front opening) and a substantially horizontal “open” position, where the door  10  is generally parallel with a supporting floor surface (i.e. perpendicular to the front opening). The door  10  in the open position thus allows one or more racks to be moved into and out of the tub so as to permit loading and unloading of dishware when the door  10  of the dishwasher appliance is in an “open” position. Door  10  may be hinged or otherwise engaged with the tub so as to be capable of pivoting about the lower end of the tub  20 . The tub  20  may be comprised of a plurality of supporting walls that define the front opening, wherein such walls may be, in some instances, integral with one another. A gasket member  50  may be provided for aiding in sealing the door  10  with the tub  20  about the front opening, wherein the gasket member  50  may be formed or otherwise engaged about the front opening of the tub  20 . For example, the front opening may be defined by a pair of opposing and substantially vertical sidewalls  24 , wherein the portion of the sidewalls  24  proximate to the front opening may define a channel  26  for receiving the gasket member  50  (which may include ribs to provide an interference fit with the gasket member  50  within the channel  26 ), wherein the channel  26  may extend approximately the entire height of the sidewalls  24 . 
     The gasket member  50  may be received within the channel  26  so as to engage a side portion or flange  12  of door  10  to form a water-tight seal with the tub  20  during operation of the dishwasher. In some instances, the gasket member  50  may comprise a thermoplastic material configured to resiliently contact the flange  12  of door  10 . In some instances, though the gasket member  50  is shown in engagement with the tub  20 , one skilled in the art will appreciate that the door  10  may be alternatively configured to receive the gasket member  50 , wherein the gasket member  50  moves with the door  10  as it pivots so as to interface with a portion of the front opening of the tub  20  to form a seal therewith. For example, the door member  10  may include or define channel  26  for receiving the gasket member  50 . In any instance, the gasket member  50  may extend along opposing sides of the door  10  and/or the tub  20 , about the front opening of the tub  20 , so as to interact with the door  10  and/or tub  20  to form the seal/interface between the door  10  and the tub  20  about the front opening. 
       FIGS. 1-4  schematically illustrate a prior art sealing arrangement between the door  10  and the tub  20  of a dishwasher during operation thereof. Such a prior art apparatus comprises a laterally-extending elongate wiper member  40  that is installed on the door  10  of the dishwasher. The wiper member  40  comprises a main body  42  and a pair of winged portions  44  attached on opposing ends of the main body  42  by, for example, ultrasonic welding. Both the main body  42  and the winged portions  44  consist of a hard plastic portion to provide structure and soft portions  46 A,  46 B (for example, comprised of “Sanoprene™”) to aid in sealing. Such components are typically manufactured using a co-extrusion process. When the door  10  is installed on the tub  20 , the majority of paths for the water to exit the tub  20  (i.e., leak) are blocked by the interface between the door  10  and the gasket member  50 . The lower soft sealing portion  46 A of the main body  42  of the wiper member  40  seals against the bottom surface  22  of the tub  20 , preventing the water from escaping between the wiper member  40  and the tub  20 . However, if water from the water jets of a spray arm (used to spray water onto the dishware disposed within the tub) impinges on or is otherwise directed toward the corner defined by the tub  20 /door  10  interface, the water may move along the face of the wiper member  40  and can escape through the interface between the ends of the winged portions  44 /sealing portion  46 B of the wiper member  40  and the corresponding side wall  24  of the tub  20 . The winged portions  44  at the opposing ends of the wiper member  40  are generally intended to prevent this leakage at the forward corners of the tub  20 . However, such measures may result in additional costs related to attaching the winged portions  44  to the main body  42 . Further, such apparatuses may also be sensitive to the proper location of the door  10  in that, with normal variation associated with manufacturing, the dishwasher may experience leakage proximate to the forward corners of the tub  20  if the winged portions  44  happen to be misaligned. Also, the addition of the winged portions  44  to the wiper member  40  may result in difficulties assembling the door  10  to the tub  20 , thereby increasing manufacturing costs and time, and possibly decreasing the effectiveness of the wiper member  40 . 
     Accordingly, embodiments of the present invention are particularly configured to prevent water from escaping/leaking from between the door and the tub of a dishwasher during operation thereof, so as to reduce the risk of water damage due to such leaks and to reduce or minimize service calls that result therefrom, while also improving the ease of manufacture thereof by minimizing variances in assembling the components of a dishwasher appliance. Embodiments of the present invention provide a flange member configured to engage at least one of the tub and door of the dishwasher so as to prevent water being sprayed from at least one spray arm disposed in the tub portion from impinging on a seal formed between the tub and the door during operation of the dishwasher. 
       FIGS. 5-9  schematically illustrate a flange member for a dishwasher according to one embodiment of the present invention, the flange member being generally indicated by the numeral  100 . Such a flange member  100  may include a main body portion  102  configured to be received within, or otherwise at least partially conform to, the channel  26  of the tub  20 . For example, the main body portion  102  may be configured to fit within the channel  26 . That is, portions of the main body portion  102  may form a substantially right-angled corner portion configured to conformally engage a corner of the channel  26  (e.g., along side wall  91  and rear wall  92  of the channel  26 ). In other instances, the main body portion  102  may be configured to conform to the entire shape of the channel  26  (e.g., a substantially U-shaped portion corresponding to the shape of the channel). In other embodiments, the channel  26  may be formed on or otherwise defined by the door member  10 . In any instance, the main body portion  102  interacts with and is secured in the portion of the tub  20  defining the channel  26 . The flange  100  may, in some instances, extend from the bottom surface  22  of the tub  20  to the top portion (not shown) thereof. In other instances, the flange  100  may partially extend from the bottom surface  22  along the sidewall  24 , without extending to the top portion of the tub  20 . 
     The main body portion  102  may be constructed of any suitable material and may be comprised of, for example, a hardened polymer material so as to provide structural support, rigidity, and robustness to the deflector member  100 . The main body portion  102  may be positioned in the channel  26  of the tub  20 , and a gasket member  50  may then be received within the channel  26 . In one embodiment, the gasket member  50  may be inserted into the channel  26  such that the main body portion  102  is disposed between the channel  26  and the gasket member  50 , thereby securing the flange member  100  with respect to the channel  26  (i.e., both by securing the flange  100  in the channel  26  and by preventing movement of the flange  100  along the channel  26 ). For instance, the gasket member  50  may be secured in channel  26  by an interference fit therebetween, which, in some instance, also secures the main body portion  102  within channel  26  by an interference fit. 
     In some embodiments, the flange member  100  may also include a wing portion  104  extending laterally outwardly from the main body portion  102  away from the channel  26  in a cantilevered manner. For example, the wing portion  104  may extend or cantilever from the main body portion  102  at an angle such that the wing portion  104  contacts the door  10  at an acute angle. Although, in some instances, the wing portion  104  may extend/cantilever from the main body portion  102  at a right angle when necessary or desirable. When the door  10  is closed with respect to the tub  20 , the wing portion  104  extends toward the door  10  (or toward the tub  20  if engaged with and secured to the door  10 ), in some instances, to interface therewith. Further, in some instances, a seal may be formed therebetween. The wing portion  104  of the flange  100  thus essentially separates the interior of the tub  20  from the seal formed between the tub  20  and the door  10  via the gasket member  50 . As such, water sprayed by the spray arms, which ends up being deflected or otherwise directed to the tub  20 /door  10  interface involving the gasket member  50 , ends up being prevented by the wing portion  104  from reaching the sealed interface. As such, any water stopped by the wing portion  104  is diverted back into the tub  20 . That is, the wing portion  104  is secured in a particular position with the door  10  in the closed position, so as to extend between the tub  20  and the door  10  about the opposing sides to deflect water away from the seal member and back into the tub  20 . In some instances, the wing portion  104  may extend from the bottom surface  22  of the tub  20  to the top portion thereof or, in other embodiments, extend only partially therebetween. In other instances, the flange member  100  extends between the tub  20  and the door member  10  at least about the lower end of the tub  20 . 
     In some embodiments, the wing portion  104  may be comprised of any suitable material and, in some instances, may be comprised of a soft polymer material configured to resiliently interact with the door  10  and the tub  20 . In some instances, the flange member  100  may be co-extruded, with the main body portion  102  comprising a hardened plastic material to provide structure and the wing portion  104  comprising a soft plastic material (e.g., “Sanoprene™”) to aid in sealing. In such instances, the flange member  100  may be cost-effectively extruded rather than injection molded (a more costly process), and does not require a locating feature associated with the tub for implementing the flange member  100  (thereby reducing tooling cost and time to implementation). 
     The flange member  100  may be configured for refitting into existing units or for implementation into new dishwasher units. In some instances, the flange member  100  may be used on both sides of the front opening of the tub  20 . In instances where the flange member  100  is positioned on both sides, the opposing flange members  100  cooperate between the tub  20  and the door  10  about each opposed side of the front opening. 
     As shown in  FIGS. 11-13 , other embodiments of the present invention may provide a flange member  200  for deflecting water away from the seal between the door  10  and the tub  20 , proximate to the front opening, during operation of the dishwasher appliance. The flange member  200  may comprise a gasket member  250  and a wing portion  204  extending outwardly in a cantilevered manner from the gasket member  250 . In some instances, the gasket member  250  and the wing portion  204  are integrally formed. The gasket member  250  may be received and secured within the channel  26 , which may be formed on or defined by the door  10  or the tub  20 . As such, the gasket member  250  may be positioned with respect to the channel  26  to interact with the flange  12  of the door  10  to form a seal therebetween, while the wing portion  204  extends between the door  10  and the tub  20  about the opposing sides to deflect water away from the gasket member  250  forming the seal between the tub  20  and the door  10 , via the flange  12 . 
     The gasket member  250  and the wing portion  204  may be comprised of any suitable material or combinations of materials and, in some instances, may be comprised of the same material such that the entire flange member  200  may be integrally extruded. For example, the flange member  200  may be extruded from a thermoplastic elastomer material, such as rubber. In some embodiments, the flange member  200  may be comprised of a soft polymer material capable of interacting with the door  10  or flange  12  associated therewith to form a seal therebetween. 
     In some embodiments, the flange member  100  or  200  may extend about the front opening so as to extend along both opposing sides thereof. In such embodiments, the flange member  100  or  200  may extend about the top or bottom of the front opening, in addition to the opposing sides, defined by the tub  20  so as extend about at least three sides defining the front opening. In any instance, the flange member  100  or  200  may be configured to cooperate with the gasket member, tub, and/or door to deflect water away from the sealing interface between the door  10  and the tub  20 . 
     Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.