Patent Publication Number: US-11656023-B2

Title: Handle assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. Provisional application Ser. No. 16/733,968, filed on Jan. 3, 2020, now U.S. Pat. No. 11,300,351, entitled “HANDLE ASSEMBLY,” the disclosure of which is hereby incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE DISCLOSURE 
     The present disclosure generally relates to an appliance, and more specifically, to a handle assembly for an appliance. 
     SUMMARY OF THE DISCLOSURE 
     According to one aspect of the present disclosure, a handle assembly for an appliance includes an elongate arcuate body with a grasping portion that has a first internal support rib and a forward wall that has a second internal support rib. The elongate arcuate body further defines a hollow profile. An insert is disposed within the hollow profile and includes at least one slot that receives at least one of the first internal support rib and the second internal support rib. An end cap is operably coupled to an end of the elongate arcuate body. At least one groove is defined at least in part by the forward wall. 
     According to another aspect of the present disclosure, an appliance includes a door and a handle assembly coupled to the door. The handle assembly includes a body that defines a hollow profile and has a rear grasping portion and a forward wall. A rib is defined on the forward wall within the body and a rib is defined on the rear grasping portion within the body. A metal insert is disposed within the hollow profile of the body. The metal insert defines slots configured to receive the ribs. An end cap is operably coupled to the ribs. 
     According to yet another aspect of the present disclosure, a handle assembly for an appliance includes an elongate arcuate body with a grasping portion that has an arcuate cross-section and a forward wall that together define a hollow profile. The elongate arcuate body further includes a first end and a second end. An insert is disposed at each of the first and second ends of the elongate arcuate body within the hollow profile. An end cap is operably coupled to each insert. 
     These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG.  1    is a side perspective view of an appliance of the present disclosure with doors and a bottom drawer in a closed position; 
         FIG.  2    is a partial front perspective view of the appliance of  FIG.  1    with the doors and bottom drawer in an open position; 
         FIG.  3    is a side perspective view of a door and a handle assembly of the present disclosure; 
         FIG.  4    is a side perspective enlarged view of a handle assembly and a door of the present disclosure; 
         FIG.  5    is a side perspective enlarged view of a handle assembly of the present disclosure; 
         FIG.  6    is a partial side perspective view of a body of a handle assembly of the present disclosure; 
         FIG.  7    is a partial enlarged view of an end of a handle assembly of the present disclosure; 
         FIG.  8    is a partial enlarged view of a metal insert and an end cap of the present disclosure with a body of a handle assembly in phantom; 
         FIG.  9 A  is a bottom perspective view of a metal insert of the present disclosure; 
         FIG.  9 B  is a top perspective view of the metal insert of  FIG.  9 A ; 
         FIG.  10    is a partial enlarged view of a support plate and an end cap of the present disclosure with a body of a handle assembly in phantom; 
         FIG.  11    is a partial enlarged side perspective view of an end cap of the present disclosure with a handle assembly, a metal bracket, and a support plate in phantom; and 
         FIG.  12    is a flow diagram for a method of manufacturing a handle assembly of the present disclosure. 
     
    
    
     The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein. 
     DETAILED DESCRIPTION 
     The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a handle assembly. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements. 
     For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in  FIG.  1   . Unless stated otherwise, the term “front” shall refer to the surface of the element closer to an intended viewer, and the term “rear” shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     The terms “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. 
     Referring to  FIGS.  1 - 12   , reference numeral  10  generally designates an appliance that includes a cabinet  14 . A door  18  is coupled to the cabinet  14 , and a handle assembly  22  is coupled to the door  18 . The handle assembly  22  includes a body  26  that defines a hollow profile  30  and has a rear grasping portion  34  and a forward wall  38 . Ribs  42  are defined on the forward wall  38  within the body  26 . A metal insert  50  is disposed within the hollow profile  30  of the body  26 . The metal insert  50  defines slots  54  configured to receive the ribs  42 , and an end cap  58  is operably coupled to the ribs  42 . 
     Referring to  FIGS.  1 - 4   , the appliance  10  is illustrated as a French-door style refrigerator with a bottom-mounted drawer. However, it is also contemplated that the handle assembly  22  may be used in other various appliances that include, but are not limited to, refrigerators, freezers, coolers, ovens, dishwashers, laundry appliances, and other similar appliances and fixtures within household and commercial settings. The appliance  10  includes first and second doors  70 ,  74  hingedly coupled to the cabinet  14  via hinges  76  and a bottom drawer  78  operably coupled to the cabinet  14 . As referenced herein, the term door  18  may refer to any one of the first and second doors  70 ,  74  as well as the bottom drawer  78 . The handle assembly  22  is coupled to each of the first and second doors  70 ,  74  as well as the bottom drawer  78  so each is operable between open and closed positions  82 ,  86  by applying a force on the handle assembly  22 . It is generally contemplated that the handle assembly  22  is vertically oriented on the first and second doors  70 ,  74 , respectively, and is horizontally oriented on the bottom drawer  78 . It is also contemplated that the handle assembly  22  may be oriented in any functional manner relative to the respective door  18 . 
     In addition to the cabinet  14 , the first and second doors  70 ,  74  and the bottom drawer  78  define an outer wrapper  90  of the appliance  10 . The outer wrapper  90  may be formed from a metal, plastic, or other material typically used in the art. The outer wrapper  90 , in relation to the door  18 , defines holes  94  through which coupling features  98  extend to couple the handle assembly  22  to each respective door  18 . The coupling features  98  are coupled to support plates  102  positioned on an inner surface  106  of the door  18  proximate to the respective holes  94 . The support plates  102  are configured to receive a pulling force applied on the handle assembly  22  in particular during the opening of the door  18 . The support plates  102  are at least partially coupled to the door  18  by a standard fastening member, such as a screw, rivet, bolt, or any other standard fastening member known in the art. The support plates  102  are coupled to the doors  18  by the coupling features  98  outwardly extend from the support plates  102  and through the door  18  to couple the handle assembly  22  to the door  18 . In general, the coupling features  98  are also operably coupled to the metal insert  50 , which is positioned within the body  26  of the handle assembly  22 , discussed in further detail below. 
     Referring to  FIGS.  3 - 6   , the handle assembly  22  is typically coupled to the door  18  at two attachment points  108 , which are defined by the location of the holes  94  and the support plates  102  relative to the respective door  18 . Additionally, the attachment points  108  generally correspond to opposing ends  126  of the body  26  of the handle assembly  22 . The body  26  extends between the two attachment points  108  to define a length L of the body  26 . As illustrated, the body  26  generally bows along the length L relative to the outer wrapper  90 . The bowing of the body  26  results in a generally arcuate shape, such that an arcuate central portion  114  of the body is defined between first and second ends  110 ,  112 . In addition, the forward wall  38  similarly follows the bowed or arcuate shape of the body  26  from the first end  110  of the body  26  to the second end  112 . It is generally contemplated that the first and second ends  110 ,  112  correspond to the opposing ends  126 . 
     Typically, the forward wall  38  has a generally planar cross-section taken at any point along the length L of the body  26 , such that an exterior surface  116  of the forward wall  38  is generally flat from a first side  118  to a second side  122  of the body  26 . The body  26  is formed from a single, pultruded piece of material in that the outer and grasping portions  38 ,  34  are integrally formed and define the hollow profile  30  therebetween. While the forward wall  38  has a generally planar cross-section, the grasping portion  34  is rounded from the first side  118  to the second side  122  of the body  26  to define a generally parabolic cross-section. While the hollow profile  30  may be formed from a variety of manufacturing methods, it is generally contemplated that the hollow profile  30  may be formed by the pultrusion of the body  26 . Pultrusion is a method in which a material is simultaneously pulled through a mold and extruded to define a shape and form. Thus, while the hollow profile  30  may be defined by the forward wall  38  and the grasping portion  34 , each of the forward wall  38  and the grasping portion  34  may be defined by the removal of material in creating the hollow profile  30 . However, it is also contemplated that the forward wall  38  may be coupled to the grasping portion  34  to then define the hollow profile  30  of the body  26 . 
     In general, the forward wall  38  can have a decorative layer or finish, such that the forward wall  38  may be constructed to have a particular aesthetic appearance. The grasping portion  34  may be constructed to have a tactile feature  124  that can at least partially increase surface resistance between a user and the grasping portion  34 . With the tactile feature  124 , when a user grasps the body  26 , the user can at least tactically distinguish the grasping portion  34  from the forward wall  38 . By way of example, not limitation, the tactile feature  124  may be a textured material that resists slipping, such as rubber or silicon, to increase the user&#39;s grip on the body  26  of the handle assembly  22 . While the tactile feature  124  may be a separate tactile material applied to the grasping portion  34 , such as silicon, it is also contemplated that the tactile feature  124  may be a coating, a film, or any other material that minimizes the likelihood of the user&#39;s grip slipping from the grasping portion  34 . Additionally or alternatively, the tactile feature  124  may be integrally formed with the grasping portion  34 , such that the grasping portion  34  defines the tactile feature  124 . 
     Referring to  FIGS.  6 - 9 B , each opposing end  126  of the body  26  generally define an oblique orientation  130  of the grasping portion  34 , such that the grasping portion  34  tapers toward the respective end  126 . An arcuate feature  134  of the grasping portion  34  is defined along the oblique orientation  130  and has an apex  138  that is oriented toward the arcuate central portion  114  ( FIG.  5   ) of the body  26  and away from a base  142  of the arcuate feature  134 . Extensions  146  project from the base  142  from which a ledge  150  extends along the length L ( FIG.  5   ) of the body  26 . A groove  154  is defined beneath the extensions  146  and the ledge  150 . The groove  154  receives the end cap  58  and the metal insert  50 , discussed in further detail below. The extensions  146  and the ledge  150  form a barrier that engages the end cap  58  when a pulling force is applied to the handle assembly  22 . It is also contemplated that the metal insert  50  may have laterally extending flanges  156  positioned beneath the ledge  150  to at least partially retain the metal insert  50  within the hollow profile  30  of the body  26 . 
     The metal insert  50  is positioned proximate to the arcuate feature  134  within the hollow profile  30  of the body  26 . The metal insert  50  defines an inner mounting aperture  170  and a side mounting aperture  174 , collectively mounting apertures  178 . The apex  138  of the arcuate feature  134  partially frames the inner mounting aperture  170 , such that the metal insert  50  is at least partially disposed beneath the grasping portion  34 . The inner mounting aperture  170  receives one of the coupling features  98  that outwardly extends from the door  18  ( FIG.  4   ). A fastener  182  extends into an opening  186  defined by the grasping portion  34  and is disposed within the side mounting aperture  174  of the metal insert  50 . The fastener  182  engages the coupling feature  98  to further secure the handle assembly  22  to the door  18 . In addition, the fastener  182  couples the metal insert  50  to the grasping portion  34  so the metal insert  50  is coupled to both the forward wall  38  and the grasping portion  34  of the body  26 . Stated differently, the fastener  182  extends through the opening  186  in either the first or second side  118 ,  122  of the body  26  to couple the grasping portion  34  to the metal insert  50 . In addition, the grasping portion  34  can be bent against the metal insert  50  to further secure the metal insert  50  within the hollow profile  30 , such that frictional engagement couples the metal insert  50  to the body  26 . Additionally, the flanges  156  that extend into the grooves  154  further retain the metal insert  50  within the hollow profile  30 . 
     To create a supportive engagement, the slots  54  of the metal insert  50  are positioned over the ribs  42  defined by an interior surface  46  of the forward wall  38  so the metal insert  50  can be correctly positioned within the hollow profile  30 . The fit of the ribs  42  within the slots  54  minimizes potential shifting movement of the metal insert  50  within the hollow profile  30 . The slots  54  are defined on a support surface  190  of the metal insert  50 , such that if a force is applied to the forward wall  38  near one of the opposing ends  126  of the handle assembly  22 , the support surface  190  at least partially distributes the force applied over a large area. The metal insert  50  also has an engagement surface  194  which defines a channel  198  that can engage a support rib  202  defined by the grasping portion  34 . Thus, when a pulling force is exerted on the grasping portion  34 , the pulling force is at least partially spread across the engagement surface  194  along the grasping portion  34  rather than localized at a particular point. Additionally, the metal insert  50  is generally formed to follow a similar curvature of the grasping portion  34  to provide additional structural support. 
     Referring to  FIGS.  6 ,  7 ,  10 , and  11   , the end cap  58  is positioned within the hollow profile  30  and is coupled to the interior surface  46  of the forward wall  38  of the body  26 . Once positioned within the hollow profile  30 , the end cap  58  and the arcuate feature  134  define the attachment portion  206  ( FIG.  5   ) where the handle assembly  22  is coupled to the door  18  ( FIG.  4   ). An elongated notch  208  is defined by the end cap  58  and is disposed over and coupled to one of the ribs  42  of the forward wall  38 . In addition, a retention feature  210  extends from a proximal edge  214  of the end cap  58  toward the apex  138  of the arcuate feature  134 . The proximal edge  214  is defined as the edge closest to the body  26 . As depicted, the retention feature  210  includes three planar portions extending toward the arcuate central portion  114  ( FIG.  5   ) of the body  26 . The retention feature  210  extends beneath the extensions  146  of the base  142  of the arcuate feature  134 . Thus, the retention feature  210  is coupled to the arcuate feature  134  beneath the extensions  146  and the forward wall  38  by the elongated notch  208  coupled to the ribs  42 . 
     The retention feature  210  of the end cap  58  may include first and second projections  218 ,  222  that extend along the first and second sides  118 ,  122  of the body  26 , respectively. The first and second projections  218 ,  222  are positioned beneath the extensions  146  of the base  142  of the arcuate feature  134 . In addition, the first and second projections  218 ,  222  inwardly extend beneath the ledge  150  toward the arcuate central portion  114  ( FIG.  5   ) of the body  26 . The retention feature  210  further includes an elongated feature  226  on which the elongated notch  208  of the end cap  58  is defined. The elongated feature  226  may further define a locating recess  230  configured to align the end cap  58  relative to the metal insert  50 , such that the elongated feature  226  may abut the metal insert  50 . By way of example, not limitation, the metal insert  50  may have a locating feature  232  that may be at least partially received by the locating recess  230  of the elongated feature  226  to align the end cap  58  with the metal insert  50 . The first and second projections  218 ,  222  and the elongated feature  226  of the retention feature  210  extend from the proximal edge  214  of the end cap  58  toward the arcuate feature  134 . 
     A distal edge  234  of the end cap  58  is generally orthogonal relative to the oblique orientation  130  of the arcuate feature  134  and corresponds to a terminal end  238  of the end cap  58 . The terminal end  238  extends between the outer wrapper  90  ( FIG.  1   ) of the cabinet  14  ( FIG.  1   ) and the forward wall  38  of the handle assembly  22 . In addition, the terminal end  238  extends orthogonally relative to the length L ( FIG.  5   ) of the body  26 , such that each of the opposing ends  126  of the handle assembly  22  terminates at the terminal end  238 . The end cap  58  tapers from the proximal edge  214  to the distal edge  234  terminating at the terminal end  238  in a similar manner as the oblique orientation  130  of the arcuate feature  134 . Stated differently, the proximal edge  214  is raised slightly relative to the distal edge  234  of the end cap  58 . As mentioned above, the end cap  58  can be inserted into the hollow profile  30  of the body  26  beneath the extensions  146  of the arcuate feature  134 . The first and second projections  218 ,  222  engage the extensions  146  of the arcuate feature  134  during the opening and closing of the door  18  ( FIG.  4   ). Thus, when a pulling force is applied to the handle assembly  22 , the end cap  58  may at least partially engage the door  18  ( FIG.  4   ). Although depicted as first and second projections  218 ,  222  and the elongated feature  226 , the retention feature  210  is also contemplated to have a single protrusion extending into the hollow profile  30  of the body  26 . In either construction, the retention feature  210  defines the elongated notch  208  to engage the ribs  42  to secure the end cap  58  to the interior surface  46  of the forward wall  38 . 
     Referring again to  FIGS.  1 - 12   , a method ( 400 ) for manufacturing the handle assembly  22  for the appliance  10  includes extruding the hollow profile  30  from the body  26  of the handle assembly  22  to define the forward wall  38  and the grasping portion  34  (step  404 ). The mounting apertures  178  are defined within the metal insert  50  (step  408 ), and the metal insert  50  is positioned within the hollow profile  30  of the body  26  (step  412 ). The grasping portion  34  of the body  26  is bent to at least partially secure the metal insert  50  (step  416 ). The end cap  58  is coupled to the forward wall  38  of the body  26  (step  420 ). An opening  186  is defined in the body  26  of the handle assembly  22  and corresponds to at least one of the mounting apertures  178  that is defined by the metal insert  50  (step  424 ). During the extrusion process of the hollow profile  30 , the ribs  42  are defined on the interior surface  46  of the forward wall  38  of the body  26  (step  428 ). In addition, the end cap  58  is aligned along the ribs  42  defined by the forward wall  38  (step  432 ), and the end cap  58  is coupled to the ribs  42  (step  436 ). 
     The handle assembly  22  provides a hollow profile  30  that minimizes the weight and cost of production of the handle assembly  22 . In addition, the metal insert  50  provides structural support for the body  26  as well as attachment support for coupling the handle assembly  22  to the door  18 . It is generally advantageous that the grasping portion  34  is generally curved to help retain the metal insert  50  by bending the grasping portion  34  around the metal insert  50 . In addition, the oblique orientation  130  of the arcuate feature  134  of the grasping portion  34  provides an even attachment portion  206  that otherwise would be offset due to the bowing of the body  26 . Accordingly, the handle assembly  22  provides for an improved method of manufacture and overall an improved handle assembly  22  for an appliance. 
     The invention disclosed herein is further summarized in the following paragraphs and is further characterized by combinations of any and all of the various aspects described therein. 
     According to one aspect of the present disclosure, an appliance includes a cabinet. A door is coupled to the cabinet, and a handle assembly is coupled to the door. The handle assembly includes a body that defines a hollow profile and has a rear grasping portion and a forward wall. Ribs are defined on the forward wall within the body. A metal insert is disposed within the hollow profile of the body. The metal insert defines slots that are configured to receive the ribs. An end cap is operably coupled to the ribs. 
     According to another aspect, a grasping portion of a body is arcuate in shape and defines an oblique orientation relative to an end cap. 
     According to yet another aspect, an attachment portion is defined by a grasping portion of a body and an end cap. A handle assembly is coupled to a door at the attachment portion. 
     According to still another aspect, an end cap has a terminal end that extends between a door and a forward wall of a body and is orthogonal relative to a length of the body. 
     According to another aspect, an end cap has a proximal edge that is defined relative to a body and a distal edge. The end cap tapers from the proximal edge to the distal edge. 
     According to another aspect, a grasping portion of a body defines an arcuate feature having an apex that defines a mounting aperture. 
     According to another aspect, a metal insert is coupled to a body by frictional engagement with a grasping portion of the body. 
     According to another aspect of the present disclosure, a handle assembly for an appliance comprises a body that defines a length and has opposite ends, a grasping portion, and a forward wall. The body further defines a hollow profile of the handle assembly. A metal insert is disposed within the hollow profile. An end cap has a proximal edge that is defined relative to the body and a distal edge. The end cap is coupled to at least one of the opposing ends of the body. A terminal end extends along the distal edge of the end cap and orthogonal relative to the length of the body. 
     According to another aspect, an arcuate feature is defined on opposing ends of a body. 
     Each arcuate feature has an apex and a base. 
     According to still another aspect, each apex extends toward a central portion of a body and away from a terminal end. 
     According to yet another aspect, an end cap includes a retention feature that extends from a proximal edge toward an apex of an arcuate feature and is coupled to a forward wall of a body at the proximal edge. 
     According to another aspect, a forward wall of a body defines ribs and a retention feature of an end cap is coupled to ribs. 
     According to yet another aspect, a forward wall and grasping portion each bow along a length of a body. 
     According to another aspect, an attachment portion is defined by a grasping portion and an end cap. 
     According to another aspect, a metal insert defines an inner mounting aperture and a side mounting aperture. A body defines an opening aligned with a side mounting aperture. 
     According to another aspect, an arcuate feature has an apex proximate to a metal insert. The apex further defines an inner mounting aperture. 
     According to yet another aspect of the present disclosure, a method for manufacturing a handle assembly for an appliance includes extruding a hollow profile from a body of the handle assembly that defines a forward wall and a grasping portion. Mounting apertures are defined within a metal insert and the metal insert is positioned within the hollow profile of the body. The method further includes bending the grasping portion of the body to secure the metal insert and coupling an end to the forward wall of the hollow profile. 
     According to another aspect, a step of defining mounting apertures further includes defining an opening in a body of a handle assembly corresponding to at least one of the mounting apertures. 
     According to yet another aspect, a step of extruding a hollow profile further includes defining ribs on an interior surface of a forward wall of a body. 
     According to still another aspect, a step of coupling an end cap further includes aligning the end cap along ribs that define a forward wall of a body, and couple an end cap to the ribs. 
     It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein. 
     For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated. 
     It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations. 
     It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.