Patent Abstract:
A dishwasher door assembly includes a frame, an inner door panel and a decorative outer door panel. The door is assembled by snap-fitting the inner door panel to the frame and then further snap-fitting the decorative outer panel over the frame. Thereafter, mechanical fasteners are inserted in aligned openings formed in the outer door panel, frame and inner door panel. This overall arrangement enables a consumer to select between various decorative outer door panels available to a retailer such that an outer door panel of a desired color and/or style can be sold with the overall dishwasher. The overall door assembly is preferably formed from plastic so as to be lightweight, yet structurally sound.

Full Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention pertains to the art of appliances and, more particularly, to a molded plastic door assembly for a dishwasher.  
           [0003]    2. Discussion of the Prior Art  
           [0004]    When purchasing a dishwasher, a consumer would typically have to select a particular model, followed by a particular style. For instance, it is common to provide three or more styles for any particular dishwasher model, with the styles generally only differing by the color of the outer surface of a door of the dishwasher. Commonly, dishwasher doors are available in white, almond and black colors. Given that the doors between these various style dishwasher door assemblies only differ in visible appearance, it has been heretofore proposed to construct a dishwasher door with interchangeable front door panels of varying colors. Therefore, it is known to provide dishwashers with interchangeable front panels which advantageously allows a consumer to simply select between various decorative outer door panels when purchasing a particular dishwasher model.  
           [0005]    Interchangeable dishwasher panels as proposed in the prior art are typically rectangular in shape and designed to only cover the front side of the dishwasher door. Such door assemblies typically utilize grooves or bracing members along a frame of the dishwasher door for receiving the decorative panel. Often the decorative panels are held in place with retainer strips positioned along an edge of the door frame. This overall arrangement requires the assembly of a fair number of components which must be maintained in respective positions in order to accommodate the retainer strips. The use of these multiple assembly components and the requirement for maintaining a certain alignment during the overall assembly is considered to lead to disadvantageous assembly costs.  
           [0006]    In today&#39;s marketplace, dishwasher door assemblies, with or without decorative front panels, almost invariably have metal frames. The use of metal in forming door frames is considered to disadvantageously add weight to the overall structure. Most typical assemblies utilize metal screws and the like which require alignment between holes formed in the various components and, inherently, longer assembly times. In any event, for at least these reasons, there exists a need in the art for a dishwasher door assembly that is preferably formed of plastic so as to be lightweight, while being structurally sound. More particularly, there exists a need in the art for a dishwasher door assembly which is simple in construction, incorporates at least a frame and a decorative front panel which can be easily interconnected to the frame in a time efficient and effective manner, with the front panel being of a selected color and/or style.  
         SUMMARY OF THE INVENTION  
         [0007]    The present invention is directed to a dishwasher door assembly including a door frame, an inner door panel and a decorative outer door panel. In accordance with the most preferred embodiment of the invention, the door frame is sandwiched between the inner and outer door panels, with each of the inner and outer door panels being snap-fittingly connected to the door frame. The decorative door panel preferably fits over at least side portions of the door frame. The door frame actually defines a housing for a control panel, as well as constituting a support for the overall door assembly. In accordance with the invention, each of the door frame, inner door panel and decorative outer door panel are formed is of plastic.  
           [0008]    In the most preferred form of the invention, side portions of the door frame are formed with slots for receiving tabs provided on each of the outer door panel and inner door panel. That is, the inner door panel includes tabs that extend outward from a body portion thereof. As the inner door panel is joined to the door frame, the tabs register with structure provided on the door frame such that a snap-fit connection is affected. In a similar manner, the decorative outer panel is formed with tabs which are snap-fitted to the door frame. More particularly, the outer door panel is formed with various projections which are slidably received within slots provided in the door frame, whereupon the outer door panel is pivoted and snap-fittingly attached to the door frame about side portions thereof. As the outer door panel and the door frame are joined, the outer door panel covers at least front and side portions of the door frame to establish an overall aesthetic arrangement. Additional mechanical fasteners can be utilized to finalize the overall assembly.  
           [0009]    With this construction, the dishwasher door assembly of the present invention presents a lightweight and structurally sound door assembly that can be easily assembled with substantially self-aligning parts being connected in a snap-fit manner. In accordance with the invention, an overall dishwasher model can be selected by a consumer, followed by a particular decorative outer door panel having a desired color and/or style, with the outer door panel being easily attached to the remainder of the door assembly to establish the final product.  
           [0010]    Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of a preferred embodiment thereof when taken in conjunction with the drawing wherein like reference numerals refer to corresponding parts in the several views. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    [0011]FIG. 1 is a front perspective view of a dishwasher incorporating a door assembly constructed in accordance with the present invention;  
         [0012]    [0012]FIG. 2 is a partial exploded view of the door assembly of the present invention, with a decorative outer door panel thereof being shown spaced apart from a remainder of the assembly;  
         [0013]    [0013]FIG. 3 is an exploded, rear perspective view of the dishwasher door assembly of the invention;  
         [0014]    [0014]FIG. 4 is an enlarged perspective view of tab structure provided on an inner door panel of the door assembly; and  
         [0015]    [0015]FIG. 5 is an enlarged perspective view of tab structure provided on an outer door panel of the door assembly. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0016]    With initial reference to FIG. 1, a dishwasher  2  is generally indicated to be positioned below a kitchen countertop  5 . Also below countertop  5  is shown cabinetry  8  including two columns of drawers  10 . Dishwasher  2  includes a door assembly  17  which is constructed in accordance with the present invention and pivotally mounted for movement relative to a tub  22  (see FIG. 2) of dishwasher  2 . Although not shown, dishwasher  2  preferably includes a support frame for tub  22 , with dishwasher door assembly  17  being pivotally connected to the support frame. As the pivotable mounting of dishwasher doors are widely known in the art and not considered part of the present invention, this pivotable mounting arrangement will not be discussed further here. As shown, dishwasher  2  includes a control panel  24 . In accordance with the preferred embodiment, control panel  24  includes a display  27 , as well as a set of buttons, generally indicated at  29 , for establishing a desired washing operation. In general, the overall control and operation of dishwasher  2  is also known in the art and will not be discussed in further detail. As further well known in the art, control panel  24  is preferably undercut, such as that indicated at  34 , so as to define a handle for use in opening and closing of door assembly  17 . Instead, the present invention is particularly directed to the construction of dishwasher door assembly  17  as will be detailed below.  
         [0017]    As best shown in FIGS. 2 and 3, dishwasher door assembly  17  has three main components, i.e., a door frame  40 , an inner door panel  45  and an outer door panel  48 . In accordance with the most preferred form of the invention, door frame  40  is molded of plastic and includes a main body portion  52  provided with various cut-out sections  55 - 58 . Arranged above cut-out portions  55 - 58  is a cross ledge  60  that is formed with various spaced, laterally extending slots  61 - 63 . Door frame  40  also includes a top wall  65 , a bottom wall  66  and lateral side walls  67  and  68 . As indicated above, outer door panel  48  is preferably molded of plastic such that main body portion  52 , cross ledge  60  and walls  65 - 68  are integrated to define a unitary piece.  
         [0018]    Each of side walls  67  and  68  are undercut, such as that indicated at  71 . With this arrangement, the lowermost portions (not separately labeled) of side walls  67  and  68  are recessed relative to the upper portions (also not separately labeled) of control panel  24  for the reasons which will be clearly identified below. Side walls  67  and  68  also include respective side edges  76  and  77 , each of which is formed with vertically spaced grooved portions  80 - 82 . Each grooved portion  80 - 82  preferably leads into a respective grooved zone  85 - 87  provided in a respective side wall  67 ,  68 . At the forwardmost portion of grooved zones  85 - 87 , side walls  67  and  68  are formed with elongated openings  88 - 90 . Between elongated opening  89  and grooved portion  81  on each side wall  67 ,  68 , a respective bore or opening  92  is provided as clearly shown in FIG. 3. As also shown in these Figures, door frame  40  is preferably molded with respective corner bosses  94 - 97 , each of which has an associated bore  100 .  
         [0019]    Inner door panel  45  is preferably defined by a main panel portion  104  having opposing faces  105  and  106 , as well as a body portion  108 . In a manner generally analogous to door frame  40 , inner door panel  45  is also preferably molded of plastic. As shown, body portion  108  includes a cut-out section  110 . In general, cut-out section  110  is provided to enable a portion of a door liner (not shown) to extend therein. As shown, main panel portion  104  includes various corner apertures  114  and, extending from face  105 , a plurality of vertically spaced side tabs  117 - 119 . As clearly shown in FIGS. 3 and 4, each side tab  117 - 119  includes a planar portion  122  which projects from face  105  and which terminates in an enlarged bead portion  124 . Each bead portion  124  is preferably rounded to enhance assembly of inner door panel  45  to door frame  40  as will be more fully discussed below. In accordance with the most preferred form of the invention, at least tab  118  is provided with a through opening  125 . Of course, although not shown based on the view taken, it should be readily apparent that a corresponding set of tabs  117 - 119  are provided on an opposing side edge of inner door panel  45 .  
         [0020]    In accordance with the invention, outer door panel  48  can vary in color and style and represents a component of door assembly  17  which can be separately selected by a consumer upon purchasing of a dishwasher  2 . In the embodiment shown, outer door panel  48  includes a main panel portion  129  having in-turned side walls  132 - 134 . In a manner analogous to door frame  40  and inner door panel  45 , outer door panel  48  is also preferably molded of plastic. As shown, main panel portion  129  includes an upper edge  137  formed with various laterally spaced and tapering projections  138 - 140 . In addition, as clearly shown in each of FIGS. 2, 3 and  5 , each of side walls  132  and  134  are provided with vertically spaced sets of cut-outs, such as that indicated at  143  and  144 . Each set of cut-outs  143  and  144  defines a respective cantilevered tab  146  which, in a manner analogous to tabs  117 - 119 , preferably terminates in an elongated bead portion  147 . However, while tabs  117 - 119  have bead is portions  124  which project outwardly therefrom, bead portions  147  provided on cantilevered tabs  146  project inward. Furthermore, in a manner directly analogous to the incorporation of opening  125  and tab  118 , at least one cantilevered tab  146  provided on each side wall  132  and  134  is preferably provided with an opening  149 .  
         [0021]    With this construction, dishwasher door assembly  17  can be readily assembled in an easy and convenient manner. More particularly, door  17  is assembled by connecting inner door panel  45  to door frame  40  after the positioning of control components behind panel  24  and thermal and/or sound insulation between main body portion  52  of door frame  40  and main panel portion  104  of inner door panel  45 . During assembly, each set of tabs  117 - 119  provided along a respective edge of main panel portion  104  is slidably received within a respective grooved zone  85 - 87 . The lateral space between the sets of tabs  117 - 119  provided on each side of main panel portion  104  causes tabs  117 - 119  to slightly deflect inward during assembly of inner door panel  45  to door frame  40  until the enlarged bead portion  124  of a respective tab  117 - 119  is received within a corresponding slot  88 - 90 . At this point, tabs  117 - 119  are deflected laterally outwardly to retain inner door panel  45  to door frame  40 . Therefore, with this arrangement, inner door panel  45  is snap-fittingly connected to door frame  40 , with the interaction between tabs  117 - 119  and grooved zones  85 - 87  aiding in assuring a proper alignment for ease of assembly. Once this attachment is made, apertures  114  provided on main panel portion  104  are automatically aligned with bores  100 . This alignment can be advantageously utilized in connecting an inner door liner (not shown), to the overall door assembly  17 , while also permitting a further mechanical attachment between inner door panel  45  and door frame  40 . In the most preferred form of the invention, threaded screws are utilized for this purpose.  
         [0022]    As indicated above, a consumer purchasing dishwasher  2  would be able to select a particular outer door panel  48  from various designs which differ in color and/or style. Once a particular outer door panel  48  is selected, the outer door panel  48  would be interconnected to door frame  40 . In accordance with the most preferred form of the invention described above, this interconnection would be performed by initially sliding projections  138 - 140  into respective slots  61 - 63 . Thereafter, outer door panel  48  is pivoted to position in-turned side walls  132 - 134  about side wall  67 , bottom wall  66  and side walls  68  respectively. During this movement of outer door panel  48 , cantilevered tabs  146  are forced to project laterally outwardly until elongated bead portion  147  of each cantilevered tab  146  reaches a respective grooved portion  80 - 82 . At this point, the cantilevered tabs  146  will shift laterally inwardly to securely attach outer door panel  48  to door frame  40 . Therefore, with this arrangement, it should be readily apparent that outer door panel  48  is also snap-fittingly connected to door frame  40 , with the cooperation between elongated bead portion  147  and grooved portions  80 - 82  assuring a proper alignment and fit. Due to the presence of undercut  71 , a smooth transition is defined between control panel  24  and outer door panel  48 . Once assembled in this manner, openings  92 ,  125  and  149  will be aligned. A mechanical fastener  150 , which can constitute a threaded fastener or a serrated plastic insert, is placed within aligned openings  92 ,  125  and  149 .  
         [0023]    Based on the above, it should be readily apparent that the dishwasher door assembly of the present invention is lightweight, can be easily assembled, requires an efficient number of parts and advantageously enables the use of a selectable, decorative outer door panel which can vary in color, shape and the like. In any event, although described with respect to a preferred embodiment of the invention, it should be readily understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. In general, the invention is only intended to be limited by the scope of the following claims.

Technology Classification (CPC): 0