Abstract:
A rack assembly for a dishwasher appliance is provided. The rack assembly includes one or more modular baskets placed in a primary rack. These baskets are easily removable and portable for loading and prewashing if desired. In addition, each of the modular baskets may have at least one sidewall that is collapsible. The collapsible sidewalls may be collapsed and adjacent baskets may be linked together using clips as needed based on the size of the dishware to be washed. In this manner, the rack assembly and modular baskets provide a convenient, configurable rack system that enables simple and effective loading, unloading, and prewashing of dishware.

Description:
FIELD OF THE INVENTION 
       [0001]    The subject matter of the present disclosure relates generally to dishwasher appliances and more particularly to rack systems for dishwasher appliances. 
       BACKGROUND OF THE INVENTION 
       [0002]    Dishwasher appliances generally include a tub that defines a wash chamber. Rack assemblies can be mounted within the wash chamber of the tub for receipt of articles for washing. Spray assemblies within the wash chamber can apply or direct wash fluid towards articles disposed within the rack assemblies in order to clean such articles. A fluid circulation assembly may include a pump for circulating fluid through the spray assemblies. 
         [0003]    Typically, an upper rack and a lower rack of the dishwasher appliance are pulled out of the wash chamber for loading and unloading of dishes. More specifically, upper rack may be attached to the tub by two slide assemblies that allow it to extend from the wash chamber. Lower rack may roll out of the wash chamber on wheels that are rotatably mounted thereto. More specifically, one or more tracks may be defined on the sides of the tub and on the dishwasher door. When the dishwasher door is pivoted into the open, horizontal position, lower rack may be rolled out of the tub onto the open dishwasher door to simplify the loading or unloading process, e.g., by not requiring a user to reach into the wash chamber to add or remove dishes. 
         [0004]    Many times, it may be desirable to remove a dishwasher rack from the dishwasher, for example, to perform a prewash cycle on only a particular rack, to soak a particular rack in a kitchen sink prior to running a wash cycle, or to simplify loading and unloading of dishes. However, conventional dishwashers have upper racks that are fixed to the tub and lower racks that are often too bulky or heavy to remove and transport easily. In addition, conventional dishwasher racks do not allow for the removal of only a portion of a rack. 
         [0005]    Accordingly, a dishwashing appliance having a rack system that allows for easy removal and transport of the dishwasher racks for loading, unloading, pre wash, or any other purpose would be useful. More particularly, a dishwasher rack system that allows for selective removal of only portions of the dishwasher rack to improve the loading, unloading, and prewashing of dishes would be especially beneficial. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0006]    The present invention provides a rack assembly for a dishwasher appliance including one or more modular baskets placed in a primary rack. These baskets are easily removable and portable for loading and prewashing if desired. In addition, each of the modular baskets may have at least one sidewall that is collapsible. The collapsible sidewalls may be collapsed and adjacent baskets may be linked together using clips, snaps, or any such engaging devices as needed based on the size of the dishware to be washed. In this manner, the rack assembly and modular baskets provide a convenient, configurable rack system that enables simple and effective loading, unloading, and prewashing of dishware. Additional aspects and advantages of the invention will be set forth in part in the following description, may be apparent from the description, or may be learned through practice of the invention. 
         [0007]    In one exemplary embodiment, a dishwasher appliance defining a vertical, a lateral, and a transverse direction is provided. The dishwasher appliance includes a wash tub that defines a wash chamber and a fluid circulation assembly for providing a fluid flow for cleaning articles placed within the wash chamber. A primary rack is slidably positioned within the wash chamber and configured for movement along the transverse direction between a first position where the primary rack is within the wash chamber and a second position where the primary rack is positioned outside the wash chamber. One or more modular baskets are configured to be removably placed in the primary rack for receipt of the articles for washing, each of the modular baskets including a bottom wall and a plurality of sidewalls, at least one of the plurality of sidewalls being collapsible. 
         [0008]    In another exemplary embodiment, a rack assembly for a dishwasher appliance defining a wash chamber and a vertical, a lateral, and a transverse direction is provided. The rack assembly includes a primary rack slidably positioned within the wash chamber and configured for movement along the transverse direction between a first position where the primary rack is within the wash chamber and a second position where the primary rack is positioned outside the wash chamber. One or more modular baskets are configured to be removably placed in the primary rack for receipt of the articles for washing, each of the modular baskets comprising a bottom wall and a plurality of sidewalls, at least one of the plurality of sidewalls being collapsible. Each of the primary rack and the modular baskets are formed from coated steel wire oriented to form a lattice structure when clamped together as a group of two or more modular baskets. 
         [0009]    These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures. 
           [0011]      FIG. 1  provides a front view of an exemplary embodiment of a dishwashing appliance of the present invention. 
           [0012]      FIG. 2  provides a side cross sectional view of the exemplary dishwashing appliance of  FIG. 1 . 
           [0013]      FIG. 3  is a perspective view of a dishwasher rack assembly containing a primary rack and four modular baskets according to an exemplary embodiment of the present subject matter. 
           [0014]      FIG. 4  is a perspective view of the modular baskets of the exemplary dishwasher rack assembly of  FIG. 3 . 
           [0015]      FIG. 5  is a top view of the exemplary dishwasher rack assembly of  FIG. 3 . 
           [0016]      FIG. 6  is a close-up view of a modular basket mounted to the primary rack of the exemplary dishwasher rack assembly of  FIG. 3 . 
           [0017]      FIG. 7  is a perspective view of a modular basket of the exemplary dishwasher rack assembly of  FIG. 3 . 
           [0018]      FIG. 8  is a perspective view of a modular basket of the exemplary dishwasher rack assembly of  FIG. 3 , with a collapsible sidewall being folded inward. 
           [0019]      FIG. 9  is a perspective view of a modular basket of the exemplary dishwasher rack assembly of  FIG. 3 , with a collapsible sidewall being folded inward. 
           [0020]      FIG. 10  is a perspective view of the exemplary dishwasher rack assembly of  FIG. 3 , with some of the collapsible walls being shown in the collapsed configuration. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
         [0022]    As used herein, the term “article” may refer to, but need not be limited to, dishes, pots, pans, silverware, and other cooking utensils and items that can be cleaned in a dishwashing appliance. The term “wash cycle” is intended to refer to one or more periods of time during the cleaning process where a dishwashing appliance operates while containing articles to be washed and uses a detergent and water, preferably with agitation, to e.g., remove soil particles including food and other undesirable elements from the articles. The term “rinse cycle” is intended to refer to one or more periods of time during the cleaning process in which the dishwashing appliance operates to remove residual soil, detergents, and other undesirable elements that were retained by the articles after completion of the wash cycle. The term “drying cycle” is intended to refer to one or more periods of time in which the dishwashing appliance is operated to dry the articles by removing fluids from the wash chamber. The term “fluid” refers to a liquid used for washing and/or rinsing the articles and is typically made up of water that may include additives such as e.g., detergent or other treatments. The use of the terms “top” and “bottom,” or “upper” and “lower” herein are used for reference only as exemplary embodiments disclosed herein are not limited to the vertical orientation shown nor to any particular configuration shown; other constructions and orientations may also be used. 
         [0023]      FIGS. 1 and 2  depict an exemplary domestic dishwasher  100  that may be configured in accordance with aspects of the present disclosure. Dishwasher  100  generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined. For the particular embodiment of  FIGS. 1 and 2 , the dishwasher  100  includes a cabinet  102  having a tub or inner liner  104  therein that defines a wash chamber  106 . The tub  104  includes a front opening (not shown) and a door  110  hinged at its bottom  112  for movement between a normally closed vertical position (shown in  FIGS. 1 and 2 ), wherein the wash chamber  106  is sealed shut for washing operation, and a horizontal open position for loading and unloading of articles from the dishwasher  100 . Latch  116  is used to lock and unlock door  110  for access to wash chamber  106 . 
         [0024]    Upper and lower guide rails  120 ,  122  are mounted on tub side walls  124  and accommodate roller-equipped upper and lower rack assemblies  126  and  128 . Each of the rack assemblies  126 ,  128  is fabricated into lattice structures including a plurality of elongated members  132  (for clarity of illustration, not all elongated members making up assemblies  126  and  128  are shown in  FIG. 2 ). Each rack  126 ,  128  is adapted for movement between an extended loading position (not shown) in which the rack is substantially positioned outside the wash chamber  106 , and a retracted position (shown in  FIGS. 1 and 2 ) in which the rack is located inside the wash chamber  106 . This is facilitated by rollers  134  and  136 , for example, mounted onto racks  126  and  128 , respectively. A silverware basket (not shown) may be removably attached to rack assembly  128  for placement of silverware, utensils, and the like, that are otherwise too small to be accommodated by the racks  126 ,  128 . 
         [0025]    The dishwasher  100  further includes a lower spray-arm assembly  140  that is rotatably mounted within a lower region  142  of the wash chamber  106  and above a tub sump portion  144  so as to rotate in relatively close proximity to lower rack  128 . A mid-level spray-arm assembly  146  is located in an upper region of the wash chamber  106  and may be located in close proximity to upper rack  126 . Additionally, an upper spray assembly  148  may be located above the upper rack  126 . 
         [0026]    The lower, mid-level, and upper spray-arm assemblies  140 ,  146 , and  148  are part of a fluid circulation assembly  150  for circulating water and dishwasher fluid in the tub  104 . The fluid circulation assembly  150  also includes a pump  152  positioned in a machinery compartment  158  located below the tub sump portion  144  (i.e., bottom wall) of the tub  104 , as generally recognized in the art. Pump  152  receives fluid from sump  144  and provides a flow to an inlet  154  of a diverter  156 . Diverter  156  can be used to selectively place pump  152  in fluid communication with spray assemblies  140 ,  146 , or  148  by way of various outlet ports (not shown). Other spray assemblies and connection configurations may be used as well. 
         [0027]    Each spray-arm assembly  140 ,  146  includes an arrangement of discharge ports or orifices for directing washing liquid received from diverter  156  onto dishes or other articles located in rack assemblies  126  and  128 . The arrangement of the discharge ports in spray-arm assemblies  140 ,  146  provides a rotational force by virtue of washing fluid flowing through the discharge ports. The resultant rotation of the spray-arm assemblies  140 ,  146  and the operation of spray assembly  148  using fluid from diverter  156  provides coverage of dishes and other dishwasher contents with a washing spray. Other configurations of spray assemblies may be used as well. For example, dishwasher  100  may have additional spray assemblies for cleaning silverware, for scouring casserole dishes, for spraying pots and pans, for cleaning bottles, etc. One skilled in the art will appreciate that the embodiments discussed herein are used for the purpose of explanation only, and are not limitations of the present subject matter. 
         [0028]    Each spray assembly may receive an independent stream of fluid, may be stationary, and/or may be configured to rotate in one or both directions. For example, a single spray arm may have multiple sets of discharge ports, each set receiving wash fluid from a different fluid conduit, and each set being configured to spray in opposite directions and impart opposite rotational forces on the spray arm. In order to avoid stalling the rotation of such a spray arm, wash fluid is typically only supplied to one of the sets of discharge ports at a time. 
         [0029]    The dishwasher  100  is further equipped with a controller  160  to regulate operation of the dishwasher  100 . The controller  160  may include one or more memory devices and one or more microprocessors, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with a cleaning cycle. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. 
         [0030]    The controller  160  may be positioned in a variety of locations throughout dishwasher  100 . In the illustrated embodiment, the controller  160  may be located within a control panel area  162  of door  110  as shown in  FIGS. 1 and 2 . In such an embodiment, input/output (“I/O”) signals may be routed between the control system and various operational components of dishwasher  100  along wiring harnesses that may be routed through the bottom  112  of door  110 . Typically, the controller  160  includes a user interface panel/controls  164  through which a user may select various operational features and modes and monitor progress of the dishwasher  100 . In one embodiment, the user interface  164  may represent a general purpose I/O (“GPIO”) device or functional block. In one embodiment, the user interface  164  may include input components, such as one or more of a variety of electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. The user interface  164  may include a display component, such as a digital or analog display device designed to provide operational feedback to a user. The user interface  164  may be in communication with the controller  160  via one or more signal lines or shared communication busses. 
         [0031]    It should be appreciated that the invention is not limited to any particular style, model, or configuration of dishwasher  100 . The exemplary embodiment depicted in  FIGS. 1 and 2  is for illustrative purposes only. For example, different locations may be provided for user interface  164 , different configurations may be provided for racks  126 ,  128 , different spray arm assemblies  140 ,  146 ,  148  may be used, and other differences may be applied as well. 
         [0032]    Referring now generally to  FIGS. 3 through 10 , lower rack assembly  128  will be described in more detail. Although discussion below refers to lower rack assembly  128 , one skilled in the art will appreciate that the features and configurations described may be used for other rack assemblies as well. For example, upper rack assembly  126  may have a similar construction and operate in a similar manner. Other variations and modifications of the exemplary embodiment described below are possible, and such variations are contemplated as within the scope of the present subject matter. 
         [0033]      FIG. 3  illustrates an exemplary embodiment of lower rack assembly  128 . Lower rack assembly  128  includes a primary rack  170  and four modular baskets  172 . Primary rack  170  has a bottom  174  and four fixed sidewalls  176  which define a rectangular compartment or cavity. Similarly, modular baskets  172  have a bottom  180  and four sides, which may be fixed, collapsible, or removable, as explained in detail below. 
         [0034]    According to the illustrated embodiment, bottom  174  of primary rack  170  is a flat and rectangular. Similarly, modular baskets  172  also have a flat rectangular bottom  180 . In this manner, primary rack  170  is configured to receive four modular baskets  172 . One skilled in the art will appreciate that primary rack  170  may be constructed in any suitable size and shape. In addition, according to some embodiments, primary rack  170  and modular baskets  172  may have additional support features, such as tines or dividers, which are configured to support dishes, align modular baskets  172 , divide the compartment, etc. 
         [0035]    Each of primary rack  170  and modular baskets  172  may be fabricated from coated steel wire oriented to form a lattice structure. According to an alternative embodiment, any other suitably rigid material, e.g., plastic, may be used. The size and shape of the apertures in the lattice structure may vary depending on the needs of the application. For example, according to some embodiments, primary rack  170  may be configured only to receive modular baskets  172  and not for directly supporting dishes. Therefore, the lattice structure of primary rack  170  may have larger apertures than modular baskets  172 , which directly receive dishes. 
         [0036]    As illustrated, modular basket  172  has two fixed sidewalls  184  and two collapsible sidewalls  186 . Fixed sidewalls  184  are adjacent to each other and are connected to form a corner of modular basket  172 . In this manner, fixed sidewalls  184  remain upright relative to bottom  180 . Collapsible sidewalls  186  are pivotally connected to bottom  180  of modular basket  172 . More specifically, a bottom end of collapsible sidewall  186  is connected along an edge of bottom  180 . As shown, the pivotal connection between bottom  180  and collapsible sidewall  186  is achieved by curling the lattice structure at an end of bottom  174  of primary rack  170  around a portion of the lattice structure of collapsible sidewall  186 . In this manner, collapsible sidewall  186  is pivotally connected to the end of bottom  174  and is free to fold down to an orientation parallel to bottom  174 . However, according to alternative embodiments, the pivotal connection may be achieved using any suitable hinge or pivot mechanism. 
         [0037]    Although collapsible sidewalls  186  are shown as being one rigid, rectangular lattice structure, one skilled in the art will appreciate that collapsible sidewalls  186  could be constructed differently and remain within the scope of the present subject matter. For example, collapsible sidewalls  186  may be removable, may fold in multiple locations, may pivot along a different direction, or may be constructed as a solid panel instead of a lattice construction. 
         [0038]    Primary rack  170  may further include one or more basket holding pins  190  and modular basket  172  may further include one or more basket holding sleeves  192 . Pins  190  are configured to slidably receive sleeves  192  to assist in positioning, aligning, and mounting modular baskets  172  within primary rack  170 . For example, according to the illustrated embodiment, primary rack  170  has a vertically oriented basket holding pin positioned at each corner. Similarly, each modular basket  172  has a vertically oriented basket holding sleeve  192  positioned on the exterior corner, for example, on the corner defined by two fixed sidewalls  184 . In this manner, pins  190  and sleeves  192  may be used to ensure all four modular baskets  172  may be positioned in primary rack  170 . 
         [0039]    Although pins  190  and sleeves  192  are shown positioned in the four corners of primary rack  170 , one skilled in the art will appreciate that this positioning is only exemplary and other configurations may be used. For example, according to alternative embodiments, pins  190  and sleeves  192  may be positioned at the center of primary rack  170 . In addition, primary rack  170  may define other features for properly aligning modular baskets  172 , e.g., alignment notches or ridges. 
         [0040]    Modular baskets  172  may be selectively placed in or removed from primary rack  170  and configured to form a variety of lower rack assembly  128  configurations depending on the size of dishes that need to be cleaned. For example, collapsible sidewalls  186  may be collapsed into their respective modular baskets  172  along a lateral direction L to create one elongated compartment on one half of primary rack  170 . In addition, or alternatively, collapsible walls  186  may be collapsed along a transverse direction T. One skilled in the art will appreciate that collapsible walls  186  may be positioned in any other suitable configuration depending on the needs of the application. 
         [0041]    According to the illustrated embodiment, collapsible sidewalls  186  are free to rotate or collapse when not otherwise supported in the upright position. Accordingly, one or more clips  194  may be used to interconnect adjacent collapsible sidewalls  186  to fix them in the upright orientation. Clips  194  may be, for example, U-shaped resilient members that are snapped onto collapsible sidewalls. In this regard, clips  194  may be constructed from plastic, coated steel, or any other suitably rigid material. 
         [0042]    The lower rack assembly  128  described above provides a convenient and versatile system including removable and configurable modular baskets  172  within primary rack  170 , thereby simplifying loading, unloading, or prewashing dishes. Using this system, a user may selectively prewash very soiled articles before running a wash cycle. Thus, the total cycle time of the dishwasher appliance  100  may be reduced and energy and water savings may be achieved. Dishes may be loaded or unloaded at a height preferable to the user and the time required to load and unload dishes may be reduced. The small, lightweight modular baskets  172  improve ergonomics and user safety when using dishwasher appliance  100 . 
         [0043]    This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.