Patent ID: 12247776

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 vacuum-insulated door. 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 inFIG.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 preceded 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 toFIGS.1-7, reference numeral10generally designates a cooling appliance (e.g., a refrigerator and/or freezer) with at least one vacuum-insulated door12for a refrigerator or freezer compartment. The vacuum-insulated door12includes a door skin14that has a perimeter defined by a top edge16, a pair of side edges18, and a bottom edge20that is spaced from the top edge16by the pair of side edges18. A vacuum-insulated cell is located within the vacuum-insulated door12. A frame assembly22includes a top bracket24that is coupled to the top edge16and a bottom bracket26that is coupled to the bottom edge20. The frame assembly22further includes at least one top hinge pin28(FIG.5) that is connected to the top bracket24and at least one bottom hinge pin30(FIG.7) that is connected to the bottom bracket26. The at least one top hinge pin28and the at least one bottom hinge pin30(FIG.7) are configured to connect to a hinge assembly32(FIG.12) of the cooling appliance10. However, it should be appreciated that the top bracket24and the bottom bracket26may be configured to attach to the hinge assembly32by other means, such as other types of mechanical fasteners, welds, and/or the like.

Referring toFIGS.2-4, the frame assembly22includes a pair of side brackets34located on opposite side edges18. The top bracket24, the bottom bracket26, and the side brackets34may cover substantially the entire perimeter of the door skin14. For example, the brackets24,26, and34may cover at least about 80% of the perimeter, at least about 85% of the perimeter, at least about 90% of the perimeter, at least about 95% of the perimeter, at least about 99% of the perimeter, the entire perimeter, or between about 95% and about 99% of the perimeter. In some embodiments, there are spaces36between each of the brackets24,26, and34. In this manner, the frame assembly22may not extend the entire perimeter. The vacuum-insulated cell is located within the vacuum-insulated door12. More particularly, the vacuum-insulated door12includes a vacuum-insulated structure23that includes the door skin14and a trim breaker25(FIG.12) that at least partially defines the vacuum-insulated cell.

Referring toFIGS.4-6, the top bracket24includes a top longitudinal body38that extends between a pair of top anchor members40. The top longitudinal body38extends along the top edge16of the perimeter and the top anchor members40extend along opposite side edges18of the perimeter. As such, an angle (e.g., about 90°) is formed between the top longitudinal body38of each of the top anchor members40. In some embodiments, the top bracket24includes a multi-piece construction such that the top longitudinal body38has a first top body portion42and a second top body portion44that are spaced from one another by one of the spaces36. The first top body portion42is connected (e.g., integrally) to one of the top anchor members40, and the second top body portion44is connected (e.g., integrally) to the other top anchor member40. Each top body portion42,44may define a length “LT” and each anchor member40may include a length “LTA” that is shorter than the length LTby a ratio of at least 2:1, for example, at least 3:1 or at least 4:1 (FIG.5).

The top longitudinal body38and the top anchor members40may each include an L-shape configuration with a top edge connection plate46and a top side-surface connection plate48. The top edge connection plate46is angled from the top side-surface connection plate48, for example, about 90°. As such, the top edge connection plate46on the longitudinal body38is coupled directly to the top edge16, the top edge connection plates46on the anchor members40are coupled directly to the side edges18, and the top side-surface connection plate48is directly coupled to a side surface of the door skin14. For example, a front surface50or a rear surface52(FIGS.12-14). In some embodiments, a boundary between the top edge connection plate46and the top side-surface connection plate48is rounded rather than linear. A recess54may be defined by the top side-surface connection plate48between the top longitudinal body38and each of the top anchor members40to facilitate bending or otherwise forming the angle between the top anchor members40and the top longitudinal body38. The recess54may include oppositely tapered walls that merge upon bending the top anchor members40with respect to the top longitudinal body38. In this manner, the angle between the top anchor members40and the top longitudinal body38may be retrofitted to a variety of door skin shapes.

With reference now toFIGS.5and6, the front surface50of the door skin14may define a stepped surface56that extends along the top edge16of the perimeter. The stepped surface56is sized to accommodate the top side-surface connection plate48. The top bracket24defines at least one top hinge aperture58coupled to the top hinge pin28. More particularly, the at least one top hinge aperture58may include a pair of top hinge apertures58located on the top edge connection plate46of the longitudinal body38and a top hinge aperture58located on the top edge connection plate46of at least one of the anchor members40. The pair of top hinge apertures58located on the longitudinal body38may be spaced along the top edge16and located adjacent to the anchor member40(e.g., within about 40% of the length LT). The top hinge aperture58located on the at least one anchor members40may be located adjacent to the angle between the longitudinal body38and the at least one anchor member40. In this configuration, the top hinge pins28may be utilized for mounting to the hinge assembly32(FIG.12). Each top hinge pin28may include a body60and a head62. The head62is sandwiched and retained between the top bracket24and the top edge16of the door skin14. The body60extends outwardly through one of the top hinge apertures58. The head62may extend radially outwardly from the body60and defines upper and lower surfaces that are planar. In some embodiments, the above-described top hinge aperture58configuration may be located on one or both the anchor members40, the first top body portion42, and/or the second top body portion44for facilitating connection to either a right-opening or left-opening hinge assembly32.

With reference now toFIG.6, the top bracket24may be coupled to the door skin14via a plurality of spot welds64. The spot welds64may be located on both the top edge connection plate46and the top side surface connection plate48. In some embodiments, the spot welds64on the top edge connection plate46are staggered from the spot welds64on the top side-surface connection plate48. For example, spot welds64on the top edge connection plate46may be aligned centrally between spot welds64on the top side-surface connection plate48. In some embodiments, a spot weld64is aligned with each of the hinge apertures58on the top side-surface connection plate48. A spot weld64may also be located between each of the hinge apertures58on the top edge connection plate46.

With reference now toFIGS.4and7, the bottom bracket26may include a similar configuration to the top bracket24. More particularly, the bottom bracket26includes a bottom longitudinal body66that extends between a pair of bottom anchor members68. The bottom longitudinal body66extends along the bottom edge20of the perimeter and the bottom anchor members68extend along opposite side edges18of the perimeter. As such, an angle (e.g., about) 90° is formed between the bottom longitudinal body66of each of the bottom anchor members68. In some embodiments, the bottom bracket26includes a multi-piece construction such that the bottom longitudinal body66has a first bottom body portion70and a second bottom body portion72that are spaced from one another by one of the spaces36. The first bottom body portion70is connected (e.g., integrally) to one of the bottom anchor members68and the second bottom body portion72is connected (e.g., integrally) to the other bottom anchor member68. Each bottom body portion70,72may define a length “LB” and each anchor member68may include a length “LBA” that is shorter than the length L B by a ratio of at least 2:1, for example, at least 3:1 or at least 4:1.

The bottom longitudinal body66and the bottom anchor members68may each include an L-shape configuration with a bottom edge connection plate76and a bottom side-surface connection plate78. The bottom edge connection plate76is angled from the bottom side-surface connection plate78, for example, about 90°. As such, the bottom edge connection plate76on the bottom longitudinal body66is coupled directly to the bottom edge20, the bottom edge connection plates76on the anchor members68are coupled directly to the side edges18, and the bottom side-surface connection plate78is directly coupled to a side surface of the door skin14, for example, the front surface50or the rear surface52. In some embodiments, a boundary between the bottom edge connection plate76and the bottom side-surface connection plate78is rounded rather than linear. A recess80may be defined by the bottom side-surface connection plate78between the bottom longitudinal body66and each of the bottom anchor members68to facilitate bending or otherwise forming the angle between the bottom anchor members68and the bottom longitudinal body66. The recess80may include oppositely tapered walls that merge upon bending the bottom anchor members68with respect to the bottom longitudinal body66. In this manner, the angle between the bottom anchor members68and the bottom longitudinal body66may be retrofitted to a variety of door skin shapes.

With continued reference toFIG.7, the stepped surface56may extend along the bottom edge20of the perimeter. The stepped surface56is sized to accommodate the bottom side-surface connection plate78. The bottom bracket26defines at least one bottom hinge aperture82coupled to the bottom hinge pin30. More particularly, the at least one bottom hinge aperture82may include a pair of bottom hinge apertures82located on the bottom edge connection plate76of the bottom longitudinal body66and a bottom hinge aperture82located on the bottom edge connection plate76of at least one of the anchor members68. The pair of bottom hinge apertures82located on the bottom longitudinal body66may be spaced along the bottom edge20and located adjacent to the anchor member68(e.g., within about 40% of the length LB). The bottom hinge aperture82located on the at least one anchor members68may be located adjacent to the angle between the bottom longitudinal body66and the at least one anchor member68. In this configuration, the bottom hinge pins30may be utilized for mounting to the hinge assembly32(FIG.12). Each bottom hinge pin30may include a body86and a head88. The head88is sandwiched and retained between the bottom bracket26and the bottom edge20of the door skin14. The body86extends outwardly through one of the bottom hinge apertures82. The head88may extend radially outwardly from the body86and defines upper and lower surfaces that are planar. In some embodiments, the above-described bottom hinge aperture82configuration may be located on one or both the anchor members68, the first bottom body portion70, and/or the second bottom body portion72for facilitating connection to either a right-opening or left-opening hinge assembly32.

With continued reference toFIG.7, the bottom bracket26may be coupled to the door skin14via a plurality of spot welds64. The spot welds64may be located on both the bottom edge connection plate76and the bottom side-surface connection plate78. In some embodiments, the spot welds64on the bottom edge connection plate76are staggered from the spot welds64on the bottom side-surface connection plate78. For example, spot welds64on the bottom edge connection plate76may be aligned centrally between spot welds64on the bottom side-surface connection plate78. In some embodiments, a spot weld64is aligned with each of the hinge apertures82on the bottom side-surface connection plate78. A spot weld64may also be located between each of the hinge apertures82on the bottom edge connection plate76.

Referring toFIGS.8-12, the side brackets34may each be mirror images of one another. Each side bracket34includes an L-shape configuration with a side edge connection plate90and a side surface connection plate92. The side edge connection plate90is angled from the side surface connection plate92, for example, about 90°. As such, the side edge connection plate90is coupled directly to one of the side edges18and the side surface connection plate92is coupled directly to a side surface of the door skin14, for example, the front surface50or the rear surface52. The stepped surface56may extend along the side edges18of the perimeter. The stepped surface56is sized to accommodate the side surface connection plate92. Each side bracket34may extend between a top end94and a bottom end96, the top end94may be spaced from the top anchor member40, and the bottom end96may be spaced from the bottom anchor member68.

The side bracket34defines at least one side hinge aperture98coupled to a side pin100. More particularly, the at least one side hinge aperture98(FIG.10) may include a plurality of side hinge apertures98located on the side edge connection plate90. Each side pin100may include a body102and a head104. The head104is sandwiched and retained between the side bracket34and the side edge18of the door skin14. The body102extends outwardly through one of the side hinge apertures98. The head104may extend radially outwardly from the body102and defines upper and lower surfaces that are planar. Each side bracket34defines at least one brace106that includes a pair of side walls108that extend outwardly from the door skin14to a top wall110that is spaced from the door skin14(FIGS.9and10). An adjustable pin112extends through the top wall110and is configured to adjustably couple a cosmetic panel114(FIGS.13and14) over the door skin14. The adjustable pin112may include a body113and a head115that extends radially outwardly from the body113and is retained against the top wall110as the body113extends therethrough. In some embodiments, the at least one brace106includes three braces106with a brace106located adjacent to the top end94, a brace106located adjacent to the bottom end96, and a brace106located centrally between the top end94and the bottom end96. In some embodiments, the side pin100may define a length that is greater than a length of the adjustable pin112. The side bracket34may be coupled to the door skin14via a plurality of spot welds64on both the side edge connection plate90and the side surface connection plate92(e.g., in a staggered configuration). A spot weld64may also be located on either side of each brace106. A spot weld64may be located on both the side edge connection plate90and the side surface connection plate92adjacent to the top end94and the bottom end96.

With reference now toFIG.12, the hinge assembly32is connected to the top bracket24. The hinge assembly32may include a hinge plate116connected to one of the top hinge pins28(e.g., the top hinge pin28on the anchor member40). The hinge plate116may include a bend with a first portion118connected to the top bracket24and a second portion120coupled to the cooling appliance10in a manner that permits pivotal movement of the vacuum-insulated door12. The hinge plate116may further include a top plate (not shown) that extends across the top longitudinal body38to permit connection with the top hinge pins28located thereon.

With reference now toFIG.13, one of the side pins100is connected to the cosmetic panel114. The cosmetic panel114may include at least one connection plate122that extends from a rear surface124of the cosmetic panel114. The at least one connection plate122may include a pair of connection plates122that extend along the side brackets34. Each connection plate122includes a side pin receiving aperture126, and the body102of the side pin100may be configured to receive a flanged nut128(e.g., via threaded engagement) that has a larger profile than the pin receiving aperture126to couple the cosmetic panel114to each of the side brackets34. With reference now toFIG.14, one of the braces106are illustrated. The cosmetic panel114may include an adjustment mechanism130that defines a bridge shape for fitting over the brace106, and the body113of the adjustable pin112may extend into the adjustment mechanism130to couple the brace106thereto. The adjustment mechanism130may include an internal body portion132that is only coupled to the cosmetic panel114. A threaded pin134may connect the internal body portion132to the adjustment mechanism130such that rotation of the threaded pin134moves the cosmetic panel114with respect to the brace106and, by extension, the door skin14.

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, a vacuum-insulated door is provided. The vacuum-insulated door includes a door skin having a perimeter defined by a top edge, a pair of side edges, and a bottom edge spaced from the top edge by the pair of side edges. A frame assembly includes a top bracket coupled to the top edge, a bottom bracket coupled to the bottom edge, and at least one top hinge pin connected to the top bracket and at least one bottom hinge pin connected to the bottom bracket. The at least one top hinge pin and the at least one bottom hinge pin are configured to connect to a hinge assembly of a cooling appliance.

According to another aspect of the present disclosure, a top bracket defines at least one top hinge aperture and a top hinge pin defines a body and a head. The head is sandwiched and retained between the top bracket and a top edge of a door skin. The body extends outwardly through the at least one top hinge aperture.

According to another aspect of the present disclosure, a bottom bracket defines at least one bottom hinge aperture and a bottom hinge pin defines a body and a head. The head is sandwiched and retained between the bottom bracket and a bottom edge of a door skin. The body extends outwardly through the at least one bottom hinge aperture.

According to another aspect of the present disclosure, at least one top hinge pin includes two or more top hinge pins, and at least one bottom hinge pin includes two or more bottom hinge pins.

According to another aspect of the present disclosure, a spot weld is located between the two or more top hinge pins, and a spot weld is located between the two or more bottom hinge pins.

According to another aspect of the present disclosure, a top bracket includes a top longitudinal body that extends along a top edge of a door skin. A pair of top anchor members on opposite sides of the top longitudinal body extend from the top longitudinal body along opposite side edges of the door skin.

According to another aspect of the present disclosure, each of a pair of top anchor members is connected to side edges of a door skin with at least one spot weld.

According to another aspect of the present disclosure, a top longitudinal body includes a first top body portion and a second top body portion that are spaced along a top edge of a door skin.

According to another aspect of the present disclosure, a top bracket and a bottom bracket each include an edge connection plate coupled to a top edge and a bottom edge of a door skin, respectively. A side surface connection plate extends at an angle from the edge connection plate and is coupled to a front surface or a rear surface of the door skin.

According to another aspect of the present disclosure, the edge connection plates are coupled to the top edge with a plurality of spot welds, and the side surface connection plates are coupled to the front surface or the rear surface with a plurality of spot welds.

According to yet another aspect, a vacuum-insulated door is provided. The vacuum-insulated door includes a door skin having a perimeter defined by a top edge, a pair of side edges, and a bottom edge spaced from the top edge by the pair of side edges. A frame assembly includes a side bracket coupled to each of the side edges, a top bracket that is coupled to and extends along the top edge. Top anchor members are coupled to and extend at least partially along each of the side edges. A bottom bracket is coupled to and extends along the bottom edge and includes bottom anchor members coupled to and that extend partially along each of the side edges.

According to another aspect of the present disclosure, a top bracket and a bottom bracket are configured to connect to a hinge assembly of a cooling appliance.

According to another aspect of the present disclosure, a top bracket and a bottom bracket each include an edge connection plate coupled to a top edge and a bottom edge of a door skin, respectively. A side surface connection plate extends at an angle from the edge connection plate and is coupled to a front surface or a rear surface of the door skin.

According to another aspect of the present disclosure, a top bracket includes a top longitudinal body having a first top body portion and a second top body portion that are spaced along a top edge of a door skin. A bottom bracket includes a bottom longitudinal body having a first bottom body portion and a second bottom body portion that are spaced along a bottom edge of the door skin.

According to another aspect of the present disclosure, a pair of side brackets each define at least one brace that includes a pair of side walls that extend outwardly from a door skin to a top wall that is spaced from the door skin. An adjustable pin extends through the top wall and is configured to adjust a cosmetic panel over the door skin.

According to another aspect of the present disclosure, each side bracket includes two or more braces.

According to another aspect of the present disclosure, a pair of side brackets each include a side aperture spaced from at least one brace. A side pin is located in each side aperture. The side pins define a length that is greater than a length of an adjustment pin.

According to yet another aspect, a vacuum-insulated door is provided. The vacuum-insulated door includes a door skin that has a perimeter defined by a top edge, a pair of side edges, and a bottom edge spaced from the top edge by the pair of side edges. A frame assembly includes a pair of side brackets, each include a side edge connection plate coupled to one of the side edges and a side-surface connection plate coupled to a front surface or a rear surface of the door skin, a top bracket that includes a top edge connection plate coupled to the top edge and a top side-surface connection plate coupled to the front surface or the rear surface of the door skin, and a bottom bracket that includes a bottom edge connection plate coupled to the bottom edge and a bottom side-surface connection plate coupled to the front surface or the rear surface of the door skin.

According to another aspect of the present disclosure, a front surface of a door skin defines a recess and a pair of side-surface connection plates, a top side-surface connection plate, and a bottom side-surface connection plate that are located in the recess.

According to another aspect of the present disclosure, a plurality of spot welds connect a pair of side brackets to side edges and a front or a rear surface of the door skin. A plurality of spot welds connect a top bracket to a top edge and the front or the rear surface of the door skin. A plurality of spot welds connect a bottom bracket to a bottom edge and the front or the rear surface of the door skin.

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, and 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.