STRUCTURAL PANEL FOR AN APPLIANCE HAVING STAMPED COMPONENTS AND METHOD THEREFOR

• US 20190308393A1
• Filed: 09/28/2016
• Published: 10/10/2019
• Est. Priority Date: 09/28/2016
• Status: Active Grant

• Current Assignee: Whirlpool Corporation
• Original Assignee: Whirlpool Corporation
• Inventors: Allard, Paul B., Deka, Lakshya J., Dherde, Eric J., Frattini, Gustavo, Gomes, Alberto R., Hunter, Lynne F., Miller, Dustin M., Naik, Abhay, Querfurth, Karen J., Visin, Jerry M.
• Granted Patent: US 11,065,842 B2
• Time in Patent Office: Days
• CPC Class Codes: B29C 65/72 by combined operations or combined techniques, e.g. welding and stitching
• CPC Class Codes: B32B 15/00 Layered products comprising a layer of metal
• CPC Class Codes: B32B 15/043 of metal B32B15/01 takes precedence
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2509/00 Household appliances
• CPC Class Codes: B32B 2509/10 Refrigerators or refrigerating equipment
• CPC Class Codes: B32B 7/08 by mechanical means
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: F25D 2201/14 using subatmospheric pressure
• CPC Class Codes: F25D 23/02 Doors; Covers F25D23/08 takes precedence locks or fastenings E05B65/0042
• CPC Class Codes: F25D 23/021 Sliding doors
• CPC Class Codes: F25D 23/064 formed by moulding, e.g. moulding in situ
• CPC Class Codes: F25D 23/08 Parts formed wholly or mainly of plastics materials
• CPC Class Codes: F25D 23/085 Breaking strips
• CPC Class Codes: Y02B 40/00 Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
• CPC Class Codes: Y10T 428/24777 Edge feature

Abstract

An operable panel for an appliance includes a metallic outer wrapper having a perimetrical wrapper edge that partially defines a perimetrical breaker channel, an inner liner and a plurality of corner brackets disposed proximate the perimetrical wrapper edge. Each corner bracket cooperates with the perimetrical wrapper edge to fully define the perimetrical breaker channel. A trim breaker is adhered to the metallic outer wrapper and the corner brackets at the perimetrical breaker channel and having a liner channel that receives a portion of the inner liner. The trim breaker extends between the inner liner and the outer wrapper. An insulation material is disposed within an insulating cavity defined between the inner liner and the outer wrapper.

Claims

1. An operable panel for an appliance, the operable panel comprising:

a metallic outer wrapper having a perimetrical wrapper edge that partially defines a perimetrical breaker channel;

an inner liner;

a plurality of corner brackets disposed proximate the perimetrical wrapper edge, each corner bracket cooperating with the perimetrical wrapper edge to fully define the perimetrical breaker channel;

a trim breaker adhered to the metallic outer wrapper and the plurality of corner brackets at the perimetrical breaker channel and having a liner channel that receives a portion of the inner liner, the trim breaker extending between the inner liner and the metallic outer wrapper; and

an insulation material disposed within an insulating cavity defined between the inner liner and the metallic outer wrapper.

2. The operable panel of claim 1, further comprising:

a gasket disposed within a gasket channel of the trim breaker, wherein the gasket channel is positioned proximate a wrapper channel that seats within the perimetrical breaker channel of the metallic outer wrapper.

3. The operable panel of claim 2, wherein the trim breaker includes a U-shaped channel, wherein one surface of the U-shaped channel defines the wrapper channel and an opposing surface of the U-shaped channel defines the gasket channel.

4. The operable panel of claim 1, wherein each corner bracket includes an engagement surface that defines a plurality of adhesion grooves that retain an adhesive therein, and wherein the adhesive at least partially secures the corner bracket to an interior surface of the metallic outer wrapper.

5. The operable panel of claim 2, wherein the perimetrical breaker channel is defined within the perimetrical wrapper edge, and wherein the wrapper channel of the trim breaker seats within the perimetrical breaker channel of the metallic outer wrapper.

6. The operable panel of claim 1, wherein the plurality of corner brackets are entirely disposed within the insulating cavity.

7. The operable panel of claim 1, wherein the plurality of corner brackets are injection molded to the metallic outer wrapper.

8. The operable panel of claim 1, wherein the metallic outer wrapper includes at least one wrapper wall that is injection molded to define at least a portion of the trim breaker.

9. A method for forming a structural panel for an appliance, the method comprising steps of:

stamping a first metallic sheet into a flat liner pattern that corresponds to an inner liner for the appliance, the inner liner having a plurality of liner walls and a perimetrical liner tab;

shaping the flat liner pattern into the inner liner;

stamping a second metallic sheet into a flat wrapper pattern that corresponds to an outer wrapper for the appliance, the outer wrapper having a plurality of wrapper walls and a perimetrical wrapper edge;

shaping the flat wrapper pattern into the outer wrapper;

forming a trim breaker having a liner channel and a wrapper channel;

securing the perimetrical liner tab and the perimetrical wrapper edge with the liner and wrapper channels, respectively; and

disposing an insulating material within an insulating cavity formed between the inner liner and the outer wrapper.

10. The method of claim 9, wherein the steps of stamping the first and second metallic sheets each include disposing guide lines within the flat liner and flat wrapper patterns, wherein the guide lines correspond to edges of the plurality of liner walls and edges of the plurality of wrapper walls.

11. The method of claim 9, wherein the step of shaping the flat wrapper pattern includes disposing corner brackets against an interior surface of the outer wrapper at each wrapper corner, respectively, wherein the outer wrapper and the corner brackets cooperate to define a perimetrical breaker channel.

12. The method of claim 11, wherein the perimetrical breaker channel is defined within the perimetrical wrapper edge, and wherein the wrapper channel of the trim breaker seats within the perimetrical breaker channel of the outer wrapper.

13. The method of claim 9, further comprising the step of:

disposing a gasket within a gasket channel of the trim breaker, wherein the gasket channel is positioned proximate the wrapper channel.

14. The method of claim 13, wherein the trim breaker includes a U-shaped channel, wherein one surface of the U-shaped channel defines the wrapper channel and an opposing surface of the U-shaped channel defines the gasket channel.

15. The method of claim 11, further comprising a step of:

sealing the wrapper corners proximate the corner brackets, wherein two distinct edges of the flat wrapper pattern define each wrapper corner, wherein the corner brackets are entirely disposed within the insulating cavity.

16. The method of claim 11, wherein each corner bracket includes an engagement surface that defines a plurality of adhesion grooves that retain an adhesive therein, and wherein the adhesive at least partially secures the corner bracket to the interior surface of the outer wrapper.

17. The method of claim 9, wherein the insulating material is a vacuum insulated panel.

18. A method for forming a structural panel for an appliance, the method comprising steps of:

forming a first planar sheet into an inner liner;

forming a second planar sheet into an outer wrapper having a plurality of wrapper walls and a wrapper edge that at least partially defines a perimetrical breaker channel;

forming a trim breaker having a liner channel for receiving a portion of the inner liner and a wrapper channel for seating within the perimetrical breaker channel;

securing the inner liner within the liner channel and placing the wrapper channel within the perimetrical breaker channel; and

disposing an insulating material within an insulating cavity formed between the inner liner and the outer wrapper.

19. The method of claim 18, wherein the step of securing the wrapper channel within the perimetrical breaker channel includes applying an adhesive within the perimetrical breaker channel and adhering the wrapper channel within the perimetrical breaker channel.

20. The method of claim 18, wherein the step of forming the outer wrapper includes disposing a plurality of corner brackets within outer corners of the outer wrapper, wherein the plurality of corner brackets and the wrapper edge cooperate to define the perimetrical breaker channel.