INJECTION MOLDED FRONT FRAME CORNERS FOR COOLING APPLIANCES
A refrigerator front frame for a refrigerator appliance, including: four profiles comprising two vertical profiles each having a first width and two horizontal profiles at least one of which has a second width, where the first width and the second width are different; and four corner connecting pieces configured to join the four profiles. Each of the four corner connecting pieces includes a horizontal receiving portion configured to receive one of the two horizontal profiles thereover and a vertical receiving portion configured to receive one of the two vertical profiles thereover. The ends of the two vertical profiles abut against sides of the two horizontal profiles or vice versa, such that a joining line between each of the two vertical profiles and each of the two horizontal profiles is either horizontal or vertical, and such that each of the four corner connecting pieces is substantially covered and hidden from view.
The present disclosure relates generally to cooling appliances and to front frames for cooling appliances. More particularly, the present disclosure relates to injection molded front frame corners for a refrigerator appliance.
BACKGROUND OF THE INVENTIONIn general, the front frame on traditional free standing refrigerators is often formed by wrapping the edges of the housing sides, top, and bottom over a thermoformed inner liner. This operation requires expensive and space intensive thermoforming equipment in the manufacturing facility. This method also limits the front frame color to the existing color of the inner liner and housing of the refrigerator. This solution also leaves an unappealing and unsightly seam that is visible when the door of the refrigerator appliance is opened.
Alternatively, the vertical and horizontal plastic front frame profiles can be used and joined at a 45 degree angle at each of the four corners to form a complete front frame for a refrigerator. This is also the standard method of producing plastic window frames or common wood or metal picture frames. However, this style of joining two frame profiles or members at 45 degrees only allows frame profiles having identical widths to be joined at the corners.
One method used for joining frame profiles of different widths is to use an additional exposed corner piece at each of the four corners. However, this method has a disadvantage in that the additional exposed corner pieces are now clearly visible from the front at each of the four corners when the frame profiles are assembled together to form a complete frame, such that the complete frame is not sleek and slim. In the final assembly, you end up with eight visible pieces instead of the four visible frame profiles that you would normally have with a standard frame where the frame profiles are joined at a 45 degree angle at the four corners.
Another method used for joining frame profiles of different widths has been used with the plastic frames of televisions (TVs) such as flat screen TVs where the two narrower width vertical frame profiles are joined to the two larger width horizontal profiles using a joint or joining line that has both an angled portion (e.g., 45 degrees) and a straight vertical portion. However, this method also results in a visible, oddly-shaped joining line at each corner of the complete frame.
SUMMARY OF THE INVENTIONAn apparatus consistent with the present disclosure provides an apparatus and method for joining frame profiles of different widths at the corners, while at the same time minimalizing the number of unsightly seams or gaps, and avoiding the use of fully exposed or visible corner pieces or the use of visible, oddly-shaped joining lines at the four corners of a complete refrigerator front frame.
An apparatus consistent with the present disclosure provides a front frame having joining lines that are horizontal, vertical, or a mixture of both, and that are as slim as possible to match the industrial design of the overall cooling appliance.
An apparatus consistent with the present disclosure provides for strong, precise joining of extruded plastic profiles of a refrigerator front frame, while at the same time providing a clean, minimalist design configuration.
An apparatus consistent with the present disclosure allows for the elimination of a visible hinge step and creates a location for hiding the hinges, the door switch, and other mechanical or electrical components.
An apparatus consistent with the present disclosure also provides for the ability to set up configurations of multiple appliances positioned adjacent to each other.
According to one aspect, the present disclosure provides a refrigerator front frame for a refrigerator appliance, comprising: four profiles comprising two vertical profiles each having a first width and two horizontal profiles at least one of which has a second width, where the first width and the second width are different; and four corner connecting pieces configured to join the four profiles to form the refrigerator front frame, wherein each of the four corner connecting pieces comprises a horizontal receiving portion configured to receive one of the two horizontal profiles thereover and a vertical receiving portion configured to receive one of the two vertical profiles thereover, and wherein ends of the two vertical profiles abut against sides of the two horizontal profiles or vice versa, such that a joining line between each of the two vertical profiles and each of the two horizontal profiles is either horizontal or vertical, and such that each of the four corner connecting pieces is substantially covered and thus hidden from view.
According to another aspect, the second width of the at least one of the two horizontal profiles is larger than the first width of each of the two vertical profiles.
According to another aspect, the at least one of the two horizontal profiles is a top horizontal profile of the refrigerator front frame of the refrigerator appliance.
According to another aspect, the horizontal receiving portion of each of the four corner connecting pieces includes an exposed end face with a flange that extends beyond the horizontal receiving portion and serves as a stop for the end of a corresponding horizontal profile.
According to another aspect, the horizontal receiving portion of each of the four corner connecting pieces includes an elongated slot configured to slidably receive a corresponding rail that projects from a rear surface of a corresponding horizontal profile.
According to another aspect, the vertical receiving portion of each of the four corner connecting pieces includes an elongated slot configured to slidably receive a corresponding rail that projects from a rear surface of a corresponding vertical profile.
According to another aspect, the at least one of the two horizontal profiles is a top horizontal profile of the refrigerator front frame of the refrigerator appliance, and wherein a lower side of the top horizontal profile is machined such that the top horizontal profile is slidable over the vertical receiving portion of a corresponding one of the four corner connecting pieces.
According to another aspect, each of the four corner connecting pieces is an injection molded plastic corner connecting piece.
According to another aspect, each of the four profiles is a plastic extrusion profile.
According to another aspect, the top horizontal profile of the refrigerator front frame of the refrigerator appliance is partitioned into a lower chamber that is foam-filled, and an upper chamber that is hollow to accommodate at least one of the following serviceable components: door hinges, a door switch, a wiring harness, an ambient light sensor, an open door assist, or other serviceable components.
According to another aspect, the top horizontal profile of the refrigerator front frame of the refrigerator appliance includes at least one service access opening along a top edge of the top horizontal profile in order to access the at least one of the serviceable components accommodated in the upper chamber.
According to another aspect, the present disclosure provides a cooling appliance including a front frame, the front frame comprising: four profiles comprising two vertical profiles each having a first width and two horizontal profiles at least one of which has a second width, where the first width and the second width are different; and four corner connecting pieces configured to join the four profiles to form a complete said front frame of the cooling appliance, wherein each of the four corner connecting pieces comprises a horizontal receiving portion configured to receive one of the two horizontal profiles thereover and a vertical receiving portion configured to receive one of the two vertical profiles thereover, and wherein ends of the two vertical profiles abut against sides of the two horizontal profiles or vice versa, such that a joining line between each of the two vertical profiles and each of the two horizontal profiles is either horizontal or vertical, and such that each of the four corner connecting pieces is substantially covered and thus hidden from view.
According to another aspect, the second width of the at least one of the two horizontal profiles is larger than the first width of each of the two vertical profiles.
According to another aspect, the horizontal receiving portion of each of the four corner connecting pieces includes an exposed end face with a flange that extends beyond the horizontal receiving portion and serves as a stop for the end of a corresponding horizontal profile.
According to another aspect, the horizontal receiving portion of each of the four corner connecting pieces includes an elongated slot configured to slidably receive a corresponding rail that projects from a rear surface of a corresponding horizontal profile.
According to another aspect, the vertical receiving portion of each of the four corner connecting pieces includes an elongated slot configured to slidably receive a corresponding rail that projects from a rear surface of a corresponding vertical profile.
According to another aspect, each of the four corner connecting pieces is an injection molded corner connecting piece.
According to another aspect, each of the four profiles is a plastic extrusion profile.
According to another aspect, the at least one of the two horizontal profiles is a top horizontal profile of the front frame of the cooling appliance, and wherein the top horizontal profile of the front frame of the cooling appliance is partitioned into a lower chamber that is foam-filled, and an upper chamber that is hollow to accommodate at least one of the following serviceable components: door hinges, a door switch, a wiring harness, an ambient light sensor, an open door assist, or other serviceable components.
According to another aspect, the top horizontal profile of the front frame of the cooling appliance includes at least one service access opening along a top edge of the top horizontal profile in order to access the at least one of the serviceable components accommodated in the upper chamber.
According to another aspect, the cooling appliance comprises a French door bottom mount (FDBM) refrigerator appliance and the front frame having the four profiles and the four corner connecting pieces forms a front frame of the (FDBM) refrigerator appliance.
According to another aspect, a plurality of the front frames is provided with each having the four profiles and the four corner connecting pieces and each forming a corresponding front frame of one of multiple adjacent cooling appliances that are installed as a group at the customer's site.
The accompanying drawing figures incorporated in and forming a part of this specification illustrate several aspects of the invention, and together with the description serve to explain the principles of the invention.
The exemplary embodiments set forth below represent the necessary information to enable those skilled in the art to practice the invention. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the invention and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.
Moreover, it should be understood that terms such as top, bottom, front, rear, middle, upper, lower, right side, left side, vertical, horizontal, downward, upward, and the like used herein are for orientation purposes with respect to the drawings when describing the exemplary embodiments and should not limit the present invention unless explicitly indicated otherwise in the claims. Also, terms such as substantially, approximately, and about are intended to allow for variances to account for manufacturing tolerances, measurement tolerances, or variations from ideal values that would be accepted by those skilled in the art.
The present application is related to Application No. ______, Attorney Docket No. 2019P03294US), entitled “EXTRUDED PLASTIC FRONT FRAME PROFILES FOR COOLING APPLIANCES,” filed on an even date herewith, and the entire contents of which are incorporated herein by reference.
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Preferably, each of the four corner connecting pieces 10 is an injection molded plastic corner connecting piece. The individual injection molded plastic corner connecting pieces 10 are preferably, but not necessarily, formed from acrylonitrile styrene acrylate (ASA) plastic. Preferably, each of the four profiles 20, 30 is a plastic extrusion profile formed by extruding a plastic such as, for example, an acrylonitrile styrene acrylate (ASA) plastic or an acrylonitrile butadiene styrene (ABS) plastic.
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With the above-described corner connecting pieces 10, a corner piece, which is mostly hidden behind the extruded profiles 20, 30, can be created. This creates a sleeker, slimmer appearance with gaps less visible. The corner connecting pieces 10 and extruded members 20, 30 are held relative to each other by an insulation foam that is injected into the walls and front frame FF of the cooling appliance R, but can also be fixed by other means such as sonic welding, posting, gluing, screwing, taping, riveting, etc., for additional strength.
Moreover, by using the above-described corner connecting pieces 10, wider horizontal profiles 20A can be used at the top than at the sides. Wider top profiles 20A allow space for two chambers. As will be described in more detail below, the lower chamber is foam-filled like the rest of the extruded profiles (side and bottom), whereas the upper chamber is hollow and allows space for various serviceable components.
The present invention has substantial opportunity for variation without departing from the spirit or scope of the present invention. For example, while the front frame connecting corner pieces 10 are describe above with respect to the front frame FF of a cooling appliance such as a home or domestic refrigerator appliance, the front frame corner portions also have application for other home appliances, picture frames, window frames, door frames, TV frames, other display screen frames, and the like where the frame has different width vertical and horizontal members. Moreover, while
Those skilled in the art will recognize improvements and modifications to the exemplary embodiments of the present invention. All such improvements and modifications are considered within the scope of the concepts disclosed herein and the claims that follow.
Claims
1. A refrigerator front frame in a refrigerator appliance, comprising:
- four profiles comprising two vertical profiles each having a length and a first width and two horizontal profiles each having a length and at least one of two horizontal profiles has a second width, where the first width and the second width are different and where the first width is oriented in a left and right direction and the second width is oriented in an up and down direction when viewing the refrigerator front frame of the refrigerator appliance in a front view; and
- four corner connecting pieces configured to join the four profiles to form the refrigerator front frame,
- wherein each of the four corner connecting pieces comprises a horizontal receiving portion configured to receive one of the two horizontal profiles thereover and a vertical receiving portion configured to receive one of the two vertical profiles thereover, and
- wherein ends of the two vertical profiles abut against sides of the two horizontal profiles or vice versa, such that a joining line between each of the two vertical profiles and each of the two horizontal profiles is either horizontal or vertical, and such that each of the four corner connecting pieces is substantially covered and thus hidden from view.
2. The refrigerator front frame of claim 1, wherein the second width of the at least one of the two horizontal profiles is larger than the first width of each of the two vertical profiles.
3. The refrigerator front frame of claim 1, wherein the at least one of the two horizontal profiles is a top horizontal profile of the refrigerator front frame of the refrigerator appliance.
4. The refrigerator front frame of claim 1, wherein the horizontal receiving portion of each of the four corner connecting pieces includes an exposed end face with a flange that extends beyond the horizontal receiving portion and serves as a stop for the end of a corresponding horizontal profile, and wherein the exposed end face is exposed from an external side of the refrigerator front frame and the flange and the joining line are exposed from a front of the refrigerator front frame when viewing the refrigerator front frame of the refrigerator appliance in a front view.
5. The refrigerator front frame of claim 1, wherein the horizontal receiving portion of each of the four corner connecting pieces includes an elongated slot configured to slidably receive a corresponding rail that projects from a rear surface of a corresponding horizontal profile.
6. The refrigerator front frame of claim 1, wherein the vertical receiving portion of each of the four corner connecting pieces includes an elongated slot configured to slidably receive a corresponding rail that projects from a rear surface of a corresponding vertical profile.
7. The refrigerator front frame of claim 1, wherein the at least one of the two horizontal profiles is a top horizontal profile of the refrigerator front frame of the refrigerator appliance, and wherein a lower side of the top horizontal profile is machined such that the top horizontal profile is slidable over the vertical receiving portion of a corresponding one of the four corner connecting pieces.
8. The refrigerator front frame of claim 1, wherein each of the four corner connecting pieces is an injection molded plastic corner connecting piece.
9. The refrigerator front frame of claim 1, wherein each of the four profiles is a plastic extrusion profile.
10. The refrigerator front frame of claim 3, wherein the top horizontal profile of the refrigerator front frame of the refrigerator appliance is partitioned into a lower chamber that is foam-filled, and an upper chamber that is hollow to accommodate at least one serviceable component including a door switch.
11. The refrigerator front frame of claim 10, wherein the top horizontal profile of the refrigerator front frame of the refrigerator appliance includes at least one service access opening along a top edge of the top horizontal profile in order to access the at least one serviceable component accommodated in the upper chamber.
12. A cooling appliance including a front frame, the front frame comprising:
- four profiles comprising two vertical profiles each having a length and a first width and two horizontal profiles each having a length and at least one of the two horizontal profiles has a second width, where the first width and the second width are different and where the first width is oriented in a left and right direction and the second width is oriented in an up and down direction when viewing the front frame of the cooling appliance in a front view; and
- four corner connecting pieces configured to join the four profiles to form a complete said front frame of the cooling appliance,
- wherein each of the four corner connecting pieces comprises a horizontal receiving portion configured to receive one of the two horizontal profiles thereover and a vertical receiving portion configured to receive one of the two vertical profiles thereover, and
- wherein ends of the two vertical profiles abut against sides of the two horizontal profiles or vice versa, such that a joining line between each of the two vertical profiles and each of the two horizontal profiles is either horizontal or vertical, and such that each of the four corner connecting pieces is substantially covered and thus hidden from view.
13. The cooling appliance of claim 12, wherein the second width of the at least one of the two horizontal profiles is larger than the first width of each of the two vertical profiles.
14. The cooling appliance of claim 12, wherein the horizontal receiving portion of each of the four corner connecting pieces includes an exposed end face with a flange that extends beyond the horizontal receiving portion and serves as a stop for the end of a corresponding horizontal profile, and wherein the exposed end face is exposed from an external side of the front frame and the flange and the joining line are exposed from a front of the front frame when viewing the front frame of the cooling appliance in a front view.
15. The cooling appliance of claim 12, wherein the horizontal receiving portion of each of the four corner connecting pieces includes an elongated slot configured to slidably receive a corresponding rail that projects from a rear surface of a corresponding horizontal profile.
16. The cooling appliance of claim 12, wherein the vertical receiving portion of each of the four corner connecting pieces includes an elongated slot configured to slidably receive a corresponding rail that projects from a rear surface of a corresponding vertical profile.
17. The cooling appliance of claim 12, wherein each of the four corner connecting pieces is an injection molded plastic corner connecting piece.
18. The cooling appliance of claim 12, wherein each of the four profiles is a plastic extrusion profile.
19. The cooling appliance of claim 12, wherein the at least one of the two horizontal profiles is a top horizontal profile of the front frame of the cooling appliance, and wherein the top horizontal profile of the front frame of the cooling appliance is partitioned into a lower chamber that is foam-filled, and an upper chamber that is hollow to accommodate at least one serviceable component including a door switch.
20. The cooling appliance of claim 19, wherein the top horizontal profile of the front frame of the cooling appliance includes at least one service access opening along a top edge of the top horizontal profile in order to access the at least one serviceable component accommodated in the upper chamber.
21. The cooling appliance of claim 12, wherein the cooling appliance comprises a French door bottom mount (FDBM) refrigerator appliance and the front frame having the four profiles and the four corner connecting pieces forms a front frame of the (FDBM) refrigerator appliance.
22. The cooling appliance of claim 12, further comprising a plurality of the front frames each having the four profiles and the four corner connecting pieces and each forming a corresponding front frame of one of multiple adjacent cooling appliances which are assembled as a group.
23. A refrigerator front frame for a refrigerator appliance, comprising:
- four profiles comprising two vertical profiles each having a first width and two horizontal profiles at least one of which has a second width, where the first width and the second width are different; and
- four corner connecting pieces configured to join the four profiles to form the refrigerator front frame,
- wherein each of the four corner connecting pieces comprises a horizontal receiving portion configured to receive one of the two horizontal profiles thereover and a vertical receiving portion configured to receive one of the two vertical profiles thereover,
- wherein ends of the two vertical profiles abut against sides of the two horizontal profiles or vice versa, such that a joining line between each of the two vertical profiles and each of the two horizontal profiles is either horizontal or vertical, and such that each of the four corner connecting pieces is substantially covered and thus hidden from view,
- wherein the at least one of the two horizontal profiles is a top horizontal profile of the refrigerator front frame of the refrigerator appliance, and
- wherein the top horizontal profile of the refrigerator front frame of the refrigerator appliance is partitioned into a lower chamber that is foam-filled, and an upper chamber that is hollow to accommodate at least one serviceable component including a door switch.
24. A cooling appliance including a front frame, the front frame comprising:
- four profiles comprising two vertical profiles each having a first width and two horizontal profiles at least one of which has a second width, where the first width and the second width are different; and
- four corner connecting pieces configured to join the four profiles to form a complete said front frame of the cooling appliance,
- wherein each of the four corner connecting pieces comprises a horizontal receiving portion configured to receive one of the two horizontal profiles thereover and a vertical receiving portion configured to receive one of the two vertical profiles thereover,
- wherein ends of the two vertical profiles abut against sides of the two horizontal profiles or vice versa, such that a joining line between each of the two vertical profiles and each of the two horizontal profiles is either horizontal or vertical, and such that each of the four corner connecting pieces is substantially covered and thus hidden from view, and
- wherein the at least one of the two horizontal profiles is a top horizontal profile of the front frame of the cooling appliance, and wherein the top horizontal profile of the front frame of the cooling appliance is partitioned into a lower chamber that is foam-filled, and an upper chamber that is hollow to accommodate at least one serviceable component including a door switch.
Type: Application
Filed: Jan 23, 2020
Publication Date: Jul 29, 2021
Inventors: Yigit Akalan (Tekirdag), Howard Cheng (Laguna Woods, CA), Samuel Harward (Knoxville, TN), Cemalettin Hasturk (Knoxville, TN), Lucas Schulte Campos (Munchen)
Application Number: 16/750,022