Note: Descriptions are shown in the official language in which they were submitted.
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DISHWASHER BOTTOM DOOR SEAL
BACKGROUND OF THE INVENTION
This invention relates generally to sealed door assemblies, and,
more specifically, to a seal assembly for the bottom of a dishwasher door.
Known dishwasher systems include a cabinet, a tub within the
cabinet that defines an open sided wash chamber, and a door assembly that
seals the open side of the wash chamber when the dishwasher is in use. Soiled
dishes, glasses, utensils, food and beverage containers, etc., are loaded into
the
dishwasher tub through the open side of the wash chamber when the door is
open, and after the door is closed, a dishwasher cycle may be executed to
clean
the items placed therein. The wash chamber includes a sump portion where
washing fluid is pumped from a fluid circulation assembly through spray arm
conduits to wash items loaded onto dishwasher racks in the wash chamber, and
also where wash fluid is collected after being circulated throughout the wash
chamber. The door assembly is attached to the dishwasher at a bottom end of
the door and pivots about a hinge between fully open and fully closed
positions.
To properly seal the wash chamber when the door is closed, a
number of sealing features are employed. For example, a number of rubber
gaskets and other known sealing members are attached to the door and/or
portions of the dishwasher wash chamber that receive an interior portion of
the
door assembly, In one type of dishwasher, a bottom door seal is attached to an
inner panel of the door assembly to seal the lower region of the wash chamber
in the vicinity of the tub sump portion where the door assembly is attached to
the dishwasher. In some dishwashers, this is accomplished with a gasket that
includes a number of ribs such that when the gasket is press-fit into a
channel at
the bottom of the door assembly, the gasket is maintained in place with an
interference fit due to compression of the gasket ribs.
While this type of press-fit gasket assembly may form an
adequate seal for the dishwasher door, the gasket can be difficult to properly
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place in the channel, thereby complicating assembly of the door and increasing
assembly costs.
BRIEF DESCRIPTION OF THE IIWENTION
In one aspect, a door panel assembly for a dishwasher is
provided. The door assembly comprises a panel comprising a formation
depending therefrom, and a seal member comprising a head portion and an
opening therein complementary in shape to said formation, said formation
received in said opening.
In another aspect, a door panel assembly for a dishwasher is
provided. The door panel assembly comprises an inner door panel comprising
a formation extending therefrom, and a seal member comprising a head portion
and an opening therethrough, said opening receiving said formation and
attaching said seal member to said formation.
In still another aspect, a door panel assembly is provided that
comprises a panel comprising a bottom portion, a formation extending
therefrom, and a barrier portion extending therefrom in a spaced apart
relationship to said formation. A seal member comprises a head portion and a
flap portion extending from said head portion, said head portion comprising an
opening therethrough for receiving said formation, said head portion engaged
to
said formation.
In yet another aspect, a door panel assembly is provided that
comprises a door panel comprising a boot-shaped formation depending
therefrom, and a seal member comprising a head portion comprising a boot-
shaped opening therethrough, said boot-shaped opening fitted to said boot-
shaped formation.
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BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a side eievational view of an exemplary dishwasher
system partially broken away.
Figure 2 is a perspective exploded view of a dishwasher door
assembly for the dishwasher shown in Figure 1.
Figure 3 is a rear plan view of an inner door panel assembly
shown in Figure 2.
Figure 4 is a cross sectional view of a portion of the inner door
shown in Figure 3 along line A-A;
Figure 5 is a cross sectional view of a portion of a seal member
shown in Figure 3 along line A-A.
Figure 6 is a cross sectional view of the door assembly shown in
Figure 3 along line A-A.
Figure 7 is a cross sectional schematic view of a portion of the
dishwasher shown in Figure 1 with the inner door panel assembly shown in
Figure 3 attached.
DETAILED DESCRIPTION OF THE INVENTION
Figure 1 is a side elevational view of an exemplary domestic
dishwasher system 100 partially broken away, and in which the present
invention may be practiced. It is contemplated, however, that the invention
may be practiced in other types of dishwashers and dishwasher systems beyond
dishwasher system 100 described and illustrated herein. Moreover, the door
construction described below may find utility and its benefits accrue to
appliances generally. Accordingly, the following description is for
illustrative
purposes only, and the invention is in no way limited to use in a particular
type
of appliance, such as a particular dishwasher system, for example dishwasher
system 100.
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Dishwasher 100 includes a cabinet 102 having a tub 104 therein
and forming a wash chamber 106. Tub 104 includes a front opening (not
shown in Figure 1) and a door assembly 120 hinged at its bottom 1.22 for
movement between a normally closed vertical position (shown in Figure 1 )
wherein wash chamber 106 is sealed shut for washing operation, and a
horizontal open position (not shown) for loading and unloading of dishwasher
contents. Upper and lower guide rails 124, 126 are mounted on tub side walls
128 and accommodate upper and lower roller-equipped racks 130, 132,
respectively. Each of upper and lower racks 130, 132 is fabricated from known
materials into lattice structures including a plurality of elongate members
134,
and each rack 130, 132 is adapted for movement between an extended loading
position (not shown) in which the rack is substantially positioned outside
wash
chamber 106, and a retracted position (shown in Figure 1 ) in which the rack
is
located inside wash chamber 106. Conventionally, a silverware basket (not
shown) is removably attached to lower rack 132 for placement of silverware,
utensils, and the like that are too small to be accommodated by upper and
lower
racks 130, 132.
A control panel (not shown in Figure 1 ) is integrated into an
escutcheon 136 that is mounted to door assembly 120, or in further and/or
alternative embodiments control selectors, (e.g., buttons, switches or knobs)
or
control displays, etc. may be mounted at a convenient location on an outer
face
138 of door assembly 120. The control panel and associated selectors and
displays are coupled to known control circuitry (not shown) and control
mechanisms (not shown) for operating a fluid circulation assembly (not shown)
that circulates water and dishwasher fluid in dishwasher tub 104. The fluid
circulation assembly is located in a machinery compartment 140 located below
a bottom sump portion 142 of tub 104. The construction and operation of the
fluid circulation assembly is believed to be beyond the scope of the present
invention but well within the purview of those in the art without detailed
explanation, and further discussion of the fluid circulation assembly is
therefore
omitted.
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A lower spray-arm-assembly 144 is rotatably mounted within a
lower region 146 of wash chamber 106 and above tub sump portion 142 so as
to rotate in relatively close proximity to lower rack 132. A mid-level spray-
arm
assembly 148 is located in an upper region of wash chamber 106 and is located
in close proximity to upper rack 130 and at a sufficient height above lower
rack
132 to accommodate a largest item, such as a dish or platter (not shown), that
is
expected to be placed in lower rack 132 and washed in dishwasher system 100.
In a further embodiment, an upper spray arm assembly (not shown) is located
above upper rack 130 at a sufficient height to accommodate a tallest item
expected to be placed in upper rack 130, such as a glass (not shown) of a
selected height.
Lower and mid-level spray-arm assemblies 144, 148 and the
upper spray arm assembly are fed by the fluid circulation assembly, and each
spray-arm assembly includes an arrangement of discharge ports or orifices for
directing washing liquid onto dishes located in upper and lower racks 130,
132,
respectively. The arrangement of the discharge ports in at least lower spray-
arm assembly 144 provides a rotational force by virtue of washing fluid
flowing
through the discharge ports. The resultant rotation of lower spray-arm
assembly 144 provides coverage of dishes and other dishwasher contents with a
washing spray. In various alternative embodiments, mid-level spray arm 148
and/or the upper spray arm are also rotatably mounted and configured to
generate a swirling spray pattern above and below upper rack 130 when the
fluid circulation assembly is activated and door assembly 120 is properly
closed
to seal wash chamber 106 for operation.
Figure, 2 is an exploded perspective view of an exemplary
dishwasher door assembly 120 that may be used, for example, with dishwasher
100 (shown in Figure 1 ). Door assembly 120 includes an outer door panel 160
and an inner door panel 162.
Inner door panel 162, in an exemplary embodiment, includes an
opening 164 therethrough for a vent assembly (not shown) and an opening 166
therethrough for receiving a detergent dispenser (not shown). Inner door panel
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162 is further contoured in a bottom region 168 for accommodating lower rack
132 (shown in Figure 1) of dishwasher 100 (shown in Figure 1). It is noted
that
exemplary inner door panel 162 and outer door panel 160 are intended for
illustrative purposes only, and that that the present invention may be used
with
differently configured inner and/or outer door panels within the scope of the
present invention.
In an illustrative embodiment, Inner door panel 162 is attached to
outer door panel 160 via attachment flanges 170 on an outer perimeter of inner
door panel 162 that are fastened to attachment flanges 172 in outer door panel
160. In one embodiment, an appliance control module (not shown) and a latch
assembly (not shown) are further accommodated into door assembly 120 as
those in the art will appreciate.
Figure 3 is a rear plan view of an innex door panel assembly 190
(the inverse of inner door panel 162 as illustrated in Figure 2). Inner door
panel
assembly 190 includes inner door panel 162 and a seal member 192 attached
thereto at a bottom end 194 thereof. In an exemplary embodiment, seal
member 192 includes an elongated head portion 196 attached to inner door 162
as explained further below, and a flap portion 198 depending from head portion
196 to prevent splash out of washing fluid at a bottom of door assembly 120.
Flap portion 198 extends substantially an entire width of inner door panel 162
between inner door panel lateral sides 200, 202, and includes tapers 204 at
each
lateral end to facilitate pivoting of door assembly 190 about its lower end
when
door assembly 190 is attached to a dishwasher, such as dishwasher 100 (shown
in Figure 1).
Seal member '192 is integrally formed in one embodiment and
fabricated from known materials, such as for, example, double durometer
rubber, according to methods and techniques familiar to those in the art to
form
a durable seal for a bottom of inner door panel 162. In alternative
embodiments, seal member 192 is fabricated from other suitable materials
capable of withstanding a dishwasher environment and being sufficiently rigid
for handling to ease installation of sealing member to inner door bottom 168.
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Figure 4 is a cross sectional view of a portion of inner door panel
162 along line A-A of Figure 3 with seal member 192 (shown in Figure 3)
removed. Specifically, a bottom portion 220 of inner door panel 162 is
illustrated, and bottom portion 220 includes a formation 222 shaped to firmly
maintain seal member 192 (shown in Figure 3) in place despite opening and
closing of door assembly 19U, and also while simplifying installation of
sealing
member 192 (shown in Figure 3) to inner door panel 162.
In an illustrative embodiment, formation 222 includes a boot-
shaped portion 224 depending from inner door panel 162 and extending
downwardly therefrom. Boot portion 224 includes a neck 226, a substantially
flat rear edge 228 partially defined by neck 226, an extended heel portion 230
depending downwardly from flat rear edge 228, and a curved arch portion 232
extending to a toe portion 234. Boot portion 224, as will be seen below, is
shaped to engage and retain sealing member 192 while avoiding manufacturing
and assembly difficulties of known door assemblies. A barrier portion 236 also
extends downwardly from inner door panel 162 in a substantially parallel
alignment with a rear edge 228 of boot portion 224. Barrier portion 236
extends for a greater length than boot portion 224 and is in a spaced
relationship with boot portion 224. In one embodiment, inner door panel 162 is
integrally formed, including boot portion 224, from known materials, such as
an injection molded plastic, although in alternative embodiments it is
contemplated that other materials may likewise be utilized according to known
methods and techniques to fabricate inner door panel 162.
Figure 5 is a cross sectional view of a portion of seal member 192
taken along line A-A of Figure 3 and removed from bottom portion 220 (shown
in Figure 4) of inner door panel 162 (shown in Figures 2-4).
Seal member head portion 196 includes an opening 250 generally
complementary in shape to boot portion 224 (shown in Figure 4) of inner door
panel bottom portion 220. As such, seal member head opening 250 includes a
heel portion 252, an arch portion 254, a toe portion 256, and a neck portion
258
for receiving respective portions of inner door panel boot portion 224 (shown
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Figure 4). Seal member flap portion 198 extends from head portion 230 to a
curl 260 at a distal end thereof.
Figure 6 is a cross sectional view of d~r assembly 190 (shown in
Figure 3) along line A-A and illustrating inner door panel boot portion 224
received in seal member head opening 250. As such, seal member 192 is
securely fastened to inner door panel, and unintentional separation of seal
member 192 from panel boot portion 224 is substantially eliminated by boot
heel portion 230 and boot toe portion 234 that resist positive and negative
forces (i.e., forces to the right and to the left in Figure 6) generated in
flap
portion 198 as dishwasher door assembly 190 is opened and closed as
dishwasher 100 (shown in Figure 1) is used.
Further, and unlike known bottom door seals, seal member 192 is
relatively easy to install with slide on action. Seal member head portion 196
is
inserted over inner door panel boot portion 224, and seal member 192 may be
slid across a length of boot heel portion 224 until seal member 192 is
completely attached to inner door panel 162 (as shown in Figure 3). Thus,
depending upon installation preference and orientation of inner door panel
162,
seal member 192 may be securely attached to inner door panel 162 with a left
to right motion, a right to left motion, a bottom to top motion, a top to
bottom
motion, or other motion to slidably attach seal member 192 to inner door panel
162. Sliding attachment allows quick installation with reduced effort relative
to
conventional press fit bottom seals, thereby saving assembly time and
associated assembly costs.
Figure 7 is a cross sectional schematic view of a portion of
dishwasher 100 (shown in Figure 1 ) with inner door panel assembly 190
attached thereto. Seal member 192 is attached to inner door panel bottom
portion 220 via boot portion 224 and seal member head portion 196. Flap
portion 198 extends beneath door panel barrier porkion 236 and contacts an
interior surface of dishwasher 100, such as sump portion 142 in an exemplary
embodiment. Flap member curl 260 seats on dishwasher interior surface 142,
preventing water seepage under flap portion 198 to an exterior of dishwasher
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10. Flap member 198 further forms a seal in conjunction with door panel
burner portion 236, thereby sealing dishwashing fluid splashed on a top
surface
262 of seal member flap portion 198 from seeping to an exterior portion of
dishwasher 100.
An effective bottom door seal 192 for a dishwasher, such as
dishwasher 100, is therefore provided with simplified installation and reduced
assembly costs.
While the invention has been described in terms of various
specific embodiments, those skilled in the art will recognize that the
invention
can be practiced with modification within the spirit and scope of the claims.
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