Dishwashing appliance sound insulation

Abstract

A method of assembling a dishwashing appliance includes applying a sheet of sound insulation material to a panel of the dishwashing appliance and bending the sheet of sound insulation material after applying the sheet of sound insulation material to the panel of the dishwashing appliance. The method also includes baking the sheet of sound insulation material, such that the sheet of sound insulation material conforms to and adheres to the panel of the dishwashing appliance.

Description

FIELD OF THE INVENTION

[0001] The present subject matter relates generally to dishwashing appliances, and more particularly to features and methods for providing sound insulation in dishwashing appliances.BACKGROUND OF THE INVENTION

[0002] Dishwashing 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. Multiple spray assemblies can be positioned within the wash chamber for applying or directing wash liquid (e.g., water, detergent, etc.) towards articles disposed within the rack assemblies in order to clean such articles. Dishwashing appliances are also typically equipped with one or more pumps, such as a circulation pump or a drain pump, for directing or motivating wash liquid from the sump to, e.g., the spray assemblies or an area outside of the dishwashing appliance.

[0003] Various cycles may be included as part of the overall cleaning process. For example, a typical, user-selected cleaning option may include a wash cycle and rinse cycle (referred to collectively as a wet cycle), as well as a drying cycle. During such cycles, various components of the dishwashing appliance are activated and deactivated, typically in a predetermined sequence and for predetermined durations.

[0004] The cycles of the dishwashing appliance may generate significant noise, such as due to the flow of wash liquid, the operation of one or more pumps, and movement of articles within the dishwashing appliance. Consumers prefer dishwashers which generate less noise. In order to diminish the level of noise that can be perceived outside of the dishwashing appliance during such cycles, a dishwashing appliance may include sound insulation, e.g., sound dampening materials, and / or other similar features to acoustically isolate the interior of the dishwashing appliance. Installation of such materials may be difficult. For example, some sound insulation materials are provided in the form of rigid sheets which must be aligned with one or more panels of the dishwashing appliance and bent to conform to the curvature of the one or more panels. These processes may result in breakage of the insulation sheet, e.g., at deep bends, and / or misalignment of the insulation sheet with the panel, which can lead to wasted materials and time.

[0005] Accordingly, systems and methods for improved assembly of sound insulation features in a dishwashing appliance would be useful.BRIEF DESCRIPTION OF THE INVENTION

[0006] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0007] In one exemplary aspect of the present disclosure, a method of assembling a dishwashing appliance is provided. The method includes applying a sheet of sound insulation material to a panel of the dishwashing appliance and bending the sheet of sound insulation material after applying the sheet of sound insulation material to the panel of the dishwashing appliance. The method also includes baking the sheet of sound insulation material, such that the sheet of sound insulation material conforms to and adheres to the panel of the dishwashing appliance.

[0008] In another exemplary aspect of the present disclosure, a dishwashing appliance is provided. The dishwashing appliance includes a panel and a sheet of sound insulation material. The sheet of sound insulation material is adhered to the panel. The sheet of sound insulation material includes a bend formed in the sheet of sound insulation material such that the sheet of sound insulation material conforms to the panel of the dishwashing appliance.

[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 disclosure.

[0012] FIG. 2 provides a perspective view of an additional exemplary embodiment of a dishwashing appliance of the present disclosure with a door in an intermediate position.

[0013] FIG. 3 provides a side, cross section view of an exemplary dishwashing appliance, such as the dishwashing appliance of FIG. 1 or FIG. 2.

[0014] FIG. 4 provides a sectioned perspective view of a door for an exemplary dishwashing appliance, such as the dishwashing appliance of FIG. 1 or FIG. 2.

[0015] FIG. 5 provides a sectioned perspective view of the door of FIG. 4 with an outer panel removed to more clearly illustrate internal features of the door.

[0016] FIG. 6 provides an elevation view of the door of FIG. 4 with the outer panel removed and in a pre-baking configuration.

[0017] FIG. 7 provides a perspective view of a sheet of sound insulation material that may be incorporated into a dishwashing appliance according to one or more exemplary embodiments of the present disclosure.

[0018] FIG. 8 provides an enlarged view of a portion of the sheet of sound insulation material of FIG. 7.

[0019] FIG. 9 provides an enlarged side section view of a lower portion of the door of FIG. 4 with the outer panel removed.

[0020] FIG. 10 provides an enlarged side section view of an upper portion of the door of FIG. 4 with the outer panel removed.

[0021] FIG. 11 provides a flow chart diagram of an exemplary method of assembling a dishwashing appliance according to one or more exemplary embodiments of the present disclosure.DETAILED DESCRIPTION

[0022] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the disclosure. 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 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.

[0023] As used herein, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). The terms “first,”“second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For instance, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows. 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 used to refer to an overall operation of the dishwashing appliance which may include two or more distinct phases. The term “wash phase” is intended to refer to one or more periods of time during which a dishwashing appliance operates while containing the articles to be washed and uses a wash liquid (e.g., water, detergent, or wash additive) and may be a portion of the wash cycle, such as a beginning or early portion of the wash cycle. The term “rinse phase” is intended to refer to one or more periods of time during 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 phase and may be a portion of the wash cycle, such as an intermediate portion of the wash cycle. The term “drain phase” is intended to refer to one or more periods of time during which the dishwashing appliance operates to discharge soiled water from the dishwashing appliance and may be a portion of the wash cycle, such as a later portion of the wash cycle. The term “wash liquid” refers to a liquid used for washing or rinsing the articles that is typically made up of water and may include additives, such as detergent or other treatments (e.g., rinse aid). Furthermore, as used herein, terms of approximation, such as “generally,”“approximately,”“substantially,” or “about,” refer to being within a ten percent (10%) margin of error. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.

[0024] Turning now to the figures, FIGS. 1 through 3 depict an exemplary dishwasher or dishwashing appliance (e.g., dishwashing appliance 100) that may be configured in accordance with aspects of the present disclosure. Generally, dishwasher 100 defines a vertical direction V, a lateral direction L, and a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular to one another and form an orthogonal direction system.

[0025] Dishwasher 100 includes a tub 104 that defines a wash chamber 106 therein. As shown in FIG. 3, tub 104 extends between a top 107 and a bottom 108 along the vertical direction V, between a pair of side walls 110 along the lateral direction L, and between a front side 111 and a rear side 112 along the transverse direction T.

[0026] Tub 104 includes a front opening 114 at the front side 111. In some embodiments, the dishwashing appliance 100 may also include a door 116 at the front opening 114. The door 116 may, for example, be coupled to the tub 104 by a hinge 200 at its bottom for movement between a normally closed vertical position (FIGS. 1 and 3), wherein the wash chamber 106 is sealed shut for washing operation, and a horizontal open position (not shown) for loading and unloading of articles from dishwasher 100. A door closure mechanism or assembly 118, e.g., a latch, may be provided to lock and unlock door 116 for accessing and sealing wash chamber 106.

[0027] In exemplary embodiments, tub side walls 110 accommodate a plurality of rack assemblies. For instance, guide rails 120 may be mounted to side walls 110 for supporting a lower rack assembly 122 and an upper rack assembly 126. In some such embodiments, upper rack assembly 126 is positioned at a top portion of wash chamber 106 above lower rack assembly 122 along the vertical direction V.

[0028] Generally, each rack assembly 122, 126 may be 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 through 3) in which the rack is located inside the wash chamber 106. In some embodiments, movement is facilitated, for instance, by rollers 128 mounted onto rack assemblies 122, 126, respectively.

[0029] Although guide rails 120 and rollers 128 are illustrated herein as facilitating movement of the respective rack assemblies 122, 126, it should be appreciated that any suitable sliding mechanism or member may be used according to alternative embodiments.

[0030] In optional embodiments, some or all of the rack assemblies 122, 126 are fabricated into lattice structures including a plurality of wires or elongated members 130 (for clarity of illustration, not all elongated members making up rack assemblies 122, 126 are shown). In this regard, rack assemblies 122, 126 are generally configured for supporting articles within wash chamber 106 while allowing a flow of wash liquid to reach and impinge on those articles (e.g., during a cleaning or rinsing phase of the wash cycle). According to additional or alternative embodiments, a silverware basket (not shown) may be removably attached to a rack assembly (e.g., lower rack assembly 122), for placement of silverware, utensils, and the like, which are otherwise too small to be accommodated by the rack assembly.

[0031] Generally, dishwasher 100 includes one or more spray assemblies for urging a flow of fluid (e.g., wash liquid) onto the articles placed within wash chamber 106.

[0032] In exemplary embodiments, dishwasher 100 includes a lower spray arm assembly 134 disposed in a lower region 136 of wash chamber 106 and above a sump 138 so as to rotate in relatively close proximity to lower rack assembly 122. In this regard, lower spray arm assembly 134 may generally be configured for urging a flow of wash liquid up through lower rack assembly 122.

[0033] In some embodiments, an upper spray assembly 142 may be located proximate to and, e.g., below, upper rack assembly 126 along the vertical direction V. In this manner, upper spray assembly 142 may be generally configured for urging of wash liquid up through upper rack assembly 126.

[0034] The various spray assemblies and manifolds described herein may be part of a fluid distribution system or fluid circulation assembly 150 for circulating wash liquid in tub 104. In certain embodiments, fluid circulation assembly 150 includes a circulation pump 152 for circulating wash liquid in tub 104. Circulation pump 152 may be mounted to sump 138 and in fluid communication with the sump 138 through a circulation outlet 151 from the sump 138.

[0035] When assembled, circulation pump 152 may be in fluid communication with an external water supply line (not shown) and sump 138. A water inlet valve (not shown) can be positioned between the external water supply line and circulation pump 152 (e.g., to selectively allow water to flow from the external water supply line to circulation pump 152). Additionally or alternatively, water inlet valve can be positioned between the external water supply line and sump 138 (e.g., to selectively allow water to flow from the external water supply line to sump 138). During use, water inlet valve may be selectively controlled to open to allow the flow of water into dishwasher 100 and may be selectively controlled to close and thereby cease the flow of water into dishwasher 100. Further, fluid circulation assembly 150 may include one or more fluid conduits or circulation piping for directing wash fluid from circulation pump 152 to the various spray assemblies and manifolds. In exemplary embodiments, such as that shown in FIG. 3, a primary supply conduit 154 extends from circulation pump 152, along rear side 112 of tub 104 along the vertical direction V to supply wash liquid throughout wash chamber 106.

[0036] In optional embodiments, circulation pump 152 urges or pumps wash liquid to a diverter 156 (FIG. 3). In some such embodiments, diverter 156 is positioned within sump 138 of dishwashing appliance 100). Diverter 156 may include a diverter disk (not shown) disposed within a diverter chamber for selectively distributing the wash liquid to the spray assemblies 134, 142, or other spray manifolds or assemblies. For instance, the diverter disk may have at least one aperture configured to align with one or more outlet ports (not shown) at the top of diverter chamber. In this manner, the diverter disk may be selectively rotated to provide wash liquid to the desired spray device(s).

[0037] In exemplary embodiments, diverter 156 is configured for selectively distributing the flow of wash liquid from circulation pump 152 to various fluid supply conduits-only some of which are illustrated in FIG. 3 for clarity. In certain embodiments, diverter 156 includes two or more outlet ports (not shown) for supplying wash liquid to a first conduit for rotating lower spray arm assembly 134 and a second conduit for supplying upper spray assembly 142 (e.g., supply conduit 154). Additional embodiments may also include one or more additional conduits, e.g., a third conduit for spraying an auxiliary rack such as a silverware rack, etc.

[0038] In some embodiments, a supply conduit 154 is used to supply wash liquid to one or more spray assemblies (e.g., to upper spray assembly 142). It should be appreciated, however, that according to alternative embodiments, any other suitable plumbing configuration may be used to supply wash liquid throughout the various spray manifolds and assemblies described herein. For instance, according to another exemplary embodiment, supply conduit 154 could be used to provide wash liquid to lower spray arm assembly 134 and a dedicated secondary supply conduit (not shown) could be utilized to provide wash liquid to upper spray assembly 142. Other plumbing configurations may be used for providing wash liquid to the various spray devices and manifolds at any location within dishwashing appliance 100.

[0039] Each spray assembly 134 and 142, or other spray device as may be included in dishwashing appliance 100, may include an arrangement of discharge ports or orifices for directing wash liquid received from circulation pump 152 onto dishes or other articles located in wash chamber 106. The arrangement of the discharge ports, also referred to as jets, apertures, or orifices, may provide a rotational force by virtue of wash liquid flowing through the discharge ports. Alternatively, spray assemblies 134, 142 may be motor-driven, or may operate using any other suitable drive mechanism. Spray manifolds and assemblies may also be stationary. The resultant movement of the spray assemblies 134, 142 and the spray from fixed manifolds provides coverage of dishes and other dishwasher contents with a washing spray. Other configurations of spray assemblies may be used as well. For instance, dishwasher 100 may have additional spray assemblies for cleaning silverware, for scouring casserole dishes, for spraying pots and pans, for cleaning bottles, etc.

[0040] Drainage of soiled wash liquid within sump 138 may by provided, for instance, by a drain pump 168 (e.g., during or as part of a drain phase). In particular, wash liquid may exit sump 138 through a drain outlet 167 and may flow through a drain conduit or directly to the drain pump 168. Thus, drain pump 168 is downstream of sump 138 and facilitates drainage of the soiled wash liquid by urging or pumping the wash liquid to a drain line external to dishwasher 100.

[0041] In some embodiments, a filter assembly may be provided, e.g., in the sump 138 and / or at a top entrance into the sump 138, e.g., to filter fluid to circulation assembly 150 and / or drain pump 168. Generally, the filter assembly removes soiled particles from the liquid that flows to the sump 138 from the wash chamber 106 during operation of dishwashing appliance 100. In exemplary embodiments, the filter assembly may include both a first filter (also referred to as a “coarse filter”) and a second filter (also referred to as a “fine filter”).

[0042] Although a separate circulation pump 152 and drain pump 168 are

[0043] described herein, it is understood that other suitable pump configurations (e.g., using only a single pump for both recirculation and draining) may be provided.

[0044] The dishwashing appliance 100 may further include a heating element 184, such as a resistance heating element, positioned in or near the sump 138. For example, the heating element 184 may be positioned “near” the sump 138 in that the heating element 184 is disposed above the sump 138 and within the lower region 136 of wash chamber 106, such as below the lower spray arm 134 and / or below the lower rack assembly 122. The heating element 184 may be positioned and configured to heat liquid in the sump 138, such as for a heated wash phase, and / or to heat air within the wash chamber 106, such as for drying articles during a dry phase.

[0045] Dishwashing appliance 100 may also include ventilation features, e.g., to promote improved, e.g., more rapid, drying of articles therein after the wash and rinse phases. For example, one or more vents 170 may be provided in the tub 104 for introducing relatively dry air from outside of the tub 104 into the wash chamber 106 and / or for removing relatively humid air from the wash chamber 106 to the outside of the tub 104. In some embodiments, a fan 172 may be provided. The fan 172 may be operable to urge air through the wash chamber 106, such as to promote air circulation and / or ventilation within and through the wash chamber. Such air movement may increase the rate of evaporation of moisture from articles in the wash chamber 106 after a wash and / or rinse phase.

[0046] In certain embodiments, dishwasher 100 includes a controller 160 configured to regulate operation of dishwasher 100 (e.g., initiate one or more wash operations). 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 wash operation or wash cycle that may include a pre-wash phase, a wash phase, a rinse phase, a drain phase, and / or a dry phase. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In some embodiments, 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. Alternatively, controller 160 may be constructed without using a microprocessor, e.g., using a combination of discrete analog or digital logic circuitry—such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like—to perform control functionality instead of relying upon software. It should be noted that controllers as disclosed herein are capable of and may be operable to perform any methods and associated method steps as disclosed herein.

[0047] Controller 160 may be positioned in a variety of locations throughout dishwasher 100. In optional embodiments, controller 160 is located within a control panel area 162 of door 116 (e.g., as shown in FIG. 1 or FIG. 2). 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 of door 116. Typically, the controller 160 includes or is operatively coupled to a user interface panel / controls 164 through which a user may select various operational features and modes and monitor progress of dishwasher 100. In some embodiments, user interface 164 includes a general purpose I / O (“GPIO”) device or functional block. In additional or alternative embodiments, user interface 164 includes 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. In further additional or alternative embodiments, user interface 164 includes a display component, such as a digital or analog display device designed to provide operational feedback to a user. When assembled, user interface 164 may be in operative communication with the controller 160 via one or more signal lines or shared communication busses.

[0048] The dishwashing appliance 100 may also include a temperature sensor 186 in operative communication with the controller 160. For example, in some embodiments, the temperature sensor 186 may be located in the sump 138 and may thereby be operable to measure a temperature of a liquid, e.g., wash liquid, within the sump 138. For example, the “temperature sensor” may include any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, temperature sensor 186 may be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, a semiconductor-based integrated circuit temperature sensor, etc. In addition, temperature sensor 186 may be positioned at any suitable location and may output a signal, such as a voltage, to the controller 160 that is proportional to and / or indicative of the temperature being measured. Although exemplary positioning of the temperature sensor 186 is described herein and depicted in FIG. 3, it should be appreciated that dishwashing appliance 100 may include any other suitable number, type, and position of temperature, humidity, and / or other sensors as well as or instead of the exemplary temperature sensor 186 according to alternative embodiments.

[0049] It should be appreciated that the invention is not limited to any particular style, model, or configuration of dishwasher 100. The exemplary embodiments depicted in FIGS. 1 through 3 are for illustrative purposes only. For instance, different locations may be provided for control panel area 162 (e.g., on the front of the door 116 as illustrated in FIG. 1 or on the top of the door 116 as illustrated in FIG. 2, or other locations as well), different configurations may be provided for rack assemblies 122, 126, different spray assemblies 134, 142 and spray manifold configurations may be used, different sensors may be used, and other differences may be applied while remaining within the scope of the present disclosure.

[0050] As may be seen, e.g., in FIGS. 2-4, the door 116 may include an inner panel 210, e.g., which adjoins and faces towards the wash chamber 106 when the door 116 is in the closed position, and an outer panel 212 which is opposite the inner panel 210, e.g., which faces away from the remainder of the dishwashing appliance 100 when the door 116 is in the closed position. One or more sound insulation materials may be provided between the inner panel 210 and the outer panel 212 of the door 116. For example, a sheet 300 of sound insulation material may be bonded to the inner panel 210 within an internal spaced of the door 116, e.g., between the inner panel 210 and the outer panel 212. In additional embodiments, sound insulation materials, e.g., sheet 300, may be provided on other panels of the dishwashing appliance as well as or instead of the inner panel 210 of the door 116, such as the outer panel 212 of the door 116, one or more side panels which form the side walls 110 of the tub 104, and / or other similar panels or portions of panels in the dishwashing appliance 100. For example, as may be seen in FIG. 5, the sheet 300 may be bonded to the inner panel 210 of the door 116 on an internal side of the inner panel 210, e.g., a side of the inner panel 210 that faces the outer panel 212 of the door 116. Thus, the sheet 300 of sound insulation material may be separated from the wash chamber 106 by the inner panel 210 of the door 116 and may face away from the wash chamber 106. Accordingly, the present disclosure should be understood as applicable to any suitable panel of the dishwashing appliance 100, and will be illustrated and described further herein with reference to the inner panel 210 as just one possible example of a panel of the dishwashing appliance to which the sheet 300 of sound insulation material may be applied.

[0051] As mentioned above, a fan 172 may be provided in the dishwashing appliance 100. As may be seen, e.g., in FIG. 5, additional features may be provided in the inner panel 210 of the door 116, such as a dispensing assembly 174. Also as may be seen in FIG. 5, the sheet 300 may include cutouts which permit such features, e.g., the fan 172 and the dispensing assembly 174, to pass through the sheet 300 of sound insulation material when the sheet 300 is applied to the inner panel 210 of the door 116.

[0052] FIG. 6 provides an elevation view of the inner panel 210 with the sheet 300 of sound insulation material applied thereto and in a pre-baking configuration. For example, the sheet 300 of sound insulation material as illustrated in FIG. 6 includes a first bend 302, e.g., a lower bend formed in a bottom portion (such as bottom half, bottom one-third, bottom quarter, or other such bottom portion) of the sheet 300. The first bend 302 may be formed along a first hinge 304 of the sheet 300 of sound insulation material. The sheet 300 may also include a second bend 306 formed along a second hinge 308. The second bend 306 and second hinge 308 may be positioned in an upper portion (such as upper half, upper one-third, upper quarter, or other such upper portion) of the sheet 300. In some embodiments, the sheet 300 of sound insulation material may be applied to the inner panel 210 before being bent along the hinges 304, 308. Thus, the first bend 302 and the second bend 306 may be formed in situ, e.g., while the sheet 300 is on the inner panel 210, and may thereby each correspond to a bend in the inner panel 210, such as a deep bend. Applying the sheet 300 to the inner panel 210 prior to forming the bend 302 or 306 may provide a guide to promote accurate alignment of the sheet 300 with the inner panel 210, e.g., may ensure the bends 302 and 306 are each formed in the correct locations to correspond to underlying curvature of the inner panel 210, e.g., the bends 302 and 306 in the sheet 300 may be the same distance apart as the bends in the inner panel 210. Each of the bends 302 and 306 may be deep bends, e.g., bends defining an angle of deflection of at least about 30° from the initial flat condition of the sheet 300 (the initial flat condition is illustrated, e.g., in FIG. 7), and which extend across a length of the sheet of sound insulation material by greater than one inch, e.g., more than one inch of sound insulation material past the deep bend, where “past the bend” is measured from the deep bend to the nearest external edge of the sheet of sound insulation material along a direction that is generally perpendicular to the nearest external edge of the sheet of sound insulation material.

[0053] The sheet 300 of sound insulation material may also include one or more short bends or shallow bends, e.g., bends that have one inch or less of material past the bend. Example locations of such shallow bends are illustrated in FIG. 6, e.g., along lines 311 and 313. The shallow bend lines 311 and 313 thus each define a flap, such as a first flap 310 defined by a first shallow bend along first line 311, where the first flap 310 is separated from the remainder of the sheet 300 by the first line 311, and a second flap 312 defined by and separated from the remainder of the sheet 300 by the second line 313. The shallow bends may be formed by heating, e.g., baking, the sheet 300 of sound insulation material, such that the sheet 300 softens and sags, e.g., bends under the force of gravity, along the shallow bend lines 311 and 313 which causes the sheet 300, e.g., the flaps 310 and 312 thereof in particular, to conform to the inner panel 210. For example, as may be seen by comparing FIGS. 5 and 6, in FIG. 6 the first flap 310 is still generally coplanar with the adjoining portions of the sheet 300 of sound insulation material, whereas FIG. 5 depicts the sheet 300 after baking, such that the first flap 310 conforms to the shape of the inner panel 210 and is positioned at an oblique angle to the adjoining portion of the sheet 300, e.g., the sheet 300 has bent along the line 311 to conform to the shape of the inner panel 210, such as after heating, e.g., baking, the sheet 300 as described.

[0054] As may be seen, e.g., in FIG. 7, the hinges 304 and 308 may be defined by one or more slots formed in and through the sheet 300 of sound insulation material. Such slots may not extend fully across the width (e.g., a dimension measured along or parallel to the lateral direction L) of the sheet 300 but may instead be interrupted by one or more tabs extending across each respective slot, such that adjoining portions of the sheet 300 on either side of the slots remain connected by the tabs. Removing the material of the sheet 300, e.g., forming the slots therein, provides a line of increased flexibility such that it is easier to bend the sheet 300 along the hinges due to the slots. In particular, as illustrated in FIG. 7, the first hinge 304 may be defined by a slot which comprises a first slot portion 316, a second slot portion 318, and a third slot portion 320 as well as intervening tabs, e.g., a first tab 322 between the first slot portion 316 and the second slot portion 318, and a second tab 324 between the second slot portion 318 and the third slot portion 320. The portions 316, 318, and 320 of the slot in the first hinge 304 may be colinear so as to define a hinge axis about which the sheet 300 of sound insulation material may be bent. Each tab 322 and 324 may extend across the slot (e.g., along or parallel to the vertical direction V when the door 116 is in the closed position) to thereby define the portions of the slot on either lateral side of each tab. Still referring to FIG. 7, the second hinge 308 may also be defined by a slot which is partitioned by at least one tab which extends across (e.g., in the vertical direction V as mentioned) the slot, such as the second hinge 308 may be defined by a second slot which comprises a fourth slot portion 326, a fifth slot portion 328, and a sixth slot portion 330, with a third tab 332 extending across the second slot to define the fourth slot portion 326 and the fifth slot portion 328, and a fourth tab 334 extending across the second slot to define the fifth slot portion 328 and the sixth slot portion 330.

[0055] Also as may be seen in FIG. 7, the sheet 300 may also include a perforated line 314, which is composed of a series of linear perforations of generally equal length and spaced apart at a regular interval. The sound insulation material may be any suitable material, such as a bitumen mastic material. For example, the material of the sheet 300 may be a rigid material, e.g., may tend to retain the flat shape illustrated in FIG. 7 which, as mentioned, depicts an original or as-manufactured condition (e.g., in contrast to an as-installed configuration when the sheet 300 is fully bonded to the panel and conforms to each curve in the panel) unless and until significant force is applied to the sheet 300, at least in areas where the sheet 300 is continuous (such as areas away from the hinges described herein).

[0056] In some embodiments, the tabs of each hinge may be relatively short, e.g., in a dimension measured along or parallel to the lateral direction L, as compared to the slots or slot portions of each hinge. Referring now to FIG. 8, where the first hinge 304 is enlarged for purposes of explaining an example of such hinge proportions, it being understood that the second hinge 308 may also have the same or similar proportions as those shown and described with reference to the example of the first hinge, e.g., as shown in FIG. 8. The sheet 300 may define an overall with 800, e.g., along or generally parallel to the lateral direction L. The first slot portion 316 may define a first length 802, e.g., parallel to the width 800 of the sheet 300, the second slot portion 318 may define a second length 804, and the third slot portion 320 may define a third length 806. Similarly, the first tab 322 may define a length 808 and the second tab 324 may define a length 810. In order to provide the desired flexibility, e.g., to promote hand-bending of the sheet 300 of sound insulation material by an operator, e.g., generally an adult human of about average strength, the collective lengths 808 and 810 of the tabs 322 and 324 may be no greater than about 30% of the overall width 800 of the sheet 300. At the same time, the sheet 300 is preferably resistant to breakage along the hinges, e.g., the hinges preferably bend but not break, such that the collective lengths 808 and 810 of the tabs 322 and 324 may be no less than about 10% of the overall width 800 of the sheet 300. In some embodiments, the hinge (or each hinge when more than one hinge is provided) may include two tabs, e.g., as illustrated in FIG. 8. In additional embodiments the hinge (or each hinge) may include more than two tabs, such as three tabs, four tabs, or more. In such embodiments, the length per tab may be less when more tabs are provided, e.g., whereby the overall total length of the tabs falls within the above-mentioned ranges.

[0057] FIGS. 9 and 10 provide close-up section views taken through the first bend 302 (FIG. 9) and the second bend 306 (FIG. 10). As may be seen in these views, the slots, e.g., third slot portion 320 which may be seen in FIG. 9 and sixth slot portion 330 which may be seen in FIG. 10, overlie sharply curved portions of the inner panel 210 and thus, the hinges 304 and 308 promote the sheet 300 of sound insulation material bending, e.g., forming deep bends, at these portions of the inner panel 210 to conform the shape of the sheet 300 to the inner panel 210.

[0058] Turning now to FIG. 11, embodiments of the present disclosure also include methods such as the exemplary method 600 of assembling a dishwashing appliance illustrated in FIG. 11. Methods such as method 600 may be used to assemble any suitable dishwashing appliance, such as but not limited to the exemplary dishwashing appliance 100 described above.

[0059] Method 600 may include (610) applying a sheet of sound insulation material to a panel of the dishwashing appliance. For example, the panel may be an inner panel 210 of a door 116. However, as noted above, a sheet of sound insulation may be applied other panels as well or instead in various embodiments of the present disclosure. Also as noted above, the sound insulation material may be a rigid material, such as a mastic material, e.g., a bitumen mastic material.

[0060] Method 600 may also include (620) bending the sheet of sound insulation material after applying the sheet of sound insulation material to the panel of the dishwashing appliance. In some embodiments, bending the sheet of sound insulation material may include bending the sheet of sound insulation material along a hinge defined in the sheet of sound insulation material. For example, the hinge may include a slot formed through the sheet of sound insulation material and a tab extending across the slot.

[0061] Method 600 may further include (630) baking the sheet of sound insulation material, whereby the sheet of sound insulation material conforms to and adheres to the panel of the dishwashing appliance. For example, a side of the sheet of sound insulation material which contacts the panel of the dishwashing appliance may include a heat-activated bonding agent, such as a hot-melt adhesive, by which the sheet is adhered to the panel of the dishwashing appliance as a result of baking at (630) in method 600. Additionally, and as mentioned above, the heat of the baking process (630) may soften the material of the sheet of sound insulation material such that the material sags down onto and around the panel of the dishwashing appliance, thereby conforming the sheet of sound insulation material to the panel.

[0062] In some embodiments, (620) bending the sheet of sound insulation material may include bending the sheet of sound insulation material at a first location to form a first bend in the sheet of sound insulation material, and may further include bending the sheet of sound insulation material at a second location to form a second bend in the sheet of sound insulation material. In such embodiments, the second bend may be generally parallel to the first bend. Also in such embodiments, bending the sheet of sound insulation material at the second location to form the second bend in the sheet of sound insulation material may be performed after applying the sheet of sound insulation material to the panel of the dishwashing appliance and before baking the sheet of sound insulation material.

[0063] Bending the sheet of sound insulation material at the first location to form the first bend in the sheet of sound insulation material may include bending the sheet of sound insulation material along a first hinge defined in the sheet of sound insulation material, and, in such embodiments, bending the sheet of sound insulation material at the second location to form the second bend in the sheet of sound insulation material may also include bending the sheet of sound insulation material along a second hinge defined in the sheet of sound insulation material. For example, the first hinge may include a first slot formed through the sheet of sound insulation material and a first tab extending across the first slot, and the second hinge may include a second slot formed through the sheet of sound insulation material and a second tab extending across the second slot.

[0064] 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 languages of the claims.

Claims

1. A method of assembling a dishwashing appliance, the method comprising:applying a sheet of sound insulation material to a panel of the dishwashing appliance;bending the sheet of sound insulation material after applying the sheet of sound insulation material to the panel of the dishwashing appliance; andbaking the sheet of sound insulation material, whereby the sheet of sound insulation material conforms to and adheres to the panel of the dishwashing appliance.

2. The method of claim 1, wherein bending the sheet of sound insulation material comprises bending the sheet of sound insulation material along a hinge defined in the sheet of sound insulation material.

3. The method of claim 2, wherein the hinge comprises a slot formed through the sheet of sound insulation material and a tab extending across the slot.

4. The method of claim 1, wherein bending the sheet of sound insulation material comprises bending the sheet of sound insulation material at a first location to form a first bend in the sheet of sound insulation material, further comprising bending the sheet of sound insulation material at a second location to form a second bend in the sheet of sound insulation material.

5. The method of claim 4, wherein the second bend is generally parallel to the first bend.

6. The method of claim 4, wherein bending the sheet of sound insulation material at the second location to form the second bend in the sheet of sound insulation material is performed after applying the sheet of sound insulation material to the panel of the dishwashing appliance and before baking the sheet of sound insulation material.

7. The method of claim 4, wherein bending the sheet of sound insulation material at the first location to form the first bend in the sheet of sound insulation material comprises bending the sheet of sound insulation material along a first hinge defined in the sheet of sound insulation material, and wherein bending the sheet of sound insulation material at the second location to form the second bend in the sheet of sound insulation material comprises bending the sheet of sound insulation material along a second hinge defined in the sheet of sound insulation material.

8. The method of claim 7, wherein the first hinge comprises a first slot formed through the sheet of sound insulation material and a first tab extending across the first slot, and wherein the second hinge comprises a second slot formed through the sheet of sound insulation material and a second tab extending across the second slot.

9. The method of claim 1, wherein the panel comprises an inner panel of a door of the dishwashing appliance.

10. The method of claim 1, wherein the sound insulation material comprises a mastic material.

11. A dishwashing appliance comprising:a panel; anda sheet of sound insulation material adhered to the panel, the sheet of sound insulation material comprising a bend formed in the sheet of sound insulation material whereby the sheet of sound insulation material conforms to the panel of the dishwashing appliance.

12. The dishwashing appliance of claim 11, wherein the bend formed in the sheet of sound insulation material is formed along a hinge defined in the sheet of sound insulation material.

13. The dishwashing appliance of claim 12, wherein the hinge comprises a slot formed through the sheet of sound insulation material and a tab extending across the slot.

14. The dishwashing appliance of claim 11, wherein the bend formed in the sheet of sound insulation material is a first bend at a first location, further comprising a second bend at a second location in the sheet of sound insulation material.

15. The dishwashing appliance of claim 14, wherein the second bend is generally parallel to the first bend.

16. The dishwashing appliance of claim 14, wherein the first bend formed in the sheet of sound insulation material is formed along a first hinge defined in the sheet of sound insulation material, and wherein the second bend formed in the sheet of sound insulation material is formed along a second hinge defined in the sheet of sound insulation material.

17. The dishwashing appliance of claim 16, wherein the first hinge comprises a first slot formed through the sheet of sound insulation material and a first tab extending across the first slot, and wherein the second hinge comprises a second slot formed through the sheet of sound insulation material and a second tab extending across the second slot.

18. The dishwashing appliance of claim 11, wherein the panel comprises an inner panel of a door of the dishwashing appliance.

19. The dishwashing appliance of claim 11, wherein the sound insulation material comprises a mastic material.

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