Locator rail for appliance door hinge

Abstract

An appliance including a case body defining a plurality of case apertures, a locator rail attached to a first side of the case body, the locator rail comprising a plurality of locator tabs, each locator tab of the plurality of locator tabs being engaged with one corresponding aperture of the plurality of case apertures, and a door hinge bracket positioned on a second side of the case body, the door hinge bracket defining a plurality of bracket apertures, each locator tab of the plurality of locator tabs being engaged with one corresponding bracket aperture of the plurality of bracket apertures, wherein the plurality of locator tabs constrains the door hinge bracket in at least three degrees of freedom.

Description

FIELD

[0001] The present subject matter relates generally to household appliances such as refrigerator appliances, and more particularly to a locator features for case bodies and / or door hinges of such appliances.BACKGROUND

[0002] Household appliances are utilized generally for a variety of tasks by a variety of users. For example, a household may include such appliances as kitchen appliances, e.g., a refrigerator appliance, an oven appliance, a microwave appliance, etc., laundry appliances, e.g., a washing machine appliance and / or dryer appliance, along with other various appliances.

[0003] Many household appliances include a cabinet or housing with one or more doors attached to the cabinet. For example, an oven appliance or microwave appliance may include a cooking chamber within the cabinet and one or more doors rotatably coupled to the cabinet, e.g., by hinges, such that the door(s) rotate between a closed position in which the cooking chamber is sealed and enclosed within the cabinet and door and an open position which permits access to the cooking chamber. As another example, laundry appliances generally include a treatment chamber, e.g., inside a drum of a dryer appliance or a tub or basket of a washing machine appliance, which is selectively enclosed or accessible via a door which may be rotatably coupled to the cabinet in a similar manner as described above with respect to cooking appliances. In yet another example, refrigerator appliances may include one or more food storage chambers with one or more doors for each chamber rotatably coupled to the cabinet for each chamber.

[0004] Precise and accurate location of the door or doors of a household appliance relative to the cabinet (and to each other when there are multiple doors) is desired in order to increase customer satisfaction and overall perception of the quality of the household appliance. Some household appliances rely on multiple part mounting and aligning systems for locating and coupling doors to the cabinet of the household appliance. Such systems may increase the complexity of assembling the household appliance, and the multiple parts may also result in tolerance stack ups which create excessive variation and difficulty in correctly and consistently locating and aligning the door or doors with each other (when there are multiple doors) and with the cabinet.

[0005] Accordingly, it is recognized in the art that improved locating systems would be beneficial for household appliances.BRIEF DESCRIPTION

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

[0007] In one exemplary embodiment, an appliance defining a vertical direction, a lateral direction, and a transverse direction is provided. The appliance includes a case body defining a plurality of case apertures, a locator rail attached to a first side of the case body, the locator rail comprising a plurality of locator tabs, each locator tab of the plurality of locator tabs being engaged with one corresponding aperture of the plurality of case apertures, and a door hinge bracket positioned on a second side of the case body, the door hinge bracket defining a plurality of bracket apertures, each locator tab of the plurality of locator tabs being engaged with one corresponding bracket aperture of the plurality of bracket apertures, wherein the plurality of locator tabs constrains the door hinge bracket in at least three degrees of freedom.

[0008] In another exemplary embodiment, a hinge bracket assembly for a door of an appliance is provided. The appliance includes a case body defining a vertical direction, a lateral direction, and a transverse direction, the case body further defining a plurality of case apertures. The hinge bracket assembly includes a locator rail attached to a first side of the case body, the locator rail comprising a plurality of locator tabs, each locator tab of the plurality of locator tabs being engaged with one corresponding aperture of the plurality of case apertures, and a door hinge bracket positioned on a second side of the case body, the door hinge bracket defining a plurality of bracket apertures, each locator tab of the plurality of locator tabs being engaged with one corresponding bracket aperture of the plurality of bracket apertures, wherein the plurality of locator tabs constrains the door hinge bracket in at least three degrees of freedom.

[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 perspective view of a refrigerator appliance according to one or more example embodiments of the present subject matter.

[0012] FIG. 2 provides an additional perspective view of the refrigerator appliance of FIG. 1 with doors of the refrigerator appliance in an open position.

[0013] FIG. 3 provides a perspective view of a case body, a locator rail, and door hinge brackets of the refrigerator appliance of FIG. 1 according to one or more example embodiments of the present subject matter.

[0014] FIG. 4 provides a top, perspective view the refrigerator appliance of FIG. 1 with the locator rail illustrated in phantom according to one or more example embodiments of the present subject matter.

[0015] FIG. 5 provides a top view the refrigerator appliance of FIG. 1 according to an example embodiment of the present subject matter.

[0016] FIG. 6 provides a top view the locator rail of FIG. 3 according to an example embodiment of the present subject matter.

[0017] FIG. 7 provides a perspective view of the door hinge bracket of FIG. 3 according to an example embodiment of the present subject matter.

[0018] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.DETAILED DESCRIPTION

[0019] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. 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 or spirit 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.

[0020] As used herein, 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 “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”).

[0021] Terms such as “inner” and “outer” refer to relative directions with respect to the interior and exterior of the refrigerator appliance, and in particular the food storage chamber(s) defined therein. For example, “inner” or “inward” refers to the direction towards the interior of the refrigerator appliance. Terms such as “left,”“right,”“front,”“back,”“top,” or “bottom” are used with reference to the perspective of a user accessing the refrigerator appliance. For example, a user stands in front of the refrigerator to open the doors and reaches into the food storage chamber(s) to access items therein.

[0022] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,”“about,”“approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and / or systems. For example, the approximating language may refer to being within a ten percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, 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.

[0023] Referring now to the figures, FIGS. 1 and 2 provide perspective views of an exemplary household appliance, which in the illustrated example is a refrigerator appliance 100, according to one or more exemplary embodiments of the present subject matter. The household appliance, e.g., refrigerator appliance, may define a vertical direction V, a lateral direction L, and a transverse direction T. The vertical direction V, the lateral direction L, and the transverse direction T may each be mutually perpendicular to one another to generally form an orthogonal coordinate system.

[0024] As illustrated in FIGS. 1 and 2, the refrigerator appliance 100 may include a housing or a cabinet 102 that may extend between a top 104 and a bottom 106 approximately along a vertical direction V, between a first side (left side) 108 and a second side (right side) 110 approximately along a lateral direction L, and between a front 112 and a back 114 approximately along a transverse direction T. The cabinet 102 may define one or more chilled chambers for receipt of food items for storage. In some embodiments, the cabinet 102 may define a fresh food chamber 122 positioned at or adjacent the top 104 of the cabinet 102 and a freezer chamber 124 arranged at or adjacent the bottom 106 of the cabinet 102. As such, the refrigerator appliance 100 may generally be referred to as a bottom mount refrigerator.

[0025] It is recognized, however, that the benefits of the present disclosure apply to other types and styles of refrigerator appliances such as, for example, a top mount refrigerator appliance, a quad door refrigerator appliance, a side-by-side refrigerator, a standalone (single chamber) refrigerator or freezer appliance, or other household appliances which generally include a cabinet with one or more doors rotatably mounted to the cabinet. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular household appliance, such as the present subject matter is not limited to any particular refrigerator chamber configuration, or the presence of a refrigerator chamber at all. For example, the present subject matter may also be used with household appliances having a cooking chamber (e.g., in a range or wall oven or microwave) or a laundry treatment chamber (e.g., in a washing machine appliance, dryer appliance, or combination washer-dryer appliance). Accordingly, it should be recognized that aspects of the present disclosure, such as the locator rail and hinge brackets, may be used with a variety of household appliances, such as any household appliance having a cabinet, a chamber defined within the cabinet, and a door rotatably mounted to the cabinet to selectively at least partially enclose the chamber.

[0026] The refrigerator doors 128 may be rotatably hinged to an edge of the cabinet 102 for selectively accessing the fresh food chamber 122. In addition, a freezer door 130 may be arranged below the refrigerator doors 128 for selectively accessing the freezer chamber 124. The freezer door 130 may be coupled to a freezer drawer (not shown) slidably mounted within the freezer chamber 124. The refrigerator doors 128 and the freezer door 130 may be shown in the closed configuration in FIG. 1.

[0027] In some embodiments, various storage components may be mounted within the fresh food chamber 122 to facilitate storage of food items therein. In particular, the storage components may include storage bins 134, drawers 136, and shelves 138 that may be mounted within the fresh food chamber 122. As such, the storage bins 134, drawers 136, and shelves 138 are configured for receipt of food items, for example, beverages or solid food items, and may assist with organizing such food items. As an example, the drawers 136 can receive fresh food items, for example, vegetables, fruits, or cheeses, and increase the useful life of such fresh food items.

[0028] In some embodiments, the refrigerator appliance 100 may also include a dispensing assembly 140 for dispensing liquid water or ice. The dispensing assembly 140 may include a dispenser 142, for example, positioned on or mounted to an exterior portion of the refrigerator appliance 100, such as on one of the refrigerator doors 128. Moreover, as shown in FIG. 1, the dispenser 142 may include a discharging outlet 144 for accessing ice and liquid water. Further, an actuating mechanism 146, shown as a paddle, may be mounted below the discharging outlet 144 for operating the dispenser 142. In alternative embodiments, any suitable actuating mechanism may be used to operate the dispenser 142. A user interface panel 148 may also be provided for controlling the mode of operation. For example, the user interface panel 148 may include a plurality of user inputs (not labeled), such as a water dispensing button and an ice-dispensing button, for selecting a desired mode of operation such as crushed or non-crushed ice.

[0029] Still referring to FIG. 1, the discharging outlet 144 and actuating mechanism 146 may be an external part of the dispenser 142 and may be mounted in a dispenser recess 150. The dispenser recess 150 may be positioned at a predetermined elevation convenient for a user to access ice or water and enabling the user to access ice without the need to bend-over and without the need to open the refrigerator doors 128. In additional embodiments, the dispenser recess 150 may be positioned at a level that approximates the chest level of a user.

[0030] In further embodiments, for example, as shown in FIG. 2, the refrigerator appliance 100 may include a sub-compartment 152 defined on the refrigerator door 128. The sub-compartment 152 is often referred to as an “icebox.” Further, the sub-compartment 152 may extend into fresh food chamber 122 when the refrigerator door 128 is in the closed position. Although the sub-compartment 152 is shown in the refrigerator door 128, additional or alternative embodiments may include the sub-compartment 152 fixed within fresh food chamber 122. In an embodiment, an ice maker and / or an ice storage bin (not shown) may be positioned or disposed within the sub-compartment 152. Accordingly, during use, ice can be supplied to the dispenser recess 150, see, for example, FIG. 1, from the ice making assembly or ice storage bin in the sub-compartment 152 on a back side of refrigerator door 128.

[0031] In additional or alternative embodiments, chilled air from a sealed system (not shown) of the refrigerator appliance 100 may be directed into components within the sub-compartment 152. For instance, the sub-compartment 152 may receive cooling air from a chilled air supply duct 154 and a chilled air return duct 156, see, for example, FIG. 2, disposed on a side portion of cabinet 102 of the refrigerator appliance 100. In this manner, the chilled air supply duct 154 and the chilled air return duct 156 may recirculate chilled air from a suitable sealed cooling system through the sub-compartment 152.

[0032] In optional embodiments, for example, as illustrated in FIG. 2, an access door 158 may be hinged to the refrigerator door 128. Thus, the access door 158 may permit selective access to the sub-compartment 152. Any manner of suitable latch 160 may be configured with the sub-compartment 152 to maintain the access door 158 in a closed position. As an example, the latch 160 may be actuated by a user in order to open the access door 158 for providing access into the sub-compartment 152. The access door 158 can also assist with insulating the sub-compartment 152 (e.g., by thermally isolating or insulating the sub-compartment 152 from the fresh food chamber 122). It is noted that although the access door 158 is illustrated in exemplary embodiments, alternative embodiments may be free of any separate access door.

[0033] Referring now to FIG. 3, a perspective view of a case body 200 according to one or more exemplary embodiments of the present subject matter is provided. In some embodiments, the case body 200 may be a portion of the cabinet 102, such as the case body 200 may define at least two external sides, e.g., the left side and the right side, of the cabinet 102. For instance, in some embodiments, the case body 200 may be formed into a “U” shape from a piece of sheet metal to provide the top 104, the left side 108, and the right side 110 of the cabinet 102. According to alternative embodiments, cabinet 102 may be “panelized” or formed from multiple independent and joined panels. In addition, the case body 200 may extend approximately along the transverse direction T to define the front 112 and the back 114 of the refrigerator appliance 100.

[0034] An exemplary locator rail 202 according to one or more exemplary embodiments of the present subject matter may also be seen in FIG. 3. As will be described in more detail below, the locator rail 202 may be coupled to the case body 200, such as at a front top edge of the case body 200, e.g., as illustrated, or at another front edge of the case body 200, e.g., an intermediate front edge between the top 104 and a bottom of the case body 200. In general, locator rail 202 may be a rigid stiffening rail present within case body 200 to provide structural support and rigidity thereto. Aspects of the present subject matter are generally directed to a novel way of using the locator rail 202 to improve the installation, alignment, and function of locator rail 202, which may generally form a part of a hinge bracket assembly 204.

[0035] As shown in FIG. 3, hinge bracket assembly 204 may further include a door hinge bracket 250 (described below) which is attached to case body 200 to rotatably support one or more doors, e.g., such as refrigerator door 128. Although hinge bracket assembly 204 is described herein as supporting a top door hinge of a door of a French door refrigerator, it should be appreciated that aspects of the present subject matter may be used to mount any suitable door, to any suitable appliance, and in any suitable configuration. For example, hinge bracket assembly 204 may be used to mount doors on laundry appliances, dishwashers, ovens, or any other suitable appliance.

[0036] As may be seen, e.g., in FIGS. 3 and 6, the locator rail 202 may be a single piece, e.g., a single unitarily formed piece of material, such as sheet metal material. The locator tail 202 may extend longitudinally from a first end 210 to a second end 212 opposite the first end 210 of the locator rail 202. For example, when installed, e.g., coupled to the case body 200, the locator rail 202 extends generally along the lateral direction L from the first end 210 to the second end 212. When installed, the first end 210 of the locator rail 202 may be positioned at the left side 108 of the cabinet 102, and the second end 212 of the locator rail 202 may be positioned at the right side 110 of the cabinet 102, such that the locator rail 202 may define a dimension of the cabinet 102 from the left to the right, such as a distance between the left side 108 of the cabinet 102 and the right side 110 of the cabinet 102, such as a width of the cabinet 102. According to the illustrated embodiment, top 104 of case body 200 defines a bottom side 214 and a top side 216 spaced apart along the vertical direction V, and locator rail 202 may be positioned against bottom side 214 of top 104. In addition, locator rail 202 may be foamed in place during the assembly operation and may provide improved rigidity to case body 200 and hinge bracket assembly 204.

[0037] The locator rail 202 may include a plurality of locator tabs 220 formed on the locator rail 202. For example, locator tabs 220 may be formed from the parent material of locator rail 202, e.g., from a single unitarily formed piece of material. For example, in some embodiments such as where the locator rail 202 is formed of sheet metal, locator tabs 220 may be stamped or punched from the same piece of sheet metal, such as all locator tabs 220 may be punched in a single operation (including various sets of locator tabs 220 which may extend from a main body of the locator rail 202, as described further below, may be punched in the single operation). In general, locator tabs 220 may be stamped and bent to extend substantially along the vertical direction V, e.g., perpendicular to a top surface of locator rail 202.

[0038] The locator tabs 220 may include a set of first side locator tabs 222 at the first end 210 of the locator rail 202 and a set of second side locator tabs 224 at the second end 212 of the locator rail 202. As explained in more detail below, the set of first side locator tabs 222 and the set of second side locator tabs 224 may be used to locate, align, and mount a first side hinge bracket and a second side hinge bracket (both identified with reference numeral 250), respectively, of hinge bracket assembly 204

[0039] As shown for example in FIGS. 5 through 6, the set of first side locator tabs 222 and the set of second side locator tabs 224 may each include a first locator tab 226 and a second locator tab 228. The first locator tab 226 may be oriented along a first direction, e.g., such as generally 45° measured relative to the transverse direction T, and the second locator tab 228 may be oriented along a second direction perpendicular to the first direction. In addition, the set of first side locator tabs 222 and the set of second side locator tabs 224 may each include a third locator tab 230 oriented generally along the first direction, e.g., generally parallel to the first locator tab 226.

[0040] As illustrated in FIG. 3, case body 200 may define a plurality of case apertures 240 that pass through top 104 of case body 200 from bottom side 214 to top side 216 along the vertical direction V. In general, locator rail 202 may be mounted to bottom side 214 of top 104 of case body 200 such that locator tabs 220 are aligned with and pass through case apertures 240. Accordingly, case apertures 240 may be defined on case body 200 such that their size and positioning facilitate easy engagement with locator tabs 220.

[0041] According to an example embodiment, the size of case apertures 240 may be varied in order to ensure ease of assembly and to prevent over constraining the part. In this regard, for example, a first portion of case apertures 240 may be pass through apertures 242 and a second portion of case apertures 240 may be locator fit apertures 244. For example, three of case apertures 240 may be pass through apertures 242 and three of case apertures 240 may be locator fit apertures 244. In general, pass through apertures 242 are defined to have a slight clearance relative to locator tabs 220, e.g., such that locator tabs 220 do not contact the sides of case body 200 that define pass through apertures 242. By contrast, locator fit apertures 244 may be formed to have a tighter tolerance relative to locator tabs 220, such that locator tabs 220 directly engage, locate, and align locator rail 202 relative to case body 200. According to example embodiments, case apertures 240 may be elongated in a directed perpendicular to the alignment direction of each respective locator tabs 220 (e.g., the first direction and second direction as identified above), such that the assembly process is insensitive to the variation in bend angle of locator tabs 220.

[0042] According to an example embodiment, hinge bracket assembly 204 may further include one or more door hinge brackets 250. For purposes of the present discussion, a single door hinge bracket 250 is described, though it should be appreciated that the same, similar, or mirror image door hinge bracket 250 may be used on an opposite side of refrigerator appliance 100. Door hinge bracket 250 may be configured to mount to locator rail 202, e.g., against top side 216 of case body 200, by mutual engagement of respective locator tabs 220 and bracket apertures 252 defined through door hinge bracket 250. In this regard, door hinge bracket 250 may include a plurality of bracket apertures 252, with each bracket aperture 252 corresponding to a respective locator tab 220. Similar to case apertures 240, bracket apertures 252 may be elongated in a directed perpendicular to the alignment direction of each respective locator tabs 220, such that the assembly process is insensitive to the variation in bend angle of locator tabs 220.

[0043] As best shown in FIG. 7, locator tabs 220 may be designed to directly engage door hinge bracket 250 within bracket apertures 252. For example, bracket apertures 252 may be designed to have a locator or contact fit with locator tabs 220, such that positioning door hinge bracket 250 onto locator tabs 220 constrains door hinge bracket 250 in at least three degrees-of-freedom. In this regard, door hinge bracket may contact the edges of locator tabs 220. For example, according to the illustrated embodiment, the receipt of locator tabs 220 within bracket apertures 252 may constrain door hinge bracket 250 to prevent translation along the lateral direction L, translation along the transverse direction T, and rotation about the vertical direction V.

[0044] According to the illustrated embodiment, locator tabs 220 are aligned diagonally along a mounting plate 254 of door hinge bracket 250. In this manner, the locator tabs 220 and bracket apertures 252 may be spaced apart on mounting plate by an increased linear distance, e.g., thereby increasing stability, alignment, and bracket location. In addition, it should be appreciated that locator tabs 220 defines a tab height (not labeled) measured from a top surface of locator rail 202 along the vertical direction V to a distal end of locator tabs 220. According to example embodiments, the tab height is greater than or equal to a case thickness of case body 200 plus a bracket thickness of door hinge bracket 250.

[0045] According to an example embodiment, door hinge bracket 250 further defines a plurality of through holes 260 and locator rail 202 defines a plurality of receiving bosses 262. Hinge bracket assembly 204 may further include a plurality of mechanical fasteners 264 that pass through the plurality of through holes 260 and are secured in the plurality of receiving bosses 262 to attach door hinge bracket 250 and form a single, rigid structure between case body 200, locator rail 202, and hinge bracket assembly 204. For example, the plurality of through holes 260 may be clearance holes that are wider than the plurality of mechanical fasteners 264. Engagement of mechanical fasteners 264 may generally constrain door hinge bracket 250 in three additional degrees of freedom. For example, the clamping force applied by mechanical fasteners 264 may prevent door hinge bracket 250 from translation along the vertical direction V, rotation about the lateral direction L, and rotation about the transverse direction T.

[0046] As explained herein, aspects of the present subject matter are generally directed to a method of locating an upper hinge bracket of a refrigerator over the refrigerator body to improve the door alignment by positioning the hinge brackets accurately. The refrigerator may include a stiffener secured to the top of its body wherein the stiffener, at both ends, includes three locating tabs protruding from the top of the refrigerator body. Two hinge brackets, one on each side, are provided on the top of the refrigerator body and each hinge bracket may include three locating slots formed on it in such a manner that they engage with the locating tabs of the stiffener. Thus, a coordinated tab and slot configuration is achieved for the top stiffener, the case top, and the hinge brackets. The use of locating features mitigates the need for fasteners for positioning hinge brackets. Further, using three tab and slot configurations on each side of the refrigerator top case results in constraining all six degrees of freedom of the hinge bracket.

[0047] 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.

Examples

Embodiment Construction

[0019]Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. 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 or spirit 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.

[0020]As used herein, 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 “includes” and “including” are...

FIELD

[0001] The present subject matter relates generally to household appliances such as refrigerator appliances, and more particularly to a locator features for case bodies and / or door hinges of such appliances.BACKGROUND

[0002] Household appliances are utilized generally for a variety of tasks by a variety of users. For example, a household may include such appliances as kitchen appliances, e.g., a refrigerator appliance, an oven appliance, a microwave appliance, etc., laundry appliances, e.g., a washing machine appliance and / or dryer appliance, along with other various appliances.

[0003] Many household appliances include a cabinet or housing with one or more doors attached to the cabinet. For example, an oven appliance or microwave appliance may include a cooking chamber within the cabinet and one or more doors rotatably coupled to the cabinet, e.g., by hinges, such that the door(s) rotate between a closed position in which the cooking chamber is sealed and enclosed within the cabinet and door and an open position which permits access to the cooking chamber. As another example, laundry appliances generally include a treatment chamber, e.g., inside a drum of a dryer appliance or a tub or basket of a washing machine appliance, which is selectively enclosed or accessible via a door which may be rotatably coupled to the cabinet in a similar manner as described above with respect to cooking appliances. In yet another example, refrigerator appliances may include one or more food storage chambers with one or more doors for each chamber rotatably coupled to the cabinet for each chamber.

[0004] Precise and accurate location of the door or doors of a household appliance relative to the cabinet (and to each other when there are multiple doors) is desired in order to increase customer satisfaction and overall perception of the quality of the household appliance. Some household appliances rely on multiple part mounting and aligning systems for locating and coupling doors to the cabinet of the household appliance. Such systems may increase the complexity of assembling the household appliance, and the multiple parts may also result in tolerance stack ups which create excessive variation and difficulty in correctly and consistently locating and aligning the door or doors with each other (when there are multiple doors) and with the cabinet.

[0005] Accordingly, it is recognized in the art that improved locating systems would be beneficial for household appliances.BRIEF DESCRIPTION

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

[0007] In one exemplary embodiment, an appliance defining a vertical direction, a lateral direction, and a transverse direction is provided. The appliance includes a case body defining a plurality of case apertures, a locator rail attached to a first side of the case body, the locator rail comprising a plurality of locator tabs, each locator tab of the plurality of locator tabs being engaged with one corresponding aperture of the plurality of case apertures, and a door hinge bracket positioned on a second side of the case body, the door hinge bracket defining a plurality of bracket apertures, each locator tab of the plurality of locator tabs being engaged with one corresponding bracket aperture of the plurality of bracket apertures, wherein the plurality of locator tabs constrains the door hinge bracket in at least three degrees of freedom.

[0008] In another exemplary embodiment, a hinge bracket assembly for a door of an appliance is provided. The appliance includes a case body defining a vertical direction, a lateral direction, and a transverse direction, the case body further defining a plurality of case apertures. The hinge bracket assembly includes a locator rail attached to a first side of the case body, the locator rail comprising a plurality of locator tabs, each locator tab of the plurality of locator tabs being engaged with one corresponding aperture of the plurality of case apertures, and a door hinge bracket positioned on a second side of the case body, the door hinge bracket defining a plurality of bracket apertures, each locator tab of the plurality of locator tabs being engaged with one corresponding bracket aperture of the plurality of bracket apertures, wherein the plurality of locator tabs constrains the door hinge bracket in at least three degrees of freedom.

[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 perspective view of a refrigerator appliance according to one or more example embodiments of the present subject matter.

[0012] FIG. 2 provides an additional perspective view of the refrigerator appliance of FIG. 1 with doors of the refrigerator appliance in an open position.

[0013] FIG. 3 provides a perspective view of a case body, a locator rail, and door hinge brackets of the refrigerator appliance of FIG. 1 according to one or more example embodiments of the present subject matter.

[0014] FIG. 4 provides a top, perspective view the refrigerator appliance of FIG. 1 with the locator rail illustrated in phantom according to one or more example embodiments of the present subject matter.

[0015] FIG. 5 provides a top view the refrigerator appliance of FIG. 1 according to an example embodiment of the present subject matter.

[0016] FIG. 6 provides a top view the locator rail of FIG. 3 according to an example embodiment of the present subject matter.

[0017] FIG. 7 provides a perspective view of the door hinge bracket of FIG. 3 according to an example embodiment of the present subject matter.

[0018] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.DETAILED DESCRIPTION

[0019] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. 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 or spirit 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.

[0020] As used herein, 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 “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”).

[0021] Terms such as “inner” and “outer” refer to relative directions with respect to the interior and exterior of the refrigerator appliance, and in particular the food storage chamber(s) defined therein. For example, “inner” or “inward” refers to the direction towards the interior of the refrigerator appliance. Terms such as “left,”“right,”“front,”“back,”“top,” or “bottom” are used with reference to the perspective of a user accessing the refrigerator appliance. For example, a user stands in front of the refrigerator to open the doors and reaches into the food storage chamber(s) to access items therein.

[0022] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,”“about,”“approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and / or systems. For example, the approximating language may refer to being within a ten percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, 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.

[0023] Referring now to the figures, FIGS. 1 and 2 provide perspective views of an exemplary household appliance, which in the illustrated example is a refrigerator appliance 100, according to one or more exemplary embodiments of the present subject matter. The household appliance, e.g., refrigerator appliance, may define a vertical direction V, a lateral direction L, and a transverse direction T. The vertical direction V, the lateral direction L, and the transverse direction T may each be mutually perpendicular to one another to generally form an orthogonal coordinate system.

[0024] As illustrated in FIGS. 1 and 2, the refrigerator appliance 100 may include a housing or a cabinet 102 that may extend between a top 104 and a bottom 106 approximately along a vertical direction V, between a first side (left side) 108 and a second side (right side) 110 approximately along a lateral direction L, and between a front 112 and a back 114 approximately along a transverse direction T. The cabinet 102 may define one or more chilled chambers for receipt of food items for storage. In some embodiments, the cabinet 102 may define a fresh food chamber 122 positioned at or adjacent the top 104 of the cabinet 102 and a freezer chamber 124 arranged at or adjacent the bottom 106 of the cabinet 102. As such, the refrigerator appliance 100 may generally be referred to as a bottom mount refrigerator.

[0025] It is recognized, however, that the benefits of the present disclosure apply to other types and styles of refrigerator appliances such as, for example, a top mount refrigerator appliance, a quad door refrigerator appliance, a side-by-side refrigerator, a standalone (single chamber) refrigerator or freezer appliance, or other household appliances which generally include a cabinet with one or more doors rotatably mounted to the cabinet. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular household appliance, such as the present subject matter is not limited to any particular refrigerator chamber configuration, or the presence of a refrigerator chamber at all. For example, the present subject matter may also be used with household appliances having a cooking chamber (e.g., in a range or wall oven or microwave) or a laundry treatment chamber (e.g., in a washing machine appliance, dryer appliance, or combination washer-dryer appliance). Accordingly, it should be recognized that aspects of the present disclosure, such as the locator rail and hinge brackets, may be used with a variety of household appliances, such as any household appliance having a cabinet, a chamber defined within the cabinet, and a door rotatably mounted to the cabinet to selectively at least partially enclose the chamber.

[0026] The refrigerator doors 128 may be rotatably hinged to an edge of the cabinet 102 for selectively accessing the fresh food chamber 122. In addition, a freezer door 130 may be arranged below the refrigerator doors 128 for selectively accessing the freezer chamber 124. The freezer door 130 may be coupled to a freezer drawer (not shown) slidably mounted within the freezer chamber 124. The refrigerator doors 128 and the freezer door 130 may be shown in the closed configuration in FIG. 1.

[0027] In some embodiments, various storage components may be mounted within the fresh food chamber 122 to facilitate storage of food items therein. In particular, the storage components may include storage bins 134, drawers 136, and shelves 138 that may be mounted within the fresh food chamber 122. As such, the storage bins 134, drawers 136, and shelves 138 are configured for receipt of food items, for example, beverages or solid food items, and may assist with organizing such food items. As an example, the drawers 136 can receive fresh food items, for example, vegetables, fruits, or cheeses, and increase the useful life of such fresh food items.

[0028] In some embodiments, the refrigerator appliance 100 may also include a dispensing assembly 140 for dispensing liquid water or ice. The dispensing assembly 140 may include a dispenser 142, for example, positioned on or mounted to an exterior portion of the refrigerator appliance 100, such as on one of the refrigerator doors 128. Moreover, as shown in FIG. 1, the dispenser 142 may include a discharging outlet 144 for accessing ice and liquid water. Further, an actuating mechanism 146, shown as a paddle, may be mounted below the discharging outlet 144 for operating the dispenser 142. In alternative embodiments, any suitable actuating mechanism may be used to operate the dispenser 142. A user interface panel 148 may also be provided for controlling the mode of operation. For example, the user interface panel 148 may include a plurality of user inputs (not labeled), such as a water dispensing button and an ice-dispensing button, for selecting a desired mode of operation such as crushed or non-crushed ice.

[0029] Still referring to FIG. 1, the discharging outlet 144 and actuating mechanism 146 may be an external part of the dispenser 142 and may be mounted in a dispenser recess 150. The dispenser recess 150 may be positioned at a predetermined elevation convenient for a user to access ice or water and enabling the user to access ice without the need to bend-over and without the need to open the refrigerator doors 128. In additional embodiments, the dispenser recess 150 may be positioned at a level that approximates the chest level of a user.

[0030] In further embodiments, for example, as shown in FIG. 2, the refrigerator appliance 100 may include a sub-compartment 152 defined on the refrigerator door 128. The sub-compartment 152 is often referred to as an “icebox.” Further, the sub-compartment 152 may extend into fresh food chamber 122 when the refrigerator door 128 is in the closed position. Although the sub-compartment 152 is shown in the refrigerator door 128, additional or alternative embodiments may include the sub-compartment 152 fixed within fresh food chamber 122. In an embodiment, an ice maker and / or an ice storage bin (not shown) may be positioned or disposed within the sub-compartment 152. Accordingly, during use, ice can be supplied to the dispenser recess 150, see, for example, FIG. 1, from the ice making assembly or ice storage bin in the sub-compartment 152 on a back side of refrigerator door 128.

[0031] In additional or alternative embodiments, chilled air from a sealed system (not shown) of the refrigerator appliance 100 may be directed into components within the sub-compartment 152. For instance, the sub-compartment 152 may receive cooling air from a chilled air supply duct 154 and a chilled air return duct 156, see, for example, FIG. 2, disposed on a side portion of cabinet 102 of the refrigerator appliance 100. In this manner, the chilled air supply duct 154 and the chilled air return duct 156 may recirculate chilled air from a suitable sealed cooling system through the sub-compartment 152.

[0032] In optional embodiments, for example, as illustrated in FIG. 2, an access door 158 may be hinged to the refrigerator door 128. Thus, the access door 158 may permit selective access to the sub-compartment 152. Any manner of suitable latch 160 may be configured with the sub-compartment 152 to maintain the access door 158 in a closed position. As an example, the latch 160 may be actuated by a user in order to open the access door 158 for providing access into the sub-compartment 152. The access door 158 can also assist with insulating the sub-compartment 152 (e.g., by thermally isolating or insulating the sub-compartment 152 from the fresh food chamber 122). It is noted that although the access door 158 is illustrated in exemplary embodiments, alternative embodiments may be free of any separate access door.

[0033] Referring now to FIG. 3, a perspective view of a case body 200 according to one or more exemplary embodiments of the present subject matter is provided. In some embodiments, the case body 200 may be a portion of the cabinet 102, such as the case body 200 may define at least two external sides, e.g., the left side and the right side, of the cabinet 102. For instance, in some embodiments, the case body 200 may be formed into a “U” shape from a piece of sheet metal to provide the top 104, the left side 108, and the right side 110 of the cabinet 102. According to alternative embodiments, cabinet 102 may be “panelized” or formed from multiple independent and joined panels. In addition, the case body 200 may extend approximately along the transverse direction T to define the front 112 and the back 114 of the refrigerator appliance 100.

[0034] An exemplary locator rail 202 according to one or more exemplary embodiments of the present subject matter may also be seen in FIG. 3. As will be described in more detail below, the locator rail 202 may be coupled to the case body 200, such as at a front top edge of the case body 200, e.g., as illustrated, or at another front edge of the case body 200, e.g., an intermediate front edge between the top 104 and a bottom of the case body 200. In general, locator rail 202 may be a rigid stiffening rail present within case body 200 to provide structural support and rigidity thereto. Aspects of the present subject matter are generally directed to a novel way of using the locator rail 202 to improve the installation, alignment, and function of locator rail 202, which may generally form a part of a hinge bracket assembly 204.

[0035] As shown in FIG. 3, hinge bracket assembly 204 may further include a door hinge bracket 250 (described below) which is attached to case body 200 to rotatably support one or more doors, e.g., such as refrigerator door 128. Although hinge bracket assembly 204 is described herein as supporting a top door hinge of a door of a French door refrigerator, it should be appreciated that aspects of the present subject matter may be used to mount any suitable door, to any suitable appliance, and in any suitable configuration. For example, hinge bracket assembly 204 may be used to mount doors on laundry appliances, dishwashers, ovens, or any other suitable appliance.

[0036] As may be seen, e.g., in FIGS. 3 and 6, the locator rail 202 may be a single piece, e.g., a single unitarily formed piece of material, such as sheet metal material. The locator tail 202 may extend longitudinally from a first end 210 to a second end 212 opposite the first end 210 of the locator rail 202. For example, when installed, e.g., coupled to the case body 200, the locator rail 202 extends generally along the lateral direction L from the first end 210 to the second end 212. When installed, the first end 210 of the locator rail 202 may be positioned at the left side 108 of the cabinet 102, and the second end 212 of the locator rail 202 may be positioned at the right side 110 of the cabinet 102, such that the locator rail 202 may define a dimension of the cabinet 102 from the left to the right, such as a distance between the left side 108 of the cabinet 102 and the right side 110 of the cabinet 102, such as a width of the cabinet 102. According to the illustrated embodiment, top 104 of case body 200 defines a bottom side 214 and a top side 216 spaced apart along the vertical direction V, and locator rail 202 may be positioned against bottom side 214 of top 104. In addition, locator rail 202 may be foamed in place during the assembly operation and may provide improved rigidity to case body 200 and hinge bracket assembly 204.

[0037] The locator rail 202 may include a plurality of locator tabs 220 formed on the locator rail 202. For example, locator tabs 220 may be formed from the parent material of locator rail 202, e.g., from a single unitarily formed piece of material. For example, in some embodiments such as where the locator rail 202 is formed of sheet metal, locator tabs 220 may be stamped or punched from the same piece of sheet metal, such as all locator tabs 220 may be punched in a single operation (including various sets of locator tabs 220 which may extend from a main body of the locator rail 202, as described further below, may be punched in the single operation). In general, locator tabs 220 may be stamped and bent to extend substantially along the vertical direction V, e.g., perpendicular to a top surface of locator rail 202.

[0038] The locator tabs 220 may include a set of first side locator tabs 222 at the first end 210 of the locator rail 202 and a set of second side locator tabs 224 at the second end 212 of the locator rail 202. As explained in more detail below, the set of first side locator tabs 222 and the set of second side locator tabs 224 may be used to locate, align, and mount a first side hinge bracket and a second side hinge bracket (both identified with reference numeral 250), respectively, of hinge bracket assembly 204

[0039] As shown for example in FIGS. 5 through 6, the set of first side locator tabs 222 and the set of second side locator tabs 224 may each include a first locator tab 226 and a second locator tab 228. The first locator tab 226 may be oriented along a first direction, e.g., such as generally 45° measured relative to the transverse direction T, and the second locator tab 228 may be oriented along a second direction perpendicular to the first direction. In addition, the set of first side locator tabs 222 and the set of second side locator tabs 224 may each include a third locator tab 230 oriented generally along the first direction, e.g., generally parallel to the first locator tab 226.

[0040] As illustrated in FIG. 3, case body 200 may define a plurality of case apertures 240 that pass through top 104 of case body 200 from bottom side 214 to top side 216 along the vertical direction V. In general, locator rail 202 may be mounted to bottom side 214 of top 104 of case body 200 such that locator tabs 220 are aligned with and pass through case apertures 240. Accordingly, case apertures 240 may be defined on case body 200 such that their size and positioning facilitate easy engagement with locator tabs 220.

[0041] According to an example embodiment, the size of case apertures 240 may be varied in order to ensure ease of assembly and to prevent over constraining the part. In this regard, for example, a first portion of case apertures 240 may be pass through apertures 242 and a second portion of case apertures 240 may be locator fit apertures 244. For example, three of case apertures 240 may be pass through apertures 242 and three of case apertures 240 may be locator fit apertures 244. In general, pass through apertures 242 are defined to have a slight clearance relative to locator tabs 220, e.g., such that locator tabs 220 do not contact the sides of case body 200 that define pass through apertures 242. By contrast, locator fit apertures 244 may be formed to have a tighter tolerance relative to locator tabs 220, such that locator tabs 220 directly engage, locate, and align locator rail 202 relative to case body 200. According to example embodiments, case apertures 240 may be elongated in a directed perpendicular to the alignment direction of each respective locator tabs 220 (e.g., the first direction and second direction as identified above), such that the assembly process is insensitive to the variation in bend angle of locator tabs 220.

[0042] According to an example embodiment, hinge bracket assembly 204 may further include one or more door hinge brackets 250. For purposes of the present discussion, a single door hinge bracket 250 is described, though it should be appreciated that the same, similar, or mirror image door hinge bracket 250 may be used on an opposite side of refrigerator appliance 100. Door hinge bracket 250 may be configured to mount to locator rail 202, e.g., against top side 216 of case body 200, by mutual engagement of respective locator tabs 220 and bracket apertures 252 defined through door hinge bracket 250. In this regard, door hinge bracket 250 may include a plurality of bracket apertures 252, with each bracket aperture 252 corresponding to a respective locator tab 220. Similar to case apertures 240, bracket apertures 252 may be elongated in a directed perpendicular to the alignment direction of each respective locator tabs 220, such that the assembly process is insensitive to the variation in bend angle of locator tabs 220.

[0043] As best shown in FIG. 7, locator tabs 220 may be designed to directly engage door hinge bracket 250 within bracket apertures 252. For example, bracket apertures 252 may be designed to have a locator or contact fit with locator tabs 220, such that positioning door hinge bracket 250 onto locator tabs 220 constrains door hinge bracket 250 in at least three degrees-of-freedom. In this regard, door hinge bracket may contact the edges of locator tabs 220. For example, according to the illustrated embodiment, the receipt of locator tabs 220 within bracket apertures 252 may constrain door hinge bracket 250 to prevent translation along the lateral direction L, translation along the transverse direction T, and rotation about the vertical direction V.

[0044] According to the illustrated embodiment, locator tabs 220 are aligned diagonally along a mounting plate 254 of door hinge bracket 250. In this manner, the locator tabs 220 and bracket apertures 252 may be spaced apart on mounting plate by an increased linear distance, e.g., thereby increasing stability, alignment, and bracket location. In addition, it should be appreciated that locator tabs 220 defines a tab height (not labeled) measured from a top surface of locator rail 202 along the vertical direction V to a distal end of locator tabs 220. According to example embodiments, the tab height is greater than or equal to a case thickness of case body 200 plus a bracket thickness of door hinge bracket 250.

[0045] According to an example embodiment, door hinge bracket 250 further defines a plurality of through holes 260 and locator rail 202 defines a plurality of receiving bosses 262. Hinge bracket assembly 204 may further include a plurality of mechanical fasteners 264 that pass through the plurality of through holes 260 and are secured in the plurality of receiving bosses 262 to attach door hinge bracket 250 and form a single, rigid structure between case body 200, locator rail 202, and hinge bracket assembly 204. For example, the plurality of through holes 260 may be clearance holes that are wider than the plurality of mechanical fasteners 264. Engagement of mechanical fasteners 264 may generally constrain door hinge bracket 250 in three additional degrees of freedom. For example, the clamping force applied by mechanical fasteners 264 may prevent door hinge bracket 250 from translation along the vertical direction V, rotation about the lateral direction L, and rotation about the transverse direction T.

[0046] As explained herein, aspects of the present subject matter are generally directed to a method of locating an upper hinge bracket of a refrigerator over the refrigerator body to improve the door alignment by positioning the hinge brackets accurately. The refrigerator may include a stiffener secured to the top of its body wherein the stiffener, at both ends, includes three locating tabs protruding from the top of the refrigerator body. Two hinge brackets, one on each side, are provided on the top of the refrigerator body and each hinge bracket may include three locating slots formed on it in such a manner that they engage with the locating tabs of the stiffener. Thus, a coordinated tab and slot configuration is achieved for the top stiffener, the case top, and the hinge brackets. The use of locating features mitigates the need for fasteners for positioning hinge brackets. Further, using three tab and slot configurations on each side of the refrigerator top case results in constraining all six degrees of freedom of the hinge bracket.

[0047] 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.

Examples

Embodiment Construction

[0019]Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. 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 or spirit 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.

[0020]As used herein, 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 “includes” and “including” are...

Claims

1. An appliance defining a vertical direction, a lateral direction, and a transverse direction, the appliance comprising:a case body defining a plurality of case apertures;a locator rail attached to a first side of the case body, the locator rail comprising a plurality of locator tabs, each locator tab of the plurality of locator tabs being engaged with one corresponding aperture of the plurality of case apertures; anda door hinge bracket positioned on a second side of the case body, the door hinge bracket defining a plurality of bracket apertures, each locator tab of the plurality of locator tabs being engaged with one corresponding bracket aperture of the plurality of bracket apertures, wherein the plurality of locator tabs constrains the door hinge bracket in at least three degrees of freedom.

2. The appliance of claim 1, wherein the plurality of case apertures are defined on a top wall of the case body, the first side of the case body is a bottom side of the top wall, and the second side of the case body is a top side of the top wall.

3. The appliance of claim 1, wherein the three degrees of freedom comprise translation along the lateral direction, translation along the transverse direction, and rotation about the vertical direction.

4. The appliance of claim 1, wherein the plurality of bracket apertures are elongated such that the plurality of locator tabs only contact the door hinge bracket along sides of the plurality of locator tabs.

5. The appliance of claim 1, wherein the plurality of bracket apertures are aligned diagonally along a mounting plate of the door hinge bracket.

6. The appliance of claim 1, wherein a first locator tab of the plurality of locator tabs is oriented along a first direction to constrain movement of the door hinge bracket along the first direction and a second locator tab of the plurality of locator tabs is oriented along a second direction approximately perpendicular to the first direction to constrain movement of the door hinge bracket along the second direction.

7. The appliance of claim 1, wherein the plurality of case apertures comprises a first set of case apertures that are pass through apertures that do not contact the plurality of locator tabs and a second set of case apertures that are locator fit apertures that contact the plurality of locator tabs.

8. The appliance of claim 1, wherein the plurality of case apertures comprise a set of first side case apertures at a first end of the case body and a set of second side case apertures at a second end of the case body, and wherein the plurality of locator tabs comprise a set of first side locator tabs at a first end of the locator rail and a set of second side locator tabs at a second end of the locator rail opposite the first end of the locator rail.

9. The appliance of claim 1, wherein the locator rail and the plurality of locator tabs are formed of a unitary construction.

10. The appliance of claim 1, wherein the locator rail is formed from a single piece of sheet metal, and wherein the plurality of locator tabs are punched and formed the single piece of sheet metal.

11. The appliance of claim 1, wherein each of the plurality of locator tabs defines a tab height measured from a top surface of the locator rail along the vertical direction, and wherein the tab height is greater than a case thickness of the case body plus a bracket thickness of the door hinge bracket.

12. The appliance of claim 1, wherein the door hinge bracket further defines a plurality of through holes and the locator rail defines a plurality of receiving bosses, the appliance further comprising:a plurality of mechanical fasteners that pass through the plurality of through holes and are secured in the plurality of receiving bosses to constrain the door hinge bracket in three additional degrees of freedom.

13. The appliance of claim 12, wherein the plurality of through holes are clearance holes that are wider than the plurality of mechanical fasteners.

14. The appliance of claim 12, wherein the three additional degrees of freedom comprises translation along the vertical direction, rotation about the lateral direction, and rotation about the transverse direction.

15. A hinge bracket assembly for a door of an appliance, the appliance comprising a case body defining a vertical direction, a lateral direction, and a transverse direction, the case body further defining a plurality of case apertures, the hinge bracket assembly comprising:a locator rail attached to a first side of the case body, the locator rail comprising a plurality of locator tabs, each locator tab of the plurality of locator tabs being engaged with one corresponding aperture of the plurality of case apertures; anda door hinge bracket positioned on a second side of the case body, the door hinge bracket defining a plurality of bracket apertures, each locator tab of the plurality of locator tabs being engaged with one corresponding bracket aperture of the plurality of bracket apertures, wherein the plurality of locator tabs constrains the door hinge bracket in at least three degrees of freedom.

16. The hinge bracket assembly of claim 15, wherein the plurality of case apertures are defined on a top wall of the case body, the first side of the case body is a bottom side of the top wall, and the second side of the case body is a top side of the top wall, and wherein the three degrees of freedom comprise translation along the lateral direction, translation along the transverse direction, and rotation about the vertical direction.

17. The hinge bracket assembly of claim 15, wherein the plurality of bracket apertures are elongated such that the plurality of locator tabs only contact the door hinge bracket along sides of the plurality of locator tabs.

18. The hinge bracket assembly of claim 15, wherein the plurality of bracket apertures are aligned diagonally along a mounting plate of the door hinge bracket.

19. The hinge bracket assembly of claim 15, wherein a first locator tab of the plurality of locator tabs is oriented along a first direction to constrain movement of the door hinge bracket along the first direction and a second locator tab of the plurality of locator tabs is oriented along a second direction approximately perpendicular to the first direction to constrain movement of the door hinge bracket along the second direction.

20. The hinge bracket assembly of claim 15, wherein the plurality of case apertures comprises a first set of case apertures that are pass through apertures that do not contact the plurality of locator tabs and a second set of case apertures that are locator fit apertures that contact the plurality of locator tabs.

Images