Rack assembly for a dishwasher appliance

Abstract

A dishwasher appliance includes a wash tub that defines a wash chamber for receipt of an article for washing. The dishwasher appliance also includes a track assembly coupled with a ceiling of the wash tub. The dishwasher appliance further includes a rack coupled with the track assembly. The rack is slidably positioned within the wash chamber and configured for movement along the transverse direction via the track assembly.

Description

FIELD OF THE INVENTION

[0001] The present disclosure relates generally to dishwasher appliances, and more particularly to rack assemblies for supporting articles to be washed within dishwasher appliances.BACKGROUND OF THE INVENTION

[0002] Dishwasher 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. Wash fluid (e.g., various combinations of water and detergent along with optional additives) may be introduced into the tub where it collects in a sump space at the bottom of the wash chamber. During wash and rinse cycles, a pump may be used to circulate wash fluid to spray assemblies within the wash chamber that can apply or direct wash fluid towards articles disposed within the rack assemblies in order to clean such articles. During a drain cycle, a pump may periodically discharge soiled wash fluid that collects in the sump space and the process may be repeated.

[0003] Conventional dishwasher appliances may include rack assemblies that are coupled with multiple tracks within the wash chamber. These multiple tracks may be coupled with the wash tub on lateral sides. Manufacturing and assembling the dishwasher appliances may require a certain degree of precision to prevent the wash tub from bowing in or out in order for the rack assembly to fit within the wash chamber. Further, the cost of manufacturing and assembling multiple track assemblies can be expensive and time consuming. Further, maintenance of the appliance requires a user to address more than one track assembly. Leak points can be caused by coupling tracks with a sidewall of the wash tub. Additionally, multiple tracks occupying useful space that could otherwise be used for loading articles.

[0004] Accordingly, a dishwasher appliance that utilizes a single track assembly would be desirable. More specifically, a rack assembly that is simple to use and assemble may be universally used with different wash racks in different model dishwashers.BRIEF DESCRIPTION OF THE INVENTION

[0005] The present subject matter provides a dishwasher appliance including a rack assembly coupled with a wash tub within a wash chamber. Additional aspects and advantages of the invention will be set forth in part in the following description, may be apparent from the description, or may be learned through practice of the invention.

[0006] In accordance with one exemplary embodiment of the present disclosure, a dishwasher appliance includes a wash tub that defines a wash chamber for receipt of an article for washing. The dishwasher appliance also includes a track assembly coupled with a ceiling of the wash tub. The dishwasher appliance further includes a rack coupled with the track assembly. The rack is slidably positioned within the wash chamber and configured for movement along the transverse direction via the track assembly.

[0007] In accordance with another exemplary embodiment of the present disclosure, a rack assembly is for a dishwasher appliance, the rack assembly includes a track assembly coupled with a wash tub of the dishwasher appliance. The track assembly includes a rail directly coupled with a ceiling of the wash tub and at least one extension member slidably coupled with the rail. The rack assembly also includes a rack coupled with the at least one extension member.

[0008] 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

[0009] 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.

[0010] FIG. 1 provides a perspective view of an exemplary embodiment of a dishwasher appliance of the present disclosure with a door in a partially open position.

[0011] FIG. 2 provides a side, cross-sectional view of the exemplary dishwasher appliance of FIG. 1.

[0012] FIG. 3 provides a perspective view of a rack assembly of the exemplary dishwasher appliance of FIG. 1.

[0013] FIG. 4 provides a side view of the rack assembly of the exemplary dishwasher appliance of FIG. 3.

[0014] FIG. 5 provides another side view of the rack assembly of FIG. 4 having a reinforcement member.

[0015] FIG. 6 provides a cross-sectional view of a clinching joint of the rack assembly of the exemplary dishwasher appliance of FIG. 3.

[0016] FIG. 7 provides an exploded view of a track assembly of the exemplary dishwasher appliance of FIG. 3.

[0017] 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 OF THE INVENTION

[0018] 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.

[0019] As used herein, 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 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 detergent and water, preferably with agitation, to e.g., remove soil particles including food and other undesirable elements from the articles. The term “rinse cycle” 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 cycle. The term “drain cycle” 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. The term “wash fluid” refers to a liquid used for washing and / or rinsing the articles and is typically made up of water that may include other additives such as detergent or other treatments. Furthermore, as used herein, terms of approximation, such as “generally,”“approximately,”“substantially,” or “about,” refer to being within a ten percent margin of error.

[0020] FIGS. 1 and 2 depict an exemplary domestic dishwasher or dishwashing appliance 100 that may be configured in accordance with aspects of the present disclosure. For the particular embodiment of FIGS. 1 and 2, the dishwasher 100 includes a cabinet 102 (FIG. 2) having a tub 104 therein that defines a wash chamber 106. As shown in FIG. 2, tub 104 extends between a top 107 and a bottom 108 along a vertical direction V, between a pair of side walls 110 along a lateral direction L, and between a front side 111 and a rear side 112 along a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular to one another.

[0021] The tub 104 includes a front opening 114 and a door 116 hinged at its bottom for movement between a normally closed vertical position (shown in FIG. 2), wherein the wash chamber 106 is sealed shut for washing operation, and a horizontal open position for loading and unloading of articles from the dishwasher 100. According to exemplary embodiments, dishwasher 100 further includes a door closure mechanism or assembly 118 that is used to lock and unlock door 116 for accessing and sealing wash chamber 106.

[0022] As best illustrated in FIG. 2, tub 104 may accommodate a plurality of rack assemblies. More specifically, a lower rack assembly 122, a middle rack assembly 124, and an upper rack assembly 200 are stacked along the vertical direction V within wash chamber 106. Each rack assembly 122, 124, 200 is adapted for movement between an extended loading position (shown in FIG. 3) in which the rack is substantially positioned outside the wash chamber 106, and a retracted position (shown in FIGS. 1 and 2) in which the rack is located inside the wash chamber 106. With respect to middle rack assembly 124, this is facilitated, for example, by guide rails 120 which are mounted to side walls 110 and rollers 128 mounted onto rack assemblies 124. In addition, as will be described in more detail below, lower rack assembly 122 (or any other rack assembly) may include a plurality of roller assemblies which slidably support lower rack assembly 122, thereby permitting the lower rack to roll out of wash chamber 106 and rest on door 116 when it is in the open (i.e., horizontal) position. Although guide rails 120 and rollers 128 are illustrated herein as facilitating movement of the respective rack assemblies 122 and 124 it should be appreciated that any suitable sliding mechanism or member may be used according to alternative embodiments.

[0023] Some or all of the rack assemblies 122, 124, 200 are fabricated into lattice structures including a plurality of wires or rack wires 204 (for clarity of illustration, not all rack wires making up rack assemblies 122, 124, 200 are shown in FIG. 2). In this regard, rack assemblies 122, 124, 200 are generally configured for supporting articles within wash chamber 106 while allowing a flow of wash fluid to reach and impinge on those articles, e.g., during a cleaning or rinsing cycle. According to another exemplary embodiment, 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, that are otherwise too small to be accommodated by rack 122. The upper rack assembly 200 is described in greater detail below.

[0024] Dishwasher 100 further includes a plurality of spray assemblies for urging a flow of water or wash fluid onto the articles placed within wash chamber 106. More specifically, as illustrated in FIG. 2, 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. Similarly, a mid-level spray arm assembly 140 is located in an upper region of wash chamber 106 and may be located below and in close proximity to middle rack assembly 124. In this regard, mid-level spray arm assembly 140 may generally be configured for urging a flow of wash fluid up through middle rack assembly 124 and upper rack assembly 200. Additionally, an upper spray assembly 142 may be located above upper rack assembly 200 along the vertical direction V. In this manner, upper spray assembly 142 may be configured for urging and / or cascading a flow of wash fluid downward over rack assemblies 122, 124, and 200. As further illustrated in FIG. 2, upper rack assembly 200 may further define an integral spray manifold 144, which is generally configured for urging a flow of wash fluid substantially upward along the vertical direction V through upper rack assembly 200.

[0025] The various spray assemblies and manifolds described herein may be part of a fluid distribution system or fluid circulation assembly 150 for circulating water and wash fluid in the tub 104. More specifically, fluid circulation assembly 150 includes a pump 152 for circulating water and wash fluid (e.g., detergent, water, and / or rinse aid) in the tub 104. Pump 152 may be located within sump 138 or within a machinery compartment located below sump 138 of tub 104, as generally recognized in the art. Fluid circulation assembly 150 may include one or more fluid conduits or circulation piping for directing water and / or wash fluid from pump 152 to the various spray assemblies and manifolds. For example, as illustrated in FIG. 2, a primary supply conduit 154 may extend from pump 152, along rear 112 of tub 104 along the vertical direction V to supply wash fluid throughout wash chamber 106.

[0026] As illustrated, primary supply conduit 154 is used to supply wash fluid to one or more spray assemblies, e.g., to mid-level spray arm assembly 140 and upper spray assembly 142. However, it should be appreciated that according to alternative embodiments, any other suitable plumbing configuration may be used to supply wash fluid throughout the various spray manifolds and assemblies described herein. For example, according to another exemplary embodiment, primary supply conduit 154 could be used to provide wash fluid to mid-level spray arm assembly 140 and a dedicated secondary supply conduit (not shown) could be utilized to provide wash fluid to upper spray assembly 142. Other plumbing configurations may be used for providing wash fluid to the various spray devices and manifolds at any location within dishwasher appliance 100.

[0027] Each spray arm assembly 134, 140, 142, integral spray manifold 144, or other spray device may include an arrangement of discharge ports or orifices for directing wash fluid received from 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 fluid flowing through the discharge ports. Alternatively, spray arm assemblies 134, 140, 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 arm assemblies 134, 140, 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 example, dishwasher 100 may have additional spray assemblies for cleaning silverware, for scouring casserole dishes, for spraying pots and pans, for cleaning bottles, etc. One skilled in the art will appreciate that the embodiments discussed herein are used for the purpose of explanation only and are not limitations of the present subject matter.

[0028] In operation, pump 152 draws wash fluid in from sump 138 and pumps it to a diverter assembly 156, e.g., which is positioned within sump 138 of dishwasher appliance. Diverter assembly 156 may include a diverter disk (not shown) disposed within a diverter chamber 158 for selectively distributing the wash fluid to the spray arm assemblies 134, 140, 142 and / or other spray manifolds or devices. For example, the diverter disk may have a plurality of apertures that are configured to align with one or more outlet ports (not shown) at the top of diverter chamber 158. In this manner, the diverter disk may be selectively rotated to provide wash fluid to the desired spray device.

[0029] According to an exemplary embodiment, diverter assembly 156 is configured for selectively distributing the flow of wash fluid from pump 152 to various fluid supply conduits, only some of which are illustrated in FIG. 2 for clarity. More specifically, diverter assembly 156 may include four outlet ports (not shown) for supplying wash fluid to a first conduit for rotating lower spray arm assembly 134, a second conduit for rotating mid-level spray arm assembly 140, a third conduit for spraying upper spray assembly 142, and a fourth conduit for spraying an auxiliary rack such as the silverware rack.

[0030] The dishwasher 100 is further equipped with a controller 160 to regulate operation of the dishwasher 100. The 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 cleaning cycle. The memory may represent random access memory such as DRAM or read only memory such as ROM or FLASH. In one embodiment, 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 and / 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.

[0031] The controller 160 may be positioned in a variety of locations throughout dishwasher 100. In the illustrated embodiment, the controller 160 may be located within a control panel area 162 of door 116 as shown in FIGS. 1 and 2. In such an embodiment, 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 a user interface panel / controls 164 through which a user may select various operational features and modes and monitor progress of the dishwasher 100. In one embodiment, the user interface 164 may represent a general purpose I / O (“GPIO”) device or functional block. In one embodiment, the user interface 164 may include 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. The user interface 164 may include a display component, such as a digital or analog display device designed to provide operational feedback to a user. The user interface 164 may be in communication with the controller 160 via one or more signal lines or shared communication busses.

[0032] It should be appreciated that the invention is not limited to any particular style, model, or configuration of dishwasher 100. The exemplary embodiment depicted in FIGS. 1 and 2 is for illustrative purposes only. For example, different locations may be provided for user interface 164, different configurations may be provided for rack assemblies 122, 124, 200, different spray arm assemblies 134, 140, 142 and spray manifold configurations may be used, and other differences may be applied while remaining within the scope of the present subject matter.

[0033] With reference to FIGS. 3 through 7, the upper rack assembly 200 includes a rack 202 for holding articles therein, e.g., for the cleaning of the articles. For instance, the rack 202 may be considered an upper rack or topmost rack. The rack 200 may include a plurality of the rack wires 204 that may each be extended in the lateral direction L, the transverse direction T, and the vertical direction V. Therefore, upper rack assembly 200 will be described herein as sharing the vertical direction V, the lateral direction L, and the transverse direction T with dishwasher 100. The plurality of rack wires 204 may be wires, rods, or any other suitable member, which may be fabricated into a lattice structure to form the shape of the rack 200.

[0034] As depicted and described herein, the upper rack assembly 200 includes a track assembly 206 coupled with the rack 202. The track assembly 206 is also coupled with a ceiling 240 of the tub 104. The track assembly 206 allows the rack 202 to slide in and out of the wash chamber 106 between the retracted position and the extended position. The track assembly may include or be provided with a rail 218 that is coupled with the ceiling 240 of the tub 104. The rail 218 may be coupled with the ceiling 240 via a clinching joint 224. The clinching joint 224 is formed by punching two pieces of metal into a mold. The clinching joint 224 may be described as a tapered recess formed in the ceiling 240 with a flared protrusion of the track assembly 206 received therein. As the punch presses down, the metal on one side spreads out and locks into the metal on the other side, creating a strong bond. The clinching joint 224 forms a round button-like connection. Even when the metals have protective coatings (like anti-rust layers), the process keeps those coatings intact, meaning the joint remains rust-resistant and corrosion-free. Furthermore, the clinching joint 224 allows for the track assembly 206 to be coupled with the ceiling of the tub 104 without puncturing fasteners or the like. Thus, there is no penetration of the tub 104 to couple the rail 218 therewith. The rail 218 may be elongate and extend in the transverse direction. Additionally, or alternatively, the rail 218 may be centrally coupled with the tub 104 along the lateral direction L.

[0035] The track assembly 206 may include a first extension member 220 slidably coupled with the rail 218. The first extension member 220 translates along the transverse direction T relative to the rail 218. The rail 218 may include, for example, edges that restricted lateral movement of the first extension member 220. The track assembly 206 may include an inner cage 238 that includes a first set of ball bearings 230 that allow the first extension member 220 to translate relative to the rail 218 with less resistance. The track assembly 206 may also include a rail cap 236 that restricts translational movement of the first extension member 220 from sliding past the rail 218 toward and away from the wash chamber 106.

[0036] The track assembly 206 may also include a second extension member 222 slidably coupled with the first extension member 220. The first extension member 220 and the second extension member 222 may be shaped complementarily such that the first extension member 220 and the second extension member 222 do not move laterally relative to the rail 218. The track assembly 206 may further include an outer cage 232 that includes a second set of ball bearings that allow the second extension member 222 to translate relative to the first extension member 220 with less resistance. The track assembly 206, including the rail 218, the first extension member 220, and the second extension member 222 may be made from a metallic or polymeric material (e.g. stainless steel or HDPE). The first extension member 220 and the second extension member 222 may be collectively, or individually, referred to as an at least one extension member.

[0037] The upper rack assembly 200 may include a bracket 208 coupled to the second extension member 222 via a fastener 212. The bracket 208 is also coupled with the rack 202. For example, the bracket 208 may include a wire slot 210 that is configured to receive the rack wire 204 of the rack 202. Thus, the track assembly 206 supports the rack 202 along the vertical direction V. The rack 202 may be coupled with the track assembly 206 via the bracket 208 such that the track assembly 206 is generally centrally located relative to the rack 202, as illustrated in the exemplary embodiments. Further, the bracket 208 may space the track assembly 206 from the rack 202 along the vertical direction V by about one inch. It should be appreciated that the track assembly 206 is not limited to the description provided herein and may include any suitable sliding cantilever that allows the rack 202 to translate in and out of the wash chamber 106 relative to the ceiling 240 of the tub 104.

[0038] The upper rack assembly 200 may also include a reinforcement member 214 coupled with the bracket 208, as illustrated in the example embodiment on FIG. 5. The reinforcement member 214 may be a sheet of metal or plastic that engages the track assembly 206 and the rack 202. The reinforcement member 214 may engage the rack 202 to provide additional stability to the rack 202 such that wobbling or oscillating movements of the rack 202 are reduced during loading and unloading of articles from the rack 202.

[0039] The rack 202 has a first lateral width W1 that substantially similar to a second lateral width W2 of the wash chamber 106. For example, W1 may be about equal to 95% of W2. The rack 202 may define a useable area A1 that includes anywhere an article can be placed on the rack 202 for washing. The useable area A1 is generally planar in the horizontal direction. The track assembly 206 may reduce the useable area A1 by less than about 15%. Additionally, or alternatively, the track assembly 206 may reduce the useable area A1 by less than about 10%. Additionally, or alternatively, the track assembly 206 may reduce the useable area A1 by less than about 5%. For example, the useable area A1 may be about 600 square inches in a horizontal plane, and the track assembly 206 overlaps with the rack 202 by less than about 60 square inches. The track assembly 206 extends transversely out of the wash chamber 106 and overlaps the rack 202. The rack 202 extends transversely out of the wash chamber 106 further than the track assembly 206. Specifically, the rack 202 extends further out of the wash chamber 106 compared to the first extension member 220 and the second extension member 222.

[0040] Advantageously, the upper rack assembly 200 described herein allows for a manufacturer to save time and money by only requiring one track assembly mounted to the ceiling of the tub. Conventional dishwashers require at least two track assemblies to allow a rack to slide in and out of the washer chamber. These conventional systems require precise dimensions in order for the rack and track assemblies to fit within the wash chamber without bowing the sidewalls on the tub. The upper rack assembly described herein does not bow the sidewalls on the tub because there is no joining between the track assembly and the sidewalls. Further, the clinching joint that allows the track assembly to be coupled with the tub allows for the tub to remain sealed and unpenetrated, thus preventing leakage.

[0041] 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 language of the claims.

Claims

1. A dishwasher appliance defining a vertical, a lateral, and a transverse direction, the dishwasher appliance comprising:a wash tub defining:a front opening;a wash chamber for receipt of an article for washing;a track assembly coupled with a ceiling of the wash tub; anda rack coupled with the track assembly, the rack is slidably positioned within the wash chamber and configured for movement along the transverse direction via the track assembly.

2. The dishwasher appliance of claim 1, wherein the track assembly is generally centrally coupled with the wash tub in the lateral direction.

3. The dishwasher appliance of claim 1, wherein the track assembly is generally centrally coupled with the rack.

4. The dishwasher appliance of claim 1, wherein the rack has a first lateral width that is substantially equal to a second lateral width of the wash chamber.

5. The dishwasher appliance of claim 4, wherein the rack slides between a retracted position within the wash chamber and an extended position, wherein the rack in the extended position extends past the front opening.

6. The dishwasher appliance of claim 1, wherein the track assembly further comprises at least one bracket coupled with a wire of the rack.

7. The dishwasher appliance of claim 6, wherein the track assembly further comprises a reinforcement member coupled with the at least one bracket.

8. The dishwasher appliance of claim 6, wherein the track assembly is spaced from the wire by the at least one bracket.

9. The dishwasher appliance of claim 6, wherein the track assembly occupies less than about 15% of a usable area of the rack for articles to be washed.

10. The dishwasher appliance of claim 1, wherein the track assembly defines a plurality of passages for washing fluids to pass through.

11. The dishwasher appliance of claim 1, wherein the track assembly is coupled with the wash tub via a clinching joint, and wherein the wash tub is free of punctures.

12. The dishwasher appliance of claim 1, wherein the track assembly is generally centrally coupled with the wash tub and the rack along the lateral direction.

13. A rack assembly for a dishwasher appliance, the rack assembly comprising:a track assembly coupled with a wash tub of the dishwasher appliance, the track assembly comprising:a rail directly coupled with a ceiling of the wash tub; andat least one extension member slidably coupled with the rail; anda rack coupled with the at least one extension member.

14. The rack assembly of claim 13, wherein track assembly is generally positioned centrally relative to the wash tub along the lateral direction.

15. The rack assembly of claim 13, wherein track assembly is generally positioned centrally relative to the rack along the lateral direction.

16. The rack assembly of claim 13, wherein the rail is coupled with the wash tub via a clinching joint, wherein the wash tub is free of punctures at the clinching joint.

17. The rack assembly of claim 13, wherein the rack assembly further comprises a plurality of brackets, wherein the plurality of brackets couples the rack with the at least one extension member.

18. The rack assembly of claim 17, wherein the plurality of brackets spaces the rack from the at least one extension member.

19. The rack assembly of claim 17, wherein the rack assembly further comprises a reinforcement member coupled with the plurality of brackets.

20. The rack assembly of claim 13, wherein the rack extends away from the wash tub further than the at least one extension member.

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