Door assembly for a laundry appliance

Abstract

A door assembly including a hinge bracket defining a first face and a second face positioned opposite the first face, a hinge bracket cover defining a first face and a second face positioned opposite the first, wherein the first face of the hinge bracket cover is positioned on the second face of the hinge bracket, a first pin and a second pin extending from the second face of the hinge bracket or the first face of the hinge bracket cover, and a first aperture and a second aperture defined on the second face of the hinge bracket or the first face of the hinge bracket cover opposite from the first pin and the second pin, wherein the first aperture is configured to receive the first pin and the second aperture is elongated along a vertical direction and configured to receive the second pin.

Description

FIELD OF THE INVENTION

[0001] The present subject matter relates generally to laundry appliances, or more specifically, to door assemblies of laundry appliances.BACKGROUND OF THE INVENTION

[0002] Washing machine appliances generally include a tub for containing water or wash fluid, e.g., water and detergent, bleach, and / or other wash additives. A basket is rotatably mounted within the tub and defines a wash chamber for receipt of articles for washing. During normal operation of such washing machine appliances, the wash fluid is directed into the tub and onto articles within the wash chamber of the basket. The basket or an agitation element can rotate at various speeds to agitate articles within the wash chamber, to wring wash fluid from articles within the wash chamber, etc. During a spin or drain cycle, a drain pump assembly may operate to discharge water from within sump.

[0003] Conventional washing machine appliances (or laundry appliances in general) include a door that is pivotally mounted to the cabinet over a front opening to provide selective access to the wash chamber. However, typical laundry appliance doors have trouble with managing part to part variation between the hinge bracket cover and the hinge bracket. For example, the hinge bracket cover is an appearance part, and consistent gaps and flushness between the hinge bracket cover and hinge bracket is desirable. Conventional laundry appliance door designs have tried to locate the hinge bracket cover to the hinge bracket with multiple touch points and locators, which results in over constraining the part in the assembly.

[0004] Accordingly, a laundry appliance having an improved door would be desirable. More specifically, an appliance door that is easy to assemble while providing improved rigidity and alignment between the hinge bracket and the hinge bracket cover would be particularly beneficial.BRIEF DESCRIPTION OF THE INVENTION

[0005] 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.

[0006] In one exemplary embodiment, a laundry appliance defining a vertical direction, a lateral direction, and a transverse direction is provided, including a tub positioned within a cabinet, a basket rotatably mounted within the tub and defining a chamber for receiving of a load of clothes, and a door assembly rotatably mounted to the cabinet to provide selective access to the chamber. The door assembly includes a hinge bracket defining a first face and a second face positioned opposite the first face along the transverse direction, a hinge bracket cover defining a first face and a second face positioned opposite the first face along the transverse direction, wherein the first face of the hinge bracket cover is positioned on the second face of the hinge bracket, a first pin and a second pin extending from the second face of the hinge bracket or the first face of the hinge bracket cover, and a first aperture and a second aperture defined on the second face of the hinge bracket or the first face of the hinge bracket cover opposite from the first pin and the second pin, wherein the first aperture is configured to receive the first pin and the second aperture is elongated along the vertical direction and configured to receive the second pin.

[0007] In another exemplary embodiment, a door assembly for a laundry appliance is provided. The laundry appliance defines a vertical direction, a lateral direction, and a transverse direction, and includes a tub positioned within a cabinet and a basket rotatably mounted within the tub and defining a chamber for receiving of a load of clothes. The door assembly includes a hinge bracket defining a first face and a second face positioned opposite the first face along the transverse direction, a hinge bracket cover defining a first face and a second face positioned opposite the first face along the transverse direction, wherein the first face of the hinge bracket cover is positioned on the second face of the hinge bracket, a first pin and a second pin extending from the second face of the hinge bracket or the first face of the hinge bracket cover, and a first aperture and a second aperture defined on the second face of the hinge bracket or the first face of the hinge bracket cover opposite from the first pin and the second pin, wherein the first aperture is configured to receive the first pin and the second aperture is elongated along the vertical direction and configured to receive the second pin.

[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 a washing machine appliance according to an example embodiment of the present subject matter.

[0011] FIG. 2 provides a front view of the example washing machine appliance of FIG. 1 with a door assembly in the open position according to an example embodiment of the present subject matter.

[0012] FIG. 3 provides a side cross-sectional view of the example washing machine appliance of FIG. 1 according to an example embodiment of the present subject matter.

[0013] FIG. 4 provides an exploded view of the example door assembly of FIG. 2 according to an example embodiment of the present subject matter.

[0014] FIG. 5 provides a rear view of the example door assembly of FIG. 2 according to an example embodiment of the present subject matter.

[0015] FIG. 6 provides an exploded rear view of the example door assembly of FIG. 2 according to an example embodiment of the present subject matter.

[0016] FIG. 7 provides a front view of a hinge bracket of the example door assembly of FIG. 2 according to an example embodiment of the present subject matter.

[0017] FIG. 8 provides a rear view of a hinge bracket cover for engaging the example hinge bracket of FIG. 7 according to an example embodiment of the present subject matter.

[0018] FIG. 9 provides an assembled, cross-sectional view of a hinge bracket and a hinge bracket cover according to an example embodiment of the present subject matter.

[0019] FIG. 10 provides a front view of a hinge bracket of the example door assembly of FIG. 2 according to another example embodiment of the present subject matter.

[0020] FIG. 11 provides a rear view of a hinge bracket cover for engaging the example hinge bracket of FIG. 10 according to another example embodiment of the present subject matter.

[0021] FIG. 12 provides a front view of a hinge bracket of the example door assembly of FIG. 2 according to another example embodiment of the present subject matter.

[0022] FIG. 13 provides a rear view of a hinge bracket cover for engaging the example hinge bracket of FIG. 12 according to another example embodiment of the present subject matter.

[0023] FIG. 14 provides a front view of a hinge bracket of the example door assembly of FIG. 2 according to another example embodiment of the present subject matter.

[0024] FIG. 15 provides a rear view of a hinge bracket cover for engaging the example hinge bracket of FIG. 14 according to another example embodiment of the present subject matter.

[0025] 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

[0026] 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.

[0027] As used herein, 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”). Approximating language, as used herein throughout the specification and claims, is 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 “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. For example, the approximating language may refer to being within a 10 percent margin.

[0028] Referring now to the figures, FIG. 1 is a perspective view of an exemplary horizontal axis washing machine appliance 100, FIG. 2 is a front view of washing machine appliance 100, and FIG. 3 is a side cross-sectional view of washing machine appliance 100. As illustrated, washing machine appliance 100 generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined. Washing machine appliance 100 includes a cabinet 102 that extends between a top 104 and a bottom 106 along the vertical direction V, between a left side 108 and a right side 110 along the lateral direction, and between a front 112 and a rear 114 along the transverse direction T.

[0029] Referring to FIGS. 2 and 3, a wash basket 120 is rotatably mounted within cabinet 102 such that it is rotatable about an axis of rotation A. A motor 122, e.g., such as a pancake motor, is in mechanical communication with wash basket 120 to selectively rotate wash basket 120 (e.g., during an agitation or a rinse cycle of washing machine appliance 100). Wash basket 120 is received within a wash tub 124 and defines a wash chamber 126 that is configured for receipt of articles for washing. The wash tub 124 holds wash and rinse fluids for agitation in wash basket 120 within wash tub 124. As used herein, “wash fluid” may refer to water, detergent, fabric softener, bleach, or any other suitable wash additive or combination thereof. Indeed, for simplicity of discussion, these terms may all be used interchangeably herein without limiting the present subject matter to any particular “wash fluid.”

[0030] Wash basket 120 may define one or more agitator features that extend into wash chamber 126 to assist in agitation and cleaning articles disposed within wash chamber 126 during operation of washing machine appliance 100. For example, as illustrated in FIG. 3, a plurality of ribs 128 extends from basket 120 into wash chamber 126. In this manner, for example, ribs 128 may lift articles disposed in wash basket 120 during rotation of wash basket 120.

[0031] Referring generally to FIGS. 1 through 3, cabinet 102 also includes a front panel 130 which defines a chamber opening 132 that permits user access to wash basket 120 of wash tub 124. More specifically, washing machine appliance 100 includes a door 134 that is positioned over chamber opening 132 and is rotatably mounted to front panel 130. In this manner, door 134 permits selective access to chamber opening 132 by being movable between an open position (FIG. 2) facilitating access to a wash tub 124 and a closed position (FIG. 1) prohibiting access to wash tub 124.

[0032] A window 136 in door 134 permits viewing of wash basket 120 when door 134 is in the closed position, e.g., during operation of washing machine appliance 100. Door 134 also includes a handle (not labeled) that, e.g., a user may pull when opening and closing door 134. Further, although door 134 is illustrated as mounted to front panel 130, it should be appreciated that door 134 may be mounted to another side of cabinet 102 or any other suitable support according to alternative embodiments.

[0033] Referring again to FIG. 3, wash basket 120 also defines a plurality of perforations 140 in order to facilitate fluid communication between an interior of basket 120 and wash tub 124. A sump 142 is defined by wash tub 124 at a bottom of wash tub 124 along the vertical direction V. Thus, sump 142 is configured for receipt of and generally collects wash fluid during operation of washing machine appliance 100. For example, during operation of washing machine appliance 100, wash fluid may be urged by gravity from basket 120 to sump 142 through plurality of perforations 140.

[0034] A drain pump assembly 144 is located beneath wash tub 124 and is in fluid communication with sump 142 for periodically discharging soiled wash fluid from washing machine appliance 100. Drain pump assembly 144 may generally include a drain pump 146 which is in fluid communication with sump 142 and with an external drain 148 through a drain hose 150. During a drain cycle, drain pump 146 urges a flow of wash fluid from sump 142, through drain hose 150, and to external drain 148. More specifically, drain pump 146 includes a motor (not shown) which is energized during a drain cycle such that drain pump 146 draws wash fluid from sump 142 and urges it through drain hose 150 to external drain 148.

[0035] A spout (such as supply conduit 152) may be configured for directing a flow of fluid into wash tub 124. For example, supply conduit 152 may be in fluid communication with a water supply 154 (FIG. 3) in order to direct fluid (e.g., clean water or wash fluid) into wash tub 124. Supply conduit 152 may also be in fluid communication with the sump 142. For example, pump assembly 144 may direct wash fluid disposed in sump 142 to supply conduit 152 in order to circulate wash fluid in wash tub 124.

[0036] As illustrated in FIG. 3, a detergent drawer 156 is slidably mounted within front panel 130. Detergent drawer 156 receives a wash additive (e.g., detergent, fabric softener, bleach, or any other suitable liquid or powder) and directs the fluid additive to wash tub 124 during operation of washing machine appliance 100. According to the illustrated embodiment, detergent drawer 156 may also be fluidly coupled to supply conduit 152 to facilitate the complete and accurate dispensing of wash additive.

[0037] In addition, a water supply valve 158 may provide a flow of water from a water supply source (such as a municipal water supply 154) into detergent dispenser 156 and into wash tub 124. In this manner, water supply valve 158 may generally be operable to supply water into detergent dispenser 156 to generate a wash fluid, e.g., for use in a wash cycle, or a flow of fresh water, e.g., for a rinse cycle. It should be appreciated that water supply valve 158 may be positioned at any other suitable location within cabinet 102. In addition, although water supply valve 158 is described herein as regulating the flow of “wash fluid,” it should be appreciated that this term includes, water, detergent, other additives, or some mixture thereof.

[0038] A control panel 160 including a plurality of input selectors 162 is coupled to front panel 130. Control panel 160 and input selectors 162 collectively form a user interface input for operator selection of machine cycles and features. For example, in one embodiment, a display 164 indicates selected features, a countdown timer, and / or other items of interest to machine users.

[0039] Operation of washing machine appliance 100 is controlled by a controller or processing device 166 (FIG. 1) that is operatively coupled to control panel 160 for user manipulation to select washing machine cycles and features. In response to user manipulation of control panel 160, controller 166 operates the various components of washing machine appliance 100 to execute selected machine cycles and features.

[0040] Controller 166 may include a memory and microprocessor, such as a general or special purpose microprocessor 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 166 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. Control panel 160 and other components of washing machine appliance 100 may be in communication with controller 166 via one or more signal lines or shared communication busses.

[0041] During operation of washing machine appliance 100, laundry items are loaded into wash basket 120 through chamber opening 132, and washing operation is initiated through operator manipulation of input selectors 162. Wash tub 124 is filled with water, detergent, and / or other fluid additives, e.g., via supply conduit 152 and or detergent drawer 156. One or more valves (e.g., water supply valve 158) can be controlled by washing machine appliance 100 to provide for filling wash basket 120 to the appropriate level for the amount of articles being washed and / or rinsed. By way of example for a wash mode, once wash basket 120 is properly filled with fluid, the contents of wash basket 120 can be agitated (e.g., with ribs 128) for washing of laundry items in wash basket 120.

[0042] After the agitation phase of the wash cycle is completed, wash tub 124 can be drained. Laundry articles can then be rinsed by again adding fluid to wash tub 124, depending on the particulars of the cleaning cycle selected by a user. Ribs 128 may again provide agitation within wash basket 120. One or more spin cycles may also be used. In particular, a spin cycle may be applied after the wash cycle and / or after the rinse cycle in order to wring wash fluid from the articles being washed. During a final spin cycle, basket 120 is rotated at relatively high speeds and drain pump assembly 144 may discharge wash fluid from sump 142. After articles disposed in wash basket 120 are cleaned, washed, and / or rinsed, the user can remove the articles from wash basket 120, e.g., by opening door 134 and reaching into wash basket 120 through chamber opening 132.

[0043] While described in the context of a specific embodiment of horizontal axis washing machine appliance 100, using the teachings disclosed herein it will be understood that horizontal axis washing machine appliance 100 is provided by way of example only. Other washing machine appliances having different configurations, different appearances, and / or different features may also be utilized with the present subject matter as well, e.g., vertical axis washing machine appliances.

[0044] Referring still to FIG. 1, a schematic diagram of an external communication system 170 will be described according to an exemplary embodiment of the present subject matter. In general, external communication system 170 is configured for permitting interaction, data transfer, and other communications between washing machine appliance 100 and one or more external devices. For example, this communication may be used to provide and receive operating parameters, user instructions or notifications, performance characteristics, user preferences, or any other suitable information for improved performance of washing machine appliance 100. In addition, it should be appreciated that external communication system 170 may be used to transfer data or other information to improve performance of one or more external devices or appliances and / or improve user interaction with such devices.

[0045] For example, external communication system 170 permits controller 166 of washing machine appliance 100 to communicate with a separate device external to washing machine appliance 100, referred to generally herein as an external device 172. As described in more detail below, these communications may be facilitated using a wired or wireless connection, such as via a network 174. In general, external device 172 may be any suitable device separate from washing machine appliance 100 that is configured to provide and / or receive communications, information, data, or commands from a user. In this regard, external device 172 may be, for example, a personal phone, a smartphone, a tablet, a laptop or personal computer, a wearable device, a smart home system, or another mobile or remote device.

[0046] In addition, a remote server 176 may be in communication with washing machine appliance 100 and / or external device 172 through network 174. In this regard, for example, remote server 176 may be a cloud-based server 176, and is thus located at a distant location, such as in a separate state, country, etc. According to an exemplary embodiment, external device 172 may communicate with a remote server 176 over network 174, such as the Internet, to transmit / receive data or information, provide user inputs, receive user notifications or instructions, interact with or control washing machine appliance 100, etc. In addition, external device 172 and remote server 176 may communicate with washing machine appliance 100 to communicate similar information.

[0047] In general, communication between washing machine appliance 100, external device 172, remote server 176, and / or other user devices or appliances may be carried using any type of wired or wireless connection and using any suitable type of communication network, non-limiting examples of which are provided below. For example, external device 172 may be in direct or indirect communication with washing machine appliance 100 through any suitable wired or wireless communication connections or interfaces, such as network 174. For example, network 174 may include one or more of a local area network (LAN), a wide area network (WAN), a personal area network (PAN), the Internet, a cellular network, any other suitable short-or long-range wireless networks, etc. In addition, communications may be transmitted using any suitable communications devices or protocols, such as via Wi-Fi®, Bluetooth®, Zigbee®, wireless radio, laser, infrared, Ethernet type devices and interfaces, etc. In addition, such communication may use a variety of communication protocols (e.g., TCP / IP, HTTP, SMTP, FTP), encodings or formats (e.g., HTML, XML), and / or protection schemes (e.g., VPN, secure HTTP, SSL).

[0048] External communication system 170 is described herein according to an exemplary embodiment of the present subject matter. However, it should be appreciated that the exemplary functions and configurations of external communication system 170 provided herein are used only as examples to facilitate description of aspects of the present subject matter. System configurations may vary, other communication devices may be used to communicate directly or indirectly with one or more associated appliances, other communication protocols and steps may be implemented, etc. These variations and modifications are contemplated as within the scope of the present subject matter.

[0049] Referring now also generally to FIGS. 4 through 15, a door assembly 200 that may be used with washing machine appliance 100 will be described according to example embodiments of the present subject matter. In this regard, door assembly 200 may be the same as or replace door 134 as described above. In addition, although door assembly 200 is described herein as being used with washing machine appliance 100, it should be appreciated that door assembly 200 may be used on any other suitable laundry appliance, e.g., such as a dryer appliance, a combination washer / dryer appliance, or any other suitable appliance to provide selective access to an interior chamber through a front opening. Although an exemplary construction of door assembly 200 is described herein, it should be appreciated that variations and modifications may be made to the door assembly 200 while remaining within the scope of the present subject matter.

[0050] As shown in FIGS. 4 through 6, door assembly 200 will be described in more detail. In this regard, FIG. 4 provides a front, exploded view of door assembly 200, FIG. 5 provides a rear view of the hinge assembly of door assembly 200, and FIG. 6 provides a rear, exploded view of the hinge bracket. As shown, the door assembly 200 may generally include various components that are stacked along the transverse direction T. It should be appreciated that the directional orientation used to describe door assembly 200 may be similar to that used to describe the washing machine appliance 100, assuming door assembly 200 is in the closed position. Door assembly 200 may include an outer door frame 202 on which to an outer window 204 may be seated to provide a front appearance piece and contact area for door assembly 200. In addition, a glass door bowl 206 may be seated within a central aperture 208 of outer door frame 202. As will be described in more detail below, one or more reinforcement brackets 210 may be mounted to or attached to outer door frame 202 to secure glass bowl 206 to door frame 202 and to provide structural support for other attachment features of door assembly 200. According to the illustrated embodiment, door assembly 200 may include two reinforcement brackets 210 and two isolator strips 212 that are positioned between reinforcement brackets 210 and glass bowl 206 to secure glass bowl 206 to outer door frame 202.

[0051] According to the illustrated embodiment, the door assembly 200 may further include a hinge assembly 220 that is designed to attach door assembly 200 to the front panel 130 of cabinet 102. Hinge assembly 220 may generally be designed to support one side of door assembly 200 and permit rotation about a vertical axis to facilitate selective access to wash chamber 126 through chamber opening 132. For example, according to the illustrated embodiment, hinge assembly 220 may generally include a hinge bracket 222 that is mounted to reinforcement bracket 210 as described in more detail below. A hinge pin 224 may rotatably couple hinge bracket 222 to a door hinge 226. In addition, a hinge bracket cover 228 may be positioned over hinge bracket 222 to prevent pinching and conceal working components of hinge assembly 220.

[0052] In addition, door assembly 200 may include a handle assembly 230 that a user may grasp to open and close door assembly 200. Handle assembly 230 may also be used to secure or lock door assembly 200 in the closed position. For example, handle assembly 230 may generally include a handle body 232 that attaches to reinforcement bracket 210 on an opposite lateral side of the door assembly 200 relative to hinge assembly 220. A striker 234 may be mounted within or attached to handle body 232 for engaging a latching or locking mechanism positioned within front panel 130 of cabinet 102. In addition, door assembly 200 may include an inner door panel 236 that mounts to outer door frame 202 and conceals various components of door assembly 200.

[0053] It should be appreciated that various components of door assembly 200 may be formed from any suitably rigid and durable material. For example, outer door frame 202, hinge bracket 222, handle body 232, and other components may be injection molded from any suitable plastic material. For example, according to exemplary embodiments, these components may be formed by injection molding, e.g., using a suitable plastic material, such as injection molding grade Polybutylene Terephthalate (PBT), Nylon 6, high impact polystyrene (HIPS), acrylonitrile butadiene styrene (ABS), polypropylene (PP), glass / talc filled polypropylene, or any other suitable blend of polymers. Alternatively, according to the exemplary embodiment, these components may be compression molded, e.g., using sheet molding compound (SMC) thermoset plastic or other thermoplastics. According to still other embodiments, portions of door assembly 200 may be formed from any other suitable rigid material. According to example embodiments, reinforcement brackets 210, hinge pin 224, and other components of door assembly 200 may be formed from metal, e.g., such as stamped, rolled, or otherwise formed sheet metal.

[0054] Notably, as described briefly above, conventional door assemblies experience issues related to part variation between the hinge bracket and the hinge bracket cover, resulting in inconsistent gaps and misalignment of the two components. Previous laundry appliance door designs have tried to locate the hinge bracket cover to the hinge bracket with multiple touch points and locators, but these conventional designs result in an assembly that is over constrained, difficult to assembly, and costly. Accordingly, aspects of the present subject matter are directed to a door assembly 200 with improved alignment features, attachment features, and simplified assembly. Although an exemplary construction is described herein, it should be appreciated that variations and modifications may be made while remaining within the scope of the present subject matter. In addition, it should be appreciated that although one configuration of door assembly 200 is described where the hinge assembly 220 is on the left and the handle assembly 230 is on the right, these components may be swapped or interchangeable for a reversible door.

[0055] According to the illustrated embodiment, hinge bracket 222 may generally define a first face 240 and a second face 242 positioned opposite first face 240 along the transverse direction T. In this regard, first face 240 may be oriented outward relative to wash chamber 126, e.g., seating against or contacting outer door frame 202, and second face 242 may be oriented toward wash chamber 126. Similarly, hinge bracket cover 228 may generally define a first face 244 and a second face 246 positioned opposite first face 244 along the transverse direction T. In this regard, first face 244 may oriented outward relative to wash chamber 126, e.g., toward second face 242 of hinge bracket 222 such that it is seated thereon when hinge assembly 220 is assembled, and second face 246 may be oriented toward wash chamber 126.

[0056] Hinge bracket cover 228, when assembled, may be positioned on hinge bracket 222, e.g., such that second face 242 of hinge bracket 222 is facing or in contact with first face 244 of hinge bracket cover 228. As will be explained in more detail below, hinge bracket 222 and hinge bracket cover 228 may define a plurality of pins 250 and complementary apertures 252 that facilitate quick and accurate alignment and assembly of hinge assembly 220, which constrains all degrees of freedom of hinge bracket 222 and hinge bracket cover 228. Although example configurations of pins 250 and apertures 252 are described below, it should be appreciated that these are only examples to facilitate discussion of the present subject matter. Pins 250 and apertures 252 may be swapped, their configurations may change, geometries may be adjusted, and other variations may be made while remaining within the scope of the present subject matter.

[0057] Referring now specifically to FIGS. 7 through 9, hinge bracket 222 may define a first pin 254 and a second pin 256 extending from second face 242 of hinge bracket 222. In addition, hinge bracket cover 228 may define a first aperture 258 and a second aperture 260 on first face 244 of hinge bracket cover 228, e.g., opposite from first pin 254 and second pin 256, respectively. In this regard, first aperture 258 is configured to receive first pin 254 and second aperture 260 is configured to receive second pin 256 to engage hinge bracket 222 and hinge bracket cover 228 in a manner that constrains translation and rotation in six degrees of freedom while also enabling quick and easy alignment and assembly. Although first pin 254 and second pin 256 are described as extending from hinge bracket 222 and first aperture 258 and second aperture 260 are described as being defined by hinge bracket cover 228, it should be appreciated that these components may be swapped, repositioned, or reconfigured while remaining within the scope of the present subject matter.

[0058] In this regard, for example, first pin 254 is illustrated as a cylindrical member protruding along the transverse direction T and first aperture 258 is illustrated as a cylindrical boss that is sized to securely receive first pin 254. More specifically, first pin 254 and first aperture 258 may be designed with a tight tolerance such that inserting first pin 254 into first aperture 258 prevents relative movement between hinge bracket 222 and hinge bracket cover 228 in four degrees of freedom. Specifically, first pin 254 and first aperture 258 may engage each other to constrain relative movement of hinge bracket 222 and hinge bracket cover 228, constraining translation along the lateral direction L and the vertical direction V and rotation about the vertical direction V and the lateral direction L.

[0059] Notably, according to the illustrated embodiment, second aperture 260 is elongated along the vertical direction V. In this regard, the width of second aperture 260 may be the same as the diameter of second pin 256, but second aperture 260 may be oversized along the vertical direction V. In this manner, second pin 256 engages second aperture 260 to prevent relative movement between hinge bracket 222 and hinge bracket cover 228 in two degrees of freedom. Specifically, second pin 256 and second aperture 260 may engage each other to constrain relative movement of hinge bracket 222 and hinge bracket cover 228, preventing translation along the transverse direction T and rotation about the transverse direction T. In this manner, when hinge bracket 222 and hinge bracket cover 228 are assembled such that first pin 254 and second pin 256 engage first aperture 258 and second aperture 260, respectively, these components are constrained in six degrees of freedom. Moreover, such a construction prevents hinge assembly 220 being over-constrained, which simplifies assembly.

[0060] According to another example embodiment, more than one aperture 252 may be elongated along the lateral direction L or the vertical direction V. For example, referring now to FIGS. 10 and 11, first aperture 258 and second aperture 260 are elongated along the vertical direction V. In addition, a third pin 262 extends from second face 242 of hinge bracket 222 and a third aperture 264 is defined on first face 244 of hinge bracket cover 228 opposite from third pin 262. As illustrated, third aperture 264 is elongated along lateral direction L and is configured to receive third pin 262. In this manner, first pin 254, second pin 256, and third pin 262 engage first aperture 258, second aperture 260, and third aperture 264, respectively, to prevent relative movement between hinge bracket 222 and hinge bracket cover 228 in six degrees of freedom.

[0061] As best shown in FIG. 9, pins 250 may be seated within aperture 252 such that they bottom out against the body of hinge bracket cover 228. In this regard, as illustrated, a distal end 270 of at least one pin 250 (e.g., first pin 254 and / or second pin 256) may be seated against a bottom surface 272 of at least one aperture 252 (e.g., first aperture 258 and / or second aperture 260). Specifically, bottom surface 272 of apertures 252 may be second face of hinge bracket cover 228. This engagement may ensure rigidity of hinge assembly 220, particularly when fastened together as described below.

[0062] Specifically, as illustrated, first pin 254 and / or second pin 256 may define a screw boss 274 that is configured to receive a mechanical fastener 276, e.g., such as a mechanical screw. In addition, hinge bracket cover 228 may define one or more screw holes or through holes 278 that mechanical fasteners 276 may pass through before engaging screw bosses 274. In this regard, by passing mechanical fasteners 276 through hinge bracket cover 228 and into screw bosses 274 defined on hinge bracket 222, hinge bracket 222 and hinge bracket cover 228 may be properly joined to form hinge assembly 220. Thus, once mechanical fasteners 276 are installed, relative motion between these components may be restrained in all degrees of freedom.

[0063] According to the illustrated embodiment, pins 250 define screw bosses 274 for receipt of mechanical fasteners 276. However, it should be appreciated that according to alternative embodiments such as that illustrated in FIGS. 12 and 13, pins 250 may be used only for alignment and separate through holes 278 and screw bosses 274 may be defined elsewhere on hinge bracket 222 and hinge bracket cover 228. Other configurations and attachment mechanisms between hinge bracket 222 and hinge bracket cover 228 may be used while remaining within the scope of the present subject matter.

[0064] In addition, although pins 250 are illustrated above as being cylindrical pins, it should be appreciated that pins 250 may alternatively refer to any protrusion or feature having any suitable size, geometry, or configuration, such as tabs, cones, or any other suitable protruding locating features. For example, referring now specifically to FIGS. 14 and 15, pins 250 may be rectangular protrusions and apertures 252 may also be rectangular. Apertures 252 may be oversized in at least one direction such that receipt of pins 250 constrains translation in one direction but not the other. According to still other embodiments, pins 250 may be cylindrical and apertures 252 may be a rectangle (e.g., instead of an elongated circle). Other pin / aperture configurations are possible and within the scope of the present subject matter.

[0065] As explained herein, aspects of the present subject matter are generally directed to a method of locating and mating two parts together to achieve key characteristics of the sub assembly and allowing for ease of assembly. According to an example embodiment, a hinge bracket cover may be assembled to the hinge bracket of a laundry appliance door via three pins and three slots: two vertical slot bosses at the top and bottom of the backside of the hinge bracket cover and one horizontal slot boss in the middle of the backside of the hinge bracket cover all being assembled to three screw boss pins protruding front the top surface of the hinge bracket. The two vertical slots may constrain the hinge bracket cover in translation and rotation while the middle slot may serve to constrain the part in translation only. Aspects of the present subject matter also solve the problem of multiple touch points by reducing the number of touch points and locators which over constrain the parts in the assembly.

[0066] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A laundry appliance defining a vertical direction, a lateral direction, and a transverse direction, the laundry appliance comprising:a tub positioned within a cabinet;a basket rotatably mounted within the tub and defining a chamber for receiving of a load of clothes; anda door assembly rotatably mounted to the cabinet to provide selective access to the chamber, the door assembly comprising:a hinge bracket defining a first face and a second face positioned opposite the first face along the transverse direction;a hinge bracket cover defining a first face and a second face positioned opposite the first face along the transverse direction, wherein the first face of the hinge bracket cover is positioned on the second face of the hinge bracket;a first pin and a second pin extending from the second face of the hinge bracket or the first face of the hinge bracket cover; anda first aperture and a second aperture defined on the second face of the hinge bracket or the first face of the hinge bracket cover opposite from the first pin and the second pin, wherein the first aperture is configured to receive the first pin and the second aperture is elongated along the vertical direction and configured to receive the second pin.

2. The laundry appliance of claim 1, wherein the first pin engages the first aperture to prevent relative movement between the hinge bracket and the hinge bracket cover in four degrees of freedom.

3. The laundry appliance of claim 2, wherein the four degrees of freedom are translation along the lateral direction and the vertical direction and rotation about the vertical direction and the lateral direction.

4. The laundry appliance of claim 1, wherein the second pin engages the second aperture to prevent relative movement between the hinge bracket and the hinge bracket cover in two degrees of freedom.

5. The laundry appliance of claim 4, wherein the two degrees of freedom are translation along the transverse direction and rotation about the transverse direction.

6. The laundry appliance of claim 1, wherein the first aperture is elongated along the vertical direction and the door assembly further comprises:a third pin extending from the second face of the hinge bracket or the first face of the hinge bracket cover; anda third aperture defined on the second face of the hinge bracket or the first face of the hinge bracket cover opposite from the third pin, wherein the third aperture is elongated along the lateral direction and is configured to receive the third pin.

7. The laundry appliance of claim 6, wherein the first pin engages the first aperture, the second pin engages the second aperture, and the third pin engages the third aperture to prevent relative movement between the hinge bracket and the hinge bracket cover in six degrees of freedom.

8. The laundry appliance of claim 1, wherein a distal end of the first pin is seated against a bottom surface of the first aperture or a distal end of the second pin is seated against a bottom surface of the second aperture.

9. The laundry appliance of claim 8, wherein the bottom surface of the first aperture or the bottom surface of the second aperture is the second face of the hinge bracket or the first face of the hinge bracket cover.

10. The laundry appliance of claim 1, wherein at least one of the first pin or the second pin is cylindrical and at least one of the first aperture or the second aperture is an elongated circle or a rectangle.

11. The laundry appliance of claim 1, wherein at least one of the first pin or the second pin is rectangular and at least one of the first aperture or the second aperture is a rectangle.

12. The laundry appliance of claim 1, wherein at least one of the first pin and the second pin defines a screw boss, the door assembly further comprising:a mechanical fastener that is inserted through the hinge bracket cover into the hinge bracket to prevent relative movement between the hinge bracket and the hinge bracket cover along the transverse direction.

13. The laundry appliance of claim 1, wherein the first pin and the second pin extend along the transverse direction.

14. The laundry appliance of claim 1, wherein the laundry appliance is a front load washing machine appliance or a front load dryer appliance.

15. A door assembly for a laundry appliance, the laundry appliance defining a vertical direction, a lateral direction, and a transverse direction, the laundry appliance comprising a tub positioned within a cabinet and a basket rotatably mounted within the tub and defining a chamber for receiving of a load of clothes, the door assembly comprising:a hinge bracket defining a first face and a second face positioned opposite the first face along the transverse direction;a hinge bracket cover defining a first face and a second face positioned opposite the first face along the transverse direction, wherein the first face of the hinge bracket cover is positioned on the second face of the hinge bracket;a first pin and a second pin extending from the second face of the hinge bracket or the first face of the hinge bracket cover; anda first aperture and a second aperture defined on the second face of the hinge bracket or the first face of the hinge bracket cover opposite from the first pin and the second pin, wherein the first aperture is configured to receive the first pin and the second aperture is elongated along the vertical direction and configured to receive the second pin.

16. The door assembly of claim 15, wherein the first pin engages the first aperture to prevent relative movement between the hinge bracket and the hinge bracket cover in four degrees of freedom, and the second pin engages the second aperture to prevent relative movement between the hinge bracket and the hinge bracket cover in two degrees of freedom.

17. The door assembly of claim 15, wherein the first aperture is elongated along the vertical direction and the door assembly further comprises:a third pin extending from the second face of the hinge bracket or the first face of the hinge bracket cover; anda third aperture defined on the second face of the hinge bracket or the first face of the hinge bracket cover opposite from the third pin, wherein the third aperture is elongated along the lateral direction and is configured to receive the third pin.

18. The door assembly of claim 15, wherein a distal end of the first pin is seated against a bottom surface of the first aperture or a distal end of the second pin is seated against a bottom surface of the second aperture.

19. The door assembly of claim 15, wherein at least one of the first pin or the second pin is cylindrical and at least one of the first aperture or the second aperture is an elongated circle or a rectangle.

20. The door assembly of claim 15, wherein at least one of the first pin or the second pin is rectangular and at least one of the first aperture or the second aperture is a rectangle.

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