LIGHTED REFRIGERATOR SHELF WITH OVERMOLD

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to refrigerators, freezers, refrigerator/freezers, other appliances, or other structures that have shelving, and in particular, lighting relative to that shelving.

2. State of the Art

A variety of types of shelving exists. Some are for storage. Some are for display of objects. Some are exposed as with of book shelving without doors. Some are enclosed. An example would be inside a cabinet with closeable doors.

It can be desirable to provide lighting or illumination at or near shelving. However, there are many competing factors. Some are subtle. For example, the shelving material must be structurally robust enough to support what is intended to be stored there. This tends to require bigger, stronger, or thicker components. Another factor is space. Most times minimization of space occupied by the shelving components leaves more space for storage or display. Another factor can be presentation or access. In many cases, the ability to reach objects on the shelf is desirable. Sometimes visibility is important. Transparent shelves are sometimes used towards that end. Another factor is aesthetics. Form factor, proportion, and optical effects can enhance aesthetics and, sometimes, the functionality at the same time. A further aspect is flexibility of storage. It is many times desirable that the shelves be moveable. One example are outwardly slideable shelves. Another would be complete removal and placement at a different vertical height.

One particular example of shelving is adjustable shelves in refrigerators, freezers, or refrigerator freezers. A conventional shelf provides a storage surface for refrigerated food items. It can span part or all of a space inside the appliance cabinet. One conventional way to vertically adjust such shelves is along vertical rails or tracks that have different mounting elevations.

Some method of at least partial illumination is typical in the interiors of such appliances to help the user identify what is being stored. However, several factors regarding refrigerated appliances make design of such illumination much more than trivial. As stated, storage space is at a premium. Therefore, any source of illumination should take up as little storage space as possible. Conditions inside the cabinet are cold or even subfreezing (if in a freezer compartment). Thus, the illumination source must be able to work and last in that environment. Also, food items can be in liquid or semi-solid form and, therefore, protection of the lighting source and electrical connections from those substances is usually important. Also, it is not necessarily easy to route electrical power to such light sources.

Still further, cost is a factor with most appliances, particularly consumer appliances. Therefore, although the best illumination would utilize a number of light sources distributed throughout the cabinet, this is normally impractical from a cost perspective. Additionally, more light sources may translate into higher energy costs during operation.

Therefore, there are competing factors involved in illumination of the interior of such appliances.

One known configuration places an illumination source in or on the liner of the appliance. This can make it difficult to adequately illuminate all parts of the compartment involved.

Attempts at placing illumination sources inside the cabinet space includes mounting light sources on shelves. However sources like incandescent or fluorescent sources take up substantial room. They require relatively large sockets or electrical connections. Additionally, mounting on a shelf that is removable or horizontally adjustable raises issues of how to reliably supply electrical power to the lights.

A variety of attempts at shelf-mounted lighting have been made. Some utilize relatively smaller sources such as LEDs. Some utilize what could be called a power strip or power rail along the mounting bracket locations for adjustable shelves. A conductive contact on the shelf contacts the conductive vertical rail to supply electrical power.

However, many of these systems tend to be somewhat complex. Some involve a number of parts. And some are not perhaps as economical as might be desirable. The lighting sources tend to be readily identifiable by a viewer.

Therefore, there remains a need in the art for alternatives or improvements regarding interior lighting of such appliances. There is a need for improved visibility, aesthetics, and economy.

SUMMARY OF THE INVENTION

It is therefore a principle object, feature, aspect, or advantage of the present invention to improve over or solve problems and deficiencies in the art.

Further objects, features, aspects, and advantages of the invention relate to shelving that includes an illumination source which:

- a. provides good visibility via illumination at or near the shelf but also good visibility to and through the shelf to even other parts of the surrounding structure or space;
- b. provides an integrated system of shelf storage position and illumination including mounting and supplying electrical power to the illumination sources;
- c. provides good aesthetics regarding shelving and/or areas around the shelving;
- d. provides flexibility regarding manufacture, durability, economy;
- e. provides good flexibility regarding type and effects of illumination;
- f. provides good utilization of useable space;
- g. promotes good efficacy of illumination;
- h. promotes ability for economical use of electrical energy;
- i. allows for beneficial use with a variety of shelving structures and storage cabinets or appliances with a variety of different internal storage components; and/or
- j. can be applied to different structures, including enclosable spaces or open shelving.

One aspect of the invention is a shelf having a transparent or at least partially light transmissive storage surface, a perimeter frame, and a lighting subassembly, wherein the frame includes forms or receivers for complimentary receipt or integration of mounting brackets. The lighting subassembly is at or along at least one edge of the supporting surface or arrayed on the surface. The frame and supporting surface are relatively thin. Electrical power to the lighting subassembly allows the lighting assembly to provide illumination through, at, or around the shelving.

Another aspect of the invention includes a refrigerator shelf having a top glass storage surface, a perimeter frame, and a lighting subassembly. The frame includes forms or receivers for complementary receipt or integration of mounting brackets. Electrical power to the lighting subassembly can be by wireless transfer or contact transfer to a source of electrical power available in the cabinet of the appliance. The framing of the glass supporting surface can include metal, plastic, or other materials that form framing components that are relatively thin to present a relatively similar thickness for the entire shelf for optimal utilization of space and aesthetics, but also carry a lighting subassembly and protect and hide the side edges of the supporting surface. The lighting subsystem can have light output that essentially distributes light through or along the glass supporting surface. It provides the look of a glass shelf essentially suspended in space but provides illumination at or near the supporting surface for the customer to identify the contents of the shelf. Alternatively, the framing of the glass supporting surface can be overmolded plastic.

In another aspect of the invention, the upper glass surface can have a relatively thin glass plate to which is overmolded an undersupport at least partially light transmissive plate of essentially the same perimeter size as the thin glass plate and one or more overmolded framing edges that protect edges of the thin glass plate. A lighting subassembly can be mounted to or overmolded into one of the molded frame edges or on the surface. The overmolding frame edges can include forms or receivers for complementary receipt of mounting brackets for the shelf. Electrical power can be through wireless transfer from a source of electrical power in the cabinet.

In another aspect of the invention a transparent or at least partially light transmissive supporting plate can be framed by overmolded plastic that includes one or more light sources or a lighting subassembly. A power connection is applied or mounted along the plate or framing and adapted for operative connection to a source of electrical power to operate the light source(s). The components are integrated in function and appearance.

These and other objects, features, aspects, and advantages of the invention will become more apparent with reference to the accompanying specification and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cabinet in which are supported one or more shelves that are adjustable vertically. In this particular example, the cabinet is a refrigerator/freezer fresh food compartment. The shelves are one example of one form the invention can take.

FIG. 2A is an enlarged perspective view of the shelves of FIG. 1 from a bottom and left view point.

FIGS. 2B and 2C are black/white and color photographs respectively of the shelves of FIG. 2A illustrating how a lighting subassembly on and optical pattern applied to each shelf provides at least the appearance of luminance from each shelf, and aesthetic and functional benefits.

FIG. 3A is a still further enlarged perspective view of a single shelf from FIG. 2A from a top and center perspective.

FIGS. 3B and 3C are black/white and color photographs respectively of the shelf of FIG. 3A illustrating how the lighting subassembly and applied optical pattern provides at least the appearance of luminance from each shelf, and aesthetic and functional benefits.

FIG. 4 is an exploded view of the components of the shelf of FIG. 3B.

FIG. 5 is an enlarged partial sectional view of the assembled front end of the shelf of FIG. 3A taken along line 5-5 of FIG. 3A.

FIG. 6A is an assembled perspective view of an alternative embodiment of a shelf according to the present invention, in particular, a quite thin top glass plate to which is overmolded an undersupport plate/protective edge framing giving the appearance and properties of glass on the top side of the shelf but using plastic to support the thin glass layer and protect its edges. A lighting subassembly is overmolded into or mounted to the framing.

FIG. 6B is an exploded view of the embodiment of FIG. 6A with diagrammatic depictions of power and control components for the lighting subassembly carried on the shelf.

FIG. 7 is an enlarged side elevation view of FIG. 6A.

FIG. 8A is a sectional view of one possible form of the assembled shelf of FIG. 6A taken along line 8-8 of FIG. 6A, in particular, the lighting subassembly is overmolded and encapsulated in a front frame portion.

FIG. 8B is similar to FIG. 8A but shows one possible alternative form of the assembled shelf of FIG. 6A taken along line 8-8 of FIG. 6A, in particular, the lighting subassembly is separately mounted in a front frame portion but projects light substantially into the shelf assembly.

FIG. 8C is similar to FIG. 8B but shows the lighting subassembly projecting light angularly down and below the shelf.

FIG. 9 is a sectional view of the shelf of FIG. 6A taken along line 9-9 of FIG. 6A.

FIG. 10A is an exploded view similar to FIG. 6B but showing a slightly alternative embodiment wherein plural LED lighting subassemblies are mounted on the thin glass plate to which is overmolded framing 90.

FIG. 10B is a sectional view basically through the center of the assembled combination of FIG. 10A in slightly enlarged fashion.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

Overview

For a better understanding of the invention, several exemplary embodiments will be described in detail below. It is to be understood that these are but a few examples of forms and configurations the invention can take and are neither inclusive nor exclusive.

The exemplary embodiments will be described in the context of a refrigerated appliance as illustrated in FIG. 1. It is to be understood, however, that the illuminated shelves can be applied to refrigerators, freezers, or refrigerator/freezers of other configurations. Still further, the illuminated shelves could be applied to other appliances with enclosures or adjustable shelving. Still further, any shelving for storage or display could utilize the principles of the invention.

The exemplary embodiments will also be described in the context of light sources that are LEDs. It is to be understood, however, that other lighting sources are possible.

Exemplary Embodiment 1

With reference to FIGS. 1-5, a first exemplary embodiment of the invention comprises plural shelves 30 that can be mounted along vertical mounting rails 22 in fresh food compartment 16 of a refrigerator/freezer appliance 10. One example one such an appliance is shown in FIG. 1. Multiple shelves 30 could be mounted at different vertical heights and in different positions in fresh food compartment 16.

FIG. 1 illustrates a French door/bottom freezer type refrigerator 10 having a cabinet 12. The fresh food compartment is defined by a liner 15 such as are well known in the art. Doors 14L and 14R (left and right) open and close off compartment 16. Freezer compartment 18 can be a slide-out drawer.

Vertical rails 22 include slots or mounting apertures 24 along their lengths. Shelf mounting brackets 26 have rear ends with hooked fingers that are complementary to slots 24 to allow such brackets to be placed at various vertical heights inside compartment 16. A pair of brackets 22 supports each shelf 30 and allows selection of vertical elevation or mounting height in compartment 16.

As is conventional in many such present appliances, a master control board or programmable microprocessor 102 is built in to cabinet 12 and can control a number of features and functions of the appliance. One examples is control of cooling. Another is adjustment of settings (e.g. temperature or features), some of which are user selectable. An electrical power source 100 (connected to commercial electrical power) can also be available in cabinet 12. A wiring harness or bus 104 is typical to route electrical hardwire connections to various parts or locations in cabinet 12.

FIGS. 2A-C illustrate one style of shelf (ref. no. 30A) that can be used in appliance 10 of FIG. 1 from a bottom perspective (this particular embodiment of shelf 30 is referred to by reference number 30A). They show how brackets 26 support each shelf on vertical rails 22. They also show the relatively thin profile of each shelf as it extends out into the space of the fresh food compartment. FIGS. 2B-C furthermore show that each shelf 30A appears to be luminous or has illumination associated with it. As can be appreciated from FIGS. 2B-C, in this configuration each shelf has a substantially transparent main supporting area and the illumination associated with it gives the appearance of the supporting surface being luminous. Such a lighting scheme presents plural shelves, each appearing to be lit up individually. This presents an aesthetic overall appearance of the shelves hovering or extended in the compartment space with illuminated horizontal supporting surfaces. However the illumination is also functional. It assists a user to see the location of each lighted shelf and items supported on each shelf. Some of the light from a lighting subassembly in each shelf also may/can illuminate other parts of surfaces of the compartment or near the compartment. For example, a soft illumination of portions of liner 15 can be seen in FIGS. 2B-C. Localized lighting at each shelf can save energy (compared to generalized cabinet illumination).

As can also be seen by reference to these figures, each shelf has the appearance of a glass shelf. Most of the area of each shelf is transparent or substantially light transmissive. A thin and relatively small surrounding frame work essentially encapsulates and protects the perimeter edge of each shelf. The thickness of the framing is not substantially greater than that of the glass plate. It can be thicker, but not many times the thickness such that it promotes the appearance of an integrated shelf (both framing and supporting plate) that is relatively consistent in thickness. However, that relatively small framework takes up little space and presents a clean, aesthetically-pleasing look for each shelf. The brackets that support each shelf are relatively thin and small. The shelves basically appear to be suspended in fresh food compartment 16. Additionally, their white transmissivity allows a view through most of their area for increased visibility of other parts of compartment 16.

FIGS. 3A-C show another optional feature possible with shelf 30A. Either its top surface 31 or its opposite bottom surface 32 (FIG. 2A) can include a layer, coating, application or printing in some form that still allows the shelf to be substantially light transmissive but also still allows a view through and optically affects light that tries to pass through that central supporting surface. Reference numbers 33, 34, 35, and 36 refer generally to the front, back, left side, and right sides of overall shelf 30A. In this example, that addition is a moiré pattern or otherwise a pattern that can diffuse some of the light that passes through the light transmissive portion of shelf 30A or at least present an interesting visual appearance. One example is a printed or applied brand name or logo. This could include words, numbers, graphic designs, or combinations. Here the moiré pattern is a mesh-like pattern, which has a configuration that appears to be roughly parallel dark and light bands. Other patterns can be applied to produce different appearance and optical effects in combination with illumination emanating from or at the shelf. It could be printed, silk-screened, etched or otherwise applied.

As further indicated in FIGS. 4 and 5, shelf 30A includes a light subassembly 70. Assembly 70 comprises a printed circuit board (PCB) or mounting board 72. On one side is operatively mounted a linear array of LEDs 74. A light assembly wiring harness or bus 76 provides hardwire electrical communication between each LED 74 on board 72 and a termination. In this exemplary embodiment, the distal termination end of harness 76 includes an electrical contact or connection 78. This allows power and information to be electrically communicated to and from LEDs 74.

Further features of shelf 30A are as follows. The supporting surface of each shelf 30A comprises a glass plate 40. Glass plate 40 has top, bottom, front, back, left side, and right side edges 41, 42 (FIGS. 5), 43, 44, 45, and 46 respectively. It can be tempered glass on the order 2-3 mm thick and 375 mm×450 mm in width and depth. Of course other shapes and sizes and even configurations are possible. Moiré or optical pattern 49 (FIG. 4; see also FIGS. 2B-C and 3B-C) is on glass plate 40. Pattern 49 can be a separate layer. It could be applied, printed, embossed, or otherwise placed on either side (or both sides) of glass plate 40.

A top frame section 50 comprises a top horizontal flange 52 and a vertical outer flange 54. Vertical flange 54 would essentially fit over and protect the perimeter edges of glass plate 40 when placed on top of glass plate 40.

A lower frame section 60 has a horizontal and vertical flanges 62 and 64 which are complementary to and fit within vertical flange 54 of top frame section 50 (see FIG. 5). As indicated in FIGS. 4 and 5, top and bottom frame sections 50 and 60 would basically mate and sandwich glass plate 40 between them. The frame halves 50, 60 would be connectable by screws 68 or other fastening means through apertures in bottom frame 60 into tapped receivers 58 extending from the bottom of top frame 50 to basically encapsulate the edges of glass plate 40 and hold it in position. Frames 50 and 60 could be made of metal. Other materials are possible. The tolerances could be such that they closely match to the perimeter of glass plate 40 and to each other to not add much to the thickness to the glass plate 40 itself to provide that integrated look as shown in FIGS. 1, 2A-C, and 3A-C. There could be cushioning or gasket material on one or more of frames halves 50, 60 to cushion and further protect the edges of glass plate 40.

LED lighting assembly 70 can be mounted as illustrated in FIG. 5 in a space between frames 50, 60 along the inside surface 56 of vertical wall 54 of top frame 50 in alignment with the front edge 43 of glass plate 40. The optical axis 77 of each LED 74 can be directed into front edge 43 and in the plane through glass plate 40 indicated at reference number 77 in FIG. 5 of glass plate 40. Glass plate 40 would basically function as a light pipe or guide. This would tend to direct or guide light energy from LEDs 74 through the interior of the entire area of plate 40. This would provide illumination at or through and/or at least the appearance of luminance from both sides of plate 40. This would help identify objects on shelf 30A but also provide some level luminance or illumination around shelf 30A. It also provides the appearance of luminance or glow in glass plate 40.

LEDs 74 could simply turn on and off upon some instruction. The instruction could simply be closing an electrical circuit from electrical power with a manually operated on/off switch. It could be from closing an electrical circuit directly from a switch that senses when one of refrigerator doors 14L or 14R is opened or closed. It could be by an activation signal from master control 102. The activation signal could be from any of a number of triggers.

LED board 72 itself could include circuitry to have certain controllable functions for LEDs 74. For example, on-board circuitry could include hardware components that would respond to and actuate certain operation of LEDs 74. An example would be an LED driver circuit that could vary the intensity of any or all LEDs 74 according to instruction. The on-board circuitry could even include another processor or controller (it also could be programmable). An example would be a program that could flash or individually actuate any LED 74 according to different possible sequences, intensities, colors, etc.

Further examples would be the ability to alter the power in voltage, current, or duty cycle to any LED 74 for various lighting effects. There could also be different colored LEDs or types that could be collectively operated or individually operated.

LEDs can have different light distribution output patterns. For example, some are relatively wide beams and some are relatively narrow beam. Selection of the LEDs and their output patterns, along with the direction of their optical axes 77, allows the designer to create different lighting effects with lighting subassembly 70. For example, the optical axes could be substantially directed through the interior of glass plate 40 by substantially total internal reflection. Glass plate 40 would basically act as a light pipe or guide, guiding at least a substantial amount of the light output of LEDs 74 from glass plate front edge 43 to back edge 44. Alternatively, the distribution pattern could be such that some light from LEDs 74 moves through and across interior of plate 40 but some light refracts out to provide light energy outside of the plane of plate 40.

Another option would be to direct the optical axes of LEDs 74 other than into an edge of glass plate 40. It could be generally parallel along the top or bottom surface of glass plate 54. It could be angularly away from the plane of glass plate 40. Different LEDs 74 could be directed in different directions.

Examples of edge-lit shelving are described at U.S. Pat. Nos. 6,210,013 and 8,322,873, which are incorporated by reference. Another example of LED shelf lighting is described at U.S. Pat. No. 7,338,180 which is incorporated by reference herein. Details about directing light into an edge of a light transmissive plate are set forth.

As indicated in FIG. 5, board 72 could be mounted to frame section 50 or 60 by any number of techniques including but not limited to screws, bolts, adhesives, interference fit, or the like. One example is shown in FIG. 4 (screws 75 through tabs 73 into tapped receivers in frame 50); another is in FIG. 5 (board 72 adhered or mounted along inside surface 56 of vertical flange 56 of frame 50). Other mounting techniques are possible. It can be desirable that any fasteners not extend outside the outer surfaces of frame sections 50 and 60.

As can be further understood, patterns such as the moiré pattern or other optical patterns could be selected according to desire or need. Typical techniques may be etched into the glass or ink applied to the glass surface. They could be utilized with a selection of LEDs 74 and their output distribution patterns for a variety of different lighting and optical effects.

FIG. 4 also shows mounting brackets for the shelf assembly. Brackets 26 could be solid or wire. They could be separate from shelf 30A or unitary or integral to shelf 30A. If separate (as shown in FIG. 4), they could basically have a top edge or flange that would complementarily work with frame sections 50, 60 and glass plate 40 in assembled form to support that assembly would sit and hold against at least lateral movement and downward movement. There could also be cooperating structure to allow the shelves to be slid forward or removed. Examples of such features are known in the art.

It could therefore be seen that shelves 30A of FIGS. 1-5 are an integrated assembly that includes a glass supporting surface. Such a surface has good aesthetic appeal, is easily cleanable, and is considered by most customers to be hygienic. Glass also has inherent optical properties that can attribute to the aesthetic appearance both when LEDs 74 are on or not. Furthermore, the frame halves 50, 60 provide a metal edge protection of glass 40 but do so on a size scale that is similar to the thickness of glass plate 40. They do not add much additional thickness to glass plate 40. Thus, a pleasing overall appearance of dimensions and size proportions is presented. This includes the supporting glass surface and the edge protection of frame sections 50 and 60. In addition, built-in integrated light subassembly 70 allows illumination and luminance at and around shelf 30A to provide additional aesthetics. Still further, brackets 26 can be formed to be complementary to and retain the appearance of a glass supporting surface floating in a fresh food compartment. In addition, the embodiment promotes good visibility or optical clarity of not only items supported on shelf 30A but on other adjacent shelves and, if appropriately configured, throughout the fresh food compartment.

The embodiment also promotes economy by allowing a relatively few number of pieces to be assembled in an integrated fashion for a shelf that could be fixed into place or removable, and optionally adjustable vertically or horizontally. This includes carrying with it an illumination source (e.g. lighting subassembly 70 with LEDs 74).

Electrical power to lighting subassembly 70 can be supplied as follows. Electrical power for shelf 30A could be available by simply running hardwire harness (one or more individual wires) 76 from board 72 along shelf 30A, or internally between a side edge of glass plate 40 and its corresponding frame, to at the rear edge of shelf 30A. As is well-known in the art, a conductive rail or channel 28 (FIG. 3A) can be formed along one of the pair of vertical shelf mounting rails 22. Contact 78 at the distal end of wire harness 76 could be mounted to extend from the rear edge of shelf 30A so that it would come into abutting contact with a conductive portion of power rail 28 when shelf 30A is in appropriate position in compartment 16. An example of such a power strip is disclosed at U.S. Pat. No. 6,813,896 (commonly owned by the owner of the present invention) and incorporated by reference herein. This combination of a hardwired harness from LEDs 74 with an electrically conductive termination 78, and a vertical power strip of conductive material along the shelf mounting rails 22, allows a shelf 30A to be placed in any vertical position along rails 22 and receive electrical power for LEDs 74. This eliminates the need for long wires or electrical plugs. However, those are other options to supply power to LEDs 74.

As can be seen by the foregoing and FIGS. 1-5, shelf 30A is an example of an integrated shelf and lighting system which addresses one or more of the objects of the invention. Its functions and appearance are illustrated in FIGS. 1-5, including the photographs of FIGS. 2A-C and 3A-C, which show the lighting system of each shelf 30A turned on.

Exemplary Embodiment 2

By referring to FIGS. 6A-B to 9, another exemplary embodiment according to the invention is shown. This shelf 30B has similarities to shelf 30A of FIGS. 1-5. By referring to FIG. 6A, shelf 30B integrates an at least partially light transmissive main supporting surface with edge framing and protection with a lighting subassembly. It builds into the framing receivers for shelf mounting brackets. It provides communication of electrical power to the lighting subassembly. Some notable differences are as follows.

In this embodiment, a thinner glass plate 80 than glass plate 40 is utilized to present a glass top supporting surface 81 for shelf 30B (see FIG. 6B). One example would be a tempered glass sheet of on the order of one millimeter thick. Overmolded to it is framing 90. Framing 90 includes an at least partially light transmissive planar supporting surface or undersupport 91 (on the same order of perimeter size as thin glass plate 80 but thicker), and front, back, left, and right side edge frame portions 93, 94, 95, and 96 that basically encapsulate front, rear, left and right edges of 83, 84, 85 and 86 of thin glass plate 80. FIGS. 8A and 9 show that encapsulation. Lighting subassembly 70 is either overmolded in frame 90 adjacent to at least one edge of glass plate 40 or supporting surface 91. As can be seen from FIG. 6A, the overall assembly 30B (like assembly 30A) presents a substantially light transmissive glass appearance supporting surface with a relatively thin framing 90, relatively unobtrusive mounting brackets 26 that fit into molded forms or receivers in frame 90 (and do not require separate or additional pieces in frame 90), and a lighting system. The entire assembly 30B gives an integrated, thin, open appearance, but includes a lighting subassembly, edge protection, mounting interfaces, and electrical power connection to power the lighting subassembly, even though shelf 30B can be removed and repositioned elsewhere along a mounting subsystem (here vertical rails 22, but it can take other forms).

Overmolding is well-known in the appliance industry. Overmolding involves injection molding of one material, usually a thermoplastic (here frame 90) onto a second material (here thin glass surface 80). If properly selected, the overmolding thermoplastic will form at least some bond with the second material that is maintained in the end use environment. One example of overmolding is called insert molding. Single shot or multiple shot injection molding machines can be used. Sometimes there can be multiple materials shot into the same mold during the same molding cycle. Some of the factors and design characteristics of overmolding are set forth in publication entitled “Overmolding Guide” at http://www.glstpes.com/pdf/literature/Overmold%20Design%20Guide.pdf, by GLS Thermoplastic Elastomers and incorporated by reference herein. Examples of overmolding is described at U.S. Pat. No. 7,748,806 (commonly owned with the owner of the present application), incorporated by reference herein. Another example of overmolding, and in particular related to refrigerator shelving can be found at U.S. 2009/0195136 commonly owned and incorporated by reference herein.

In this embodiment, the overmolded thermoplastic of at least undersupporting surface 91 is a resin material having light pipe or light guiding properties. An example of utilizing thermoplastic molded material as a light pipe or guide can be found at U.S. 2011/0085287, owned by Whirlpool Corp., and incorporated by reference herein. Additional discussion of light guide or pipe materials can be found at “Light Guide Techniques Using LED Lamps”, application brief I-003, by Avago technologies available at http://www.avagotech.com/docs/5988-7057EN and incorporated by reference herein. It is possible that frame 90 could also have light guide or light pipe characteristics.

In this example, the overmolded resin material is polycarbonate (Lexan®) with 85-91% transmission. Cost, mechanical performance, moldability, light path design and transmission desired will affect the resin material selected and can be considered by the designer.

FIG. 6B shows diagrammatically and in isolation overmold frame 90, with its light transmissive undersupport 91 and side framing portions 93, 94, 95, and 96, and thin glass plate 80 exploded above it. Overmolding would begin with glass plate 80 placed into the mold. Flowable plastic material would then be injected into the mold and flow under and around the edges of glass plate 80. It would cool and harden to support the underside of glass plate 80 and encapsulate and protect the edges of glass plate 80 as illustrated in FIGS. 8A and 9. It would have the integrated appearance of FIG. 6A.

As further illustrated in FIGS. 6A-B, 7, 8A-C, and 9, in this exemplary embodiment the overmolding provides not only an underlying support surface 91 for thin glass plate 80 across its entire area but also essentially encapsulates all four of its edges to protect those potentially fragile edges. The combination therefore presents an actual glass top supporting surface 81, with its desirable features, but utilizes only a very thin glass plate or sheet 80. The overmolded undersupport surface 91 is also light transmissive; basically transparent or optically clear or substantially so, if desired. The overmolding process can be controlled to essentially mold that undersupport 91 to the bottom of thin glass plate 80 such that there are essentially no gaps or air bubbles between the two. This promotes the appearance of a single supporting surface even though it is two layers; one made from glass plate 80 and the other undersupporting plastic layer 91. The resin and overmolding process can also be controlled so that undersupporting layer 91 can have at least similar optical properties (e.g. transparency) to glass layer 80 to promote the appearance of a single layer. But it does not have to have the same optical properties. Either glass plate 80 or underlayer 91 can also be modified to have other optical properties. One example is adding a moiré pattern, logos, informational text or other optically altering aesthetic enhancing effects.

As also indicated in FIG. 7, overmolded frame 90 could be molded to have receivers (see slots 98 in FIG. 9) for shelf mounting brackets 26. Receiver 98 could be a recess or form molded into each opposite side frame portions 95 and 96 into which the top edge of a shelf mounting bracket 26 would complementarily fit and prevent movement of shelf 30B at least downwardly and laterally. If appropriately formed, slots 98 could also prevent fore and aft movement relative to cabinet 12.

As further illustrated in FIGS. 6-9, shelf 30B can include a lighting subassembly 70 similar to that of the first embodiment. In this example, a linear array of LEDs 74 on a PCB 72 is positioned along front edge 93 of overmolded frame 90. It is to be understood, however, that additional arrays could also be positioned along one or more other edges. They could be linear or other configurations.

FIGS. 8A-C illustrate several optional LED mountings. FIG. 8A shows the whole lighting subassembly 70 (PCB 72, LEDs 74, and wire harness 76) could be overmolded into frame 90. Those components would be placed into the plastic mold with glass sheet 80 and basically encapsulated into place. Because at least undersupport 91 of frame 90 is light transmissive, the light output of LEDs 74 (if their optical axes along plane 97A are directed along the plane of undersupport 91) would be guided along undersupport 91 and provide the luminance/illumination along the whole area of undersupport 91. The light transmissivity of glass plate 80 would allow persons to see that luminance/illumination. It would glow like a shelf 30A of FIGS. 2A and 3A. PCB 72 could also be mounted so that optical axes 97A would extend parallel but underneath undersupport layer 91 so that the beams from LEDs 74 would project along the bottom of shelf 30B.

Alternatively, as shown in FIG. 8B, overmolded frame 90 could have a recess 99 under its front edge 93 to which a linear array of LEDs 74 could be mounted. The optical axes of LEDs 74 could be positioned to direct light from LEDs 74 into a front edge of undersupport 91 and/or the front edge 83 of glass plate 80 such that light could be directed through one or both of those layers along plane 97B.

Another option is shown at FIG. 8C. LED board 72 could be angled slightly downward such that the optical axes of one or more of LEDs 74 is angled downwardly from the front edge 93 of shelf 30B along plane 97C (or at different angels). All or part of the light distribution from LEDs 74 could then provide illumination downward. The beams from LEDs 74 would project downward and illuminate the space and any structure(s) below shelf 30B. Still further, board 72 and LED 74 could be configured both to provide edge lighting for either glass surface 80 or undersupport 91 and light distribution in one or more other directions.

As illustrated diagrammatically in FIGS. 6A and 6B, an alternative way of providing electrical power to LEDs 74 is through inductive, capacitive or magnetic transfer. This is sometimes called touchless or wireless electrical transfer. A receiving antenna 116 on shelf 30B can have a terminal end in operative proximity of radiating antenna 106 behind liner 15. Antenna 116 can be any of a variety of forms. One example is a thin foil or layer metal or other electrically conducting material mounted flush to the top or bottom surface of either undersupport 91 or thin glass plate 80. The mounting can be by adhesive, thin layer deposition, printing or otherwise. A similar thin foil or layer trace 117 is in electrical communication with hard wire harness 76 to each LED 74 on board 72 at solder point (or other electrical connection point) 115. This arrangement does not take up any storage space and is contained on shelf 30B.

Radiating antenna 106 is electrically connected to electrical power source 100 in appliance 10 (e.g. via conducting section 107 to solder or connection 105 and then wire harness 104) and master control 102. By methods known in the art, electrical power from power source 100 can be transferred wirelessly or touchlessly between antennas 106 and 116 in a manner that can be utilized to power LEDs 74. An example of such touchless coupling is described in U.S. Pat. No. 7,293,422, commonly owned by the owner of the present invention and incorporated by reference herein.

In this method, by having at least one antenna 106 in sufficient proximity to all possible positions for shelf 30B, electrical power would be available for different vertical or horizontal positions of shelf 30B. Thus, LEDs 74 could be operated at any time including if shelf 30B were slid outwardly or moved to a different elevation in cabinet 12. Antenna 106 could be foamed-in-place when a refrigerator compartment is thermoformed.

An additional possible feature includes not only touchless or wireless transmission of electrical power from power source 100 to LEDs 74 but also transmission in either direction of data or information in electrical form. Such data or information transmission is also described in U.S. Pat. No. 7,293,422, which is incorporated by reference herein. A variety of commercial venders provide commercial products that allow such shared communication of both power and instructions or feedback. This will allow master controller 102 to provide any of a variety of operational instructions to operation of LEDs 74 or to other functions at circuit board 72 without having to be hardwired or have touch or contact through a conducting path.

One definition of contact or contactless power is transmission of electrical energy from a power source to an electrical load without man-made connectors. U.S. Pat. No. 7,293,422 describes inductive or capacitive power transfer and data exchange in both directions in the context of a refrigerator appliance. US 2012/0140440 and U.S. Pat. No. 7,522,878, incorporated by reference herein, describe contactless power and communication.

Resonant inductive coupling is one type of wireless or touchless electronic transmission method. Such power transfer is in use in a variety of commercially available products. At least the receiver structure 116/117 on shelf 30B can be of a form factor that is thin layered. Thus, it could be applied to shelving without occupying much space. It can also be relatively thin and not physically or visually disrupt the look of and any light transmission associated with the shelf. The transmitting part 106/107 could be behind the back or side wall of the supporting structure for the shelf. For example in the case of a refrigerator, it could be hardwired to electrical power in an appropriate transmitting components for wireless power and data transmission behind the refrigerator liner. It is generally better to have the two contactless components as close together as possible. Transmitting components 106 could be placed at various levels throughout the cabinet supporting shelves and be available for shelves of multiple different positions or multiple shelves.

Alternatively, electrical power to LEDs 74 on shelf 30B could be by other techniques. For example, it could be by any of the techniques described with respect to embodiment 1, including through a contact arrangement or hard wiring.

Options and Alternatives

As can be appreciated by those skilled in the art, the invention can take many forms and embodiments. Variations obvious to those skilled in the art will be included within the invention. Some specific examples are as follows.

The lighting subassembly 70 could be separately mounted (screws, bolts, adhesive, or other fastening techniques) to the overmolded portion 90 or metal frame portion 50 or 60 for shelves 30B and 30A respectively. Alternatively, they could be more integrated. An example would be to overmold to board 72 in an overmolded frame such as shown in FIG. 8A. An alternative is illustrated at FIGS. 10A and 10B. Instead of positioning the lighting subassembly in the perimeter framing of the overmolding, one or more lighting subassemblies 70 (here for illustration 70A-D; but there could be more or less or different configurations than linear raised) could be mounted at or on the glass plate 80. For example, by deposition or printing processes known in the art, LED 74 and electrically conductive traces to them could be printed directly on the underside of thin glass plate 80. Conductive trace 117 could also be printed to that surface and in electrical communication with some sort of power connection 78′ (it could be contact, contactless, or inductive/magnetic/capacitive connection to electrical power and/or information transfer). That combination (thin glass plate 80 plus the LED lighting assemblies) printed on plate 80 and the electrical traces to power connection (can be low voltage) can then be placed in an insert mold and the overmolded framing and undersupport 90 overmolded to that combination. Of course, the lighting subassemblies could also be positioned in the mold so that they would end up inside the overmolded undersupport of overmold framing 90 and electrical connections made to the power connection. Such lighting assemblies could also be used in conjunction with those around the perimeter of framing 90. FIG. 10A shows lighting subassembly 70A-D printed on the underside of thin glass plate 80 prior to being overmolded with framing 90 separated for illustration purposes only.

FIG. 10B shows the cross-section of the glass plate 80 with printed lighting subassemblies and the overmolded framing, including the undersupport 91. This provides light sources all along the optically clear portion of the assembled shelf. It retains its thin and glass appearance but has lighting available across that area.

The types, characteristics, and configuration of the light sources can vary. For example, it does not have to be necessarily a linear array, although such does work well with keeping the overall appearance of either shelf assembly thin. The spacing, number, and arrangement can vary. As indicated in FIGS. 8A-C, for example, some part of the overmolding could extend outwardly from glass surface 80 and could be shaped or configured to receive any number of light sources or configurations. As previously mentioned, a pattern on the shelf surface could be some sort of pattern that optically alters light that issues from the shelf surface. One example is a moiré pattern. Other diffusion patterns are known in the art. As it is further well known in the art, facets or forms can be made in other patterns in the shelf supporting surface if plastic. Some patterns can be printed to glass. It is to be understood that any number of single or multiple patterns are possible at any surface or along any part of the shelf. Some of the patterns can optically alter the light distribution. Some could be informational or even aesthetic. An example would be printing a logo. The printing or embossment or engravement or other patterning could actually have both visual and light affecting functions. Still further, arrangement of the LEDs and/or such optical enhancements can provide different visual effects. This is akin or analogous to use of LED lighting arrays in certain configurations alone or with lens or optical patterns to create brand identity with automobile taillights or headlights. For example, one or more shelves of each brand of appliance could have a consistent LED array configuration and/or optical pattern so that when a consumer views the shelf there could be identification with a brand or a sub-brand of a certain company. Optical patterns could be molded into plastic. They could be silk screened or printed on plastic or glass. There could be a combination of patterns with the embodiment 30B—one printed or silk screen on the thin glass 80, another molded into the undersupport plastic part of the framing.

Still further, light sources could be distributed along other edges of the shelf assembly. While the exemplary embodiment shows them along just the front edge, they could be at any other side or edge. They could be at two edges, three or all four.

And, as mentioned, the type and characteristics of the light sources can be uniform or they could vary. For example, they could vary as to color, light output distribution, output intensity, or other characteristics. They could be individual controlled, controlled together. They could be controlled in subsets.

Furthermore, the materials related to the supporting surfaces or parts thereof could affect light guiding or optical manipulation of the light from the light sources. Reflective surfaces, lenses, light absorbing surfaces, or other optical components could be added at the light sources, or other locations on or near the shelves.

Circuit board 72 could include some intelligence such as microprocessor, circuitry, and memory that could help with or add to the variety of functions related to the light sources or other features.

Another possible feature would be to have some sort of sensor at or near the shelf or in some other location relative the appliance 10. For example, as illustrated diagrammatically in FIG. 6A, a sensor 108 could be mounted somewhere on or in appliance 10 and in electrical communication with master control 102. It could be included on circuit board 72. It could feed back information to master control board 102 via a wiring harness or bus, or contact or touchless transfer back to master control board 102. An example of sensor 108 is a switch. It could inform control 102 that a refrigerator door 14 has been opened. Control 102 could then communicate an instruction to turn on LEDs 74 of one or more shelves 30. Another sensor example is a temperature sensor. It could inform master control board 102 of temperature at or near a shelf 30. Master control 102 could instruct some sort of indication correlated to that temperature sensing by LEDs 74 of that shelf 30. For example, if sensed temperature is above user set point for that shelf or compartment 16, LEDs 74 could be flashed to alert the appliance user. Another example would use different colors. If LEDs of different color output were mounted on a PCB 72 for a shelf 30 (e.g. red, blue and white), control 102 could activate the red LEDs if temperature set point range is exceeded to indicate to the user the temperature is too high. Blue could be turned on (and red and white not turned on) to indicate temperature below a set point range. White LEDs could be operated if temperature is within set point range. Another example for sensor 108 would be a proximity or motion detector. It could detect proximity or motion indicative of the presence of a person, and controller 102 could turn on LEDs 74 for one or more shelves 30. Once detector 108 ceases to detect such proximity or motion, controller 102 could turn LEDs 74 off. Such a detector could be placed at or near a specific shelf 30 and be calibrated to alert proximity or motion only if at or near that shelf. In this way a single shelf could be illuminated.

Alternatively, any number of lighting schemes could be presented to the user either randomly by master control 102 or according to user choices. For example, one scheme might be to turn LEDs 74 on at a highest intensity level when a refrigerator door 14 is first opened (e.g., to help the user see items supported on the shelf 30). After a certain time period the intensity could drop or it could slowly ramp down. It could ramp down to a dimmer level or completely to turn off. Another example would be to run the LEDs at steady state when a shelf is back in a home position in compartment 16 but if the shelf can be selectively slid out, to flash or otherwise change output to make the user aware the shelf needs to be pushed back in before closing door 14. Any of a number of a variety of lighting schemes is possible.

Still further, the overmolded version 30B could have just the overmolded frame portions 93, 94, 95, and 96 and not the undersupport 91. Or it could just have the undersupport 91 somehow adhered to the thin glass surface 80. Or combinations of undersupport in just one edge frame portion, two frame portions, three or four are possible. Alternatively, brackets 26 could be inserted in a mold and, in the example of shelf assembly 30B, the overmolding 90 could be overmolded to the brackets. They would then be incorporated or integrated into the combination but not removable therefrom. Brackets could also be fixed to the other part of the shelf. For example, with embodiment 30A, by adhesive, screws, or other techniques, brackets 26 could be fixed in place. This could be true similarly of embodiment 30B. But in some examples, the overmolding or the framing could have forms in the perimeter framing that would receive complimentary shapes in brackets 26 to support the shelf on the brackets in a stable manner.

As with Exemplary Embodiment 1, left and right side frame portions 95 and 96 could be molded to have a slot that is complementary to mounting bracket 26 such that shelf 30B can simply be set down onto a pair of brackets 26 and held in place against lateral, forward, or downward further movement.

Additionally, the antennas 106 and 116 possible for touchless power/data transfer can be thin film or applied to the top or bottom side of undersupport 91 or glass plate 80 and not take up any space. They could be applied on the outside or inside of the overmolded frame portions. Or they could be a separate piece. As has been mentioned, electrically conductive leads could be printed onto either a glass surface or plastic surface to decrease materials cost, maintain thinness and good clean appearance and the like.

As can be appreciated, in many structures, particularly appliances that have functions in addition to illumination, an intelligent control exists. In the example of a refrigerator appliance, many current such appliances have such an intelligent controller or master control. It can manage electrical power to other functional components (e.g. cooling subsystem, ice making subsystem, dispenser subsystem, user selectable interfaces, etc.). In the context of the exemplary embodiments, such a master control could be programmed or could take user input and translate that into lighting effects for the light subassemblies at each shelf. Examples of such a master control or intelligent control are described at U.S. Pat. No. 7,765,819, U.S. Pat. No. 7,891,198, and US 2009/0277210, all incorporated by reference herein. For example, the intelligent control could be programmed to activate lights at the shelf on any of a number of triggers or states relative the appliance. One example would be to turn the lights on for a shelf when an intelligent control senses the door in front of the shelf has been opened. Another example would be to automatically turn on the lights when the door is opened but turn them off if the shelf is moved (e.g. slid forward) a given distance. Another would be to keep the lights off at a shelf unless a touch sensor or other user activated switch is touched or a proximity sensor senses a user's hand within range of the sensor.

The ability of the master control or intelligent control to monitor different sensed conditions, states of the appliance, or user inputs, as well known. The incorporated by reference U.S. Pat. Nos. 7,768,189, 7,891,198, and US 2009/0277210 provide examples of different sensed conditions, states of the appliance, or user inputs that could be monitored and utilized in the effecting a lighting effect with the light subsystem at one or more shelves. Examples could include sensing temperature at or near the shelf and illuminating a certain color output of LED out of plural different colors on the shelf. An example would be if the shelf is intended for storing fresh food items and the temperature around it is within range of a default range or a user selectable range. The lights could be blue to indicate within range temperature. However, if the temperature sensors sense temperature above the range, red LEDs could be illuminated and the blue LEDs turned off. A third color such as white could indicate some other condition. Another example would be sensors on, at, or near a shelf 30 when it is in operative position in an appliance (see, e.g. FIG. 6B). The sensor could feed back information to an appliance controller that could inform or influence a lighting affect at shelf 30. An example would be a temperature sensor at or near the top supporting surface of shelf 30. If temperature at that location in a refrigerated appliance exceeds some sort of set point, red LEDs could be turned on by the controller to indicate to the appliance user the temperature has gone above set point. If below set point, LEDs could be turned on to indicate normal condition but illuminate the shelf. On the other hand, if temperature goes below a set point, blue LEDs could be turned on.

Another example would relate perhaps more to a bin or drawer. Some bins or drawers can actually have heater elements. An example would be a thawing drawer. Frozen food could be placed in the thawing drawer and a temperature regiment applied to promote safe but quick thawing. LEDs in the drawer could be controlled by feedback from a temperature sensor sensing temperature in the drawer to inform the user that the food is not yet thawed (e.g., blue lights). Then when it is sensed that the food is thawed, red LEDs could be turned on. Another example could be a sensor that senses some characteristic of food to inform a lighting affect. An example would be a chemical sensor that could sense if food is spoiling or rotting. It could then feed that information to the controller which could turn on red LEDs or some other color to alert the user. Instead of color, flashing or other variable driving of the LEDs could be implemented. A designer could utilize any of a variety of feedback information and any of a variety of lighting effects. A benefit of that combination is that each shelf or drawer or bin has its own control and communication of information to the user. Each shelf or drawer or the like at least appears to be “smart” in this context.

Still further, an intelligent control could be programmed to provide different lighting effects from any lighting subassembly on a shelf. One example would be to flash if the user's hand comes in proximity to the shelf, if the shelf is slid forward and needs to be slid back to home position before door could be closed, or if temperature sensed around it is out of range. Another example would simply be to ramp up the intensity of the lights based on time or some other factor.

As can be appreciated, the driving of the LEDs based on some sensed condition or trigger could take any number of forms. The designer could select the same based on some desired indication to the user that conveys some information relative to the shelf, what is on the shelf, or the area around the shelf. It could also be for aesthetic purposes.

It is to be understood that the invention could take a wide variety of forms and configurations. Variations obvious to those skilled in the art will be included within the invention.

Different features of the different exemplary embodiments can be utilized in still further embodiments. For example, the two piece framing of exemplary embodiment one could be substituted by the overmolded framing of exemplary embodiment two. Or the two layer middle supporting plates of exemplary embodiment two could be a single plate of glass or plastic more robust than the thin top glass plate of embodiment two.

LIGHTED REFRIGERATOR SHELF WITH OVERMOLD

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