Information
-
Patent Grant
-
6811045
-
Patent Number
6,811,045
-
Date Filed
Monday, January 10, 200024 years ago
-
Date Issued
Tuesday, November 2, 200419 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Cuomo; Peter M.
- Harris; Erica B.
Agents
- Houser, esq.; H. Neil
- Armstrong Teasdale, LLP
-
CPC
-
US Classifications
Field of Search
US
- 211 153
- 312 404
- 312 408
-
International Classifications
-
Abstract
A shelf for a refrigerator includes a plate, a cross support, a side support, and a frame. The plate includes first and second surfaces. The frame is adhered to a first surface of the plate and forms a sealed spill containment area. The second surface of the plate adhered to a cross support or side support for an easily manufactured and assembled spillproof shelf.
Description
BACKGROUND OF THE INVENTION
This invention relates generally to shelves and, more particularly, to refrigerator shelves.
A refrigerator typically includes a number of shelves for the storage of food and beverage containers of many shapes and sizes. As the containers are retrieved, returned and/or rearranged on the shelves, occasional leaks and spilling of food and liquid may occur. Cleaning up after a spill on a crowded refrigerator shelf can be difficult, especially when spilled liquid leaks onto lower shelves.
To contain liquid spills on a refrigerator shelf, it is known to use “picture frame” shelves. See, for example U.S. Pat. No. 5,677,030. Picture frame shelves include edges that are wrapped around, attached, or otherwise fitted to a glass plate to form a dam around the edges of the plate for containing spilled liquid.
The seal of the picture frame, however, is dependent on the external dimensions of the glass plate which vary somewhat from plate to plate. In addition, insert molding, or glass encapsulation processes, used to manufacture picture frame shelves may depend on shrinkage of the plastic used to fabricate the frame. Because of the plastic shrinkage, the edges of the glass plate must be notched and edged for the frame to properly seal the glass. Further, picture frame shelves are typically supported only on the edges of the plate and therefore require a glass plate having a thickness sufficient to support the entire load of the shelf.
Accordingly, it would be desirable to provide a refrigerator shelf that contains spills that is not as dependent on the external dimensions of the glass plate as a picture frame shelf. In addition, it would be desirable if the shelf seal does not depend on shrinkage of the fabrication material. Further, it would desirable if the shelf could be manufactured inexpensively and assembled easily.
BRIEF SUMMARY OF THE INVENTION
In an exemplary embodiment of the invention, a refrigerator shelf includes a substantially flat plate, a cross support and a frame. The frame is sealed to a substantially flat surface of the glass to contain spilled liquids.
The plate includes a substantially flat first surface and a substantially flat second surface. The cross support extends beneath the plate first surface and between a pair of shelf side supports. The cross support transfers a load of the shelf to the side supports.
The shelf frame is sealed to the second surface of the plate with an adhesive around the edges of the second surface. Consequently, the frame seal is independent of the size of the glass plate and independent of shrinkage of the material used to make the frame. Rather, the sealing of the frame depends on the flatness of the glass, which is easier to control than plate dimensions and plastic shrinkage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a perspective view of a first exemplary embodiment of a refrigerator shelf including a frame.
FIG. 2
is a perspective view of the frame shown in FIG.
1
.
FIG. 3
is a top plan view of the frame shown in FIG.
2
.
FIG. 4
is a side elevational view of the frame shown in FIG.
3
.
FIG. 5
is a cross-sectional view of the refrigerator shelf shown in
FIG. 1
along line
5
—
5
.
FIG. 6
is a cross-sectional view of the refrigerator shelf shown in
FIG. 1
along line
6
—
6
.
FIG. 7
is a perspective view of a second embodiment of a refrigerator shelf.
FIG. 8
is a cross-sectional view of the refrigerator shelf shown in
FIG. 7
along line
8
—
8
;
FIG. 9
is an exploded view of a third embodiment of a refrigerator shelf;
FIG. 10
is a perspective view of the shelf frame shown in
FIG. 1
;
FIG. 11
is a cross sectional view of the shelf frame shown in
FIG. 10
taken along line
11
—
11
; and
FIG. 12
is a perspective view of the shelf support system shown in FIG.
9
.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1
illustrates a perspective view of a refrigerator shelf
10
including a plate
12
, a plurality of cross supports
14
, a plurality of side supports
16
and a frame
18
. Frame
18
forms a sealed containment area
20
on plate
12
to contain spilled liquids. Plate
12
is substantially flat, is fabricated from glass, plastic or other material, and is capable of supporting items placed thereon. In addition, plate
12
is substantially rectangular in shape and includes four side edges (not shown in FIG.
1
).
FIG. 2
illustrates a perspective view of the underside of frame
18
. Frame
18
is a one piece, substantially rectangular frame fabricated from molded plastic, and forms a center opening
22
that, together with plate
12
(FIG.
1
), forms containment area
20
(FIG.
1
). A curved lip
24
at the front of frame
18
prevents scrapes and snags with a front edge (not shown) of plate
12
during use of shelf
10
inside the refrigerator. Shelf
10
also includes an underside channel
26
that allows frame
18
to be adhered to plate
12
(FIG.
1
).
Frame
18
is fabricated from inexpensive, integrally molded plastic. In alternative embodiments, frame
18
is fabricated from other materials, including, but not limited to, talc filled polypropylene, acrylonitrile-butadiene-styrene (ABS), or High Impact Polystyrene (HIPS). In a further alternative embodiment, the frame is assembled from a plurality of frame segments having underside channels that form a substantially continuous underside channel around an outer periphery of the plate when the segments are assembled.
FIG. 3
is a top plan view of frame
18
including a front side
28
, a left side
30
, a right side
32
, and a rear side
34
. Each side includes an inner edge
36
partially defining center opening
22
, and an outer edge
38
partially defining an exterior of frame
18
. Frame
18
has a uniform dimension between inner edge
36
and outer edge
38
on left side
30
, rear side
34
, and right side
32
, and an increased dimension between inner edge
36
and outer edge
38
on a front side
28
by virtue of front lip
24
. Underside channel
26
extends continuously around frame
18
between inner edges
36
and outer edges
38
of sides
28
,
30
,
32
,
34
, and includes rounded corners
40
that increase the structural integrity of shelf
10
(
FIG. 1
) by reducing stress on the corners of plate
12
(
FIG. 1
) when frame
18
is adhered to plate
12
.
FIG. 4
is a side elevational view of frame
18
including positioning ribs
42
adjacent front side
28
and rear side
34
of frame
18
. Front positioning rib
42
is spaced from front lip
24
forming a gap
44
to insulate plate
12
(
FIG. 1
) from frontal impact. Therefore, frame
18
will absorb frontal impact and prevent direct impact with the front edge (not shown) of plate
12
(shown in FIG.
1
). In addition a side extension
46
extends below underside channel
26
to facilitate positioning of frame
18
in relation to plate
12
(FIG.
1
).
FIG. 5
is a longitudinal cross sectional view of shelf
10
illustrating the attachment of frame
18
to plate
12
. A first surface
50
of plate
12
is adhered to a cross support
14
and a second surface
54
of plate
12
is adhered to frame
18
along an outer periphery
56
, which is generally defined by a portion of second plate surface
54
adjacent plate edges
48
. Frame side extensions
46
are positioned adjacent plate side edges
48
, and a barrier portion
58
of frame
18
substantially covers plate outer periphery
56
and forms a generally impermeable containment area
20
(
FIG. 1
) after frame
18
is adhered to plate
12
.
Underside channel
26
extends underneath barrier portion
58
along the entire plate outer periphery
56
. A sealing adhesive
60
occupies underside channel
26
and frame
18
is adhered to plate second surface
54
. Overflow channels
62
on either side of underside channel
26
contain overflow of sealing adhesive
60
, or, alternatively are also filled with sealing adhesive
60
to form a triple seal frame. Sealing adhesive
60
is one of several suitable adhesives known in the art, including, but not limited to, RTV (room temperature vulcanization) silicones with adequate adhesion and non-corrosive properties. Thus, a seal extends around containment area
20
(
FIG. 1
) and contains spilled liquid within barrier portion
58
.
A pair of cross supports
14
are attached to plate first surface
50
with a suitable adhesive well known in the art, including, but not limited to, double sided tape, RTV and tape combinations, and fast or triggered curing liquid adhesive. Each cross support
14
is fabricated from steel, is substantially cylindrical, and includes a first end
66
and a second end
68
.
A pair of steel side supports
16
extend substantially perpendicular to plate
12
. Side supports
16
are fabricated to support a preselected load on shelf
10
and are attached to inside walls (not shown) of a refrigerator (not shown). While the illustrated side supports
16
are upright, i.e., substantially vertically oriented, supports, in an alternative embodiment side supports
16
are substantially horizontally oriented cantilever beam elements attached to an inside wall of the refrigerator. In a further alternative embodiment, the side supports are freestanding inside the refrigerator. In yet another embodiment, the side supports are integrally molded into or attached to the walls of the refrigerator.
First end
66
and second end
68
of each cross support
14
are connected substantially perpendicularly to side supports
16
and support plate
12
as beam elements between side supports
16
. Cross supports
14
are positioned substantially level within the refrigerator so that food and beverage containers may be stored on plate
12
without tipping and spilling. In an alternative embodiment, one, three or more cross supports
14
support plate
12
.
FIG. 6
illustrates a lateral cross section of shelf
10
. Plate
12
is positioned between front and rear positioning ribs
42
. Cross supports
14
are connected to side supports
16
and extend substantially parallel to plate side edges
48
. Frame underside channel
26
extends substantially parallel to plate side edges
48
. Sealing adhesive
60
in underside channel
26
forms a continuous seal between barrier portion
58
and plate second surface
54
along plate outer periphery
56
.
A method for assembling shelf
10
includes filling frame underside channel
26
with a sealing adhesive
60
and adhering frame
18
to second surface
54
of plate
12
along outer periphery
56
. Adhesive may be applied to cross supports
14
and/or plate first surface
50
, and cross supports
14
adhered to plate first surface
50
. Each cross support
14
is then attached to side supports
16
at first end
66
and second end
68
(
FIG. 5
) so that plate
12
is substantially level.
Shelf
10
therefore provides an easily assembled spillproof shelf. Adhesively sealed frame
18
cooperates with glass plate
12
to contain a spill within containment area
20
. The seal of the frame is primarily dependent upon the flatness of plate
12
, rather than the external dimensions of plate
12
and shrinkage of material used to fabricate frame
18
. The flatness of plate
12
is easier to consistently control as compared to external dimensions of plate
12
. Finally, adhesively attached cross supports
14
transfer a shelf load from plate
12
to side supports
16
and therefore reduce the structural requirements of plate
12
. Hence, plate
12
need not be dimensioned to support the entire load itself, and savings may be realized in a thinner plate
12
. For all the above reasons, shelf
10
may be fabricated and assembled relatively quickly and inexpensively in comparison to known picture frame shelves.
A second exemplary embodiment of a refrigerator shelf
80
is shown in FIG.
7
and includes a plate
82
, cross supports
84
, side supports
86
, and a frame
88
. Frame
88
forms a sealed containment area
90
on plate
82
to contain spilled liquids.
FIG. 8
is a cross sectional view of shelf
80
including frame
88
that includes an L-shaped bracket portion
92
adhered to a second plate surface
94
. Plate
82
includes side edges
96
and L-shaped bracket portion
92
extends around plate edges
96
, and snap fits to side supports
86
. In an alternative embodiment, the bracket portion is connected to the side supports according to other known attachment methods. Bracket portion
92
retains plate
82
between a barrier portion
98
of frame
88
and side supports
86
and cross supports
84
. Barrier portion
98
is sealed to plate outer periphery
100
with a sealing adhesive
102
in underside channel
104
, and cross supports
84
are adhered to plate first surface
106
. Spillover adhesive is contained in overflow channels
108
on either side of underside channel
104
.
A method for assembling shelf
80
includes filling underside channel
104
of frame with sealing adhesive
102
and adhering frame
88
to plate second surface
94
along outer periphery
100
. Adhesive may be applied to cross supports
84
and/or plate first surface
106
, and cross supports
84
are then adhered to plate first surface
106
. Each cross support
84
is then attached to side supports
86
so that plate
82
is substantially level. Bracket portion
92
is then attached to side supports
86
.
A third exemplary embodiment of a refrigerator shelf
120
is shown in FIG.
9
and includes a frame
122
, a plate
124
, a shelf support
126
, and a plurality of strips of a solid double sided adhesive
128
for adhering frame
122
to plate
124
and plate
124
to shelf support
126
. Using a solid double sided adhesive
128
, such as double sided tape, shelf
120
can be assembled relatively quickly and easily in comparison to known shelf constructions.
In a particular embodiment, double sided adhesive
128
, is double sided tape fabricated from {fraction (1/16)} inch thick closed cell polyethylene foam with rubber adhesive on opposite sides of the foam. The closed cell polyethylene foam prevents fluid passage through the tape, and allows relative movement between plate
124
and frame
122
due to different coefficients of thermal expansion of the respective materials in the cold environment of a refrigerator. In alternative embodiments, double sided tape is fabricated from urethane, acrylic, or neoprene with an adhesive on opposite sides. In a further alternative embodiment, double sided adhesive is a thermoplastic film that becomes adhesive when heated.
Frame
122
is fabricated from inexpensive, integrally molded plastic. In alternative embodiments, frame
122
is fabricated from other materials, including, but not limited to, talc filled polypropylene, acrylonitrile-butadiene-styrene (ABS), or High Impact Polystyrene (HIPS). In a further alternative embodiment, frame
122
is assembled from a plurality of frame segments that form a spill containment area
130
around the edges of plate
124
. Frame
122
is secured to a second surface
132
of plate
124
along each side of a plate outer periphery
134
using strips of double sided adhesive
128
. Additionally, a sealing adhesive (not shown), such as RTV silicon, is used at each corner of plate
124
where double sided adhesive strips
128
intersect to ensure that plate outer periphery
134
is sealed to form a spill containment area
130
.
A first surface
136
of plate
124
is secured to shelf support
126
using a strip of double sided adhesive
128
along the lateral edges of plate
124
. Plate first surface
136
lateral edges
138
rest upon and are adhered to flat shoulders
140
of shelf side supports
142
. Side supports
142
are connected to one another by cross supports
144
and are configured at a proximal end
146
for attachment to a refrigerator wall (not shown) so that shelf
120
extends from the refrigerator wall as a cantilever beam. In an alternative embodiment, shelf side supports
142
are configured for lateral engagement with a refrigerator wall, such as, for example, by fitting side supports into grooves or indentations formed in a refrigerator liner.
FIG. 10
is a perspective view of frame
122
and
FIG. 11
is a cross sectional view of frame
122
from front to back. A curved lip
148
at the front of frame
122
prevents scrapes and snags with a front edge (not shown) of plate
124
(
FIG. 9
) during use of shelf
120
inside a refrigerator. An underside
150
of frame
122
is substantially flat to facilitate a strong bond with double sided adhesive
128
(FIG.
9
), and deformable sealing lips
152
form a seal with plate
124
(
FIG. 9
) to contain spills on shelf
120
(FIG.
9
). In an alternative embodiment, underside
150
of frame
122
includes channels or grooves (not shown), such as those described above with reference to
FIGS. 2 and 3
.
FIG. 12
is a perspective view of shelf support
126
including two side supports
142
and two cross supports
144
fabricated from steel or other materials known in the art for supporting a predetermined shelf load. Flat shoulders
140
extend along a top edge
154
of each side support
142
to facilitate bonding of each side support
142
to shelf plate
124
(FIG.
9
). Cross supports
144
extend below side plate shoulders
140
so that cross supports
144
are separated from shelf plate
124
.
A method of assembling shelf
120
includes placing double sided adhesive strips
128
around the edges of plate
124
and placing a small amount of liquid adhesive at each corner of plate
124
. Frame
122
and plate
124
are pressed together to form an adhesive bond, and frame sealing lips
152
create a sealed spill containment area
130
on plate second surface
132
. Double sided adhesive strips are then adhered to one of plate lateral edges
138
and side support shoulders
140
of shelf support
126
. Shelf support
126
and plate
124
with adhered frame
122
are pressed together to form an adhesive bond between plate
124
and shelf support
126
.
Thus, shelf
120
may be manufactured relatively simply and quickly relative to known refrigerator shelf constructions. As frame
122
is adhered to the flat surface of plate
124
, complicated insert molding and glass encapsulation processes are avoided.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
Claims
- 1. A shelf for a refrigerator, said shelf comprising:a substantially flat plate including a first surface, a second surface different from said first surface, and an outer periphery; at least one cross support extending below and joined to said plate first surface by a solid adhesive; a frame separate from said at least one cross support, said frame adhered to said outer periphery of said plate second surface and forming a seal; and at least one side support connected to said cross support and configured for attachment to a refrigerator, said frame adhered to one of said cross support and said side support.
- 2. A shelf in accordance with claim 1 wherein said frame is adhered to said second surface with a solid adhesive.
- 3. A shelf in accordance with claim 1 wherein said frame comprises a channel, said seal positioned at least partially within said channel.
- 4. A shelf in accordance with claim 3 wherein said frame further comprises a bracket connected to said cross support.
- 5. A shelf in accordance with claim 1 wherein said frame comprises molded plastic.
- 6. A shelf in accordance with claim 1 wherein said seal comprises an adhesive seal.
- 7. A shelf for a refrigerator, said shelf comprising:a plate including a first surface, a second surface different from said first surface, and an outer periphery; first and second side supports supporting said plate first surface; at least one cross support connecting said first and second side supports, wherein said at least one cross support is adhered to said first surface of said plate with an adhesive; and a frame separate from said at least one cross support and adhered to said second surface of said plate by an adhesive, said frame extending along said plate outer periphery to form a spill containment area.
- 8. A shelf in accordance with claim 7 wherein said frame comprises a sealing lip.
- 9. A shelf in accordance with claim 8 wherein said frame further includes a bracket, said bracket connected to said side support.
- 10. A shelf in accordance with claim 7 wherein said frame comprises at least one underside channel.
- 11. A shelf in accordance with claim 10 wherein said shelf further comprises a sealing adhesive contained in said underside channel.
- 12. A shelf in accordance with claim 7 wherein said frame and said side supports are adhered to said plate with a solid adhesive.
- 13. A shelf for a refrigerator, said shelf comprising:a substantially flat plate including first and second surfaces and an outer periphery; at least one steel cross support extending below said plate first surface; a frame adhered to said outer periphery of said plate second surface and forming a seal; at least one side support connected to said cross support and configured for attachment to a refrigerator, said frame adhered to one of said cross support and said side support; and an adhesive adhering said at least one cross support to said plate first surface.
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