US20150197881A1

US20150197881A1 - Continuous glass fiber reinforced polymer composites in appliances

Info

Publication number: US20150197881A1
Application number: US14/591,962
Authority: US
Inventors: Charles R. Cravens; Vincent D. Csapos
Original assignee: Whirlpool Corp
Current assignee: Whirlpool Corp
Priority date: 2014-01-16
Filing date: 2015-01-08
Publication date: 2015-07-16

Abstract

The use of a continuous glass reinforced fiber containing polymer composite capable of being thermally formed into various shapes and used in-home appliances such as a clothes washing or drying drum or basket or a dishwasher tub. The polymer composites can also be used to produce a garage wall panel or components for washer drums or baskets.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 61/928,099, filed on Jan. 16, 2014, the entire disclosure of which is hereby incorporated by reference.

TECHNICAL FIELD

The present disclosure pertains to molded thermoplastic composites using continuous glass fibers and their use in appliances.

BACKGROUND

Contemporary appliances and garage systems incorporate of a variety of metallic and plastic materials. These materials are used in components that require various shapes and degrees of strength. Current solutions have many disadvantages such as large tooling costs, variable material costs, heavy wall thickness, and high processing costs.

SUMMARY

One aspect of the present invention is a reinforced washer drum. The reinforced washer drum includes a washer drum having an exterior surface and an interior surface in which the exterior surface includes a composite of thermoplastic molded reinforcing layers, wherein each layer of material includes a plurality of interwoven or layered continuous glass fiber reinforced thermoplastics.
Another aspect of the present invention is a method of producing a non-metallic shaft receiving back panel for a washing machine drum. The method includes the steps of: interweaving a plurality of continuous glass fiber reinforced thermoplastics to form a sheet of glass reinforced thermoplastic substrate; and thermoforming the sheet of reinforced thermoplastic substrate to form the shaft receiving back panel for the washing machine drum. The back panel includes a bearing-receiving channel having a plurality of bearings securely retained within the bearing-receiving channel.
Another aspect of the present invention is reinforced dishwasher tub. The reinforced dishwasher tub includes a dishwasher tub having an exterior surface and an interior surface in which the exterior surface includes a composite of thermoplastic molded reinforced layers wherein each layer includes a plurality of interwoven continuous glass fiber reinforced thermoplastics.
Yet another aspect of the present invention is a method of producing a wall panel containing a plurality of slots that receive a plurality of tool engaging members. The method includes the steps of: coextruding a continuous glass reinforced fiber polymer material between two other polymer component containing layers to form a wall panel material comprising at least two layers of material; passing the wall panel material through a mold that produces a plurality of spaced apart slots in one planer surface of the wall panel material; and cutting the wall panel components to a predetermined length.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary fabric treatment appliance in the form of a washing machine according to one embodiment of the invention.

FIG. 2 is a schematic view of the fabric treatment appliance of FIG. 1.

3A is a perspective view of the rear of a washer drum for the fabric treatment appliance of FIG. 1.

FIG. 3B is a perspective view of the rear of an exemplary reinforced washer drum for the fabric treatment appliance of FIG. 1.

FIG. 4 is a schematic, cross-sectional view of a dishwasher according to a second embodiment of the invention.

FIG. 5 is a schematic view of a controller of the dishwasher of FIG. 4.

FIG. 6 is a perspective view of slotwall panel for a garage storage system according to a third embodiment of the invention.

In the drawings, like reference numerals refer to corresponding parts in the several views. To facilitate explanation, elements shown in the figures are not necessarily drawn to scale and may or may not be drawn in proportionate size to one another.

DETAILED DESCRIPTION OF THE DRAWINGS

While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific exemplary embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
Referring now to the figures, FIG. 1 is a schematic view of an exemplary fabric treatment appliance in the form of a washing machine 10 according to one embodiment of the invention. The fabric treatment appliance may be any machine that treats fabrics, and examples of the fabric treatment appliance may include, but are not limited to, a washing machine, including top-loading, front-loading, vertical axis, and horizontal axis washing machines; a dryer, such as a tumble dryer or a stationary dryer, including top-loading dryers and front-loading dryers; a combination washing machine and dryer; a tumbling or stationary refreshing/revitalizing machine; an extractor; a non-aqueous washing apparatus; and a revitalizing machine. For illustrative purposes, the invention will be described first with respect to a washing machine with the fabric being a clothes load. The invention will also be described with respect to a dishwasher and a garage storage system, with it being understood that the invention may be adapted for use with any type of fabric treatment appliance for treating fabric and to other appliances, such as refrigerators, and cooking appliances, including ovens and microwave ovens, in which improved reduced material costs without loss of strength is desired.
FIG. 2 provides a schematic view of the fabric treatment appliance of FIG. 1. The washing machine 10 of the illustrated embodiment may include a cabinet 12 that houses a stationary tub 14, which defines an interior chamber 15. A rotatable drum 16 mounted within the interior chamber 15 of the tub 14 may include a plurality of perforations 18, and liquid may flow between the tub 14 and the drum 16 through the perforations 18. The drum 16 may further include a plurality of baffles 20 disposed on an inner surface of the drum 16 to lift fabric items contained in the drum 16 while the drum 16 rotates. A motor 22 coupled to the drum 16 through a belt 24 and a drive shaft 25 may rotate the drum 16. Alternately, the motor 22 may be directly coupled with the drive shaft 25. Both the tub 14 and the drum 16 may be selectively closed by a door 26. A bellows 27 couples an open face of the tub 14 with the cabinet 12, and the door 26 seals against the bellows 27 when the door 26 closes the tub 14. The drum 16 may define a cleaning chamber 28 for receiving fabric items to be cleaned.
The tub 14 and/or the drum 16 may individually or collectively be considered a receptacle, and the receptacle may define a treatment chamber for receiving fabric items to be treated. While the illustrated washing machine 10 includes both the tub 14 and the drum 16, it is within the scope of the invention for the fabric treatment appliance to include only one receptacle, with the receptacle defining the treatment chamber for receiving the fabric items to be treated.
Washing machines are typically categorized as either a vertical axis washing machine or a horizontal axis washing machine. As used herein, the “vertical axis” washing machine refers to a washing machine having a rotatable drum that rotates about a generally vertical axis, relative to a surface that supports the washing machine. Typically the drum is perforate or imperforate, and holds fabric items and a fabric moving element, such as an agitator, impeller, and the like, that induces movement of the fabric items to impart mechanical energy to the fabric articles for cleaning action. However, the rotational axis need not be vertical. The drum can rotate about an axis inclined relative to the vertical axis. As used herein, the “horizontal axis” washing machine refers to a washing machine having a rotatable drum that rotates about a generally horizontal axis relative to a surface that supports the washing machine. The drum may be perforated or imperforate, and holds fabric items and typically washes the fabric items by the fabric items rubbing against one another and/or hitting the surface of the drum as the drum rotates. In horizontal axis washing machines, the clothes are lifted by the rotating drum and then fall in response to gravity to form a tumbling action that imparts the mechanical energy to the fabric articles. In some horizontal axis washing machines, the drum rotates about a horizontal axis generally parallel to a surface that supports the washing machine. However, the rotational axis need not be horizontal. The drum can rotate about an axis inclined relative to the horizontal axis, with fifteen degrees of inclination being one example of inclination.
Vertical axis and horizontal axis machines are best differentiated by the manner in which they impart mechanical energy to the fabric articles. In vertical axis machines, the fabric moving element moves within a drum to impart mechanical energy directly to the clothes or indirectly through wash liquid in the drum. The clothes mover is typically moved in a reciprocating rotational movement. In horizontal axis machines, mechanical energy is imparted to the clothes by the tumbling action formed by the repeated lifting and dropping of the clothes, which is typically implemented by the rotating drum. The illustrated exemplary washing machine of FIGS. 1 and 2 is a horizontal axis washing machine.
With continued reference to FIG. 2, the motor 22 may rotate the drum 16 at various speeds in opposite rotational directions. In particular, the motor 22 may rotate the drum 16 at tumbling speeds wherein the fabric items in the drum 16 rotate with the drum 16 from a lowest location of the drum 16 towards a highest location of the drum 16, but fall back to the lowest location of the drum 16 before reaching the highest location of the drum 16. The rotation of the fabric items with the drum 16 may be facilitated by the baffles 20. Typically, the radial force applied to the fabric items at the tumbling speeds may be less than about 1G. Alternatively, the motor 22 may rotate the drum 16 at spin speeds wherein the fabric items rotate with the drum 16 without falling. In the washing machine art, the spin speeds may also be referred to as satellizing speeds or sticking speeds. Typically, the force applied to the fabric items at the spin speeds may be greater than or about equal to 1 G. As used herein, “tumbling” of the drum 16 refers to rotating the drum at a tumble speed, “spinning” the drum 16 refers to rotating the drum 16 at a spin speed, and “rotating” of the drum 16 refers to rotating the drum 16 at any speed.
The washing machine 10 of FIG. 2 may further include a liquid supply and recirculation system. Liquid, such as water, may be supplied to the washing machine 10 from a water supply 29, such as a household water supply. A first supply conduit 30 may fluidly couple the water supply 29 to a detergent dispenser 32. An inlet valve 34 may control flow of the liquid from the water supply 29 and through the first supply conduit 30 to the detergent dispenser 32. The inlet valve 34 may be positioned in any suitable location between the water supply 29 and the detergent dispenser 32. A liquid conduit 36 may fluidly couple the detergent dispenser 32 with the tub 14. The liquid conduit 36 may couple with the tub 14 at any suitable location on the tub 14 and is shown as being coupled to a front wall of the tub 14 in FIG. 1 for exemplary purposes. The liquid that flows from the detergent dispenser 32 through the liquid conduit 36 to the tub 14 typically enters a space between the tub 14 and the drum 16 and may flow by gravity to a sump 38 formed in part by a lower portion 40 of the tub 14. The sump 38 may also be formed by a sump conduit 42 that may fluidly couple the lower portion 40 of the tub 14 to a pump 44. The pump 44 may direct fluid to a drain conduit 46, which may drain the liquid from the washing machine 10, or to a recirculation conduit 48, which may terminate at a recirculation inlet 50. The recirculation inlet 50 may direct the liquid from the recirculation conduit 48 into the drum 16. The recirculation inlet 50 may introduce the liquid into the drum 16 in any suitable manner, such as by spraying, dripping, or providing a steady flow of the liquid.
The exemplary washing machine 10 may further include a steam generation system. The steam generation system may include a steam generator 60 that may receive liquid from the water supply 29 through a second supply conduit 62 via a reservoir 64. The inlet valve 34 may control flow of the liquid from the water supply 29 and through the second supply conduit 62 and the reservoir 64 to the steam generator 60. The inlet valve 34 may be positioned in any suitable location between the water supply 29 and the steam generator 60. A steam conduit 66 may fluidly couple the steam generator 60 to a steam inlet 68, which may introduce steam into the tub 14. The steam inlet 68 may couple with the tub 14 at any suitable location on the tub 14 and is shown as being coupled to a rear wall of the tub 14 in FIG. 2 for exemplary purposes. The steam that enters the tub 14 through the steam inlet 68 may subsequently enter the drum 16 through the perforations 18. Alternatively, the steam inlet 68 may be configured to introduce the steam directly into the drum 16. The steam inlet 68 may introduce the steam into the tub 14 in any suitable manner.
An optional sump heater 52 may be located in the sump 38. The sump heater 52 may be any type of heater and is illustrated as a resistive heating element for exemplary purposes. The sump heater 52 may be used alone or in combination with the steam generator 60 to add heat to the chamber 15. Typically, the sump heater 52 adds heat to the chamber 15 by heating water in the sump 38.
The washing machine 10 may further include an exhaust conduit (not shown) that may direct steam that leaves the tub 14 externally of the washing machine 10. The exhaust conduit may be configured to exhaust the steam directly to the exterior of the washing machine 10. Alternatively, the exhaust conduit may be configured to direct the steam through a condenser prior to leaving the washing machine 10. Examples of exhaust systems are disclosed in the following patent applications, which are incorporated herein by reference in their entirety: U.S. patent application Ser. No. 11/464,506, titled “Fabric Treating Appliance Utilizing Steam,” U.S. patent application Ser. No. 11/464,501, titled “A Steam Fabric Treatment Appliance with Exhaust,” U.S. patent application Ser. No. 11/464,521, titled “Steam Fabric Treatment Appliance with Anti-Siphoning,”and U.S. patent application Ser. No. 11/464,520, titled “Determining Fabric Temperature in a Fabric Treating Appliance,” all filed Aug. 15, 2006.
The steam generator 60 may be any type of device that converts the liquid to steam. For example, the steam generator 60 may be a tank-type steam generator that stores a volume of liquid and heats the volume of liquid to convert the liquid to steam. Alternatively, the steam generator 60 may be an in-line steam generator that converts the liquid to steam as the liquid flows through the steam generator 60. As another alternative, the steam generator 60 may utilize the sump heater 52 or other heating device located in the sump 38 to heat liquid in the sump 38. The steam generator 60 may produce pressurized or non-pressurized steam.
Exemplary steam generators are disclosed in U.S. patent application Ser. No. 11/464,528, titled “Removal of Scale and Sludge in a Steam Generator of a Fabric Treatment Appliance,” U.S. patent application Ser. No. 11/450,836, titled “Prevention of Scale and Sludge in a Steam Generator of a Fabric Treatment Appliance,” and U.S. patent application Ser. No. 11/450,714, titled “Draining Liquid From a Steam Generator of a Fabric Treatment Appliance,” all filed Jun. 9, 2006, in addition to U.S. patent application Ser. No. 11/464,509, titled “Water Supply Control for a Steam Generator of a Fabric Treatment Appliance,” U.S. patent application Ser. No. 11/464,514, titled “Water Supply Control for a Steam Generator of a Fabric Treatment Appliance Using a Weight Sensor,” and U.S. patent application Ser. No. 11/464,513, titled “Water Supply Control for a Steam Generator of a Fabric Treatment Appliance Using a Temperature Sensor,” all filed Aug. 15, 2006, which are incorporated herein by reference in their entirety.
In addition to producing steam, the steam generator 60, whether an in-line steam generator, a tank-type steam generator, or any other type of steam generator, may heat water to a temperature below a steam transformation temperature, whereby the steam generator 60 produces hot water. The hot water may be delivered to the tub 14 and/or drum 16 from the steam generator 60. The hot water may be used alone or may be optionally mixed with cold or warm water in the tub 14 and/or drum 16. Using the steam generator 60 to produce hot water may be useful when the steam generator 60 couples only with a cold water source of the water supply 29. Optionally, the steam generator 60 may be employed to simultaneously supply steam and hot or warm water to the tub 14 and/or drum 16.
The liquid supply and recirculation system and the steam generation system may differ from the configuration shown in FIG. 2, such as by inclusion of other valves, conduits, wash aid dispensers, and the like, to control the flow of liquid and steam through the washing machine 10 and for the introduction of more than one type of detergent/wash aid. For example, a valve may be located in the liquid conduit 36, in the recirculation conduit 48, and in the steam conduit 66. Furthermore, an additional conduit may be included to couple the water supply 29 directly to the tub 14 or the drum 16 so that the liquid provided to the tub 14 or the drum 16 does not have to pass through the detergent dispenser 32. Alternatively, the liquid may be provided to the tub 14 or the drum 16 through the steam generator 60 rather than through the detergent dispenser 32 or the additional conduit. As another example, the liquid conduit 36 may be configured to supply liquid directly into the drum 16, and the recirculation conduit 48 may be coupled to the liquid conduit 36 so that the recirculated liquid enters the tub 14 or the drum 16 at the same location where the liquid from the detergent dispenser 32 enters the tub 14 or the drum 16.
Other alternatives for the liquid supply and recirculation system are disclosed in U.S. patent application Ser. No. 11/450,636, titled “Method of Operating a Washing Machine Using Steam;” U.S. patent application Ser. No. 11/450,529, titled “Steam Washing Machine Operation Method Having Dual Speed Spin Pre-Wash;” and U.S. patent application Ser. No. 11/450,620, titled “Steam Washing Machine Operation Method Having Dry Spin Pre-Wash,” all filed Jun. 9, 2006, which are incorporated herein by reference in their entirety.
Turning now to FIG. 3A, the rear drum 16 of a conventional washing machine is shown. The drum 16 includes a shaft receiving back panel 19, which is operably connected to a cross piece 17. The cross piece 17 provides stability and strength during rotation of the drum 16. The cross piece 17 is also operably connected to the drive shaft 25 to rotate the drum 16 when the motor 22 is actuated. In conventional washing machines, the drum 16 is typically formed from stainless steel, and the cross piece 17 is typically formed from aluminum.
FIG. 3B depicts an exemplary rear of a drum 16 according to the present invention. In FIG. 3B, the shaft receiving back panel 19 is a compression-molded panel made from a composite material containing a continuous fiber-reinforced thermoplastic molding compound, including, but not limited to polyethylene (PE), polypropylene (PP), and polyvinylchloride (PVC). The continuous glass fiber is the structural material. The composite may be compression molded, thermoformed, or injection molded, among others. In a preferred embodiment, the continuous glass fiber-reinforced thermoplastic contains about 20 to 50% of at least one thermoplastic polyolefin, about 50 to 80 wt % of at least one glass-like reinforcing fiber, and about 1 to 30% of at least one mineral filler.
Preferably, the composite material includes about 70% oriented continuous glass fiber PP. A-olefin polymers like ethylene and propylene can also be used as the thermoplastic polyolefin. Examples include, but are not limited to, PE with high, medium, or low density, PP, and copolymers of these olefins. The polymers can be either straight-chain or branched. Mixtures of the aforementioned polymers may also be used. Preferred thermoplastic polyolefins include high-density polyethylene and polypropylene. Other polymers that may be used include, but are not limited to, PVC, styrenics, polyesters, copolyesters, nylons, and acetals.
A variety of materials can be used as reinforcement fibers. Preferred reinforcement fibers include those with high melting or softening points, including but not limited to, glass fibers, carbon fibers, metal fibers, and polyamide fibers. Glass fibers are the preferred reinforcement fibers.
Mineral fillers may be added to the thermoplastic polymer. Examples of mineral fillers include, but are not limited to, calcite, glass spheres, gypsum, barium sulfate, nanoclay, and silica in their respective forms.
The molding compound may also include: a) oxidation stabilizers, like sterically hindered phenols, thioethers, phosphites or phosphonites in an amount from about 0.1 to 1 wt %, b) sulfur- and phosphorus-containing costabilizers from about 0.1 to 1 wt %, c) metal deactivators up to about 1.5 wt %, d) processing auxiliaries like strongly polar to nonpolar polypropylene or polyethylene waxes up to about 1 wt % and e) ethylene-propylene or ethylene-propylene terpolymer rubber from about 0 to 10 wt %, in which all the wt % data mentioned above under a) to e) refer to the total weight of the molding compound produced from the mixture of individual components.
In one embodiment, the molding compound is in the form of a thermoplastic bound continuous glass reinforced tape in which reinforced fibers are combined with thermoplastic polymers to produce the thermoplastic composite tape. Such tape can be used in the production of a variety of appliance components, including, but not limited to the drum rear 19 and the drum exterior 21 in FIG. 3B. In another embodiment, continuous glass fiber reinforced thermoplastics are interwoven to form a sheet of continuous glass reinforced thermoplastics. The sheet of reinforced thermoplastic substrates can then be thermoformed to form the shaft receiving back panel 19 of a washer drum 16 or alternatively, other parts or the entire drum 16.
Referring again to FIG. 3B, the drum 16 has an interior surface (not shown) and an exterior surface 21. In one embodiment, the exterior surface includes a composite of continuous glass reinforced thermoplastic molded reinforcing layers. Each layer may include a plurality of interwoven continuous glass fiber reinforced thermoplastics. The shaft receiving back panel 19 may be formed such that the shaft receiving back panel includes a metal insert into which the shaft is pressed.
In another embodiment, the drum 16 may also be formed from the composite material. In such an embodiment, the drum may be produced by extruding a polymer pipe that is reinforced with the continuous glass fiber reinforced thermoplastic tape described above. It is also possible to create the composite by layering the glass fiber reinforced thermoplastic tape.
Turning now to FIG. 4, an automated dishwasher 110 according to a first embodiment is illustrated. The dishwasher 110 shares many features of a conventional automated dishwasher, which will not be described in detail herein except as necessary for a complete understanding of the invention. A chassis 112 may define an interior of the dishwasher 110 and may include a frame, with or without panels mounted to the frame. An open-faced tub 114 may be provided within the chassis 112 and may at least partially define a treating chamber 116, having an open face, for washing dishes. A door assembly 118 may be movably mounted to the dishwasher 110 for movement between opened and closed positions to selectively open and close the open face of the tub 114. Thus, the door assembly provides accessibility to the treating chamber 116 for the loading and unloading of dishes or other washable items.
It should be appreciated that the door assembly 118 may be secured to the lower front edge of the chassis 112 or to the lower front edge of the tub 114 via a hinge assembly (not shown) configured to pivot the door assembly 118. When the door assembly 118 is closed, user access to the treating chamber 116 may be prevented, whereas user access to the treating chamber 116 may be permitted when the door assembly 118 is open.
Dish holders, illustrated in the form of upper and lower dish racks 126, 128, are located within the treating chamber 116 and receive dishes for washing. The upper and lower racks 126, 128 are typically mounted for slidable movement in and out of the treating chamber 116 for ease of loading and unloading. Other dish holders may be provided, such as a silverware basket. As used in this description, the term “dish(es)” is intended to be generic to any item, single or plural, that may be treated in the dishwasher 110, including, without limitation, dishes, plates, pots, bowls, pans, glassware, and silverware.
A spray system is provided for spraying liquid in the treating chamber 116 and is provided in the form of a first lower spray assembly 134, a second lower spray assembly 136, a rotating mid-level spray arm assembly 138, and/or an upper spray arm assembly 140. Upper sprayer 140, mid-level rotatable sprayer 138 and lower rotatable sprayer 134 are located, respectively, above the upper rack 126, beneath the upper rack 126, and beneath the lower rack 124 and are illustrated as rotating spray arms. The second lower spray assembly 136 is illustrated as being located adjacent the lower dish rack 128 toward the rear of the treating chamber 116. The second lower spray assembly 136 is illustrated as including a vertically oriented distribution header or spray manifold 144. Such a spray manifold is set forth in detail in U.S. Pat. No. 7,594,513, issued Sep. 29, 2009, and titled “Multiple Wash Zone Dishwasher,” which is incorporated herein by reference in its entirety.
A recirculation system is provided for recirculating liquid from the treating chamber 116 to the spray system. The recirculation system may include a sump 130 and a pump assembly 131. The sump 130 collects the liquid sprayed in the treating chamber 116 and may be formed by a sloped or recess portion of a bottom wall of the tub 114. The pump assembly 131 may include both a drain pump 132 and a recirculation pump 133. The drain pump 132 may draw liquid from the sump 130 and pump the liquid out of the dishwasher 110 to a household drain line (not shown). The recirculation pump 133 may draw liquid from the sump 130 and the liquid may be simultaneously or selectively pumped through a supply tube 142 to each of the assemblies 134, 136, 138, 140 for selective spraying. While not shown, a liquid supply system may include a water supply conduit coupled with a household water supply for supplying water to the treating chamber 116.
A heating system including a heater 146 may be located within the sump 130 for heating the liquid contained in the sump 130.
A controller 150 may also be included in the dishwasher 110, which may be operably coupled with various components of the dishwasher 110 to implement a cycle of operation. The controller 150 may be located within the door 118 as illustrated, or it may alternatively be located somewhere within the chassis 112. The controller 150 may also be operably coupled with a control panel or user interface 156 for receiving user-selected inputs and communicating information to the user. The user interface 156 may include operational controls such as dials, lights, switches, and displays enabling a user to input commands, such as a cycle of operation, to the controller 150 and receive information.
Referring now to FIG. 5, the dishwasher tub 114 has an interior surface 170 and an exterior surface 172. In one embodiment, the exterior surface 172 includes a continuous glass reinforced composite of thermoplastic molded reinforcing layers. Each layer may include a plurality of interwoven glass fiber reinforced thermoplastic substrates. In another embodiment, the thermoplastic composite tape described above can be interwoven to produce a plurality of thermoplastic molded layers thermoformed together into a sheet. The sheet may be formed using conventional forming methods to produce a reinforced dishwasher tub 114.
Referring now to FIG. 6, a slotwall storage system incorporating a slotwall panel 210 having a plurality of generally “T” shaped slots 211 forming a plurality of generally “T” shaped slats 212 is provided with a hanger bracket for mounting a device on the slotwall panel. The slotwall panel 210 can have a front face 213 and a rear face 214, and upper and lower edges 216, 218, respectively. This slotwall storage system may be of the type sold by Whirlpool Corporation under the Gladiator® trademark and disclosed in U.S. Pat. No. 6,811,043. However, the invention is not limited to any type of slotwall.
The front face 213 is generally planar except where interrupted by the slots 220. The rear face 214 has an undulating surface that can follow the contour of the slots 220. The rear face 214 could have a planar surface with the recesses being filled by solid material. However, to reduce the weight of the overall slotwall and the cost of manufacturing, it is preferred to optimize the amount of material when making the slotwall panel 210.
The upper end 216 includes a longitudinal rib 224, which corresponds to a longitudinal recess 226 formed in the lower end 218. Slotwall panels 210 can be attached to a framed wall or similar building structure element, with horizontally orientated slotwall panels 210 stacked vertically such that the longitudinal rib 224 of one slotwall panel is received in the longitudinal recess 226 of the adjacent slotwall panel.
It is worth noting that while for simplicity sake the invention is described in the context of the extruded slotwall panel 210, the invention is not limited to any particular slotwall element, e.g. a panel, sheet, slotwall panel, etc. Nor is the invention limited to any particular configuration for a particular slotwall element.
Typically, the slotwall panel is formed of extruded polyvinyl chloride material. The slotwall storage system according to the present invention can be used in a residential garage to provide storage for outdoor tools and equipment. A variety of storage options can be provided. The slotwall storage system can also be used in a workroom or workshop, or in commercial and industrial locations. The slotwall storage system can be used in conjunction with a Modular Workbench System as disclosed in U.S. Pat. No. 6,926,376, which is hereby incorporated by reference.
In FIG. 6, a slotwall panel 210 is shown. It should be understood that the slotwall panel 210 shown in FIG. 6 is only a portion of such panels that can extend longitudinally for any desired length. Typically, slotwall panels can be extruded in 8 feet long lengths to facilitate handling and installation. However, it should be understood that panels longer or shorter than 8 feet can be fabricated and used. Further, a single panel can be used or an entire wall can be covered with panels. One embodiment of a hanger bracket 220 is shown mounted on the panel 210 and is shown with one example of a hook device 240 attached to the hanger bracket 220. Other well-known and available hooks and hanging devices can be attached to one or more hanger brackets 220 as will be understood by one skilled in the art. While a few examples of types of hook and other storage devices that can be attached to one or more hanger brackets are disclosed in this application, one skilled in the art will understand that there are many available hooks and storage devices available on the market that could be used with the brackets and slotwall panels according to this invention.
In one embodiment, the slotwall panel 210 is produced by coextruding the glass fiber reinforced thermoplastic polymer composite between two other polymer components on opposing sides of the panel 210. This could be done using a pultrusion process. This would significantly reduce the weight of the panel 210 while maintaining the requisite strength of the panel 210. After coextruding the panel 210, it can be passed through a mold that forms the generally “T” shaped slots 211 and generally “T” shaped slats 212. The panel 210 can then be cut to the desired length. This method produces a panel in which the glass fibers may not be visible on either the front surface 213 or the back surface 214.
While the disclosure has been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.
There are a number of advantages of the present disclosure arising from the various features of the apparatus, system, and method described herein. It will be noted that alternative embodiments of the apparatus, system, and method of the present disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of the apparatus, system, and method that incorporate one or more of the features of the present invention and fall within the spirit and scope of the present disclosure as defined by the appended claims.

Claims

1. A reinforced washer drum comprising:

a washer drum having an exterior surface and an interior surface in which the exterior surface comprises a composite of thermoplastic molded reinforcing layers, wherein each layer material comprises a plurality of interwoven or layered continuous glass fiber reinforced thermoplastics.

2. The reinforced washer drum of claim 1 wherein the plurality of interwoven or layered continuous glass fiber reinforced thermoplastics comprises about 30 to 90 wt % of at least one thermoplastic polyolefin.

3. The reinforced washer drum of claim 2 wherein the plurality of interwoven or layered continuous glass fiber reinforced thermoplastics further comprises about 9 to 69 wt % of at least one continuous glass-like reinforcement fiber.

4. The reinforced washer drum of claim 3 wherein the plurality of interwoven glass fiber reinforced thermoplastic substrates further comprises about 1 to 30 wt % of at least one mineral filler.

5. A method of producing a non-metallic shaft receiving back panel for a washing machine drum comprising the steps of:

interweaving a plurality of continuous glass fiber reinforced thermoplastics to form a sheet of glass reinforced thermoplastic substrate; and

molding the sheet of reinforced thermoplastic substrate to form the shaft receiving back panel for the washing machine drum such that the back panel includes a bearing-receiving channel having a plurality of bearings securely retained within the bearing-receiving channel.

6. The method of claim 5, wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics comprises about 30 to 90 wt % of at least one thermoplastic polyolefin.

7. The method of claim 6, wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics further comprises about 9 to 69 wt % of at least one glass-like reinforcement fiber.

8. The method of claim 7, wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics further comprises about 1 to 30 wt % of at least one mineral filler.

9. A reinforced dishwasher tub comprising:

a dishwasher tub having an exterior surface and an interior dish treating area facing surface in which the exterior surface comprises a composite of thermoplastic molded reinforced layers wherein each layer comprises a plurality of interwoven interwoven continuous glass fiber reinforced thermoplastics.

10. The reinforced dishwasher drum of claim 9 wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics comprises about 30 to 90 wt % of at least one thermoplastic polyolefin.

11. The reinforced dishwasher drum of claim 10 wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics further comprises about 9 to 69 wt % of at least one glass-like reinforcement fiber.

12. The reinforced dishwasher drum of claim 11 wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics further comprises about 1 to 30 wt % of at least one mineral filler.

13. A method of producing a wall panel containing a plurality of slots that receive a plurality of tool engaging members comprising the steps of:

coextruding a continuous glass reinforced fiber polymer material between two other polymer component containing layers to form a wall panel material comprising three layers of material;

passing the wall panel material through a mold that produces a plurality of spaced apart slots in one planer surface of the wall panel material; and

cutting the wall panel components to a predetermined length.

14. The method of claim 13, wherein the continuous glass reinforced fiber polymer material comprises about 30 to 90 wt % of at least one thermoplastic polyolefin.

15. The method of claim 14, wherein the continuous glass reinforced fiber polymer material further comprises about 9 to 69 wt % of at least one glass-like reinforcement fiber.

16. The method of claim 15, wherein the continuous glass reinforced fiber polymer material further comprises about 1 to 30 wt % of at least one mineral filler.