U.S. patent application number 11/756857 was filed with the patent office on 2007-11-22 for methods of making refrigerator storage assemblies.
Invention is credited to Daniel Lyvers.
Application Number | 20070266543 11/756857 |
Document ID | / |
Family ID | 34987995 |
Filed Date | 2007-11-22 |
United States Patent
Application |
20070266543 |
Kind Code |
A1 |
Lyvers; Daniel |
November 22, 2007 |
Methods Of Making Refrigerator Storage Assemblies
Abstract
A method of making a removable refrigerator storage assembly is
provided. The method includes feeding a polymeric or metal material
into an extruder and directing the material through a die having an
aperture with a first and second leg formed therein, thereby
forming an intermediate shelf extrusion. The intermediate shelf
extrusion is cut into a predetermined length to form the shelf
extrusion having a bottom wall integrally formed with a side wall.
The shelf extrusion is painted or plated to a specific finish. The
method also encompasses attaching to both ends of the shelf
extrusion end walls having brackets formed thereon for removably
engaging supports formed on the door of a refrigerator.
Inventors: |
Lyvers; Daniel; (Cordova,
TN) |
Correspondence
Address: |
WOMBLE CARLYLE SANDRIDGE & RICE, PLLC
ATTN: PATENT DOCKETING 32ND FLOOR
P.O. BOX 7037
ATLANTA
GA
30357-0037
US
|
Family ID: |
34987995 |
Appl. No.: |
11/756857 |
Filed: |
June 1, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10806979 |
Mar 23, 2004 |
7228612 |
|
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11756857 |
Jun 1, 2007 |
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Current U.S.
Class: |
29/527.1 ;
264/148 |
Current CPC
Class: |
B29C 48/21 20190201;
B29L 2031/7622 20130101; B29C 48/12 20190201; B29C 48/001 20190201;
B29C 48/09 20190201; B29K 2027/06 20130101; B29K 2055/02 20130101;
B29K 2069/00 20130101; B29K 2025/00 20130101; F25D 25/005 20130101;
B29C 2793/009 20130101; B29K 2077/00 20130101; B29C 48/151
20190201; B29C 48/0022 20190201 |
Class at
Publication: |
029/527.1 ;
264/148 |
International
Class: |
B22D 11/126 20060101
B22D011/126 |
Claims
1. A method for forming a refrigerator storage assembly comprising:
feeding a material to an extruder; extruding the material through a
die of the extruder to form a first intermediate extrusion; cutting
the first intermediate extrusion to a first predetermined length to
form a first shelf extrusion; injection molding a first pair of end
walls, wherein each of the first pair of end walls includes a
bracket formed on a distal face thereof for engaging a support in a
refrigerator; attaching the first pair of end walls to the ends of
the first shelf extrusion; forming a second intermediate extrusion
by extruding the material through the die; cutting the second
intermediate extrusion to a second predetermined length to form a
second shelf extrusion, wherein the first predetermined length is
unequal to the second predetermined length; and, attaching a second
pair of end walls to the ends of the second shelf extrusion,
wherein each of the second pair of end walls includes a bracket for
engaging a support in a refrigerator.
2. The method of claim 1, wherein the material is a polymeric
composition selected from polyvinyl chlorides, polycarbonates,
polyesters, chlorinated polyethylenes, acrylics, polystyrenes,
acrylonitrite-butadiene-styrene copolymers, nylons and combinations
thereof.
3. The method of claim 2, wherein the material is a metal selected
from aluminum, copper and steel
4. The method of claim 1, further comprising aligning a wall
section in a channel formed in the first shelf extrusion and
engaging the ends of the wall section with the first pair of end
walls.
5. The method of claim 4, further comprising disposing a cap over
the wall section and engaging the ends of the cap with the first
pair of end walls.
6. The method of claim 1, wherein attaching the first pair of end
walls to the ends of the first shelf extrusion includes engaging
the first shelf extrusion and one of the first pair end walls with
a fastener.
7. The method of claim 6, wherein the fastener is a screw
threadably engaged with the first shelf extrusion and one of the
first pair of end walls.
8. The method of claim 1, wherein one of the first pair of end
walls is substantially identical to one of the second pair of end
walls.
9. The method of claim 1, further comprising coating the first
intermediate extrusion.
10. The method of claim 9, wherein the step of coating comprises a
step selected from painting and plating.
11. The method of claim 9, further comprising coating the second
intermediate extrusion.
12. The method of claim 11, wherein the step of coating comprises a
step selected from painting and plating.
13. A method of making removable refrigerator storage assemblies
comprising: feeding a material to an extruder, wherein the material
is selected from a metal or a polymeric composition; extruding the
material through a die of the extruder to form a first intermediate
extrusion, wherein the die includes an aperture defining a first
leg and a second leg; cutting the first intermediate extrusion to a
predetermined length to form a first shelf extrusion having a first
bottom wall integrally formed with a first side wall; injection
molding a first and a second pair of end walls, wherein each of the
first and second pairs of end walls includes a distal face having a
bracket formed therein for engaging a support disposed in a
refrigerator; attaching the first pair of end walls to the ends of
the first shelf extrusion, wherein each of the first pair of end
walls engages the first bottom wall and the first side wall of the
first shelf extrusion; forming a second intermediate extrusion by
extruding the material through the die; cutting the second
intermediate extrusion to a second predetermined length to form a
second shelf extrusion, wherein the first predetermined length is
unequal to the second predetermined length, and wherein the second
shelf extrusion has a second bottom wall integrally formed with a
second side wall; and attaching the second pair of end walls to the
ends of the second shelf extrusion, wherein each of the second pair
of end walls engages the second bottom wall and the second side
wall of the second shelf extrusion.
14. The method of claim 13, wherein the polymeric composition is
selected from polyvinyl chlorides, polycarbonates, polyesters,
chlorinated polyethylenes, acrylics, polystyrenes,
acrylonitrite-butadiene-styrene copolymers, nylons and combinations
thereof.
15. The method of claim 13, wherein the metal is selected from
aluminum, copper and steel.
16. The method of claim 13, further comprising aligning a wall
section in a channel formed in the first shelf extrusion and
engaging the ends of the wall section with the first pair of end
walls.
17. The method of claim 16, further comprising disposing a cap over
the wall section and engaging the ends of the cap with the first
pair of end walls.
18. The method of claim 13, wherein attaching the first pair of end
walls to the ends of the first shelf extrusion includes engaging
the first shelf extrusion and one of the first pair end walls with
a fastener.
19. The method of claim 18, wherein the fastener is a screw
threadably engaged with the first shelf extrusion and one of the
first pair of end walls.
20. The method of claim 13, wherein one of the first pair of end
walls is substantially identical to one of the second pair of end
walls.
21. The method of claim 13, further comprising coating the first
shelf extrusion.
22. The method of claim 21, wherein coating comprises a step
selected from painting and plating.
23. The method of claim 21, further comprising coating the second
shelf extrusion.
24. The method of claim 23, wherein coating comprises a step
selected from painting and plating.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of co-pending U.S. patent
application Ser. No. 10/806,979, filed Mar. 23, 2004, which is
hereby incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention generally relates to methods of
forming storage assemblies and, more particularly, to methods of
making adjustable storage assemblies for refrigerators.
BACKGROUND
[0003] Over the years, household refrigerators have evolved to
accommodate ever increasing functional demands by users. In
addition to preserving food, refrigerators must be functionally
versatile, easy to maintain and reasonably priced. Consumers desire
refrigerators with adjustable storage compartments that can
accommodate a variety of food and that are easily accessible to
facilitate cleaning and maintenance. As a result, various
manufacturers have offered refrigerators with removable shelves and
storage assemblies.
[0004] Presently, refrigerators usually include various sized
storage assemblies that are formed of injection molded polymeric
components. In order to produce these various-sized storage
assemblies, however, a manufacturer must construct a separate mold
for each size of component. These molds can be expensive, add to
the cost of the final product and lengthen the time needed to bring
a new product to market.
SUMMARY
[0005] The present invention is directed to a method of making
storage assemblies for refrigerators. The method includes feeding a
material to an extruder and extruding the material through a die to
form an intermediate extrusion. The intermediate extrusion is cut
to a predetermined length to form a shelf extrusion and coated to
form a specific finish. An end wall having a bracket for engaging a
support in a refrigerator is attached to each end of the shelf
extrusion to complete the refrigerator storage assembly. By this
method, storage assemblies of varying lengths can be produced from
the same equipment, thereby eliminating the need for a separate
mold for each sized storage assembly.
[0006] In a first embodiment, the method of making a refrigerator
storage assembly includes feeding to an extruder a material
selected from a metal or a polymeric composition, and extruding the
material through a die of the extruder to form a first intermediate
extrusion. The die includes an aperture defining a first leg and a
second leg. The method also includes cutting the first intermediate
extrusion to a predetermined length to form a first shelf extrusion
having a bottom wall integrally formed with a side wall. The first
shelf extrusion can be coated to form a specific finish. Once
complete, the first shelf extrusion can be attached to a first pair
of end walls of the first shelf extrusion. Each of the first pair
of end walls engages both the bottom wall and the side wall of the
first shelf extrusion. The end walls each include a distal face
having a bracket for engaging a support disposed in a refrigerator.
The method also can include aligning a wall section in a channel
formed in the side wall of the shelf extrusion, and aligning a cap
over the wall section.
[0007] In a second embodiment, the method includes feeding a
material to an extruder, extruding the material through a die of
the extruder to form a first intermediate extrusion, cutting the
first intermediate extrusion to a first predetermined length to
form a first shelf extrusion and coating the first extrusion. This
method also includes injection molding a first pair of end walls,
each having a bracket formed on a distal face for engaging a
support in a refrigerator, and then attaching the first pair of end
walls to the ends of the first shelf extrusion. A second
intermediate extrusion is formed by extruding the material through
the die, cutting the second intermediate extrusion to a second
different predetermined length coating the second extrusion to form
a second shelf extrusion. A second pair of end walls, also
including a bracket for engaging a support in a refrigerator, are
attached to the ends of the second shelf extrusion. The end walls
can be attached to the shelf extrusions using fasteners or
adhesives, such as screws, pins or glue. The materials from which
the extrusions are formed are selected from metals or polymeric
materials.
[0008] In a third embodiment, the method includes feeding to an
extruder a material selected from a metal or a polymeric
composition, and extruding the material through a die of the
extruder to form a first intermediate extrusion. In this
embodiment, the die includes an aperture defining a first leg and a
second leg. The method also includes cutting the first intermediate
extrusion to a predetermined length to form a first shelf extrusion
having a first bottom wall integrally formed with a first side
wall, coating the first shelf extrusion to a specific finish and
injection molding a first and a second pair of end walls. The first
pair of end walls is attached to the ends of the first shelf
extrusion. Each of the first and second pairs of end walls includes
a distal face having a bracket for engaging a support, such as a
channel guide, disposed in the refrigerator. Each of the first pair
of end walls engages both the first bottom wall and the first side
wall of the first shelf extrusion. This method also includes
forming a second intermediate extrusion by extruding the material
through the die, cutting the second intermediate extrusion to a
second predetermined length to form a second shelf extrusion and
coating the second shelf extrusion to a specific finish. The first
predetermined length is unequal to the second predetermined length,
and the second shelf extrusion has a second bottom wall integrally
formed with a second side wall. The second pair of end walls are
attached to the ends of the second shelf extrusion, and each of the
second pair of end walls also engages the second bottom wall and
the second side wall of the second shelf extrusion.
[0009] These and other aspects of the present invention are set
forth in greater detail below and in the drawings which are briefly
described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a diagram of a method of forming a refrigerator
storage assembly according to the present invention.
[0011] FIG. 2 is a diagram of a second method of forming a
refrigerator storage assembly according to the present
invention.
[0012] FIG. 3 is a diagram of a third method of forming a
refrigerator storage assembly according to the present
invention.
[0013] FIG. 4 is a perspective view of a refrigerator including
storage assemblies formed by one of the methods of FIGS. 1-3.
[0014] FIG. 5 is an exploded perspective view of a storage
assembly, formed by a method of the present invention, disposed in
the refrigerator shown in FIG. 4.
[0015] FIG. 6 is an exploded perspective view of another storage
assembly disposed in the refrigerator shown in FIG. 4.
[0016] FIG. 7 is a cross-sectional view of the shelf extrusion of
FIG. 6.
DETAILED DESCRIPTION
[0017] The present invention is directed to methods of forming
storage assemblies for refrigerators, such as shelves, drawers or
bins. The methods generally include extruding a material through a
die to form an intermediate extrusion that is cut to a
predetermined length to form a shelf extrusion and coating the
extrusion to a specific finish. The shelf extrusion forms the
portion of the storage assembly upon which refrigerator contents
are placed. Using such shelf extrusions in refrigerator storage
assemblies allows for storage assemblies of various lengths to be
produced using the same equipment, and avoids the necessity of
obtaining a separate tooling mold for each sized assembly, as would
be required if the molded components were used instead. The storage
assemblies formed by the methods of the present invention, however,
can be substantially indistinguishable from assemblies that are
constructed from molded parts. The term "shelf extrusion" refers to
an extruded structure with a generally uniform cross-section along
its entire length and which includes at least a generally planar
component that, when disposed within a refrigerator, supports items
resting thereon. Although the cross-section of the shelf extrusion
of the present invention is generally uniform along its entire
length, the term can encompass an extruded structure having one or
more features, such as notches, holes, slots and tabs that are
formed by cutting away or removing a portion of material from the
extruded structure. Also, while the component which supports items
is generally planar, the term "shelf extrusion" can encompass
components having one or more ridges, channels or similar features
that constitute one or more support surfaces aligned within a plane
to support the items.
[0018] Referring to the Figures, wherein like numbers refer to like
parts throughout the several views, FIGS. 1-3 show various methods
of forming refrigerator storage assemblies encompassed by the
present invention. FIG. 1 shows a process for forming a
refrigerator storage assembly that begins with feeding material to
an extruder in step 100. The material preferably is from a
polymeric or metal material suitable for forming durable
components. The polymeric materials can be selected from polyvinyl
chlorides, polycarbonates, polyesters, chlorinated polyethylenes,
acrylics, polystyrenes, acrylonitrite-butadiene-styrene copolymers,
nylons and any combinations or variations thereof. Additionally,
metals, such as aluminum, copper or steel can be used in the
method. The polymeric or metal material can be fed to the extruder
in solid form, typically pellets, chips or billets.
[0019] The polymeric extruder includes a feed hopper connected to a
barrel in which one or two conveyor screws are disposed. The
screw(s) are rotated to carry the material toward a die. The
material can be in a softened state by heat from the shear action
of the screw(s) and/or by heat supplied to the barrel. The screw
then forces or extrudes the material through the die in step 110.
Extruding metal material includes placing a billet into equipment
that heats the billet to a prescribed temperature. The heated metal
then is pushed by a ram through the die. The opening in or formed
by the die can have a variety of cross-sections depending upon the
desired structure of the shelf extrusion to be formed. For example,
the opening can have a cross-section shown in FIG. 7. In this case,
the opening has a first leg corresponding to the bottom wall 22 of
the shelf extrusion 20, and a second leg corresponding to the side
wall 24.
[0020] The material solidifies and cools as it exits the die to
form an intermediate extrusion in step 120. The intermediate
extrusion has the desired cross-section, such as that shown in FIG.
7, or any other suitable cross-section, but also has an
indeterminate length. The intermediate extrusion then is cut to a
predetermined length in step 130. In one embodiment, simply cutting
the intermediate extrusion to the predetermined length forms a
shelf extrusion as step 140. In alternative embodiments, however,
the step of forming the shelf extrusion 140 also can include
bending, stamping, embossing, drilling, cutting, notching and other
process steps, either singly or in combination, to form apertures,
notches, tabs, grooves, channels, and other substructures within
the extrusion. The shelf extrusion can be run through a coating
process to form a specific finish. The coating of step 145 can
occur before the intermediate extrusion is cut to a predetermined
length in step 130, or after the intermediate extrusion is cut but
before the shelf extrusion is finally formed, or after the shelf
extrusion is formed in step 140. The coating step 145 can include
painting the extrusion with a powder coating, or plating a material
thereon to form a specific finish.
[0021] The method also includes in step 150 attaching one or more
end walls to the end(s) of the shelf extrusion. This step can
include interlocking tabs, ribs, notches or other structures formed
on the end walls and/or shelf extrusion, frictionally engaging the
end walls to the shelf extrusion, or connecting them together with
one or more fasteners, such as clips, screws, pins, adhesives or
the like.
[0022] As shown in FIGS. 2 and 3, the methods of the present
invention encompasses forming two or more shelf extrusions of
varying length with the same extruder and die. As with the process
set forth in FIG. 1, the method set forth in FIG. 2 includes in
step 100, feeding material to an extruder, extruding the material
in step 110 through the die of the extruder, forming in step 120 an
intermediate extrusion. This method, however, includes cutting the
intermediate extrusion to a first predetermined length in step 230,
and cutting an intermediate extrusion to a second predetermined
length in step 330. The first predetermined length is not equal to
the second predetermined length.
[0023] The method shown in FIG. 2 also includes the step 235 in
which the first extrusion is coated to form a specified finish.
Likewise, the second extrusion is coated to form a specified finish
in step 335. As with the method shown in FIG. 1, the steps 235 and
335 can occur before the intermediate extrusions are cut to
predetermined lengths, after cutting but before formation of the
shelf extrusion, or after the shelf extrusions are formed in steps
240 and 340. Additionally, steps 235 and 335 need not occur at the
same point within the two different sequences of forming the first
and second shelf extrusions. The first shelf extrusion is formed in
step 240 from the portion of the intermediate extrusion cut to a
first predetermined length, and the second shelf extrusion is
formed in step 340 from the portion of the intermediate extrusion
cut to the second predetermined length. As with the method of FIG.
1, steps 240 and 340 can include a variety of intermediate
steps.
[0024] Other steps include attaching in step 250 a first pair of
end walls to the ends of the first shelf extrusion, and attaching
in step 255 a second pair of end walls to the second shelf
extrusion. The steps of attaching first and second pairs of end
walls to the ends of the first and second shelf extrusions can
include a variety of different processes as set forth above. These
intermediate steps of forming and attachment can, but need not, be
the same for the first and second shelf extrusions.
[0025] As shown in FIG. 3, the method can include in step 260
injection molding the first and second pairs of end walls. One or
both of each pair of end walls can be identical or substantially
similar to one or both of the other pairs of end walls, depending
upon the desired form of the storage assemblies. The step 260 of
injection molding the first and second pairs of end walls includes
providing a mold of at least one of the end walls and injecting
into the mold a material, which is typically a polymeric material,
such as polyvinyl chlorides, polycarbonates, polyesters,
chlorinated polyethylenes, acrylics, polystyrenes,
acrylonitrite-butadiene-styrene copolymers, nylons and any
combinations or variations thereof. The end walls can be formed
from one or more components. In one embodiment, two molds are
provided corresponding to the two end walls that are to be attached
to either end of the shelf extrusion. Each mold includes the
structure of a bracket formed therein, so that the bracket is
integrally formed on the face of the end wall distal to the shelf
extrusion. The end wall can be formed from a single mold and
storage assemblies of varying length can include identical or
substantially similar end walls.
[0026] Each of the methods of forming refrigerator storage
assemblies described herein can include aligning a translucent,
metal or polymeric wall section in a channel formed in the side
wall of the shelf extrusion, in which the end walls of the storage
assembly engage the sides of the wall section. Additionally, the
methods including this step can include an additional step of
disposing a cap over the wall section. The cap can be engaged by
the end walls of the assembly. Each of the methods can include the
step of embossing the shelf extrusion to provide on the storage
assembly one or more designs and/or indicia, such as the stylistic
designs and company logos.
[0027] FIG. 4 shows a refrigerator 10 including two sets of
differently sized storage assemblies 18a and 18b that can be formed
by the methods of the present invention. The refrigerator 10
includes a cabinet 11 formed of a plurality of insulated walls 36.
A divider wall 36a is disposed in the interior of the cabinet 11,
and cooperates with the other insulated walls 36 to form two
separate compartments; one of which is a freezer compartment 38a
and the other is a refrigeration compartment 38b in the embodiment
shown in FIG. 4.
[0028] The refrigerator 10 also includes a first door 12a and a
second door 12b, each of which are pivotally mounted to the cabinet
11 and cooperate with the plurality of insulated walls 36 to
enclose the compartments 38a and 38b, respectively. The first door
dike 14a is formed on the first door 12a. The first door dike 14a
can be attached to or integrally formed with the first door 12a and
includes one or more supports 16. As shown in FIG. 4, a plurality
of supports 16 are vertically spaced along the side of the first
door dike 14a and are aligned to cooperate with other supports 16
spaced along the opposite side of the first door dike 14a in order
to support the shelf extrusions 18a. The supports 16 are shown as
projections or ribs extending from the sides of the first door dike
14a.
[0029] A plurality of storage assemblies 18a are mounted on the
first door 12a and supported by the first door dike 14a. The
supports 16 engage brackets 27, as shown in FIGS. 4-5, formed on
the side walls of each storage assembly 18a, which are described in
greater detail below.
[0030] The second door 12b has mounted thereon a second door dike
14b, which includes a plurality of spaced supports 16 that support
a plurality of second storage assemblies 18b. As shown in FIG. 4,
the length of each of the first storage assemblies 18a is shorter
than the length of each of the second storage assemblies 18b.
Although, the first and second storage assemblies 18a and 18b can
be otherwise identical, simply the difference in lengths of each
would necessitate producing different tooling molds to form the
shelf sections of the assemblies, if these shelf sections were
fabricated by molding as is presently known. If the shelf
extrusions 20a and 20b are formed by the methods of the present
invention, however, there is no need for separate molds for each
sized storage assembly, thus reducing cost and improving
fabrication efficiency.
[0031] FIG. 5 shows one of the first storage assemblies 18a. The
shelf extrusion 20a includes a first bottom wall 22a integrally
formed with a first side wall 24a. The first side wall 24a includes
a first channel 21a formed therein and extending along its length
for receiving a first wall section 32a. The first wall section 32a
can be metal, polymeric or glass. A first cap 34a fits over the
edge of first wall section 32a. The first wall section 32a can be
translucent so as to allow visual inspection of the contents of the
first storage assembly 18a. Ridges 35 are formed in the top surface
of the first bottom wall 22a, and the trough 39 formed at the
juncture of the first side wall 24a and the first bottom wall 22a.
Pair of end walls 26a and 26b are attached to opposite ends of the
first shelf extrusion 20a. Each end wall 26a and 26b includes a
proximal face 28 and a distal face 30. The proximal faces 28 are
aligned toward the first shelf extrusion 20a, while the distal
faces 30 are aligned away from the first shelf extrusion 20a. In
the assembly shown in FIG. 5, the proximal faces 28 of the end
walls 26a and 28b each include a protrusion 25 that engages the end
of the shelf extrusion 20a. The protrusion 25 includes a first leg
31 and a second leg 33. The first leg 31 mates with the first
bottom wall 22a of the shelf extrusion 20a. The second leg 33 of
the protrusion 25 mates with the first side wall 24a. The first leg
31 of the brace 25 include a series of indentations therein that
mate with the top surface of the first bottom wall 20a in an
overlapping relationship. The protrusion 25 also functions as a
self-locating feature for the shelf extrusion.
[0032] The distal faces 30 of the end walls 26a and 26b include
brackets 27 that engage and mate with the supports 16 on the first
rack 14a. The brackets 27 are shaped to define bracket channels 37
and protrusions 38 that allow for the first storage assembly 18a to
be removed from one set of supports 16 and reinserted on another
set of supports 16. Thus, the first storage assembly 18a is
removably disposed on the first door 12a. The end walls 26a and 26b
are attached to the first shelf extrusion 20a by fasteners 19 that
are threaded through holes in the end walls 26a and 26b and through
fastener channels 23 formed in the first shelf extrusion 20a. The
fasteners 19 shown in the example in FIG. 5 are screws. Attaching
the end walls to the shelf extrusion, however, can include
fastening with other fasteners, such as, for example, pins, bolts,
adhesives, and the like.
[0033] FIG. 6 shows one of the second storage assemblies 18b. The
components of the second storage assembly 18b generally are the
same as the components of the first storage assembly 18a, although
the lengths of the second shelf extrusion 20b, the second wall
section 32b and the second cap 34b are longer than the lengths of
the first shelf extrusion 20a, the first wall section 32a and the
first cap 34a of the first storage assembly 18a. The end walls 26a
and 26b of the second storage assembly 18b are identical to the end
walls of the first storage assembly 18a. The second bottom wall
22b, the second side wall 24b and the second channel 21b have the
same cross-section along their entire lengths as the first bottom
wall 22a, the first side wall 24a, and the first channel 21a of the
first shelf extrusion 20a. Accordingly, FIGS. 5 and 6 illustrate
how various sized storage assemblies having otherwise identical
features can be fabricated according to the methods of the present
invention.
[0034] FIG. 7 shows the cross-section of second shelf extrusion
20b, which is identical to the cross-sections of the first shelf
extrusion 20a and to the opening in the extrusion die used in the
methods of forming the storage assemblies. The cross-section shown
in FIG. 7 is uniform along the entire length of the second shelf
extrusion 20b. The side wall 24b is integrally formed with the
bottom wall 22b and connected at the lower end thereof to one
lengthwise side of the bottom wall 22b. The channel 21b is formed
at the top of the side wall 24b by an L-shaped flange 43. A wall
section can be aligned in the channel 21b. The trough 39 is formed
at the juncture of the bottom wall 22b and the side wall 24b. The
bottom wall 22b includes a plurality of ridges 35 formed on the top
face thereof. A pair of fastener channels 23 are spaced along the
bottom of bottom wall 22b so as to receive fasteners 19, such as
pins in one embodiment, which connect the shelf extrusion 20b to
the end walls 26a and 26b. As described above, however, other types
of fastening can be used.
[0035] The storage assemblies 20a and 20b are provided and
described for purposes of illustrating at least two of the examples
of refrigerator storage assemblies that can be formed by the
methods of the present invention. The methods are not limited by
these examples, however, and can be used to form storage assemblies
with shelf extrusions of various designs. For example, the storage
assemblies formed by the methods of the present invention can
include only a bottom wall and no side walls, or can include two
opposed side walls connected by a bottom wall to form a trough or
similar chamber in which items can be stored on or in the storage
assembly within a refrigerator. These and other designs are
contemplated and encompassed by the methods set forth herein.
[0036] While the present invention has been described in detail
herein in accord with certain embodiments, modifications can be
made by those skilled in the art that fall within the scope of the
invention.
* * * * *