U.S. patent application number 13/071995 was filed with the patent office on 2011-09-29 for washing machine shipping system and method.
This patent application is currently assigned to Owens Corning Intellectual Property, LLC. Invention is credited to Weigang Qi, Anthony L. Rockwell.
Application Number | 20110233086 13/071995 |
Document ID | / |
Family ID | 44511785 |
Filed Date | 2011-09-29 |
United States Patent
Application |
20110233086 |
Kind Code |
A1 |
Rockwell; Anthony L. ; et
al. |
September 29, 2011 |
WASHING MACHINE SHIPPING SYSTEM AND METHOD
Abstract
Washing machine shipping systems that inhibit movement of one or
more moveable component with respect to one or more stationary
component of a washing machine during shipping and handling of the
washing machine. The shipping systems engage a moveable component,
such as a motor or a basket, to substantially prevent side-to-side
and/or vertical movement of the moveable component with respect to
a stationary component, such as a cabinet or frame, during
shipment. In an exemplary embodiment, the shipping system is
removed from the washing machine for installation of the washing
machine at the consumer's residence. In some exemplary embodiments,
the washing machine system engages an outer surface of an external
rotor of a motor to substantially prevent side-to-side and/or
vertical movement of the motor with respect to the washing machine
cabinet.
Inventors: |
Rockwell; Anthony L.;
(Pickerington, OH) ; Qi; Weigang; (Westerville,
OH) |
Assignee: |
Owens Corning Intellectual
Property, LLC
Toledo
OH
|
Family ID: |
44511785 |
Appl. No.: |
13/071995 |
Filed: |
March 25, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61318072 |
Mar 26, 2010 |
|
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Current U.S.
Class: |
206/320 |
Current CPC
Class: |
D06F 39/001
20130101 |
Class at
Publication: |
206/320 |
International
Class: |
B65D 85/00 20060101
B65D085/00 |
Claims
1. A washing machine shipping system for shipping a washing machine
having a cabinet and a motor assembly having an external rotor
positioned within the cabinet, the shipping system comprising: an
engagement device configured to mate with an outer surface of the
external rotor of the motor assembly in a removable manner; and an
interface configured for retention at least partially within the
cabinet of the washing machine during shipment; wherein the
interface is configured to couple the engagement device and
external rotor to the cabinet during shipment such that
side-to-side movement of the motor assembly with respect to the
cabinet is substantially prevented during shipping and handling of
the washing machine; wherein the interface is removable from the
cabinet after the shipping and handling of the washing machine.
2. The shipping system of claim 1 wherein the engagement device is
removable from the outer surface of the external rotor by pulling
the engagement device linearly downward away from the rotor.
3. The shipping system of claim 1 wherein the engagement device
includes a plurality of slots that are sized and spaced to fit over
a plurality of fins of the outer surface of the external rotor to
mate the engagement device to the outer surface of the external
rotor in a removable manner.
4. The shipping system of claim 1 wherein the engagement device is
configured for use as a tool for preventing rotation of the rotor
during servicing of the washing machine after the shipping and
handling of the washing machine and removal of the interface.
5. The shipping system of claim 1 wherein the interface comprises
wood frame members.
6. The shipping system of claim 1 wherein the washing machine
includes a tub associated with the motor assembly and wherein a
damping element is stretched over and attached to a tub.
7. The shipping system of claim 1 wherein the washing machine
includes a basket positioned within the cabinet and wherein a
removable plug extends from the basket to the cabinet, the
removable plug configured to prevent movement of the basket
relative to the cabinet.
8. A method for shipping and handling a washing machine having a
cabinet and a motor assembly with an external rotor positioned
within the cabinet, the method comprising: removably mating an
engagement device with an outer surface of the external rotor;
coupling the engagement device and external rotor to the cabinet
during shipment such that side-to-side movement of the motor
assembly with respect to the cabinet is substantially prevented
during shipping and handling of the washing machine; decoupling the
engagement device and the external rotor from the cabinet after
said shipping and handling of the washing machine.
9. The method of claim 8 further comprising removing the engagement
device from the external rotor after said shipping and handling of
the washing machine by pulling the engagement device linearly
downward from the external rotor.
10. The method of claim 8 wherein the engagement device includes a
plurality of slots that are sized and spaced to fit over a
plurality of fins of the outer surface of the external rotor to
mate the engagement device to the outer surface of the external
rotor in a removable manner.
11. The method of claim 8 further comprising stretching a damping
element over a tub of the washing machine.
12. The method of claim 8 further comprising positioning a plug in
an opening of the cabinet and the opening of a basket of the
washing machine to prevent movement of the basket relative to the
cabinet.
13. A washing machine shipping system for shipping a washing
machine having a cabinet and a motor assembly that includes an
external rotor positioned within the cabinet, the shipping system
comprising: a removable framework retained at least partially
within the cabinet of the washing machine, the removable framework
including a plurality of support members configured to support at
least one cross-member; wherein the cross member is configured to
engage an outer surface of the external rotor in a manner that
substantially reduces side-to-side movement of the motor assembly
within the cabinet during shipping and handling of the washing
machine.
14. The shipping system of claim 13 wherein a plurality of frame
members are attached to the cross member, the plurality of frame
members being positioned to correspond to an outer diameter of the
external rotor of the motor assembly.
15. A washing machine shipping system for shipping a washing
machine having a cabinet and a motor assembly that includes an
external rotor positioned within the cabinet, the shipping system
comprising: a plurality of intersecting support members forming a
framework; a plurality of framing blocks attached to the
intersecting support members, the framing blocks configured to
define a gap; and a resilient member positioned within the gap;
wherein the framework is retained within the cabinet of the washing
machine and configured to support the external rotor of the motor
assembly; wherein the resilient member is configured to
substantially reduce side-to-side movement of the motor assembly
within the cabinet of the washing machine during shipping and
handling of the washing machine.
16. The shipping system of claim 15 wherein the resilient member is
at least one hose supplied with the washing machine for connecting
the washing machine to a water supply.
Description
RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
provisional application Ser. No. 61/318,072, filed on Mar. 26, 2010
which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Washing machines are commonly manufactured by production
facilities and transported to retail outlets via trucks or by rail.
Subsequent to a sale to a consumer, a washing machine is
transported from the retail outlet to the consumer's residence,
often by a truck. Washing machines can include moveable components
such as tubs, baskets, and motors that move with respect to
stationary components, such as cabinets and support frames during
operation of the washing machine.
SUMMARY
[0003] The present application discloses exemplary embodiments of
washing machine shipping systems that inhibit movement of one or
more moveable component with respect to one or more stationary
component of a washing machine during shipping and handling of the
washing machine. The shipping systems engage a moveable component,
such as a motor or a basket, to substantially prevent side-to-side
and/or vertical movement of the moveable component with respect to
a stationary component such as a cabinet or frame. In an exemplary
embodiment, the shipping system is removed from the washing machine
for installation of the washing machine at the consumer's
residence. In some exemplary embodiments, the washing machine
system engages an outer surface of an external rotor of a motor to
substantially prevent side-to-side and/or vertical movement of the
motor with respect to the washing machine cabinet.
[0004] Multiple exemplary embodiments of shipping systems are
disclosed by the present application. Shipping systems in
accordance with the present invention may include any combination
or subcombination of the features or concepts disclosed by the
present application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] In the accompanying drawings which are incorporated in and
constitute a part of the specification, embodiments of the
invention are illustrated, which, together with a general
description of the invention given above, and the detailed
description given below, serve to example the principles of this
invention.
[0006] FIG. 1 is an exploded side view, in cross-section, of a
washing machine and a shipping system including an optional
engagement device and an interface.
[0007] FIG. 2 is a side view, in cross-section, of the washing
machine and shipping system of FIG. 1 illustrated in an assembled
state;
[0008] FIG. 3 is a perspective view of a rotor of the washing
machine shown in FIG. 1 illustrating rotor fins.
[0009] FIG. 4 is a perspective view of the engagement device that
is included in the shipping system shown in FIG. 1;
[0010] FIG. 5 is a perspective view of the engagement device that
is included in the shipping system shown in FIG. 4 illustrated in
an engaged position with the rotor of FIG. 3;
[0011] FIG. 6 is a perspective view of the interface that is
included in the shipping system shown in FIG. 1;
[0012] FIG. 7 is a side view, in cross-section, of a second
embodiment of a washing machine and a shipping system;
[0013] FIG. 8 is a side view, in cross-section, of a third
embodiment of a washing machine and a shipping system;
[0014] FIG. 9 is a side view, partially in cross-section, of a
second embodiment of an interface illustrating a leveling foot
boot;
[0015] FIG. 10 is a top plan view of another embodiment of an
interface illustrating intersecting cross members;
[0016] FIG. 11 is a side elevational view of the interface of FIG.
10;
[0017] FIG. 12 is a top plan view of another embodiment of an
interface illustrating diagonal frame members;
[0018] FIG. 13 is a side elevational view of the interface of FIG.
12;
[0019] FIG. 14 is a top plan view of another embodiment of an
interface illustrating cross members forming a support frame;
[0020] FIG. 15 is a side elevational view of the interface of FIG.
14;
[0021] FIG. 16 is a top plan view of another embodiment of an
interface illustrating a cross member supporting a support
frame;
[0022] FIG. 17 is a side elevational view of the interface of FIG.
16.
[0023] FIG. 18 is a top plan view of another embodiment of an
interface illustrating intersecting support members and a resilient
member;
[0024] FIG. 19 is a side elevational view of an interface of FIG.
18; and
[0025] FIG. 20 is a top plan view of the interface of FIG. 18 shown
in an installed position within a washing machine.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present invention will now be described with occasional
reference to the specific embodiments of the invention. This
invention may, however, be embodied in different forms and should
not be construed as limited to the embodiments set forth herein.
Rather, these embodiments are provided so that this disclosure will
be thorough and complete, and will fully convey the scope of the
invention to those skilled in the art.
[0027] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only and is not intended to be
limiting of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise.
[0028] Unless otherwise indicated, all numbers expressing
quantities of dimensions such as length, width, height, and so
forth as used in the specification and claims are to be understood
as being modified in all instances by the term "about."
Accordingly, unless otherwise indicated, the numerical properties
set forth in the specification and claims are approximations that
may vary depending on the desired properties sought to be obtained
in embodiments of the present invention. Notwithstanding that the
numerical ranges and parameters setting forth the broad scope of
the invention are approximations, the numerical values set forth in
the specific examples are reported as precisely as possible. Any
numerical values, however, inherently contain certain errors
necessarily resulting from error found in their respective
measurements.
[0029] The description and figures disclose shipping systems and
methods for washing machines. Generally, the shipping system is
configured to restrain movable internal components of the washing
machine and inhibit movement of the movable internal components
during shipping and handling of the washing machine. In one
exemplary embodiment, the moveable internal components may be
restrained such that some movement of the internal components
relative to a cabinet of the washing machine is allowed during
shipping and handling. However, the restraint limits movement of
the internal components with respect to the cabinet to prevent
damage to the internal components. In another exemplary embodiment,
the moveable internal components are secured to prevent the
moveable internal components from moving with respect to the
cabinet during shipping. Once the washing machine arrives at a
final destination, the shipping system is removed from the washing
machine. Some portions of the shipping system may be recycled and
other portions of the shipping system may be retained for use in
subsequent maintenance and repair efforts.
[0030] The term "washing machine" as used herein, is defined to
mean a machine designed to wash laundry items, such as clothing,
towels and sheets, that uses water as the primary cleaning
solution.
[0031] Referring now to FIG. 1, a washing machine shipping system,
illustrated generally at 10, is shown with an associated washing
machine 12. The washing machine shipping system 10 includes an
engagement device 14 and an interface 16. In the FIG. 1 example,
the engagement device 14 and the interface 16 are illustrated as
separate components. However, the engagement device 14 may be
incorporated into the interface 16. The washing machine shipping
system 10 will be discussed in more detail below.
[0032] Referring again to FIG. 1, the illustrated washing machine
12 is a "top loading" machine. The term "top loading", as used
herein, is defined to mean that an internal basket configured to
retain laundry items during the washing cycle is oriented in an
upright position and that the laundry items enter the basket from a
top opening in the washing machine 10. However, the concepts of the
washing machine shipping system can be applied to any type of
washing machine. The illustrated washing machine 12 includes a
cabinet 20, a tub 22, a motor assembly 24 and a basket 26.
[0033] As shown in FIG. 1, the cabinet 20 is configured to provide
an enclosure for the internal components of the washing machine 12.
The illustrated cabinet 20 includes a top surface 30, side surfaces
32 and bottom frame assemblies 34. However, the cabinet 20 can take
a variety of different forms. The cabinet 20 can be made from sheet
metal and covered with a finish such as an enamel based finish. The
cabinet can be made from a wide variety of different materials
and/or combinations of materials. Examples of suitable materials
for the cabinet include, but are not limited to plastic, fiberglass
reinforced plastic, any type of sheet metal, etc. The cabinet 20
may have any finish. The cabinet 20 can be made from stainless
steel sheet metal, and can have other desired finishes, such as for
example a clear lacquer finish. The top surface 30 of the cabinet
includes an opening 36. The opening will be discussed in more
detail below. While the illustrated embodiment shows the cabinet as
having a generally rectangular cross-sectional shape, it should be
appreciated that the cabinet can have other cross-sectional
shapes.
[0034] Referring again to the example of FIG. 1, the illustrated
tub 22 is suspended within the cabinet 20 and is configured to
retain water used for washing the laundry items. The tub 22 can
take a wide variety of different forms and can be made from a wide
variety of different materials. The tub 22 may be generally
cylindrical with an open top 40 as shown, but may take a variety of
different shapes. The tub may be made from plastic/polymeric
materials, or metals, such as steel stainless steel, and aluminum.
Preferably, the tub is made from a material that is resistant to
corrosion when exposed to water or at least the inside surface of
the tub is coated with a material that is resistant to corrosion
when exposed to water.
[0035] As shown in the example of FIG. 1, the tub 22 is connected
to ends of a plurality of suspension devices 38. The other ends of
the suspension devices 38 being coupled to the cabinet 20. In the
illustrated embodiment, the suspension devices 38 are coupled to
the top surface 30 of the cabinet 20. The suspension devices 38 are
configured to allow some vertical movement of the tub 22 with
respect to the cabinet 20 while limiting rotational movement of the
tub 22 with respect to the cabinet 20. However, the tub 22 may be
coupled to the cabinet 20 in a wide variety of different ways. In
the illustrated embodiment, the suspension devices 38 are a
combination of rods, springs and attachment mechanisms. In other
embodiments, the suspension devices 38 can be any desired
structure, mechanism or device sufficient to suspend the tub 22
within the cabinet 20. The suspension devices 38 may allow vertical
movement of the tub 22 with respect to the cabinet 20 or otherwise
couple the tub 22 to the cabinet 20. The tub 22 has a top opening
40.
[0036] Referring again to the example illustrated by FIG. 1, the
motor assembly 24 is positioned below the tub 22. The illustrated
motor assembly 24 is configured to rotate the basket 26 via shaft
42. However, the motor assembly 24 may take a wide variety of
different forms and may be coupled to the basket 26 in many
different ways. The illustrated motor assembly 24 includes an
external rotor 44 connected to the shaft 42 with a stator of the
motor being secured to the tub 22 by a connection 45.
Alternatively, the motor assembly 24 may include an external stator
that is secured to the tub 22 with the internal rotor connected to
shaft 42. Any rotor/stator configuration and coupling to the basket
26 may be employed. The illustrated rotor 44 is configured to
enclose the motor assembly 24 and includes a hub 46 and a plurality
of optional spaced apart fins 48 radiating from the hub 46, as
shown in FIG. 3. In the illustrated embodiment, the hub 46 has a
circular cross-sectional shape. Alternatively, the hub 46 can have
other cross-sectional shapes, including the non-limiting example of
a square cross-sectional shape. The hub 46 has a hub diameter HD.
In the illustrated embodiment, the hub diameter HD is approximately
1.25 inches. In other embodiments, the hub diameter HD can be more
than or less than approximately 1.25 inches.
[0037] Referring again to FIG. 3, the illustrated hub 46 includes
optional gaps 50 between the spaced apart fins 48. The gaps 50 will
be discussed in more detail below. While the embodiment illustrated
in FIG. 3 shows a quantity of ten spaced apart fins 48, it should
be appreciated that other embodiments of the rotor 44 can include
more or less than ten spaced apart fins 48.
[0038] Referring again to the example illustrated by FIG. 1, the
basket 26 is positioned within the tub 22 and configured to retain
the laundry items during the washing cycle. The basket 26 can take
a wide variety of different foams and can be made from a wide
variety of different materials. The basket 26 may be generally
cylindrical with an open top as shown, but may take a variety of
different shapes. The tub may be made from plastic/polymeric
materials, or metals, such as steel, stainless steel, and aluminum.
Preferably, the tub is made from a material that is resistant to
corrosion when exposed to water or the tub is coated with a
material that is resistant to corrosion when exposed to water.
[0039] As shown in the example illustrated by FIG. 1 and discussed
above, the illustrated washing machine shipping system 10 includes
the engagement device 14 and the interface 16. In this embodiment,
the engagement device 14 is configured to engage the rotor 44 (or
other moveable component) and the interface. For example, the
engagement device may be configured to mate with an external
surface of the rotor 44 and be configured to mate with a portion of
the interface 16. The interface 16 couples the engagement device 14
and the rotor 44 to another component of the washing machine 12,
such as the cabinet 20 and/or the bottom frame assembly 34. In some
exemplary embodiments, the interface is at least partially retained
within the cabinet of the washing machine for this coupling. The
coupling of the rotor 44 (or other moveable component) to the
cabinet 20, bottom frame assembly 34 or other fixed component of
the washing machine 12 prevents or substantially reduces
side-to-side movement and/or vertical movement of the suspended tub
22 and motor assembly 24 during shipping and handling of the
washing machine 12. The interface and/or the engagement device are
removable from the cabinet 20 after the shipping and handling for
installation of the washing machine at the consumer's
residence.
[0040] FIG. 4 illustrates an exemplary embodiment of an engagement
device 14. In the illustrated embodiment, the engagement device 14
is configured to engage the tub 46 and fins 48 of the rotor 44.
However, the engagement device 14 can be configured to engage the
rotor 44 (or other moveable component of the washing machine 12) in
a wide variety of different ways. In an exemplary embodiment, the
engagement device 14 is configured to engage the outer surface of
the rotor 44 by pushing the engagement device linearly onto the
rotor in the vertical direction and to disengage the outer surface
of the rotor 44 by pulling the engagement device linearly downward
away from the rotor 44.
[0041] The illustrated engagement device 14 includes an opening 52
or recess having a generally circular cross-sectional shape. The
cross-sectional shape of the opening 52 may correspond to the
cross-sectional shape of the hub 46 of the rotor 44. In other
embodiments, the cross-sectional shape of the opening can be other
desired shapes sufficient to fit with the cross-sectional shape of
the hub 46 of the rotor 44. The opening 52 has an opening diameter
ID. The opening diameter ID is configured to generally correspond
to the hub diameter HD of the hub 46 such that a "close fit" is
achieved. The term "close fit", as used herein, is defined to mean
that the difference between the hub diameter HD and the opening
diameter ID is within a range of from about 0.001 inches to about
0.025 inches.
[0042] Referring again to FIG. 4, the illustrated engagement device
14 has a length LED. In the illustrated embodiment, the length LED
of the engagement device 14 is in a range of from about 1.50 inches
to about 3.0 inches. In other embodiments, the length LED of the
engagement device 14 can be less than about 1.5 inches or more than
about 3.0 inches.
[0043] As shown in FIG. 4, the illustrated engagement device 14 has
an upper end 54 and a lower end 56. A plurality of slots 56 extend
from the upper end 54 toward the lower end 56 in a direction
generally parallel to the length LED of the engagement device 14.
The plurality of slots 56 defines a plurality of teeth 58. The
plurality of slots 56 and the plurality of teeth 58 are configured
to engage the rotor 44 such that the spaced apart fins 48 fit
within the slots 56 and the teeth 58 fit in the gaps 50 between the
spaced apart fins 48. In the illustrated embodiment, the engagement
device 14 has the same quantity of slots 56 as the quantity of
spaced apart fins 48 of the rotor 44. However, in other
embodiments, the engagement device 14 can have a quantity of slots
56 that is more or less than the quantity of spaced apart fins
48.
[0044] FIG. 5, illustrates the exemplary engagement device 14 is
shown in an engaged position with the rotor 44. As discussed above,
in this position the spaced apart fins 48 fit within the slots 56
and the teeth 58 fit in the gaps 50 between the spaced apart fins
48. While the embodiment shown in FIG. 5 illustrates the upper end
54 of the engagement device 14 seating against a lower surface 60
of the rotor 44, it should be appreciated that in other
embodiments, the engagement device 14 can be configured to prevent
or substantially reduce side-to-side movement and/or vertical
movement of the suspended tub 22 and motor assembly 24 without the
upper end 54 of the engagement device 14 seating against a lower
surface 60 of the rotor 44.
[0045] Referring to the example illustrated by FIG. 4, the
illustrated engagement device 14 includes optional opposing
apertures 57. The opposing apertures 57 are configured for
insertion of a tool, such as the non-limiting example of a
screwdriver, for use in preventing rotation of the engagement
device 14. In this manner, the engagement device 14 can engage the
rotor 44 and prevent rotation of the rotor 44 during servicing of
the washing machine after the shipping and handling of the washing
machine and removal of the interface. Accordingly, the engagement
device 14 can function as a maintenance and service tool for the
washing machine 12.
[0046] Referring again to the example illustrated by FIG. 1, the
washing machine shipping system 10 includes the interface 16. The
interface 16 can take a wide variety of different forms. The
interface 16 can be any structure configured to couple a moveable
component, such as the motor assembly 24, the tub 22, or basket to
a stationary component such as the cabinet 20 and the bottom frame
assembly 34, either directly or through the engagement device 14.
The interface 16 may be a framework formed from frame members, such
as wooden frame members and/or may comprise one or more members
that are molded or otherwise formed to match the shape(s) of one or
more components of the washing machine. The interface 16 can be
made from a wide variety of different materials or combinations of
materials. In the illustrated exemplary embodiment, the interface
16 is configured to be attached to a component of the washing
machine 12 and to support the engagement device 14 during shipping
and handling of the washing machine 12.
[0047] In the example illustrated by FIG. 6, the interface 16 is a
framework that includes a cross member 70 attached to opposing
support members 72. The cross member 70 includes a recess 74. The
recess 74 is configured to contain the engagement device 14. In the
illustrated embodiment, the recess 74 has a circular
cross-sectional shape generally corresponding to the circular
cross-sectional shape of the engagement device 14. It should be
appreciated that in other embodiments, the recess 74 can have other
cross-sectional shapes corresponding to the cross-sectional shape
of the engagement device 14. Referring to FIGS. 1 and 6, the recess
74 is positioned on the cross-member such that the engagement
device 14 engages the rotor 44, as described above, when the
engagement device 14 is contained in the recess 74.
[0048] In the illustrated embodiment, the cross member 70 and the
support members 72 are made of wood. Manufacturing the cross member
70 and the support members 72 from wood advantageously adds to the
recyclability of the shipping system 10. However, in other
embodiments, the cross member 70 and the support members 72 can be
made from other desired materials.
[0049] Referring again to FIG. 6, the illustrated support members
72 include cutouts 76. The cutouts 76 are configured as a clearance
space for leveling legs 78 positioned on the bottom frame 34 of the
cabinet 20, as shown in FIG. 1. The positions of the leveling legs
78 in the cutouts 76 couples or sets the relative position of the
interface 16 with respect to the cabinet 20 and bottom frame 34.
The cutouts 76 can have any desired cross-sectional shape.
[0050] As shown in FIG. 6, the framework 16 can include optional
pads 80 attached to the ends of the support members 72. The
optional pads 80 are configured to cushion the washing machine 12
against impact during shipping and handling. In the illustrated
embodiment, the optional pads 80 are made from layered cardboard.
In other embodiments, the optional pads 80 can be made from other
materials, such as the non-limiting example of rubber or foam. The
optional pads 80 can be attached to the support members in any
desired manner.
[0051] Referring again to FIG. 1, washing machine 12 may be
prepared for shipping by the following process. First, the
engagement member 14 is positioned to engage the fins of the rotor
44 as discussed above. Next, the interface 16 is positioned such
that the engagement member 14 is contained within the recess 74 of
the interface 16. The interface 16 is raised into the cabinet 20
such that the cross-member 70 of the interface 16 is positioned
between the bottom frames 34 of the cabinet. In the illustrated
embodiment, the cross-member 70 of the interface 16 is retained
within the cabinet as a result of a friction fit with the bottom
frame 34 of the cabinet 20. In other embodiments, the interface 16
can be retained within the cabinet 20 by other desired structures
or mechanisms, such as for example, clips or clamps. The shipping
system 10, assembled to the washing machine 12 is illustrated in
FIG. 2. In this position, the shipping system 10 is configured to
prevent or substantially reduce side-to-side movement and/or
vertical movement of the suspended tub 22 and motor assembly 24
during shipping and handling of the washing machine 12.
[0052] Referring now to FIG. 7, another embodiment of a washing
machine shipping system is illustrated. In this embodiment, a
washing machine shipping system 110 includes a damping element 182.
As will be described in more detail below, the shipping system 110
and the damping element 182 function together to secure a tub 122
and a motor assembly 124 in place within a cabinet 120 of a washer
112 during shipping and handling. In the illustrated embodiment,
the shipping system 110, cabinet 120, tub 122 and motor assembly
124 are the same as, or similar to, the shipping system 10, cabinet
20, tub 22 and motor assembly 24 discussed above and illustrated in
FIG. 1. However, in other embodiments, the shipping system 110,
cabinet 120, tub 122 and motor assembly 124 can be different from
the shipping system 10, cabinet 20, tub 22 and motor assembly
24.
[0053] Referring again to FIG. 7, the damping element 182 is formed
of a sleeve 184 of resilient material that is stretched over and
attached to the tub 122. The sleeve 184 may be attached to the tub
122 in any desired manner, including the non-limiting examples of
using mechanical fasteners and/or adhesives or by a friction fit.
While the embodiment illustrated in FIG. 7 shows the damping
element 182 as having a latticework pattern, it should be
appreciated that the damping element 182 can have other desired
patterns or a solid sheet with no pattern.
[0054] In the illustrated embodiment, the damping element 182 is
made from a fibrous polymeric material, such as for example
polyester. In other embodiments, the damping element 182 can be
made from other desired materials, including the non-limiting
examples of a polyester olefin blend, polyethylene terephthalate,
polybutylene terephthalate, a polyethylene terephthalate and
polypropylene blend, a polybutylene terephthalate and polypropylene
blend and combinations thereof. In still other embodiments, the
damping element 182 can be made from laminated materials including
a core layer of fiberglass reinforced polymer material sandwiched
between layers of polyester material.
[0055] The use of polymeric materials provides the damping element
182 with excellent resiliency and wear resistance to provide a long
service life. At the same time, the acoustic properties of the
fibrous polymeric material may be tuned to better control noise and
vibration. This may be done by adjusting the density as well as the
diameter and length of the fibers utilized in the damping element
182. It should also be appreciated that the damping element 182 can
be further tuned to provide a desired spring rate for maximizing
the damping of the horizontal energy or motion of the tub 122
within the cabinet 120.
[0056] Referring again to FIG. 7, a gap 186 is formed between the
damping element 184 and the cabinet 120. The gap 186 is configured
so as to not impair the rotational torque movement of the tub 122
during start and stop movements of the washing machine 112.
[0057] As noted above, the shipping system 110 and damping element
182 are positioned as illustrated in FIG. 7 to prevent or inhibit
horizontal shifting and/or vertical movement of the tub 122 in the
cabinet 120 during shipping. Once the washer 112 is permanently
positioned, the shipping system 110 is removed while the damping
element 182 remains positioned around the tub 122 for the life of
the washer 112.
[0058] Referring now to FIG. 8, another embodiment of a washing
machine shipping system is illustrated. In this embodiment, a
washing machine shipping system 210 includes a damping element 282
and a removable plug 288. As will be described in more detail
below, the shipping system 210, damping element 282 and plug 288
function together to secure a tub 222 and a motor assembly 224 in
place within a cabinet 220 of a washer 212 during shipping and
handling. In the illustrated embodiment, the shipping system 210,
cabinet 220, tub 222, motor assembly 224 and damping element 282
are the same as, or similar to, the shipping system 110, cabinet
120, tub 122, motor assembly 124 and damping element 182 discussed
above and illustrated in FIG. 7. However, in other embodiments, the
shipping system 210, cabinet 220, tub 222, motor assembly 224 and
damping element 282 can be different from the shipping system 110,
cabinet 120, tub 122, motor assembly 124 and damping element
182.
[0059] Referring again to FIG. 8, the removable plug 288 includes a
lower portion 290 that is sized, shaped and contoured to fit snugly
in a top opening 240 of the tub 222. The removable plug 288 also
includes an upper portion 292 that is sized, shaped and contoured
to fit snugly in an opening 236 in the top surface 230 of the
cabinet 220. Optionally, the upper portion 292 can include a flat
sidewall segment (not shown) matching the shape of the opening 236.
The flat sidewall segment functions to lock the removable plug 288
in position.
[0060] Since the plug 288 fits snugly in both the opening 236 of
the cabinet 220 and the tub 222 of the washing machine 212, it
should be appreciated that the plug 288 may function to
substantially prevent horizontal movement and/or vertical movement
of the tub 222 relative to the cabinet 212 during shipping and
handling of the washing machine 212. The plug 288 can be made from
any desired material including, but not limited to, expanded
polystyrene, molded plastic, cardboard, and mixtures thereof.
[0061] As noted above, the shipping system 210, damping element 282
and plug 288 are positioned as illustrated in FIG. 8 to prevent or
inhibit horizontal shifting and/or vertical movement of the tub 222
in the cabinet 220 during shipping and handling. Once the washer
212 is permanently positioned, the shipping system 210 and the plug
288 are removed while the damping element 282 remains positioned
around the tub 222 for the life of the washer 212.
[0062] Another exemplary embodiment is illustrated in FIG. 9. In
this embodiment, the interface 316 comprises a framework that is
attached to a bottom frame 334 of the cabinet 320 using a boot 394.
As shown in FIG. 9, a leveling leg 378 is attached to the bottom
frame 334 of the cabinet 320. In the illustrated embodiment, the
framework 316, cabinet 320, bottom frame 334 and leveling leg 378
are the same as, or similar to, the interface 16, cabinet 20,
bottom frame 34 and leveling leg 78 discussed above and illustrated
in FIG. 9. Alternatively, the interface 316, cabinet 320, bottom
frame 334 and leveling leg 378 can be different from the interface
16, cabinet 20, bottom frame 34 and leveling leg 78.
[0063] Referring again to FIG. 9, the boot 394 includes an upper
portion 395 and a lower portion 396. The upper portion 395 has a
circular cross-sectional shape generally corresponding to the shape
of the leveling leg 378. The upper portion 395 of the boot 394 is
configured for positioning over the leveling leg 378 such that a
friction fit results between the upper portion 395 and the leveling
leg 378. The lower portion 396 is attached to the upper portion 395
and has a conical shape. The combination of the friction fit of the
upper portion 395 to the leveling leg and the conical shape of the
lower portion 396 provides for retention of a support member 372 to
the bottom frame 334 of the cabinet 320. The boot 394 and the
interface 316 are removed after the washing machine is permanently
positioned. The boot 394 can be made from any desired material,
including the non-limiting examples of rubber or polymeric
materials.
[0064] Referring now to FIGS. 10 and 11, another embodiment of a
framework that may be used as the interface is illustrated
generally at 416. In this embodiment, the engagement device 14 may
be omitted. In this embodiment, opposing support members 472 are
connected to intersecting diagonal cross members 470. The diagonal
cross members 470 include cutouts 471. The cutouts 471 are sized to
correspond with the outer diameter of a rotor 444 of the motor
assembly (not shown). As shown in FIG. 11, the rotor 444 seats
within the cutouts 471. In this position, the cutouts 471 and the
diagonal cross members 470 support the rotor 444, thereby
preventing or substantially reducing side-to-side movement and/or
vertical movement of a suspended tub and motor assembly during
shipping and handling of the washing machine.
[0065] Referring now to FIGS. 12 and 13, another embodiment of a
framework that may be used as the interface is illustrated
generally at 516. In this embodiment, the engagement device 14 may
be omitted. In this embodiment, cross member 570 spans and connects
opposing support members 572. The cross member 570 supports
diagonal frame members 573. The diagonal frame members 573 are
positioned to correspond with the outer diameter of a rotor 544 of
the motor assembly (not shown). As shown in FIG. 13, the rotor 544
seats on the cross member 570 and within the diagonal frame members
573. In this position, the diagonal frame members 573 support the
rotor 544, thereby preventing and/or substantially reducing
side-to-side movement and vertical movement of a suspended tub (not
shown) and motor assembly during shipping and handling of the
washing machine.
[0066] Referring now to FIGS. 14 and 15, another embodiment of a
framework that may be used as the interface is illustrated
generally at 616. In this embodiment, the engagement device 14 may
be omitted. In this embodiment, cross member 670 spans and connects
opposing support members 672. The cross member 670 supports a
plurality of frame members 673. The frame members 673 are
positioned to correspond with the outer diameter of a rotor 644 of
the motor assembly (not shown). As shown in FIG. 15, the rotor 644
seats on the cross member 670 and within the area formed by the
frame members 673. In this position, the frame members 673 support
the rotor 644, thereby preventing or substantially reducing
side-to-side movement and/or vertical movement of a suspended tub
(not shown) and motor assembly during shipping and handling of the
washing machine.
[0067] Referring now to FIGS. 16 and 17, another embodiment of a
framework that may be used as the interface is illustrated
generally at 716. In this embodiment, the engagement device 14 may
be omitted. In this embodiment, cross member 770 spans and connects
opposing support members 772. The cross member 770 supports
platform member 773. The platform member 773 includes an aperture
775. The aperture 775 of the platform member 773 is positioned to
correspond with the outer diameter of a rotor 744 of the motor
assembly (not shown). As shown in FIG. 17, the rotor 744 seats
within the aperture 775 of the cross member 770. In this position,
the platform member 773 support the rotor 744, thereby preventing
or substantially reducing side-to-side movement and vertical
movement of a suspended tub (not shown) and motor assembly during
shipping and handling of the washing machine.
[0068] Referring now to FIGS. 18-20, another embodiment of a
framework that may be used as the interface is illustrated
generally at 816. In this embodiment, the engagement device 14 may
be omitted. Referring first to FIGS. 18 and 19, the framework 816
includes intersecting support members 872. The support members 872
support a first framing block 880 and a second framing block 882. A
gap 883 is formed between the first framing block 880 and the
second framing block 882. The gap 883 is configured such that an
engagement device, such as a resilient member 884 is inserted into
the gap 883. As will be discussed in more detail below, the
resilient member 884 is configured to support and cushion the rotor
844, thereby preventing or substantially reducing side-to-side
movement and vertical movement of a suspended tub (not shown) and
motor assembly during shipping and handling of the washing machine.
In the illustrated embodiment, the resilient member 884 is a hot
and/or cold water hose supplied with the washing machine and rolled
into a stack within the gap 883. The hot and/or cold water hoses
may be configured to connect the washing machine to the water
supply at the consumer's residence. However, in other embodiments,
the resilient member 884 can be other structures, members or
devices.
[0069] Referring now to FIG. 20, the washing machine is illustrated
generally at 812. The washing machine 812 includes a bottom frame
834. In the illustrated embodiment, the washing machine 812 and the
bottom frame 834 are the same as, or similar to, the washing
machine 12 and the bottom frame 34 discussed above and shown in
FIG. 1. Alternatively, the washing machine 812 and the bottom frame
834 can be different from the washing machine 12 and the bottom
frame 34. The framework 816 is installed within the washing machine
812 such that the rotor 844 rests on the second framing blocks 882
and within the area formed by the resilient member 884. The ends of
the first framing blocks 880 are positioned between the bottom
frames 834 of the cabinet 820. In the illustrated embodiment, the
first framing blocks 880 are retained within the cabinet 820 as a
result of a friction fit with the bottom frame 834 of the cabinet
820. In other embodiment, the framework 816 can be retained within
the cabinet 820 by other desired structures or mechanisms, such as
for example, clips or clamps.
[0070] The principle and mode of operation of the washing machine
shipping systems and methods have been described in certain
embodiments. However, it should be noted that the washing machine
shipping system and methods may be practiced otherwise than as
specifically illustrated and described without departing from its
scope.
[0071] While the present invention has been illustrated by the
description of embodiments thereof, and while the embodiments have
been described in considerable detail, it is not the intention of
the applicant to restrict or in any way limit the scope of the
appended claims to such detail. Additional advantages and
modifications will readily appear to those skilled in the art. For
example, the specific locations of the component connections and
interplacements can be modified. Still further, while rectangular
and annular components have been shown and described herein, other
geometries can be used including polygonal (e.g., square,
triangular, hexagonal, etc.), circular, etc. Therefore, the
invention, in its broader aspects, is not limited to the specific
details, the representative apparatus, and illustrative examples
shown and described. Accordingly, departures can be made from such
details without departing from the spirit or scope of the
applicant's general inventive concept.
* * * * *