Formed door for refrigerators

Abstract

A door for a refrigerated appliance is provided which includes an outer metal panel having a generally rectangular front surface area lying generally in a first plane. Top, left, right and bottom side surface areas are formed as extensions from the front surface area, and are connected thereto via radiused bends to orient said side surface areas in planes approximately 90 degrees from the plane of the front surface area. The side areas are formed without seams or other discontinuations between any of the front or side surface areas. Flanges may extend from each of the top, left, right and bottom sides, the flanges being oriented generally in a plane approximately parallel to the plane of the front surface area. Adjacent flanges have overlapping areas which are secured together with metal fastening elements. The side surface areas may be joined at bends having radii in the range of 6-20 mm.

1 . A door for a refrigerated appliance, comprising: 
 an outer metal panel having a generally rectangular front surface area lying generally in a first plane, top, left, right and bottom side surface areas formed as extensions from said front surface area, and connected thereto via radiused bends to orient said side surface areas in planes approximately 90 degrees from said plane of said front surface area, without seams or other discontinuations between any of the front or side surface areas, and flanges extending from each of said top, left, right and bottom sides, said flanges being oriented generally in a plane approximately parallel to said plane of said front surface area, adjacent flanges having overlapping areas which are secured together with metal fastening elements.    
   
   
       2 . A door according to  claim 1 , including a plastic door liner engaged with said flanges, and a foamed-in-place insulation material adhering between said liner and an inner surface of said outer metal panel.  
   
   
       3 . A door according to  claim 1 , wherein said metal fastening elements comprise toggle locks.  
   
   
       4 . A door according to  claim 1 , wherein said metal fastening elements comprise rivets.  
   
   
       5 . A door according to  claim 1 , wherein said metal fastening elements comprise welds.  
   
   
       6 . A door according to  claim 1 , wherein said metal fastening elements comprise threaded fasteners.  
   
   
       7 . A door according to  claim 1 , wherein said front surface has an outwardly convex shape.  
   
   
       8 . A door according to  claim 1 , wherein said front surface has a planar shape.  
   
   
       9 . A door according to  claim 1 , wherein adjacent side surface areas are joined at bends having a radius in the range of 6-20 mm.  
   
   
       10 . A door according to  claim 1 , wherein said side surface areas are joined to said front surface area at bends having a radius in the range of 6-20 mm.  
   
   
       11 . A door according to  claim 1 , wherein said side surface areas extend away from said front surface area a distance of 5 cm to 15 cm.  
   
   
       12 . A door according to  claim 1 , wherein said flanges extend away from said side surface areas a distance of 1 cm to 6 cm.  
   
   
       13 . A door for a refrigerated appliance, comprising: 
 an outer metal panel having a generally rectangular front surface area lying generally in a first plane, top, left, right and bottom side surface areas formed as extensions from said front surface area, and connected thereto via radiused bends to orient said side surface areas in planes approximately 90 degrees from said plane of said front surface area, without seams or other discontinuations between any of the front or side surface areas, wherein adjacent ones of each of said side surface areas are joined at bends having radii in the range of 6-20 mm.    
   
   
       14 . A door according to  claim 13 , including flanges extending from said side surface areas approximately parallel to said first plane, a plastic door liner engaged with said flanges, and a foamed-in-place insulation material adhering between said liner and an inner surface of said outer metal panel.  
   
   
       15 . A door according to  claim 13 , wherein said front surface has an outwardly convex shape.  
   
   
       16 . A door according to  claim 13 , wherein said front surface has a planar shape.  
   
   
       17 . A door according to  claim 13 , wherein adjacent side surface areas are joined at bends having a radius in the range of 6-20 mm.  
   
   
       18 . A door according to  claim 13 , wherein said side surface areas are joined to said front surface area at bends having a radius in the range of 6-20 mm.  
   
   
       19 . A door according to  claim 13 , wherein said side surface areas extend away from said front surface area a distance of 5 cm to 15 cm.  
   
   
       20 . A refrigerated appliance, comprising: 
 a cabinet enclosing a refrigerated space and a door hinged to said cabinet to provide access to said refrigerated space,    said door comprising an outer metal panel having a generally rectangular front surface area lying generally in a first plane, top, left, right and bottom side surface areas formed as extensions from said front surface area, and connected thereto via radiused bends to orient said side surface areas in planes approximately 90 degrees from said plane of said front surface area, without seams or other discontinuities between any of the front or side surface areas, and flanges extending from each of said top, left, right and bottom sides, said flanges being oriented generally in a plane approximately parallel to said plane of said front surface area, adjacent flanges having overlapping areas which are secured together with metal fastening elements.    
   
   
       21 . A refrigerated appliance according to  claim 1 , including a plastic door liner engaged with said flanges, and a foamed-in-place insulation material adhering between said liner and an inner surface of said outer metal panel.