Appliance lid that incorporates interior structural foam reinforcement

Abstract

An operable panel for a laundry appliance includes a base member that includes a plurality of structural shear cavities that are separated by structural ribs. An upper member extends over the base member and the shear cavities. The upper member is configured to enclose at least a portion of the shear cavities. A plurality of foam members includes a central portion and opposing lateral portions. The plurality of foam members are positioned distal from a front portion and distal from a rear portion of the base member.

What is claimed is: 
     
         1 . A method for forming an operable panel fora laundry appliance comprising:
 forming a base member having a plurality of structural ribs and a base platform that is disposed within a medial region of the base member, and wherein lateral regions of the base member are positioned outside of the base platform, the plurality of structural ribs positioned to provide a relatively lower level of rigidity compared to the plurality of structural ribs located in the lateral regions;   disposing foam members on the base member and between a portion of the plurality of structural ribs;   forming an upper member; and   disposing the upper member onto the base member and the foam members to form a plurality of shear cavities.   
     
     
         2 . The method of  claim 1 , further comprising:
 attaching at least one torsion rod to the base member, wherein the torsion rod is configured to bias the base member toward a closed position.   
     
     
         3 . The method of  claim 1 , further comprising:
 attaching the base member to a cabinet, wherein the operable panel is selectively operable relative to the cabinet between open and closed positions.   
     
     
         4 . The method of  claim 1 , wherein the plurality of structural ribs include a pair of intersecting walls that are disposed on the base platform and that continuously and linearly extend a full width of the medial region to define the relatively lower level of rigidity. 
     
     
         5 . The method of  claim 4 , wherein the pair of intersecting walls define enlarged triangular cavities that occupy the medial region. 
     
     
         6 . The method of  claim 1 , wherein the step of disposing the foam members includes disposing expandable foam on the base member and between a portion of the plurality of structural ribs. 
     
     
         7 . The method of  claim 1 , wherein the step of disposing the foam members includes disposing pre-cut foam members on the base member and between a portion of the plurality of structural ribs. 
     
     
         8 . The method of  claim 1 , wherein the step of forming the base member includes injection molding the base member as a single integral piece. 
     
     
         9 . The method of  claim 1 , wherein the medial region above the base platform includes a central portion of the foam members having a thickness that is less than a thickness of lateral portions of the foam members that are positioned within the lateral regions of the base member to further define the relatively lower level of rigidity of the base platform. 
     
     
         10 . The method of  claim 5 , wherein the foam members includes enlarged triangular foam members that rest upon the base platform and occupy the enlarged triangular cavities, respectively. 
     
     
         11 . The method of  claim 10 , wherein the foam members within the medial region include four of the enlarged triangular foam members that fully occupy the enlarged triangular cavities, respectively. 
     
     
         12 . The method of  claim 1 , wherein the step of forming the upper member includes forming a metallic sheet. 
     
     
         13 . A method for forming an operable panel for a laundry appliance comprising:
 forming a base member having a base platform and lateral regions that are positioned outside of the base platform, wherein the base member includes a plurality of structural ribs within the lateral regions and within a medial region defined by the base platform, the plurality of structural ribs positioned to provide a relatively lower level of rigidity within the medial region compared to the plurality of structural ribs located in the lateral regions;   disposing pre-cut foam members on the base member and between a portion of the plurality of structural ribs;   forming a metallic upper member; and   disposing the metallic upper member onto the base member and the pre-cut foam members to form a plurality of shear cavities.   
     
     
         14 . The method of  claim 13 , wherein the plurality of structural ribs include a pair of intersecting walls that are disposed on the base platform and that continuously and linearly extend a full width of the medial region to define the relatively lower level of rigidity. 
     
     
         15 . The method of  claim 14 , wherein the pair of intersecting walls define enlarged triangular cavities that occupy the medial region. 
     
     
         16 . The method of  claim 15 , wherein the pre-cut foam members includes enlarged triangular foam members that rest upon the base platform and occupy the enlarged triangular cavities, respectively. 
     
     
         17 . The method of  claim 16 , wherein the pre-cut foam members within the medial region include four of the enlarged triangular foam members that fully occupy the enlarged triangular cavities, respectively. 
     
     
         18 . The method of  claim 13 , wherein the step of forming the base member includes injection molding the base member as a single integral piece. 
     
     
         19 . A method for forming an operable panel for a laundry appliance comprising:
 forming a base member having a base platform and lateral regions that are positioned outside of the base platform, wherein the base member includes a plurality of structural ribs within the lateral regions and within a medial region defined by the base platform, the plurality of structural ribs positioned to provide a relatively lower level of rigidity within the medial region compared to the plurality of structural ribs located in the lateral regions;   disposing pre-cut foam members on the base member and between a portion of the plurality of structural ribs, wherein the medial region above the base platform includes a central portion of the pre-cut foam members having a thickness that is less than a thickness of lateral portions of the pre-cut foam members that are positioned within the lateral regions of the base member to further define the relatively lower level of rigidity of the base platform;   forming a metallic upper member; and   disposing the metallic upper member onto the base member and the pre-cut foam members to form a plurality of shear cavities.   
     
     
         20 . The method of  claim 19 , wherein the plurality of structural ribs include a pair of intersecting walls that are disposed on the base platform and that continuously and linearly extend a full width of the medial region to define the relatively lower level of rigidity.