Structural panel for an appliance having stamped components and method therefor

Abstract

An operable panel for an appliance includes a metallic outer wrapper having a perimetrical wrapper edge that partially defines a perimetrical breaker channel, an inner liner and a plurality of corner brackets disposed proximate the perimetrical wrapper edge. Each corner bracket cooperates with the perimetrical wrapper edge to fully define the perimetrical breaker channel. A trim breaker is adhered to the metallic outer wrapper and the corner brackets at the perimetrical breaker channel and having a liner channel that receives a portion of the inner liner. The trim breaker extends between the inner liner and the outer wrapper. An insulation material is disposed within an insulating cavity defined between the inner liner and the outer wrapper.

1 . An operable panel for an appliance, the operable panel comprising:
 a metallic inner liner having a main body and opposing outer walls extending from the main body, wherein the opposing outer walls partially define a perimetrical breaker channel;   end caps that engage the main body and the opposing outer walls, the end caps cooperating with the opposing outer walls to form a continuous outer wall and to fully define the perimetrical breaker channel as a continuous groove that extends around a perimeter of the continuous outer wall; and   a trim breaker coupled to the metallic inner liner and the end caps at the continuous groove of the perimetrical breaker channel, wherein the trim breaker is configured to receive a metallic outer wrapper to define an insulating cavity.   
     
     
         2 . The operable panel of  claim 1 , wherein the trim breaker includes a gasket channel that is at least partially surrounded by the perimetrical breaker channel. 
     
     
         3 . The operable panel of  claim 1 , further comprising:
 a gasket disposed within a gasket channel of the trim breaker, wherein the gasket channel is positioned proximate a liner channel that seats within the perimetrical breaker channel of the metallic inner liner and the end caps.   
     
     
         4 . The operable panel of  claim 1 , wherein the trim breaker is adhered to the perimetrical breaker channel. 
     
     
         5 . The operable panel of  claim 3 , wherein the perimetrical breaker channel partially surrounds a U-shaped channel of the trim breaker to form a nested configuration. 
     
     
         6 . The operable panel of  claim 5 , wherein one surface of the U-shaped channel defines the liner channel and an opposing surface of the U-shaped channel defines the gasket channel. 
     
     
         7 . The operable panel of  claim 1 , wherein each end cap of the end caps includes an engagement surface that defines a plurality of adhesion grooves that retain an adhesive therein, and wherein the adhesive at least partially secures each end cap to an outer edge of the metallic inner liner. 
     
     
         8 . The operable panel of  claim 2 , wherein the perimetrical breaker channel is defined within a perimetrical liner edge of the opposing outer walls, and wherein a liner channel of the trim breaker seats within the perimetrical breaker channel. 
     
     
         9 . The operable panel of  claim 1 , wherein the end caps each abut the opposing outer walls and are aligned with the perimetrical breaker channel. 
     
     
         10 . The operable panel of  claim 1 , wherein the metallic inner liner is a planar metallic sheet that is folded to define the main body and the opposing outer walls. 
     
     
         11 . The operable panel of  claim 10 , wherein the planar metallic sheet is rectangular. 
     
     
         12 . An operable panel for an appliance, the operable panel comprising:
 an inner liner comprising a folded metallic sheet that partially defines a perimetrical breaker channel, the inner liner comprising the folded metallic sheet;   an outer wrapper;   at least one end cap that is coupled to the inner liner and cooperates with the inner liner to fully define the perimetrical breaker channel as a continuous channel; and   a trim breaker adhered to the inner liner and the at least one end cap at the perimetrical breaker channel, the trim breaker having a wrapper channel that receives a portion of the outer wrapper, the trim breaker extending between the inner liner and the outer wrapper.   
     
     
         13 . The operable panel of  claim 12 , further comprising:
 a gasket disposed within a gasket channel of the trim breaker, wherein the gasket channel is positioned proximate a liner channel that seats within the perimetrical breaker channel of the outer wrapper, wherein the perimetrical breaker channel partially surrounds the gasket channel of the trim breaker.   
     
     
         14 . The operable panel of  claim 13 , wherein the trim breaker includes a U-shaped channel, wherein one surface of the U-shaped channel defines the wrapper channel and an opposing surface of the U-shaped channel defines the gasket channel. 
     
     
         15 . The operable panel of  claim 12 , wherein the inner liner includes a base portion and opposing outer walls that extend therefrom, and wherein the at least one end cap includes two opposing end caps that are each engaged to the base portion and the opposing outer walls to define the perimetrical breaker channel. 
     
     
         16 . The operable panel of  claim 12 , wherein the at least one end cap is injection molded onto the inner liner. 
     
     
         17 . An operable panel for an appliance, the operable panel comprising:
 an inner liner that includes a base portion and includes a plurality of outer walls that partially define a perimetrical breaker channel;   a metallic outer wrapper;   at least one end cap that is coupled to the inner liner and cooperates with the inner liner to fully define the perimetrical breaker channel as a continuous channel;   a trim breaker adhered to the inner liner and the at least one end cap at the perimetrical breaker channel, the trim breaker having an elongated flange that receives an engagement tab of the inner liner, the metallic outer wrapper having a wrapper wall that receives a portion of the trim breaker, the trim breaker extending between the inner liner and the metallic outer wrapper; and   a gasket disposed within a gasket channel of the trim breaker, wherein the gasket channel is positioned proximate the wrapper wall that engages a portion of the perimetrical breaker channel, wherein the perimetrical breaker channel partially surrounds the gasket channel of the trim breaker.   
     
     
         18 . The operable panel of  claim 17 , wherein the inner liner includes a base portion and opposing outer walls that extend therefrom, and wherein the at least one end cap includes two opposing end caps that are each engaged to the base portion and the opposing outer walls to define the perimetrical breaker channel. 
     
     
         19 . The operable panel of  claim 17 , wherein the at least one end cap is injection molded onto the inner liner. 
     
     
         20 . The operable panel of  claim 19 , wherein the trim breaker is adhered to the perimetrical breaker channel.