US20110233086A1

US20110233086A1 - Washing machine shipping system and method

Info

Publication number: US20110233086A1
Application number: US13/071,995
Authority: US
Inventors: Anthony L. Rockwell; Weigang Qi
Original assignee: Owens Corning Intellectual Capital LLC
Current assignee: Owens Corning Intellectual Capital LLC
Priority date: 2010-03-26
Filing date: 2011-03-25
Publication date: 2011-09-29
Also published as: WO2011119927A2; WO2011119927A3

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.

Description

RELATED APPLICATIONS

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

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

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.
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

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.

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.

FIG. 2 is a side view, in cross-section, of the washing machine and shipping system of FIG. 1 illustrated in an assembled state;

FIG. 3 is a perspective view of a rotor of the washing machine shown in FIG. 1 illustrating rotor fins.

FIG. 4 is a perspective view of the engagement device that is included in the shipping system shown in FIG. 1;

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;

FIG. 6 is a perspective view of the interface that is included in the shipping system shown in FIG. 1;

FIG. 7 is a side view, in cross-section, of a second embodiment of a washing machine and a shipping system;

FIG. 8 is a side view, in cross-section, of a third embodiment of a washing machine and a shipping system;

FIG. 9 is a side view, partially in cross-section, of a second embodiment of an interface illustrating a leveling foot boot;

FIG. 10 is a top plan view of another embodiment of an interface illustrating intersecting cross members;

FIG. 11 is a side elevational view of the interface of FIG. 10;

FIG. 12 is a top plan view of another embodiment of an interface illustrating diagonal frame members;

FIG. 13 is a side elevational view of the interface of FIG. 12;

FIG. 14 is a top plan view of another embodiment of an interface illustrating cross members forming a support frame;

FIG. 15 is a side elevational view of the interface of FIG. 14;

FIG. 16 is a top plan view of another embodiment of an interface illustrating a cross member supporting a support frame;

FIG. 17 is a side elevational view of the interface of FIG. 16.

FIG. 18 is a top plan view of another embodiment of an interface illustrating intersecting support members and a resilient member;

FIG. 19 is a side elevational view of an interface of FIG. 18; and

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

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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.

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.