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A method of making an appliance door includes inserting a door pan into a fixture having first and second forming molds, which are pressed together. An inner door liner is placed over the door pan and secured thereto to form a base door. A mold cavity is formed between the door pan and the inner doo

A method of making an appliance door includes inserting a door pan into a fixture having first and second forming molds, which are pressed together. An inner door liner is placed over the door pan and secured thereto to form a base door. A mold cavity is formed between the door pan and the inner door liner. An insulative material is injected into the mold cavity defined by the space between the door pan and the inner door liner. A removable decorative exterior skin is extended over the base door. A support frame and a plurality of utility lines are provided. An insulative material contacts the support frame. A base door is formed by an inner door liner secured to the insulative material and the support frame.

대표청구항 ▼

1. A method of making an appliance door comprising: forming a support frame having a generally rectangular perimeter, the support frame having an aperture in a central area;inserting the support frame into a fixture having first and second forming molds; inserting utility lines into the fixture; pre

1. A method of making an appliance door comprising: forming a support frame having a generally rectangular perimeter, the support frame having an aperture in a central area;inserting the support frame into a fixture having first and second forming molds; inserting utility lines into the fixture; pressing the first and second forming molds together to from a cavity;injecting an insulative material into the cavity, wherein the support frame is encased in the insulative material;inserting a block into the fixture before the first and second forming molds are pressed together to form an aperture in a central area of the insulative material and maintain the aperture in the central area of the support frame, wherein the apertures in the central areas of the support frame and of the insulative material are configured to receive an ice machine;setting the injected insulative material, wherein the insulative material is cured around the support frame, thereby connecting or bonding the support frame to the insulative material;providing an inner door liner having a generally rectangular perimeter having a shape and size that closely corresponds to the rectangular perimeter of the support frame;securing the inner door liner to the set injected insulative material and support frame to form a base door; andsecuring a rigid decorative exterior skin over the base door, the decorative exterior skin including a face wall and a plurality of peripheral sidewalls that extend orthogonal to each side of the face wall. 2. The method of claim 1, further comprising: placing a gasket assembly adjacent the inner door liner and the exterior skin. 3. The method of claim 2, further comprising: extending a door flange over the gasket assembly that secures the gasket assembly in position around a periphery of the appliance door. 4. The method of claim 1, wherein: the step of inserting a support frame further comprises inserting a support frame having tubular support members. 5. The method of claim 1, wherein: the step of inserting a support frame further comprises inserting a support frame having a single support member extending longitudinally through a central portion of the door. 6. The method of claim 1, wherein: the step of inserting a support frame further comprises inserting a support frame made from rigid plastic. 7. The method of claim 1, wherein: the step of inserting a support frame further comprises inserting a support frame formed from a single piece of stamped metal. 8. The method of claim 1, wherein: the step of removably securing a decorative exterior skin further comprises fastening the rigid decorative exterior skin onto the base door with mechanical fasteners. 9. The method of claim 1, further comprising: cutting an aperture from the base door before the decorative exterior skin is removably secured over the base door. 10. The method of claim 1, wherein: the support frame comprises a metal frame that is formed by bending and cutting metal prior to insertion of the metal frame into the mold, and wherein the metal frame defines an interior space within the rectangular perimeter; and:the step of injecting insulative material into the cavity includes distributing insulative material in the interior space while the metal frame is in the mold to thereby form, upon solidification of the insulative material, a unitary base panel structure having a central portion comprising insulative material and a generally rectangular perimeter defined by the metal frame. 11. The method of claim 10, wherein: the metal frame includes a hinge structure. 12. The method of claim 10, wherein: the insulative material includes opposite side faces defining a first thickness there between; andthe rectangular perimeter of the support frame defines a second thickness that is approximately equal to the first thickness. 13. An appliance door comprising: a support frame having a generally rectangular perimeter, the support frame having an aperture in a central area;a plurality of utility lines;an insulative material that is injected into a cavity formed between first and second forming molds; the insulative material encasing the support frame, wherein the insulative material is cured around the support frame;a block inserted into the cavity before the first and second forming molds are pressed together forms an aperture in a central area of the insulative material and maintains the aperture in the central area of the support frame, wherein the apertures in the central areas of the support frame and of the insulative material are configured to receive an ice machine;an inner door liner that is secured to the insulative material and support frame, forming a base door, the inner door liner having a generally rectangular perimeter having a shape and size that closely corresponds to the rectangular perimeter of the support frame; anda rigid decorative exterior skin that is secured over a front and sides of the base door to provide aesthetic variation in shape, color, finish, or type of material for the appliance door. 14. The appliance door of claim 13, further comprising: a gasket assembly disposed adjacent the inner door liner and the decorative exterior skin and a door flange that extends over the gasket assembly, securing the gasket assembly in position around a periphery of the appliance door. 15. The appliance door of claim 13, further comprising: outer end caps for covering a top end and a bottom end of the base door. 16. The appliance door of claim 13, wherein: the support frame includes tubular support members. 17. The appliance door of claim 13, wherein: the support frame includes a single support member that extends longitudinally through a central portion of the door. 18. The appliance door of claim 13, wherein: the support frame is formed from a single piece of stamped metal. 19. The appliance door of claim 13, wherein: an aperture is formed in the insulative material for receiving a component. 20. The appliance door of claim 13, wherein: an aperture is cut in the base door before the decorative exterior skin is removably secured over the base door.