Dishwashing Appliance Sound Insulation

The present subject matter relates generally to dishwashing appliances, and more particularly to features and methods for providing sound insulation in dishwashing appliances.

Dishwashing appliances generally include a tub that defines a wash chamber. Rack assemblies can be mounted within the wash chamber of the tub for receipt of articles for washing. Multiple spray assemblies can be positioned within the wash chamber for applying or directing wash liquid (e.g., water, detergent, etc.) towards articles disposed within the rack assemblies in order to clean such articles. Dishwashing appliances are also typically equipped with one or more pumps, such as a circulation pump or a drain pump, for directing or motivating wash liquid from the sump to, e.g., the spray assemblies or an area outside of the dishwashing appliance.

Various cycles may be included as part of the overall cleaning process. For example, a typical, user-selected cleaning option may include a wash cycle and rinse cycle (referred to collectively as a wet cycle), as well as a drying cycle. During such cycles, various components of the dishwashing appliance are activated and deactivated, typically in a predetermined sequence and for predetermined durations.

The cycles of the dishwashing appliance may generate significant noise, such as due to the flow of wash liquid, the operation of one or more pumps, and movement of articles within the dishwashing appliance. Consumers prefer dishwashers which generate less noise. In order to diminish the level of noise that can be perceived outside of the dishwashing appliance during such cycles, a dishwashing appliance may include sound insulation, e.g., sound dampening materials, and/or other similar features to acoustically isolate the interior of the dishwashing appliance. Installation of such materials may be difficult. For example, some sound insulation materials are provided in the form of rigid sheets which must be aligned with one or more panels of the dishwashing appliance and bent to conform to the curvature of the one or more panels. These processes may result in breakage of the insulation sheet, e.g., at deep bends, and/or misalignment of the insulation sheet with the panel, which can lead to wasted materials and time.

Accordingly, systems and methods for improved assembly of sound insulation features in a dishwashing appliance would be useful.

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one exemplary aspect of the present disclosure, a method of assembling a dishwashing appliance is provided. The method includes applying a sheet of sound insulation material to a panel of the dishwashing appliance and bending the sheet of sound insulation material after applying the sheet of sound insulation material to the panel of the dishwashing appliance. The method also includes baking the sheet of sound insulation material, such that the sheet of sound insulation material conforms to and adheres to the panel of the dishwashing appliance.

In another exemplary aspect of the present disclosure, a dishwashing appliance is provided. The dishwashing appliance includes a panel and a sheet of sound insulation material. The sheet of sound insulation material is adhered to the panel. The sheet of sound insulation material includes a bend formed in the sheet of sound insulation material such that the sheet of sound insulation material conforms to the panel of the dishwashing appliance.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the disclosure. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

As used herein, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). The terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For instance, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows. The term “article” may refer to, but need not be limited to dishes, pots, pans, silverware, and other cooking utensils and items that can be cleaned in a dishwashing appliance. The term “wash cycle” is used to refer to an overall operation of the dishwashing appliance which may include two or more distinct phases. The term “wash phase” is intended to refer to one or more periods of time during which a dishwashing appliance operates while containing the articles to be washed and uses a wash liquid (e.g., water, detergent, or wash additive) and may be a portion of the wash cycle, such as a beginning or early portion of the wash cycle. The term “rinse phase” is intended to refer to one or more periods of time during which the dishwashing appliance operates to remove residual soil, detergents, and other undesirable elements that were retained by the articles after completion of the wash phase and may be a portion of the wash cycle, such as an intermediate portion of the wash cycle. The term “drain phase” is intended to refer to one or more periods of time during which the dishwashing appliance operates to discharge soiled water from the dishwashing appliance and may be a portion of the wash cycle, such as a later portion of the wash cycle. The term “wash liquid” refers to a liquid used for washing or rinsing the articles that is typically made up of water and may include additives, such as detergent or other treatments (e.g., rinse aid). Furthermore, as used herein, terms of approximation, such as “generally,” “approximately,” “substantially,” or “about,” refer to being within a ten percent (10%) margin of error. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.

Turning now to the figures,depict an exemplary dishwasher or dishwashing appliance (e.g., dishwashing appliance) that may be configured in accordance with aspects of the present disclosure. Generally, dishwasherdefines a vertical direction V, a lateral direction L, and a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular to one another and form an orthogonal direction system.

Dishwasherincludes a tubthat defines a wash chambertherein. As shown in, tubextends between a topand a bottomalong the vertical direction V, between a pair of side wallsalong the lateral direction L, and between a front sideand a rear sidealong the transverse direction T.

Tubincludes a front openingat the front side. In some embodiments, the dishwashing appliancemay also include a doorat the front opening. The doormay, for example, be coupled to the tubby a hingeat its bottom for movement between a normally closed vertical position (), wherein the wash chamberis sealed shut for washing operation, and a horizontal open position (not shown) for loading and unloading of articles from dishwasher. A door closure mechanism or assembly, e.g., a latch, may be provided to lock and unlock doorfor accessing and sealing wash chamber.

In exemplary embodiments, tub side wallsaccommodate a plurality of rack assemblies. For instance, guide railsmay be mounted to side wallsfor supporting a lower rack assemblyand an upper rack assembly. In some such embodiments, upper rack assemblyis positioned at a top portion of wash chamberabove lower rack assemblyalong the vertical direction V.

Generally, each rack assembly,may be adapted for movement between an extended loading position (not shown) in which the rack is substantially positioned outside the wash chamber, and a retracted position (shown in) in which the rack is located inside the wash chamber. In some embodiments, movement is facilitated, for instance, by rollersmounted onto rack assemblies,, respectively.

Although guide railsand rollersare illustrated herein as facilitating movement of the respective rack assemblies,, it should be appreciated that any suitable sliding mechanism or member may be used according to alternative embodiments.

In optional embodiments, some or all of the rack assemblies,are fabricated into lattice structures including a plurality of wires or elongated members(for clarity of illustration, not all elongated members making up rack assemblies,are shown). In this regard, rack assemblies,are generally configured for supporting articles within wash chamberwhile allowing a flow of wash liquid to reach and impinge on those articles (e.g., during a cleaning or rinsing phase of the wash cycle). According to additional or alternative embodiments, a silverware basket (not shown) may be removably attached to a rack assembly (e.g., lower rack assembly), for placement of silverware, utensils, and the like, which are otherwise too small to be accommodated by the rack assembly.

Generally, dishwasherincludes one or more spray assemblies for urging a flow of fluid (e.g., wash liquid) onto the articles placed within wash chamber.

In exemplary embodiments, dishwasherincludes a lower spray arm assemblydisposed in a lower regionof wash chamberand above a sumpso as to rotate in relatively close proximity to lower rack assembly. In this regard, lower spray arm assemblymay generally be configured for urging a flow of wash liquid up through lower rack assembly.

In some embodiments, an upper spray assemblymay be located proximate to and, e.g., below, upper rack assemblyalong the vertical direction V. In this manner, upper spray assemblymay be generally configured for urging of wash liquid up through upper rack assembly.

The various spray assemblies and manifolds described herein may be part of a fluid distribution system or fluid circulation assemblyfor circulating wash liquid in tub. In certain embodiments, fluid circulation assemblyincludes a circulation pumpfor circulating wash liquid in tub. Circulation pumpmay be mounted to sumpand in fluid communication with the sumpthrough a circulation outletfrom the sump.

When assembled, circulation pumpmay be in fluid communication with an external water supply line (not shown) and sump. A water inlet valve (not shown) can be positioned between the external water supply line and circulation pump(e.g., to selectively allow water to flow from the external water supply line to circulation pump). Additionally or alternatively, water inlet valve can be positioned between the external water supply line and sump(e.g., to selectively allow water to flow from the external water supply line to sump). During use, water inlet valve may be selectively controlled to open to allow the flow of water into dishwasherand may be selectively controlled to close and thereby cease the flow of water into dishwasher. Further, fluid circulation assemblymay include one or more fluid conduits or circulation piping for directing wash fluid from circulation pumpto the various spray assemblies and manifolds. In exemplary embodiments, such as that shown in, a primary supply conduitextends from circulation pump, along rear sideof tubalong the vertical direction V to supply wash liquid throughout wash chamber.

In optional embodiments, circulation pumpurges or pumps wash liquid to a diverter(). In some such embodiments, diverteris positioned within sumpof dishwashing appliance). Divertermay include a diverter disk (not shown) disposed within a diverter chamber for selectively distributing the wash liquid to the spray assemblies,, or other spray manifolds or assemblies. For instance, the diverter disk may have at least one aperture configured to align with one or more outlet ports (not shown) at the top of diverter chamber. In this manner, the diverter disk may be selectively rotated to provide wash liquid to the desired spray device(s).

In exemplary embodiments, diverteris configured for selectively distributing the flow of wash liquid from circulation pumpto various fluid supply conduits-only some of which are illustrated infor clarity. In certain embodiments, diverterincludes two or more outlet ports (not shown) for supplying wash liquid to a first conduit for rotating lower spray arm assemblyand a second conduit for supplying upper spray assembly(e.g., supply conduit). Additional embodiments may also include one or more additional conduits, e.g., a third conduit for spraying an auxiliary rack such as a silverware rack, etc.

In some embodiments, a supply conduitis used to supply wash liquid to one or more spray assemblies (e.g., to upper spray assembly). It should be appreciated, however, that according to alternative embodiments, any other suitable plumbing configuration may be used to supply wash liquid throughout the various spray manifolds and assemblies described herein. For instance, according to another exemplary embodiment, supply conduitcould be used to provide wash liquid to lower spray arm assemblyand a dedicated secondary supply conduit (not shown) could be utilized to provide wash liquid to upper spray assembly. Other plumbing configurations may be used for providing wash liquid to the various spray devices and manifolds at any location within dishwashing appliance.

Each spray assemblyand, or other spray device as may be included in dishwashing appliance, may include an arrangement of discharge ports or orifices for directing wash liquid received from circulation pumponto dishes or other articles located in wash chamber. The arrangement of the discharge ports, also referred to as jets, apertures, or orifices, may provide a rotational force by virtue of wash liquid flowing through the discharge ports. Alternatively, spray assemblies,may be motor-driven, or may operate using any other suitable drive mechanism. Spray manifolds and assemblies may also be stationary. The resultant movement of the spray assemblies,and the spray from fixed manifolds provides coverage of dishes and other dishwasher contents with a washing spray. Other configurations of spray assemblies may be used as well. For instance, dishwashermay have additional spray assemblies for cleaning silverware, for scouring casserole dishes, for spraying pots and pans, for cleaning bottles, etc.

Drainage of soiled wash liquid within sumpmay by provided, for instance, by a drain pump(e.g., during or as part of a drain phase). In particular, wash liquid may exit sumpthrough a drain outletand may flow through a drain conduit or directly to the drain pump. Thus, drain pumpis downstream of sumpand facilitates drainage of the soiled wash liquid by urging or pumping the wash liquid to a drain line external to dishwasher.

In some embodiments, a filter assembly may be provided, e.g., in the sumpand/or at a top entrance into the sump, e.g., to filter fluid to circulation assemblyand/or drain pump. Generally, the filter assembly removes soiled particles from the liquid that flows to the sumpfrom the wash chamberduring operation of dishwashing appliance. In exemplary embodiments, the filter assembly may include both a first filter (also referred to as a “coarse filter”) and a second filter (also referred to as a “fine filter”).

Although a separate circulation pumpand drain pumpare

described herein, it is understood that other suitable pump configurations (e.g., using only a single pump for both recirculation and draining) may be provided.

The dishwashing appliancemay further include a heating element, such as a resistance heating element, positioned in or near the sump. For example, the heating elementmay be positioned “near” the sumpin that the heating elementis disposed above the sumpand within the lower regionof wash chamber, such as below the lower spray armand/or below the lower rack assembly. The heating elementmay be positioned and configured to heat liquid in the sump, such as for a heated wash phase, and/or to heat air within the wash chamber, such as for drying articles during a dry phase.

Dishwashing appliancemay also include ventilation features, e.g., to promote improved, e.g., more rapid, drying of articles therein after the wash and rinse phases. For example, one or more ventsmay be provided in the tubfor introducing relatively dry air from outside of the tubinto the wash chamberand/or for removing relatively humid air from the wash chamberto the outside of the tub. In some embodiments, a fanmay be provided. The fanmay be operable to urge air through the wash chamber, such as to promote air circulation and/or ventilation within and through the wash chamber. Such air movement may increase the rate of evaporation of moisture from articles in the wash chamberafter a wash and/or rinse phase.

In certain embodiments, dishwasherincludes a controllerconfigured to regulate operation of dishwasher(e.g., initiate one or more wash operations). Controllermay include one or more memory devices and one or more microprocessors, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with a wash operation or wash cycle that may include a pre-wash phase, a wash phase, a rinse phase, a drain phase, and/or a dry phase. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In some embodiments, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controllermay be constructed without using a microprocessor, e.g., using a combination of discrete analog or digital logic circuitry—such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like—to perform control functionality instead of relying upon software. It should be noted that controllers as disclosed herein are capable of and may be operable to perform any methods and associated method steps as disclosed herein.

Controllermay be positioned in a variety of locations throughout dishwasher. In optional embodiments, controlleris located within a control panel areaof door(e.g., as shown inor). Input/output (“I/O”) signals may be routed between the control system and various operational components of dishwasheralong wiring harnesses that may be routed through the bottom of door. Typically, the controllerincludes or is operatively coupled to a user interface panel/controlsthrough which a user may select various operational features and modes and monitor progress of dishwasher. In some embodiments, user interfaceincludes a general purpose I/O (“GPIO”) device or functional block. In additional or alternative embodiments, user interfaceincludes input components, such as one or more of a variety of electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. In further additional or alternative embodiments, user interfaceincludes a display component, such as a digital or analog display device designed to provide operational feedback to a user. When assembled, user interfacemay be in operative communication with the controllervia one or more signal lines or shared communication busses.

The dishwashing appliancemay also include a temperature sensorin operative communication with the controller. For example, in some embodiments, the temperature sensormay be located in the sumpand may thereby be operable to measure a temperature of a liquid, e.g., wash liquid, within the sump. For example, the “temperature sensor” may include any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, temperature sensormay be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, a semiconductor-based integrated circuit temperature sensor, etc. In addition, temperature sensormay be positioned at any suitable location and may output a signal, such as a voltage, to the controllerthat is proportional to and/or indicative of the temperature being measured. Although exemplary positioning of the temperature sensoris described herein and depicted in, it should be appreciated that dishwashing appliancemay include any other suitable number, type, and position of temperature, humidity, and/or other sensors as well as or instead of the exemplary temperature sensoraccording to alternative embodiments.

It should be appreciated that the invention is not limited to any particular style, model, or configuration of dishwasher. The exemplary embodiments depicted inare for illustrative purposes only. For instance, different locations may be provided for control panel area(e.g., on the front of the dooras illustrated inor on the top of the dooras illustrated in, or other locations as well), different configurations may be provided for rack assemblies,, different spray assemblies,and spray manifold configurations may be used, different sensors may be used, and other differences may be applied while remaining within the scope of the present disclosure.

As may be seen, e.g., in, the doormay include an inner panel, e.g., which adjoins and faces towards the wash chamberwhen the dooris in the closed position, and an outer panelwhich is opposite the inner panel, e.g., which faces away from the remainder of the dishwashing appliancewhen the dooris in the closed position. One or more sound insulation materials may be provided between the inner paneland the outer panelof the door. For example, a sheetof sound insulation material may be bonded to the inner panelwithin an internal spaced of the door, e.g., between the inner paneland the outer panel. In additional embodiments, sound insulation materials, e.g., sheet, may be provided on other panels of the dishwashing appliance as well as or instead of the inner panelof the door, such as the outer panelof the door, one or more side panels which form the side wallsof the tub, and/or other similar panels or portions of panels in the dishwashing appliance. For example, as may be seen in, the sheetmay be bonded to the inner panelof the dooron an internal side of the inner panel, e.g., a side of the inner panelthat faces the outer panelof the door. Thus, the sheetof sound insulation material may be separated from the wash chamberby the inner panelof the doorand may face away from the wash chamber. Accordingly, the present disclosure should be understood as applicable to any suitable panel of the dishwashing appliance, and will be illustrated and described further herein with reference to the inner panelas just one possible example of a panel of the dishwashing appliance to which the sheetof sound insulation material may be applied.

As mentioned above, a fanmay be provided in the dishwashing appliance. As may be seen, e.g., in, additional features may be provided in the inner panelof the door, such as a dispensing assembly. Also as may be seen in, the sheetmay include cutouts which permit such features, e.g., the fanand the dispensing assembly, to pass through the sheetof sound insulation material when the sheetis applied to the inner panelof the door.

provides an elevation view of the inner panelwith the sheetof sound insulation material applied thereto and in a pre-baking configuration. For example, the sheetof sound insulation material as illustrated inincludes a first bend, e.g., a lower bend formed in a bottom portion (such as bottom half, bottom one-third, bottom quarter, or other such bottom portion) of the sheet. The first bendmay be formed along a first hingeof the sheetof sound insulation material. The sheetmay also include a second bendformed along a second hinge. The second bendand second hingemay be positioned in an upper portion (such as upper half, upper one-third, upper quarter, or other such upper portion) of the sheet. In some embodiments, the sheetof sound insulation material may be applied to the inner panelbefore being bent along the hinges,. Thus, the first bendand the second bendmay be formed in situ, e.g., while the sheetis on the inner panel, and may thereby each correspond to a bend in the inner panel, such as a deep bend. Applying the sheetto the inner panelprior to forming the bendormay provide a guide to promote accurate alignment of the sheetwith the inner panel, e.g., may ensure the bendsandare each formed in the correct locations to correspond to underlying curvature of the inner panel, e.g., the bendsandin the sheetmay be the same distance apart as the bends in the inner panel. Each of the bendsandmay be deep bends, e.g., bends defining an angle of deflection of at least about° from the initial flat condition of the sheet(the initial flat condition is illustrated, e.g., in), and which extend across a length of the sheet of sound insulation material by greater than one inch, e.g., more than one inch of sound insulation material past the deep bend, where “past the bend” is measured from the deep bend to the nearest external edge of the sheet of sound insulation material along a direction that is generally perpendicular to the nearest external edge of the sheet of sound insulation material.

The sheetof sound insulation material may also include one or more short bends or shallow bends, e.g., bends that have one inch or less of material past the bend. Example locations of such shallow bends are illustrated in, e.g., along linesand. The shallow bend linesandthus each define a flap, such as a first flapdefined by a first shallow bend along first line, where the first flapis separated from the remainder of the sheetby the first line, and a second flapdefined by and separated from the remainder of the sheetby the second line. The shallow bends may be formed by heating, e.g., baking, the sheetof sound insulation material, such that the sheetsoftens and sags, e.g., bends under the force of gravity, along the shallow bend linesandwhich causes the sheet, e.g., the flapsandthereof in particular, to conform to the inner panel. For example, as may be seen by comparing, inthe first flapis still generally coplanar with the adjoining portions of the sheetof sound insulation material, whereasdepicts the sheetafter baking, such that the first flapconforms to the shape of the inner paneland is positioned at an oblique angle to the adjoining portion of the sheet, e.g., the sheethas bent along the lineto conform to the shape of the inner panel, such as after heating, e.g., baking, the sheetas described.

As may be seen, e.g., in, the hingesandmay be defined by one or more slots formed in and through the sheetof sound insulation material. Such slots may not extend fully across the width (e.g., a dimension measured along or parallel to the lateral direction L) of the sheetbut may instead be interrupted by one or more tabs extending across each respective slot, such that adjoining portions of the sheeton either side of the slots remain connected by the tabs. Removing the material of the sheet, e.g., forming the slots therein, provides a line of increased flexibility such that it is easier to bend the sheetalong the hinges due to the slots. In particular, as illustrated in, the first hingemay be defined by a slot which comprises a first slot portion, a second slot portion, and a third slot portionas well as intervening tabs, e.g., a first tabbetween the first slot portionand the second slot portion, and a second tabbetween the second slot portionand the third slot portion. The portions,, andof the slot in the first hingemay be colinear so as to define a hinge axis about which the sheetof sound insulation material may be bent. Each tabandmay extend across the slot (e.g., along or parallel to the vertical direction V when the dooris in the closed position) to thereby define the portions of the slot on either lateral side of each tab. Still referring to, the second hingemay also be defined by a slot which is partitioned by at least one tab which extends across (e.g., in the vertical direction V as mentioned) the slot, such as the second hingemay be defined by a second slot which comprises a fourth slot portion, a fifth slot portion, and a sixth slot portion, with a third tabextending across the second slot to define the fourth slot portionand the fifth slot portion, and a fourth tabextending across the second slot to define the fifth slot portionand the sixth slot portion.

Also as may be seen in, the sheetmay also include a perforated line, which is composed of a series of linear perforations of generally equal length and spaced apart at a regular interval. The sound insulation material may be any suitable material, such as a bitumen mastic material. For example, the material of the sheetmay be a rigid material, e.g., may tend to retain the flat shape illustrated inwhich, as mentioned, depicts an original or as-manufactured condition (e.g., in contrast to an as-installed configuration when the sheetis fully bonded to the panel and conforms to each curve in the panel) unless and until significant force is applied to the sheet, at least in areas where the sheetis continuous (such as areas away from the hinges described herein).

In some embodiments, the tabs of each hinge may be relatively short, e.g., in a dimension measured along or parallel to the lateral direction L, as compared to the slots or slot portions of each hinge. Referring now to, where the first hingeis enlarged for purposes of explaining an example of such hinge proportions, it being understood that the second hingemay also have the same or similar proportions as those shown and described with reference to the example of the first hinge, e.g., as shown in. The sheetmay define an overall with, e.g., along or generally parallel to the lateral direction L. The first slot portionmay define a first length, e.g., parallel to the widthof the sheet, the second slot portionmay define a second length, and the third slot portionmay define a third length. Similarly, the first tabmay define a lengthand the second tabmay define a length. In order to provide the desired flexibility, e.g., to promote hand-bending of the sheetof sound insulation material by an operator, e.g., generally an adult human of about average strength, the collective lengthsandof the tabsandmay be no greater than about 30% of the overall widthof the sheet. At the same time, the sheetis preferably resistant to breakage along the hinges, e.g., the hinges preferably bend but not break, such that the collective lengthsandof the tabsandmay be no less than about 10% of the overall widthof the sheet. In some embodiments, the hinge (or each hinge when more than one hinge is provided) may include two tabs, e.g., as illustrated in. In additional embodiments the hinge (or each hinge) may include more than two tabs, such as three tabs, four tabs, or more. In such embodiments, the length per tab may be less when more tabs are provided, e.g., whereby the overall total length of the tabs falls within the above-mentioned ranges.

provide close-up section views taken through the first bend() and the second bend(). As may be seen in these views, the slots, e.g., third slot portionwhich may be seen inand sixth slot portionwhich may be seen in, overlie sharply curved portions of the inner paneland thus, the hingesandpromote the sheetof sound insulation material bending, e.g., forming deep bends, at these portions of the inner panelto conform the shape of the sheetto the inner panel.

Turning now to, embodiments of the present disclosure also include methods such as the exemplary methodof assembling a dishwashing appliance illustrated in. Methods such as methodmay be used to assemble any suitable dishwashing appliance, such as but not limited to the exemplary dishwashing appliancedescribed above.

Methodmay include () applying a sheet of sound insulation material to a panel of the dishwashing appliance. For example, the panel may be an inner panelof a door. However, as noted above, a sheet of sound insulation may be applied other panels as well or instead in various embodiments of the present disclosure. Also as noted above, the sound insulation material may be a rigid material, such as a mastic material, e.g., a bitumen mastic material.

Methodmay also include () bending the sheet of sound insulation material after applying the sheet of sound insulation material to the panel of the dishwashing appliance. In some embodiments, bending the sheet of sound insulation material may include bending the sheet of sound insulation material along a hinge defined in the sheet of sound insulation material. For example, the hinge may include a slot formed through the sheet of sound insulation material and a tab extending across the slot.

Methodmay further include () baking the sheet of sound insulation material, whereby the sheet of sound insulation material conforms to and adheres to the panel of the dishwashing appliance. For example, a side of the sheet of sound insulation material which contacts the panel of the dishwashing appliance may include a heat-activated bonding agent, such as a hot-melt adhesive, by which the sheet is adhered to the panel of the dishwashing appliance as a result of baking at () in method. Additionally, and as mentioned above, the heat of the baking process () may soften the material of the sheet of sound insulation material such that the material sags down onto and around the panel of the dishwashing appliance, thereby conforming the sheet of sound insulation material to the panel.

In some embodiments, () bending the sheet of sound insulation material may include bending the sheet of sound insulation material at a first location to form a first bend in the sheet of sound insulation material, and may further include bending the sheet of sound insulation material at a second location to form a second bend in the sheet of sound insulation material. In such embodiments, the second bend may be generally parallel to the first bend. Also in such embodiments, bending the sheet of sound insulation material at the second location to form the second bend in the sheet of sound insulation material may be performed after applying the sheet of sound insulation material to the panel of the dishwashing appliance and before baking the sheet of sound insulation material.