MOLDED PULP EXTERNAL PACKING MEMBER FOR A DISHWASHER APPLIANCE

Abstract

A pack member for a dishwasher appliance including a door having an inner door panel and an outer door panel includes a main panel defining a first face facing a first direction and a second face facing a second direction opposite the first face; a first wing panel extending from the main panel along a third direction, the first wing panel being offset from the main panel along the second direction; and a second wing panel extending from the main panel along a fourth direction opposite the third direction, the second wing panel being offset from the main panel along the second direction, the pack member being formed from a recyclable molded pulp material.

Claims

1. A dishwasher appliance defining a vertical direction, a lateral direction, and a transverse direction, the dishwasher appliance comprising: a tub defining a receiving chamber; a door attached to the tub and movable between an open position and a closed position to provide selective access to the receiving chamber, wherein the door comprises an inner door panel and an outer door panel; and a pack member positioned between the inner door and the outer door, the pack member comprising: a main panel defining a first face facing a first direction and a second face facing a second direction opposite the first face; a first wing panel extending from the main panel along a third direction, the first wing panel being offset from the main panel along the second direction; and a second wing panel extending from the main panel along a fourth direction opposite the third direction, the second wing panel being offset from the main panel along the second direction, wherein the pack member is formed from a recyclable molded pulp material.

2. The dishwasher appliance of claim 1, wherein the first wing panel defines an upper surface facing the first direction and a lower surface facing the second direction, and wherein the second wing panel defines a top surface facing the first direction and a bottom surface facing the second direction.

3. The dishwasher appliance of claim 2, wherein each of the lower surface of the first wing panel and the bottom surface of the second wing panel is positioned below the second surface of the main panel along the second direction.

4. The dishwasher appliance of claim 2, wherein the lower surface of the first wing panel is positioned below the bottom surface of the second wing panel along the second direction.

5. The dishwasher appliance of claim 2, wherein the pack member further comprises: a plurality of first protrusions protruding from the upper surface of the first wing panel along the first direction; and a plurality of second protrusions protruding from the top surface of the second wing panel along the first direction.

6. The dishwasher appliance of claim 2, wherein the pack member further comprises: at least one first cavity formed into the lower surface of the first wing panel along the first direction; and at least one second cavity formed into the bottom surface of the second wing panel along the first direction.

7. The dishwasher appliance of claim 1, wherein a length of the second wing panel along the fourth direction is greater than a length of the first wing panel along the third direction.

8. The dishwasher appliance of claim 1, further comprising: a first tab extending from the lower surface of the first wing panel along the third direction; and a second tab extending from the bottom surface of the second wing panel along the fourth direction.

9. The dishwasher appliance of claim 1, wherein the pack member comprises a wax coating.

10. A pack member for a dishwasher appliance, the dishwasher appliance comprising a door, the door comprising an inner door panel and an outer door panel, the pack member comprising: a main panel defining a first face facing a first direction and a second face facing a second direction opposite the first face; a first wing panel extending from the main panel along a third direction, the first wing panel being offset from the main panel along the second direction; and a second wing panel extending from the main panel along a fourth direction opposite the third direction, the second wing panel being offset from the main panel along the second direction, wherein the pack member is formed from a recyclable molded pulp material.

11. The pack member of claim 10, wherein the first wing panel defines an upper surface facing the first direction and a lower surface facing the second direction, and wherein the second wing panel defines a top surface facing the first direction and a bottom surface facing the second direction.

12. The pack member of claim 11, wherein each of the lower surface of the first wing panel and the bottom surface of the second wing panel is positioned below the second surface of the main panel along the second direction.

13. The pack member of claim 11, wherein the lower surface of the first wing panel is positioned below the bottom surface of the second wing panel along the second direction.

14. The pack member of claim 11, wherein the pack member further comprises: a plurality of first protrusions protruding from the upper surface of the first wing panel along the first direction; and a plurality of second protrusions protruding from the top surface of the second wing panel along the first direction.

15. The pack member of claim 11, wherein the pack member further comprises: at least one first cavity formed into the lower surface of the first wing panel along the first direction; and at least one second cavity formed into the bottom surface of the second wing panel along the first direction.

16. The pack member of claim 10, wherein a length of the second wing panel along the fourth direction is greater than a length of the first wing panel along the third direction.

17. The pack member of claim 10, further comprising: a first tab extending from the lower surface of the first wing panel along the third direction; and a second tab extending from the bottom surface of the second wing panel along the fourth direction.

18. The pack member of claim 10, wherein the pack member comprises a wax coating.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

[0010] FIG. 1 provides a perspective view of an exemplary embodiment of a dishwashing appliance of the present disclosure with a door in a partially open position.

[0011] FIG. 2 provides a side, cross-sectional view of the exemplary dishwashing appliance of FIG. 1.

[0012] FIG. 3 provides a top perspective view of an external pack member for a dishwasher appliance according to exemplary embodiments of the present disclosure.

[0013] FIG. 4 provides a bottom perspective view of the external pack member of FIG. 3 according to exemplary embodiments of the present disclosure.

[0014] FIG. 5 provides a perspective view of a door of the exemplary dishwashing appliance of FIG. 1 with an inner door panel separated from an outer door panel and the external pack member of FIG. 3 positioned therein.

[0015] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION

[0016] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. 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.

[0017] As used herein, 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 includes and including are intended to be inclusive in a manner similar to the term comprising. Similarly, the term or is generally intended to be inclusive (i.e., A or B is intended to mean A or B or both). In addition, here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms a, an, and the include plural references unless the context clearly dictates otherwise.

[0018] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as generally, about, approximately, and substantially, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, 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.

[0019] The word exemplary is used herein to mean serving as an example, instance, or illustration. In addition, references to an embodiment or one embodimentdoes not necessarily refer to the same embodiment, although it may. Any implementation described herein as exemplary or an embodiment is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, 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.

[0020] Turning now to the figures, FIGS. 1 and 2 depict an exemplary dishwasher or dishwasher appliance (e.g., dishwasher appliance 100) that may be configured in accordance with aspects of the present disclosure. Generally, dishwasher 100 defines 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.

[0021] Dishwasher 100 may include a cabinet 102 having a tub 104 therein that defines a wash chamber 106. As shown in FIG. 2, tub 104 extends between a top 107 and a bottom 108 along the vertical direction V, between a pair of side walls 110 along the lateral direction L, and between a front side 111 and a rear side 112 along the transverse direction T.

[0022] Tub 104 may include a front opening 114 (FIG. 1). In some embodiments, dishwasher appliance 100 may also include a door 116 at the front opening 114. Door 116 may, for example, be hinged at its bottom for movement between a normally closed vertical position, wherein wash chamber 106 is sealed shut for washing operations, and a horizontal open position for loading and unloading of articles from dishwasher 100. A door closure mechanism or assembly 118 may be provided to lock and unlock door 116 for accessing and sealing wash chamber 106.

[0023] Door 116 may be a multi-piece door assembly. For instance, door 116 may include an inner door (or inner door panel) 117 and an outer door (or outer door panel) 119. Inner door 117 may be attached or connected with inner door 119. A cavity 121 may be formed between inner door 117 and outer door 119. According to some embodiments, certain elements may be accommodated within cavity 121. For instance, a detergent assembly and associated electronics may be accommodated within cavity 121.

[0024] In exemplary embodiments, tub side walls 110 accommodate a plurality of rack assemblies. For instance, guide rails 120 may be mounted to side walls 110 for supporting a lower rack assembly 122, a middle rack assembly 124, or an upper rack assembly 126. In some such embodiments, upper rack assembly 126 is positioned at a top portion of wash chamber 106 above middle rack assembly 124, which is positioned above lower rack assembly 122 along the vertical direction V.

[0025] Generally, each rack assembly 122, 124, 126 may be adapted for movement between an extended loading position (not shown) in which the rack is substantially positioned outside the wash chamber 106, and a retracted position (shown in FIGS. 1 and 2) in which the rack is located inside the wash chamber 106. In some embodiments, movement is facilitated, for instance, by rollers 128 mounted onto rack assemblies 122, 124, 126, respectively. Although guide rails 120 and rollers 128 are illustrated herein as facilitating movement of the respective rack assemblies 122, 124, 126, it should be appreciated that any suitable sliding mechanism or member may be used according to alternative embodiments.

[0026] In optional embodiments, some or all of the rack assemblies 122, 124, 126 are fabricated into lattice structures including a plurality of wires or elongated members 130 (for clarity of illustration, not all elongated members making up rack assemblies 122, 124, 126 are shown in FIG. 2). In this regard, rack assemblies 122, 124, 126 are generally configured for supporting articles within wash chamber 106 while allowing a flow of wash liquid to reach and impinge on those articles (e.g., during a cleaning or rinsing cycle). According to additional or alternative embodiments, a silverware basket may be removably attached to a rack assembly (e.g., lower rack assembly 122), for placement of silverware, utensils, and the like, that are otherwise too small to be accommodated by the rack assembly.

[0027] Generally, dishwasher 100 may include one or more spray assemblies for urging a flow of fluid (e.g., wash liquid) onto the articles placed within wash chamber 106. In exemplary embodiments, dishwasher 100 includes a lower spray arm assembly 134 disposed in a lower region 136 of wash chamber 106 and above a sump 138 so as to rotate in relatively close proximity to lower rack assembly 122. In additional or alternative embodiments, a mid-level spray arm assembly 140 is located in an upper region of wash chamber 106 (e.g., below and in close proximity to middle rack assembly 124). In this regard, mid-level spray arm assembly 140 may generally be configured for urging a flow of wash liquid up through middle rack assembly 124 and upper rack assembly 126.

[0028] In further additional or alternative embodiments, an upper spray assembly 142 is located above upper rack assembly 126 along the vertical direction V. In this manner, upper spray assembly 142 may be generally configured for urging or cascading a flow of wash liquid downward over rack assemblies 122, 124, and 126. In yet further additional or alternative embodiments, upper rack assembly 126 may further define an integral spray manifold 144. As illustrated, integral spray manifold 144 may be directed upward, and thus generally configured for urging a flow of wash liquid substantially upward along the vertical direction V through upper rack assembly 126.

[0029] In still further additional or alternative embodiments, a filter clean spray assembly 145 is disposed in a lower region 136 of wash chamber 106 (e.g., below lower spray arm assembly 134) and above a sump 138 so as to rotate in relatively close proximity to a filter assembly (not shown). For instance, filter clean spray assembly 145 may be directed downward to urge a flow of wash liquid across a portion of filter assembly or sump 138.

[0030] The various spray assemblies and manifolds described herein may be part of a fluid distribution system or fluid circulation assembly 150 for circulating wash liquid in tub 104. In certain embodiments, fluid circulation assembly 150 includes a circulation pump 152 for circulating wash liquid in tub 104. Circulation pump 152 may be located within sump 138 or within a machinery compartment located below sump 138 of tub 104.

[0031] When assembled, circulation pump 152 may be in fluid communication with an external water supply line (not shown) and sump 138. A water inlet valve 153 may be positioned between the external water supply line and circulation pump 152 (e.g., to selectively allow water to flow from the external water supply line to circulation pump 152). Additionally or alternatively, water inlet valve 153 may be positioned between the external water supply line and sump 138 (e.g., to selectively allow water to flow from the external water supply line to sump 138). During use, water inlet valve 153 may be selectively controlled to open to allow the flow of water into dishwasher 100 and may be selectively controlled to close and thereby cease the flow of water into dishwasher 100. Further, fluid circulation assembly 150 may include one or more fluid conduits or circulation piping for directing wash fluid from circulation pump 152 to the various spray assemblies and manifolds. In exemplary embodiments, such as that shown in FIG. 2, a primary supply conduit 154 extends from circulation pump 152, along rear 112 of tub 104 along the vertical direction V to supply wash liquid throughout wash chamber 106.

[0032] In some embodiments, primary supply conduit 154 is used to supply wash liquid to one or more spray assemblies (e.g., to mid-level spray arm assembly 140 or upper spray assembly 142). 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, primary supply conduit 154 could be used to provide wash liquid to mid-level spray arm assembly 140 and a dedicated secondary supply conduit (not shown) could be utilized to provide wash liquid to upper spray assembly 142. Other plumbing configurations may be used for providing wash liquid to the various spray devices and manifolds at any location within dishwashing appliance 100.

[0033] Each spray arm assembly 134 and 140, upper spray assembly 142, integral spray manifold 144, filter clean assembly 145, or other spray device may include an arrangement of discharge ports or orifices for directing wash liquid received from circulation pump 152 onto dishes or other articles located in wash chamber 106. 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 134, 140, 142, 145 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 134, 140, 142, 145 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, dishwasher 100 may have additional spray assemblies for cleaning silverware, for scouring casserole dishes, for spraying pots and pans, for cleaning bottles, etc.

[0034] In optional embodiments, circulation pump 152 urges or pumps wash liquid (e.g., from the filter assembly) to a diverter 156 (FIG. 2). In some such embodiments, diverter 156 is positioned within sump 138 of dishwashing appliance 100). Diverter 156 may include a diverter disk (not shown) disposed within a diverter chamber 158 for selectively distributing the wash liquid to the spray assemblies 134, 140, 142, or other spray manifolds. For instance, the diverter disk may have a plurality of apertures that are configured to align with one or more outlet ports (not shown) at the top of diverter chamber 158. In this manner, the diverter disk may be selectively rotated to provide wash liquid to the desired spray device.

[0035] In exemplary embodiments, diverter 156 is configured for selectively distributing the flow of wash liquid from circulation pump 152 to various fluid supply conduitsonly some of which are illustrated in FIG. 2 for clarity. In certain embodiments, diverter 156 includes four outlet ports (not shown) for supplying wash liquid to a first conduit for rotating lower spray arm assembly 134, a second conduit for supplying wash liquid to filter clean assembly 145, a third conduit for spraying an auxiliary rack such as the silverware rack, and a fourth conduit for supply mid-level or upper spray assemblies 140, 142 (e.g., primary supply conduit 154).

[0036] The dishwasher 100 is further equipped with a controller 160 to regulate operation of the dishwasher 100. The controller 160 may 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 cleaning cycle. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, 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, controller 160 may 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.

[0037] The controller 160 may be positioned in a variety of locations throughout dishwasher 100. In the illustrated embodiment, the controller 160 may be located within a control panel area of door 116, as shown in FIGS. 1 and 2. In such an embodiment, input/output (I/O) signals may be routed between the control system and various operational components of dishwasher 100 along wiring harnesses that may be routed through the bottom of door 116. Typically, the controller 160 may be in operative communication with a user interface panel 162 through which a user may select various operational features and modes and monitor progress of the dishwasher 100. In one embodiment, the user interface 162 may represent a general purpose I/O (GPIO) device or functional block. In certain embodiments, the user interface 162 includes input components 164, such as one or more of a variety of electrical, mechanical or electro-mechanical input devices including capacitive touch screens/buttons, rotary dials, push buttons, and touch pads. The user interface 162 may further include one or more display components, such as a digital display device or one or more indicator light assemblies designed to provide operational feedback to a user. The user interface 162 may be in communication with the controller 160 via one or more signal lines or shared communication busses.

[0038] Referring now to FIGS. 3 through 5, an exemplary packaging piece will be described in detail. Dishwasher 100 may include one or more packaging materials which secure or protect pieces (e.g., door 116, latch assembly 118, etc.) during packing and transport of the appliance. The packaging materials may include a pack member 200. Pack member 200 may be selectively attached or positioned within door 116 (e.g., between inner door 117 and outer door 119). Pack member 200 may serve to provide stability and protection to certain sensitive elements at or within door 116, such as a detergent assembly (e.g., detergent cup, detergent feeder mechanism, etc.), any gaskets within door 116, electronics, or the like.

[0039] Pack member 200 may be formed from a molded pulp material. In detail, molded pulp may include one or more recycled or recyclable materials, such as recycled paperboard, newsprint, paper packaging, cardboard, or the like. External pack member 200 may include thick-walled molded, or slush molded pulp material capable of providing rigidity and maintaining shape through minor force applied thereto. In additional or alternative embodiments, external pack member 200 includes thin-walled molded pulp, including two or more layers of thin-walled molded pulp to form a single external pack member 200. However, it should be understood that the disclosure is not limited to the examples provided herein, and external pack member 200 may include thermoformed fiber molded pulp, processed molded pulp, any combination of two or more forms of molded pulp, or the like.

[0040] Pack member 200 may include a main panel 202. In detail, main panel 202 may define a first face 204 and a second face 206 opposite first face 204. First face 204 may face a first direction. According to some embodiments, the first direction may be parallel with the vertical direction V (e.g., when door 116 is in an open position, FIG. 5). Accordingly, the first direction may be directed upward along the vertical direction V while the second direction may be directed downward along the vertical direction V. First face 204 may thus face upward while second face 206 may face downward. It should be understood that the associated directions are provided by way of example and that main panel 202 (and pack member 200) may be oriented in any suitable direction.

[0041] Main panel 202 may define a first length L1 and a first width W1. Referring to the example orientation above, first length L1 may extend along the lateral direction L while first width W1 may extend along the transverse direction T. Additionally or alternatively, main panel 202 may define a first thickness T1 along the first direction (e.g., the vertical direction V).

[0042] Pack member 200 may include a first wing panel 208. First wing panel 208 may extend from main panel 202. For instance, first wing panel 208 may extend along a third direction different from the first direction and the second direction. Referring again to the example orientation above, the third direction may be parallel with the lateral direction L. First wing panel 208 may be offset from main panel 202 along the second direction (e.g., downward along the vertical direction V).

[0043] First wing panel 208 may define an upper surface 210 and a lower surface 212. Upper surface 210 may face the first direction (e.g., upward along the vertical direction V) while lower surface 212 may face the second direction (e.g., downward along the vertical direction V). Upper surface 210 may be offset downward from first face 204 of main panel 202. For instance, upper surface 210 may be positioned below first face 204 along the second direction. Accordingly, lower surface 212 may be positioned below second face 206 of main panel 202 along the second direction.

[0044] Pack member 200 may include a second wing panel 214. Second wing panel 214 may extend from main panel 202. For instance, second wing panel 214 may extend along a fourth direction different from the first direction and the second direction. The fourth direction may be opposite the third direction. For instance, referring again to the example orientation above, the third direction may be parallel with the lateral direction L. Second wing panel 214 may be offset from main panel 202 along the second direction (e.g., downward along the vertical direction V).

[0045] Second wing panel 214 may define a top surface 216 and a bottom surface 218. Top surface 216 may face the first direction (e.g., upward along the vertical direction V) while bottom surface 218 may face the second direction (e.g., downward along the vertical direction V). Top surface 216 may be offset downward from first face 204 of main panel 202. For instance, top surface 216 may be positioned below first face 204 along the second direction. Accordingly, bottom surface 218 may be positioned below second face 206 of main panel 202 along the second direction.

[0046] According to some embodiments, lower surface 212 of first wing panel 208 is positioned below bottom surface 218 of second wing panel 214 along the second direction. For instance, first wing panel 208 may define a second thickness T2 and second wing panel 214 may define a third thickness T3. Third thickness T3 may be greater than second thickness T2 (e.g., along the vertical direction V). In some instances, upper surface 210 and top surface 216 are coplanar with each other (e.g., along the lateral direction L). Thus, due to the greater thickness along the vertical direction, lower surface 212 may be provided lower than bottom surface 218 along the second direction.

[0047] First wing panel 208 may define a second length L2 along the third direction. Second wing panel 214 may define a third length L3 along the fourth direction. According to some embodiments, third length L3 is greater than second length L2 (e.g., along the lateral direction L). Thus, second wing panel 208 may extend further (e.g., along the fourth direction) from main panel 202 than first wing panel 208 (e.g., along the third direction).

[0048] Pack member 200 may include a plurality of first protrusions 220. The plurality of first protrusions 220 may protrude from upper surface 210 of first wing panel 208 (e.g., along the first direction). For instance, the plurality of first protrusions 220 may be arranged along upper surface 210 in a predetermined pattern. According to some embodiments, six first protrusions 220 are provided. However, it should be noted that any suitable number or amount of first protrusions 220 may be included according to specific embodiments. Additionally or alternatively, the plurality of first protrusions 220 may be spaced apart from each other (e.g., along the transverse direction T and the lateral direction L or third direction).

[0049] Hereinafter, a single first protrusion 220 will be described with the understanding that the description applies to each of the plurality of first protrusions 220. First protrusion 220 may have a predetermined shape. For instance, first protrusion 220 may be predominantly pyramid shaped. According to some embodiments, a base of first protrusion 220 (e.g., at upper surface 210) is larger than a distal end thereof (e.g., upward along the vertical direction V or first direction). Thus, first protrusion 220 may taper upward from the base toward the distal end. Advantageously, first protrusion 220 may be selectively accepted within a cavity (described below) of an adjacent rack member 220 (e.g., for ease of stacking and packaging of multiple rack pieces).

[0050] Pack member 200 may include a plurality of second protrusions 222. The plurality of second protrusions 222 may protrude from top surface 216 of second wing panel 214 (e.g., along the first direction). For instance, the plurality of second protrusions 222 may be arranged along top surface 216 in a predetermined pattern. According to some embodiments, nine second protrusions 222 are provided. However, it should be noted that any suitable number or amount of second protrusions 222 may be included according to specific embodiments. Additionally or alternatively, the plurality of second protrusions 222 may be spaced apart from each other (e.g., along the transverse direction T and the lateral direction L or third direction).

[0051] Hereinafter, a single second protrusion 222 will be described with the understanding that the description applies to each of the plurality of second protrusions 222. Similar to first protrusion 220, second protrusion 222 may have a predetermined shape. For instance, second protrusion 222 may be predominantly pyramid shaped. According to some embodiments, a base of second protrusion 222 (e.g., at top surface 216) is larger than a distal end thereof (e.g., upward along the vertical direction V or first direction). Thus, second protrusion 222 may taper upward from the base toward the distal end. Advantageously, second protrusion 222 may be selectively accepted within a cavity (described below) of an adjacent rack member 220 (e.g., for ease of stacking and packaging of multiple rack pieces).

[0052] Pack member 200 may include a first cavity 224 (FIG. 4). First cavity 224 may be formed into lower surface 212 of first wing panel 208. For instance, first cavity 224 may be formed upward into lower surface 212 (e.g., along the vertical direction V or the first direction). As mentioned above, first cavity 224 may correspond with the plurality of first protrusions 220 such that when a first pack member 200 is stacked on a second pack member 200, each first protrusion 220 may be accepted or received within first cavity 224. Therefore, a depth of first cavity 224 may be greater than a height of first protrusion 220. Additionally or alternatively, first cavity 224 may include or be divided into a plurality of cavities (e.g., as shown in FIG. 4).

[0053] Pack member 200 may include a second cavity 226 (FIG. 4). Second cavity 226 may be formed into bottom surface 218 of second wing panel 214. For instance, similar to first cavity 224, second cavity 226 may be formed upward into bottom surface 218 (e.g., along the vertical direction V or the first direction). As mentioned above, second cavity 226 may correspond with the plurality of second protrusions 222 such that when first pack member 200 is stacked on second pack member 200, each second protrusion 222 may be accepted or received within second cavity 226. Therefore, a depth of second cavity 226 may be greater than a height of second protrusion 222. Additionally or alternatively, second cavity 226 may include or be divided into a plurality of cavities (e.g., as shown in FIG. 4).

[0054] Pack member 200 may include a first tab 228. First tab 228 may extend from first wing panel 208 (e.g., along the third direction). For instance, first tab 228 may extend from lower surface 212 of first wing panel 208. In some instances, first tab 228 is coplanar with lower surface 212 of first wing panel 208. First tab 228 may be predominantly plate shaped. In some instances, a width of first tab 228 is substantially equal to the width of first wing panel 208 (e.g., along the transverse direction T). Accordingly, pack member 200 may be selectively coupled to door 116 (e.g., inner door panel 117 or outer door panel 119) via first tab 228 (e.g., by way of an adhesive, a fastener, or the like).

[0055] Pack member 200 may include a second tab 230. Second tab 230 may extend from second wing panel 214 (e.g., along the fourth direction). For instance, second tab 230 may extend from bottom surface 218 of second wing panel 214. In some instances, second tab 230 is coplanar with bottom surface 218 of second wing panel 214. Second tab 230 may be predominantly plate shaped. In some instances, a width of second tab 230 is substantially equal to the width of second wing panel 214 (e.g., along the transverse direction T). Accordingly, pack member 200 may be selectively coupled to door 116 (e.g., inner door panel 117 or outer door panel 119) via second tab 230 (e.g., by way of an adhesive, a fastener, or the like) together with first tab 228.

[0056] According to some embodiments, pack member 200 may include a coating 232. Coating 232 may be applied to pack member 200 after a formation thereof. As mentioned, pack member 200 may be formed from a recyclable molded pulp material (e.g., through shaping, compressing, etc.). Once the general shape of pack member 200 is defined, pack member 200 may be provided with coating 232 (e.g., by dipping, painting, spraying, or the like). Coating 232 may include a wax coating. Advantageously, pack member 200 may be waterproofed before being installed to door 116 (or any other portion or member within or outside of appliance 100).

[0057] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.