Thermoplastic refrigeration appliance handle with overmolded inserts

1. A door handle configured for mounting onto a surface of an appliance, comprising:

a gas-assist thermoplastic molded body having a central grip section intermediate of a mounting foot provided at each opposite end of said body, said central grip section being substantially hollow such that said central grip portion defines a channel therein;

at least one mounting foot of said molded body having a flat planar cross-sectional end face oriented relative to said body for mounting flush entirely against a front surface of the appliance, the at least one mounting foot of said molded body defining a passage between said mounting foot end face and the channel of said central grip portion, the passage of the at least one mounting foot of said molded body configured for permitting a flow of pressurized molding gas therethrough; and

a tubular metal insert overmolded in the at least one mounting foot of said molded body such that said insert is retained within the at least one mounting foot of said molded body by thermoplastic body material molded around at least a portion of said inert, a gas exit recess formed into said mounting foot end face between said insert and an extreme end of the at least one mounting foot of said molded body;

said insert having an open end generally flush with said mounting foot end face such that said mounting foot end face and insert mount flush entirely onto the front surface of the appliance, said insert having an inner cross-sectional profile configured for engagement over a stud provided on the front surface of the appliance;

wherein said insert comprises a contoured outer circumferential surface for enhanced retention in the at least one mounting foot of said molded body, said outer circumferential surface comprises an increasing diameter from said open end to an opposite end;

wherein said increasing diameter is defined in a plurality of incremental steps, the passage of the at least one mounting foot of said molded body positioned between the opposite end of said insert and a wall of the at least one mounting foot of said molded body;

wherein the at least one mounting foot of said molded body and said insert define a setscrew aperture therethrough.

2. The door handle as in claim 1 , wherein said body comprises a front side and opposite side surfaces, said set screw aperture defined in one of said side surfaces transverse to a longitudinal axis of said insert.

3. The door handle as in claim 1 , wherein said handle is configured as a refrigeration appliance handle.

4. The door handle as in claim 1 , wherein said insert comprises a generally cylindrical member.

5. The door handle as in claim 1 , further comprising a setscrew received within said setscrew aperture, said setscrew configured for engaging the stud provided on the front surface of the appliance in order to attach the at least one mounting foot of said molded body to the appliance.

6. The door handle as in claim 5 , wherein said molded body defines a setscrew hole aligned with said setscrew aperture, said setscrew received within the setscrew hole of said molded body in order to attach the at least one mounting foot of said molded body to the appliance.

7. The door handle as in claim 1 , wherein a final mounting step of the plurality of incremental step defines a curved lip, the curved lip positioned proximate the opposite end of the insert.

8. The door handle as in claim 1 , wherein said insert is surrounded by thermoplastic material of the at least one mounting foot of said molded body except for the open end of said insert that defines an exposed end face.

9. An appliance, comprising:

a cabinet defining an interior volume;

a door mounted to said cabinet, said door having a front surface;

an elongated handle attached to said front surface of said door, said handle comprising

a gas-assist thermoplastic molded body having a central grip section intermediate of a mounting foot provided at each opposite end of said body, said central grip section being substantially hollow such that said central grip portion defines a channel therein;

at least one mounting foot of said molded body having a flat planar cross-sectional end face oriented relative to said body for mounting flush entirely against said front surface of said door, the at least one mounting foot of said molded body defining a passage between said mounting foot end face and the channel of said central grip portion, the passage of the at least one mounting foot of said molded body configured for permitting a flow of pressurized molding gas therethrough;

a tubular metal insert overmolded in the at least one mounting foot of said molded body such that said insert is retained within the at least one mounting foot of said molded body by thermoplastic body material molded around at least a portion of said inert, said insert having an open end generally flush with said mounting foot end face such that said mounting foot end face and inert mount flush entirely onto said front surface of said door, said insert having an inner cross-sectional profile configured for engagement over a stud protruding from said front the surface of said door, a gas exit recess formed into said mounting foot end face between said insert and an extreme end of the at least one mounting foot of said molded body; and

a setscrew aperture defined through the at least one mounting foot of said molded body and said insert;

wherein said insert comprises a contoured outer circumferential surface for enhanced retention in the at least one mounting foot of said molded body, said outer circumferential surface comprises an increasing diameter from said open end to an opposite end;

wherein said increasing diameter is defined in a plurality of incremental steps, the passage of said the at least one mounting foot of said molded body positioned between the opposite end of said insert and a wall of said molded body.

10. The appliance as in claim 9 , wherein said body comprises a front side and opposite side surfaces, said set screw aperture defined in one of said side surfaces transverse to a longitudinal axis of said insert.

11. The appliance as in claim 9 , wherein said appliance is a refrigeration appliance.

12. The appliance as in claim 9 , wherein said insert comprises a generally cylindrical member.

13. The appliance as in claim 9 , further comprising a setscrew received within said setscrew aperture, said setscrew configured for engaging the stud protruding from said front the surface of said door in order to attach the at least one mounting foot of said molded body to the door.

14. The appliance as in claim 13 , wherein said molded body defines a setscrew hole aligned with said setscrew aperture, said setscrew received within the setscrew hole of said molded body in order to attach the at least one mounting foot of said molded body to the door.

15. The appliance as in claim 9 , wherein a final mounting step of the plurality of incremental step defines a curved lip, the curved lip positioned proximate the opposite end of the insert.

16. The appliance as in claim 9 , wherein said insert is surrounded by thermoplastic material of the at least one mounting foot of said molded body except for the open end of said insert that defines an exposed end face.