Information
-
Patent Grant
-
6773668
-
Patent Number
6,773,668
-
Date Filed
Monday, April 17, 200024 years ago
-
Date Issued
Tuesday, August 10, 200419 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Till; Terrence R.
- Chorbaji; Monzer R.
Agents
-
CPC
-
US Classifications
Field of Search
US
- 422 1
- 422 28
- 422 119
- 422 232
- 422 255
- 422 261
- 422 265
- 422 283
- 422 292
- 422 300
- 422 307
- 422 311
- 422 264
- 422 279
- 134 26
- 134 34
- 134 36
- 134 42
- 134 93
- 068 17 R
- 137 268
- 423 6585
- 210 1981
- 210 199
- 210 752
- 222 130
- 222 1455
- 222 1456
- 222 1811
- 222 1851
- 222 477
- 222 476
- 222 318
- 222 564
-
International Classifications
- A61L200
- B08B700
- D06F2900
- E03B1100
- B01D1500
-
Abstract
A solid detergent dispenser for use with a dishwashing machine includes a chamber and a lid. The chamber is configured and arranged to receive a solid detergent having a particular composition. A water inlet receives water from a water source, and the water flows through a tunnel into the bottom of the chamber. The chamber is flooded with water from the bottom to ensure relatively constant erosion of the solid detergent, which ensures that a relatively constant concentration of the solid detergent is used in the dishwashing machine. A water outlet allows water to flow out of the chamber into the dishwashing machine. The water must flow into the chamber faster than it flows out of the chamber to ensure that the appropriate amount of dissolution of the solid detergent occurs. The only valve used in the preferred embodiment is a valve to control the amount of water flowing into the water inlet.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a detergent dispenser, and more specifically, the present invention relates to a solid detergent dispenser for use with a dishwashing machine.
2. Description of the Prior Art
A variety of spray-type dispensers for dispensing various cleaning compositions have been disclosed in U.S. Pat. Nos. 4,826,661; 4,690,305; 4,687,121; 4,426,362; and Re 32,818. Generally, a spray-type dispenser functions by impinging a liquid spray upon an exposed surface of a solid cleaning composition to dissolve a portion of the composition. Then, the concentrate solution comprising the dissolved composition is immediately directed out of the dispenser to a storage reservoir or directly to a point of use.
U.S. Pat. No. 4,826,661 by Copeland et al. discloses a solid block chemical dispenser for cleaning systems. The dispenser comprises a spray nozzle for directing a uniform dissolving spray onto an exposed surface of the solid block of cleaning composition and a spring or hydraulic piston coupled to the nozzle for biasing the nozzle towards the solid block and thereby maintaining a substantially constant distance between the nozzle and the exposed surface of the solid block of cleaning composition even though the exposed surface recedes due to dissolution by the dissolving spray.
U.S. Pat. No. 4,690,305 to Copeland discloses another solid block chemical dispenser for cleaning systems. The dispenser comprises a substantially horizontal support screen within a housing which retainably supports a solid block of wash chemical thereabove. The support screen divides the housing into an upper cylindrical storage portion and a lower funnel shaped collector portion. A spray forming nozzle is mounted within the collector portion below the generally horizontal screen for directing a spray of water at substantially the entire downwardly facing surface of the wash chemical block supportably retained above the support screen. The dissolved wash chemical passes through the support screen, is collected by the collector portion of the housing, and directed to its utilization point. Spray controls, either manual or electronic, control the spray of water through the nozzle in response to a control signal. The dispenser is configured for mounting to a vertical surface and is loaded through an upper access port normally closed by a door. A safety switch prevents the spray of water from the nozzle whenever the door is open.
Another solid block chemical dispenser for cleaning systems is disclosed in U.S. Pat. No. 4,687,121 by Copeland. A spray-type dispenser for on-demand dispensing of a solid block of chemical retained within a container in the form of an aqueous chemical solution of substantially constant concentration comprises an upwardly disposed spray nozzle, a three-dimensional support screen for supporting the solid block of chemical above the spray nozzle, and a housing enclosing the spray nozzle and support screen. The housing and support screen define an annular cavity. In operation, a container retaining a solid block of a water-soluble chemical is placed within the dispenser such that the support screen contacts the chemical but not the container, thereby allowing the container to descend, by force of gravity, into the annular cavity as the chemical retained therein is dissolved. The ability of the container to move in relation to dissolution of the chemical retained therein allows the dispenser to maintain a substantially constant distance between the spray nozzle and the exposed dissolving surface of the chemical and thereby maintains a substantially constant concentration of the aqueous chemical solution dispensed.
A detergent dispenser for efficiently converting one or more solid block detergent compositions into concentrated detergent solutions is disclosed in U.S. Pat. No. 4,426,362 by Copeland et al. A housing configured for mounting to a solid surface defines a substantially enclosed inner cavity, access and discharge ports, and an opening into the inner cavity. Retaining means holds a charge of solid block detergent composition, which may include a plurality of different and even chemically incompatible detergent composition components, in fixed predetermined position within the inner cavity, exposing at least one broad surface of the detergent block. Nozzle means projects into the cavity and directs a pressurized liquid spray against substantially the entire exposed detergent surface(s), dissolving a portion thereof, which is collected by the housing and passes through the discharge port. The nozzle means may be disposed above or below the exposed detergent surface. One embodiment of the retaining means comprises a disposable or rechargeable cartridge receptacle member, which is capable of being removably inserted into the inner cavity through the access port. The cartridge receptacle may include an overlying screen member and may be configured to define a plurality of different receptacles. Closure means and safety switching means cooperatively prevent hazardous spray from leaving the inner cavity.
Finally, U.S. Pat. No. Re 32,818 discloses a cast detergent-containing article and method of using the same. Solid cast detergent-containing articles are produced for use in automatic dishwashing machines. A liquid detergent composition is cast into a mold where it is allowed to solidify. The solid cast detergent, surrounded on all but its upper surface by the mold, is used in automatic dishwashing machines having a dispensing device designed to dispense a liquid aqueous detergent formed from the solid cast detergent using an impinging liquid spray. The liquid aqueous detergent flows out of the dispensing device generally simultaneously with its formation in the dispenser. The cast detergent composition includes an alkaline hydratable chemical and optionally further includes one or more preformed cores or plugs comprising an available chlorine source, a defoamer, or the like.
Therefore, in sum, prior art utilizes a solid detergent block and relies on an impinging liquid spray to form a liquid detergent. The impinging liquid spray usually results in strange erosion of the detergent block, which negatively affects the rate of dissolution as the block is dissolved unevenly over time. Furthermore, prior art requires the use of additional valves and electronics to control the amount of water used in the dispenser. The present invention prevents the uneven erosion of the solid detergent block without the use of additional valves and/or electronics.
SUMMARY OF THE INVENTION
The present invention relates to a detergent dispenser, and more specifically, the present invention relates to a solid detergent dispenser for use with a washing machine. In a preferred embodiment method for dispensing a use solution from a solid detergent into a washing machine, a solid detergent having a bottom is placed in a dispenser having a chamber. The chamber defines a cavity and includes a water inlet and a water outlet, and the cavity is configured and arranged to receive the solid detergent. Water is supplied to a level within the cavity of the chamber so the solid detergent is in contact with the water. The solid detergent is flooded with water from the bottom of the solid detergent, and an amount of the solid detergent is dissolved in the water to form a use solution. Then, the use solution is dispensed from the water outlet into the washing machine.
In a preferred embodiment detergent dispenser, a chamber defines a cavity configured and arranged to receive a solid detergent and water. The chamber includes a bottom, a water inlet, and a water outlet. The water inlet is configured and arranged to receive water from a water source, and the water flows from the water inlet into the cavity where it floods the solid detergent from the bottom of the solid detergent and dissolves a portion of the solid detergent to form a use solution. The water outlet is configured and arranged to dispense substantially all of the use solution out of the chamber, and substantially all of the use solution is dispensed out of the chamber when the detergent dispenser is not in use.
In a preferred embodiment dispenser for dispensing a use solution from a solid detergent into a washing machine, a chamber includes a front portion, a first side portion, a second side portion, a back portion, a bottom portion, a top portion, and an opening. The chamber defines a cavity configured and arranged to receive the solid detergent and the water. The back portion of the chamber further comprises a water inlet proximate the top portion and a water outlet proximate the bottom portion. The water inlet is configured and arranged to receive the water from the water source. The water flows from the water inlet into the cavity from the bottom of the chamber where it contacts the solid detergent and dissolves a portion of the solid detergent to form a use solution. An air gap is proximate the water inlet to prevent the water from returning to the water source. A tunnel is proximate the back portion and the second side portion, wherein water travels from the water inlet, through the tunnel, and into the bottom portion of the chamber. The water fills the chamber to a level within the cavity to contact the solid detergent, wherein uniform dissolution of the solid detergent occurs thereby maintaining a relatively constant concentration and a relatively constant shape of the solid detergent. The water outlet is configured and arranged to dispense substantially all of the use solution out of the chamber and into the washing machine so that substantially all of the water is dispensed out of the chamber when the dispenser is not in use. A lid is connected to the top portion of the chamber to cover the opening of the chamber into the cavity.
In a preferred embodiment method for dispensing detergent, a detergent with a particular composition is placed into a dispenser having a cavity, a water inlet, and a water outlet. The cavity is configured and arranged to receive and support the detergent. Water is supplied to the water inlet and a valve is used to control the amount of water flowing into the water inlet. The dispenser is flooded with water to a level within the cavity wherein water contacts the detergent and dissolves a portion of the detergent to form a use solution. The use solution is then released through the water outlet, whereby a particular concentration of the use solution is dispensed. Water outlet is always open, and water is supplied to the water inlet at a rate faster than water is released through the water outlet, thus allowing water to contact the detergent and dissolve a portion of the detergent to form the use solution.
In a preferred embodiment dispenser for dispensing a use solution from a solid detergent into a washing machine, a dispenser includes a cavity, a water inlet, and a water outlet. The cavity is configured and arranged to receive and support a solid detergent. A conduit connects the water inlet to a water source, and a valve connected to the conduit controls the flow of water from the water source into the water inlet. The cavity is flooded with water to a level within the cavity, water contacts the solid detergent from the bottom of the solid detergent to form a use solution, and uniform dissolution of the solid detergent occurs, thus maintaining a relatively constant concentration and shape of the solid detergent. A hose member connects the water outlet to a washing machine, and substantially all of the use solution is dispensed out of the cavity through the water outlet and into the washing machine via the hose member.
In a preferred embodiment detergent dispenser for use with a washing machine, a dispenser has a chamber including a cavity, a water inlet, and a water outlet. A conduit connects the water inlet to a water source, and a valve is operatively connected to the conduit to control the amount of water flowing from the water source into the water inlet. A hose member is operatively connected to the water outlet and has a curvature. The curvature extends in an upward direction at a height greater than the water outlet and then extends downward below the water outlet. A first level of water within the cavity is controlled by the valve to reach a height below the curvature and does not flow out of the cavity. A second level of water within the cavity is controlled by the valve to reach a height greater than the curvature, and a siphoning effect occurs so all the water flows out of the dispenser via the water outlet.
In another preferred embodiment method of dispensing a use solution from a solid detergent into a washing machine, a solid detergent is placed inside a dispenser having a cavity, a water inlet, a water outlet, and a hose member operatively connected to the water outlet. The hose member has a curvature, wherein the curvature extends in an upward direction at a height greater than the water outlet and then extends downward below the water outlet. Water is supplied to the water inlet, and water flows from the water inlet to the cavity. The amount of water flowing into the water inlet is controlled by a valve. Water is flooded into the cavity to a first level, and the first level of water contacts the solid detergent contained within the dispenser to form a use solution. Water is then flooded into the cavity to a second level, and the second level of water initiates the flow of substantially all of the use solution out of the water outlet into a washing machine
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a side perspective view of a preferred embodiment dispenser constructed according to the principles of the present invention.
FIG. 2
is another side perspective view of the dispenser shown in FIG.
1
.
FIG. 3
is a rear perspective view of the dispenser shown in FIG.
1
.
FIG. 4
is a top perspective view of the dispenser shown in
FIG. 1
with the lid removed.
FIG. 5
is another side perspective view of the dispenser shown in FIG.
1
.
FIG. 6
is another side perspective view of the dispenser shown in FIG.
1
.
FIG. 7
is a front view of a solid block detergent for use with the dispenser shown in FIG.
1
.
FIG. 8
is a perspective view of a solid pellet detergent for use with the dispenser shown in FIG.
1
.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment dispenser constructed according to the principles of the present invention is designated by the numeral
10
in
FIGS. 1-6
.
FIG. 16
show a preferred embodiment dispenser
10
in various views. FIG.
5
and
FIG. 6
show numerous hidden lines adjacent the edges and these hidden lines are to show the curvature of the edges, but it is understood that the edges could be square edges. Dispenser
10
includes chamber
11
and lid
34
. Chamber
11
includes a rounded front portion
12
connected on one side to first side portion
13
and connected on the opposite side to second side portion
14
. First side portion
13
and second side portion
14
are also connected to back portion
15
on the sides opposite those connected to front portion
12
. Bottom portion
16
is connected to the bottom edges of portions
12
-
15
, thus enclosing the bottom of chamber
11
. Top portion
17
is a narrow, rectangular shaped portion of chamber
11
connected to the top edge of back portion
15
and interconnecting the top edge of first side portion
13
proximate back portion
15
and first side
22
of water inlet
21
. Top portion
17
does not extend along the full length of back portion
15
and only covers a relatively small segment of the top surface of chamber
11
. Therefore, top portion
17
does not enclose the top of chamber
11
, thus leaving opening
32
into chamber
11
.
Chamber
11
defines cavity
31
, which is accessible through opening
32
and is configured and arranged to receive solid detergent
50
or
60
and water from water inlet
21
. Within cavity
31
, solid detergent
50
or
60
rests on top of support member
42
, shown in FIG.
5
and
FIG. 6
, which is proximate bottom portion
16
and extends across cavity
31
. Support member
42
is a screen type structure that holds solid detergent
50
or
60
and allows water to pass through. Back portion
15
of chamber
11
includes water inlet
21
proximate top portion
17
and second side portion
14
and water outlet
29
proximate bottom portion
16
and first side portion
13
. Back portion
15
also includes overflow outlet
30
, which allows excess water inside cavity
31
of chamber
11
to readily escape in the event too much water flows into cavity
31
.
Water inlet
21
includes first side
22
, second side
23
, top
25
, and tunnel
27
. First side
22
is proximate back portion
15
and second side portion
14
, and second side
23
is proximate back portion
15
and top portion
17
. First side
22
and second side
23
are parallel to one another and extend approximately 1½ inches above top portion
17
. The top edges of first side
22
and second side
23
are interconnected by top
25
, which includes opening
26
where water flows from a water source into water inlet
21
. Opening
26
has a diameter of approximately ¼ to ½ inch. The space between first side
22
and second side
23
forms air gap
24
. A one inch gap in air gap
24
is sufficient to ensure that excess water flowing into water inlet
21
does not return to the water source, thereby contaminating the water source. Providing air gap
24
is mandated by the ASSE plumbing code for back flow prevention.
Water inlet
21
is configured and arranged to receive water from a water source via conduit
56
. Conduit
56
is operatively connected to water inlet
21
and to the water source, and valve V regulates the amount of water flowing from the water source into water inlet
21
. Tunnel
27
is approximately 6½ inches long with wall dimensions of approximately one inch by one inch and extends from top portion
17
to approximately 1½ inches above bottom portion
16
, and opening
28
of tunnel
27
allows water to flow into cavity
31
. Therefore, the water flows into opening
26
, through tunnel
27
, and out of opening
28
into cavity
31
proximate bottom portion
16
of chamber
11
. In the preferred embodiment, chamber
11
is filled with water from the bottom and the water level increases as water flows into the bottom of cavity
31
from opening
28
. Opening
28
is located proximate bottom portion
16
at approximately the same height as support member
42
. Therefore, the water fills cavity
31
beneath solid detergent
50
or
60
first and then rises above support member
42
to contact solid detergent
50
or
60
from the bottom of the detergent. Filling cavity
31
with water from the bottom of cavity
31
minimizes the vortices and the eddies, which tend to erode detergents unevenly. Less turbulence in the water occurs when cavity
31
is filled with water from the bottom, and this allows for less detergent to be dispensed than is typically dispensed in spray-type dispensers. In addition, this results in uniform dissolution of the detergent and a relatively constant concentration and shape of the detergent is maintained. Although it is recognized that cavity
31
may be flooded from the top, more turbulence in the water will occur and the detergents will likely erode unevenly resulting in a variance in concentration and shape of the detergent.
As cavity
31
is flooded with water from the bottom of chamber
11
to a level proximate the middle of chamber
11
, the water contacts the solid detergent
50
or
60
and dissolves a portion of the solid detergent
50
or
60
, creating a use solution. In the preferred embodiment, chamber
11
is flooded with water approximately 3 to 4 inches above support member
42
. Only a relatively small portion of solid detergent
50
or
60
is dissolved each time water fills cavity
31
and contacts solid detergent
50
or
60
. In the preferred embodiment, the amount of water flowing into cavity
31
may be adjusted by valve V controlling the amount of water flowing into water inlet
21
, and the water level within cavity
31
is important to ensure the correct concentration of detergent used in the dishwashing machine. Since different models of dishwashing machines may have different sump sizes, the use solution may require different concentrations of detergent, and the concentration of detergent is controlled by allowing either more or less water into cavity
31
of dispenser
10
. In a preferred embodiment dispenser
10
, a solenoid valve or a meter valve is used to pump water into water inlet
21
, but it is understood that any valve known in the art for pumping water into water inlet
21
may be used. A valve may not even be necessary if the dependent dishwashing machine has a solenoid valve controlling the input of the rinse water (e.g. Hobart AM Series). Also, particular detergents must be used with dispenser
10
to ensure the correct concentration of detergent is dissolved in the water. This is discussed in greater detail below.
Water outlet
29
is configured and arranged to allow substantially all of the water and the use solution to flow out of cavity
31
and into the dishwashing machine. Water outlet is approximately ¼ inch above bottom portion
16
of chamber
11
. When substantially all of the water and the use solution flow out of cavity
31
, substantially all means that enough of the water and the use solution are dispensed so that the water and the use solution are not in contact with solid detergent
50
or
60
. The diameter of water outlet
29
is approximately ½ inch, and a hose is connected to water outlet
29
to allow the water and dissolved detergent to flow into the dishwashing machine. Although it is unlikely that solid pellet detergent
60
would flow out of cavity
31
along with the use solution, it is possible, especially if overflow outlet
30
is used. Therefore, a screen or other sieve type member known in the art may be used to prevent solid pellet detergent
60
from flowing out of water outlet
29
or overflow outlet
30
along with the water and dissolved detergent.
In a preferred embodiment, water outlet
29
is always open and substantially all of the water in cavity
31
is dispensed through water outlet
29
so that no water is in contact with solid detergent
50
or
60
when no water is flowing into water inlet
21
and dispenser
10
is not in use. Therefore, in order for dispenser
10
to work properly, the rate of flow of water into cavity
31
must be greater than the rate of flow of water out of water outlet
29
. The rate of water flowing into water inlet
21
depends upon several factors including the diameter and length of conduit
56
connected to water inlet
21
and the amount of pressure in the water supply. The maximum outflow of water from water outlet
29
is approximately 1.8 gallons per minute.
In another preferred embodiment, a hose member
57
is operatively connected to water outlet
29
to dispense the water and the use solution into the dishwashing machine. Hose member
57
extends downward below water outlet
29
to connect to the dishwashing machine. As hose member
57
approaches water outlet
29
, hose member
57
extends upward at a height greater than the height of water outlet
29
with respect to its location on back portion
15
and then extends downward to operatively connect to water outlet
29
. This curvature of hose member
57
prevents water at a level below the curvature from readily flowing out of water outlet
29
because the water is not initially able to flow up and beyond the point of curvature of hose member
57
. However, once water begins flowing into cavity
31
at a level above the curvature, water will begin flowing out of cavity
31
via hose member
57
connected to water outlet
29
. Adding water to a level above the curvature initiates the flow of substantially all of the use solution out of water outlet
29
, and water will flow out of water outlet
29
because a siphoning effect occurs. The siphoning effect occurs because once water reaches a level above the curvature of hose member
57
, water outlet
29
fills up with water completely before the water drains out of water outlet
29
very quickly. Once the water begins flowing out of water outlet
29
, it will continue to flow until the water level within cavity
31
is below water outlet
29
. This is because the siphoning effect creates a vacuum within hose member
57
and water drains out of water outlet
29
even though water is no longer being supplied to water inlet
21
. As a result, the only valve necessary for dispenser
10
is valve V to control the water flowing from the water source into water inlet
21
, and an additional valve is not required to control the amount of water flowing out of water outlet
29
. The rate of water flowing out of water outlet
29
depends upon the diameter of hose member
57
, but the maximum outflow of water from water outlet
29
is approximately 1.8 gallons per minute.
The preferred embodiment including hose member
57
is best suited for use with solid block detergent
50
because a longer exposure time with water is necessary to obtain the desired concentration of detergent in the use solution. This is because there is less effective surface area in contact with the water and, therefore, detergent
50
has a lower solubility rate than detergent
60
. The preferred embodiment allows cavity
31
to be filled with a level of water below the curvature of hose member
57
for a period of time, allowing the water to contact detergent
50
for the period of time without draining out of cavity
31
. Therefore, the detergent soaks in the water to create a use solution, and then the water and use solution drain out of water outlet
29
when more water is added to cavity
31
. The addition of more water within cavity
31
above the curvature of hose member
57
initiates the siphoning effect of water outlet
29
, thus dispensing the use solution into the dishwashing machine.
Lid
34
includes a rounded front
36
, which is connected on one side to first side
37
and is connected on its opposite side to second side
38
. The center portion of front
36
is wider than the side portions of front
36
, and therefore front
36
tapers slightly as it approaches sides
37
and
38
. In addition, sides
37
and
38
are wider where they connect to front
36
and taper as they approach back portion
15
. The tapering of front
36
and sides
37
and
38
from front to back ensures that opening
32
of cavity
31
remains covered by lid
34
even though lid
34
may not be closed completely on chamber
11
. Therefore, as shown in
FIG. 5
, lid
34
still covers opening
32
of cavity
31
when top
35
is at an angle of approximately 0° to 30° with respect to bottom portion
16
. Front
36
, first side
37
, and second side
38
of lid
34
conform to front portion
12
, first side portion
13
, and second side portion
14
of chamber
11
, respectively. Top
35
of lid
34
is connected to the top edges of front
36
, first side
37
, and second side
38
and effectively covers opening
32
of cavity
31
when lid
34
is attached to chamber
11
. Back
39
of top
35
is connected to top portion
17
of chamber
11
via a hinge member. It is understood that detergent dispenser
10
may be its own, separate unit or it may be combined within a unit including electronic controls for the dishwashing machine and a rack.
An additional feature of chamber
11
is low level indicator tab
18
. Low level indicator tab
18
is an extension of the center top edge of front portion
12
and protrudes through opening
40
of top
35
when the level of solid detergent
50
or
60
is low. A label displaying the word “low” or some other word or phrase on it may be placed on tab
18
as a reminder that the level of solid detergent
50
or
60
is low and should be refilled. Curved structures
41
, shown in FIG.
5
and
FIG. 6
, are proximate opening
40
on the inside surface of top
35
of lid
34
. Curved structures
41
are configured and arranged to contact solid detergent
50
or
60
and as the level of solid detergent
50
or
60
decreases, lid
34
lowers. As lid
34
gradually lowers onto chamber
11
, tab
18
gradually begins to protrude through opening
40
and indicates when solid detergent
50
or
60
should be refilled.
Other additional features of chamber
11
include first connecting member
19
and second connecting member
20
. First connecting member
19
includes apertures
19
a
and second connecting member
20
includes apertures
20
a
. Screws or some other type of fastening means are positioned through apertures
19
a
and
20
a
to secure connecting members
19
and
20
to a dishwashing machine, thus securing dispenser
10
to a dishwashing machine.
As stated previously, only particular detergents may be used with dispenser
10
to ensure the right rate of dissolution of the detergent is achieved, thus ensuring the right concentration of detergent is used in the dishwashing machine. Typically, powder detergents are unsuitable detergents to be used with dispenser
10
because they tend to dissolve too quickly and clog dispenser
10
. A problem that may occur with solid caustic detergents is that sloughing may occur when the detergents become too saturated with water. When a detergent absorbs too much water, it becomes pasty and falls apart in clumps that are not effective for use with a dispenser because the desired concentration cannot be obtained. Solid detergents
50
and
60
have a composition that prevents this from happening.
In the preferred embodiment, only a relatively small portion of solid detergent
50
or
60
is dissolved each time water floods cavity
31
. Therefore, a uniform erosion pattern of the detergent occurs when it is dissolved in water to ensure the right concentration of detergent is used in the dishwashing machine. Uniform erosion is important because there is a linear relationship between the surface area of the detergent exposed to the water and the number of grams of detergent dispensed. Therefore, if the shape of the detergent remains relatively constant, the surface area of the detergent will remain relatively constant and the exposure to water will keep dispensing rate relatively constant.
Generally, there are three variables that determine the rate of dissolution of the detergent, but these variables are not exhaustive. These variables are the amount of water used within cavity
31
to dissolve the detergent, the length of time the detergent is exposed to the water, and the temperature of the water. The more water that flows into cavity
31
to contact the detergent and the longer the detergent is exposed to the water, the more detergent will dissolve into the water. Although the temperature of the water used to flood cavity
31
does not make a huge difference in the rate of dissolution of the particular detergents used in dispenser
10
, it affects the rate of dissolution more as the length of time the detergents are exposed to the water increases. See Tables 1, 2, and 3 below.
TABLE 1
|
|
Solubility Ranges for Solid Block Detergent (500 g)
|
in 1000 ml of Water
|
Water Temperature
Time
Weight Dissolved
|
(Fahrenheit)
(seconds)
(grams)
|
|
120
30
0.60
|
120
60
1.62
|
140
30
4.60
|
140
60
10.20
|
160
30
7.42
|
160
60
18.30
|
|
TABLE 2
|
|
Solubility Ranges for Solid Pellet Detergent (500 g) in
|
1000 ml of Water
|
Temperature
Time
Weight Dissolved
|
(Fahrenheit)
(seconds)
(grams)
|
|
120
30
2.10
|
120
60
5.75
|
140
30
16.32
|
140
60
36.55
|
160
30
35.87
|
160
60
52.40
|
|
TABLE 3
|
|
Solubility Ranges for Solid Caustic Detergent (500 grams)
|
in 1000 ml of Water
|
Temperature
Time
Weight Dissolved
|
(Fahrenheit)
(seconds)
(grams)
|
|
120
30
30.20
|
120
60
101.80
|
140
30
60.80
|
140
60
220.40
|
|
Table 1 represents detergents having the same composition as solid block detergent
50
, and Table 2 represents detergents having the same composition as solid pellet detergent
60
. Table 3 represents typical powder detergents having compositions that will dissolve too quickly and, therefore, they will be unsuitable detergents for use with dispenser
10
.
TABLE 4
|
|
Solubility of Solid Carbonate Based Detergent with
|
Varying Effective Surface Areas
|
Effective Surface Area
Product Dispensed
|
(in
2
)
(grams)
|
|
25.12
43.20
|
35.33
48.00
|
60.44
62.40
|
125.60
168.00
|
|
Table 4 shows how the effective surface area, the area in which water has the opportunity to come in contact with the surface of the detergent, affects the amount of detergent dispensed. Dispenser
10
was loaded with various shapes of the solid carbonate based detergent. The 25.12 in
2
effective surface area represents a cylindrical shaped detergent with a four inch diameter, the 35.33 in
2
effective surface area represents a cylindrical shaped detergent with a five inch diameter, and the 60.44 in
2
effective surface area represents a cylindrical shaped detergent with a seven inch diameter. The 125.60 in
2
effective surface area represents a pellet shaped detergent. Then, six gallons of water was passed through dispenser
10
at a rate of two gallons per minute. The effluent from dispenser
10
was collected and the water was evaporated, and the resulting solid was weighed. From this test, the results of which are shown in Table 4, it was determined that the smaller the effective surface area, the less number of grams available for dispensing into the wash tank. Therefore, to get the desired concentration of use solution from the various shapes of detergent, the three variables discussed above may be adjusted to accommodate the different effective surface areas. For example, the length of time the detergent is exposed to water should be shortened for pellets due to the greater effective surface area, and therefore, dispenser
10
should be used without hose member
57
to eliminate the siphoning effect.
FIG. 7
shows a solid block detergent
50
. Solid block detergent
50
has a unique elliptical profile. The characteristics ensure that solid block detergent
50
may be placed inside only particular dispensers having a correspondingly shaped location for receiving detergent. The shape of solid block detergent
50
and the correspondingly shaped location for receiving the detergent within a particular dispenser also ensures that an unsuitable substitute may not easily be placed inside the dispenser for use in a dishwashing machine. In
FIG. 7
, the solid block detergent
50
is shown having a cast solid block
51
, which is revealed by removal of part of the packaging
52
. Solid block detergent
50
has a mass of at least 500 grams, preferably 1 to 10 kilograms. Packaging
52
includes score lines
55
. Score lines
55
provide easy removal of packaging
52
from cast solid block
51
. Examples of how the composition of solid block detergent
50
is processed are disclosed in U.S. patent application Ser. Nos. 08/781,493 and 08/782,457 by Lentsch et al. filed on Jan. 13, 1997, the disclosures of which are incorporated by reference herein.
Typically two thin solid blocks
51
are stacked upon one another inside cavity
31
to retain a relatively constant supply of detergent within dispenser
10
. A constant supply of detergent is important to maintain a relatively constant rate of dissolution of the detergent and therefore to maintain a relatively constant concentration of detergent for use in a dishwashing machine. Solid block detergent
50
has a dimension of approximately 2.13 by 4.00 by 6.36 inches. The solubility ranges for solid block detergent
50
are shown above in Table 1, and the preferred concentration of the use solution created from solid block detergent
50
flowing out of dispenser
10
is approximately 0.25% to 0.50% weight to weight.
In the preferred embodiment, the preferred shape of the solid detergent for use in dispenser
10
is a pellet.
FIG. 8
shows a perspective view of solid pellet detergent
60
. Solid pellet detergent
60
has a dimension of approximately 0.75 by 2.00 inches. Approximately 50 pellets are used with dispenser
10
. The solubility ranges for solid pellet detergent
60
are shown above in Table 2, and the preferred concentration of the use solution created from solid pellet detergent
60
flowing out of dispenser
10
is approximately 0.75% to 1.25% weight to weight. The preferred concentration of the use solution created from solid pellet detergent
60
is higher than the use solution created from solid block detergent
50
, and this is due to the increased surface area of solid pellet detergent
60
exposed to the water flowing into cavity
31
.
The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
Claims
- 1. A method for dispensing a use solution from a solid detergent into a washing machine, comprising the steps of:a. placing a solid detergent having a bottom in a dispenser, the dispenser having a chamber, the chamber defining a cavity and including a water inlet and a water outlet, and the cavity being configured and arranged to receive the solid detergent; b. supplying water to the water inlet of the dispenser, wherein the water is supplied to a level within the cavity of the chamber thereby having contact with the solid detergent; c. flooding the cavity with water from the bottom of the solid detergent; d. dissolving a relatively small portion of the solid detergent in the water and forming a use solution, the solid detergent being dispensed completely over more than one flooding of water within the cavity; and e. releasing the use solution from the dispense via the water outlet, wherein the use solution flows out of the chamber through the water outlet and into the washing machine.
- 2. The method for dispensing a use solution from a solid detergent into a washing machine of claim 1, wherein the level of water within the cavity of the chamber is approximately ¼ inch to 3 inches.
- 3. The method for dispensing a use solution from a solid detergent into a washing machine of claim 1, wherein the water has a temperature of approximately 80 to 180° F.
- 4. The method for dispensing a use solution from a solid detergent into a washing machine of claim 1, wherein the water outlet is always open and the water flows into the water inlet at approximately 0.1 gallon to 2 gallons per minute and the water flows out of the water outlet at approximately 0.1 to 1 gallon per minute.
- 5. The method for dispensing a use solution from a solid detergent into a washing machine of claim 1, wherein the use solution from the solid detergent is dispensed into the washing machine having a concentration of 0.1% to 1.5% weight to weight.
- 6. The method for dispensing a use solution from a solid detergent into a washing machine of claim 1, wherein uniform dissolution of the solid detergent occurs, thereby maintaining a relatively constant concentration and a relatively constant shape of the solid detergent.
- 7. The method for dispensing a use solution from a solid detergent into a washing machine of claim 1, further comprising flooding said cavity with water to a first level, wherein said first level of water contacts said solid detergent contained within said cavity to form a use solution, said solid detergent being dispensed completely over more than one flooding of water within said cavity, and flooding said cavity with water to a second level, wherein said second level of water initiates the flow of substantially all of said use solution out of said water outlet into a washing machine.
- 8. A detergent dispenser, comprising:a. solid detergent having a bottom; b. a water source providing water to the detergent dispenser and c. a chamber defining a cavity configured and arranged to receive the solid detergent and the water, said chamber including a water inlet and a water outlet, the water inlet being configured and arranged to receive the water from the water source, wherein the water flows into the cavity, floods the solid detergent from the bottom of the solid detergent and dissolves a portion of the solid detergent to form a use solution, the solid detergent being dispensed completely over more than one flooding of water within the cavity, and wherein the water outlet is configured and arranged to dispense substantially all of the use solution out of the chamber when the detergent dispenser is not in use.
- 9. The detergent dispenser of claim 8, further comprising a level of water within the cavity of the chamber, wherein the level of water is approximately ¼ inch to 3 inches.
- 10. The detergent dispenser of claim 8, wherein the water has a temperature of approximately 80 to 180° F.
- 11. The detergent dispenser of claim 8, wherein the we outlet is always open and the water flows into the water inlet at approximately 0.1 gallon to 2 gallons per minute and the water flows out of the water outlet at approximately 0.1 to 1 gallon per minute.
- 12. The detergent dispenser of claim 8, wherein the use solution from the solid detergent is dispensed into the washing machine having a concentration of 0.1% to 1.5% weight to weight.
- 13. The detergent dispenser of claim 8, wherein uniform dissolution of the solid detergent occurs, thereby maintaining a relatively constant concentration and a relatively constant shape of the solid detergent.
- 14. The detergent dispenser of claim 8, further comprising:a. a hose member operatively connected to said water outlet and having a curvature, wherein said curvature extends in an upward direction at a height greater than said water outlet and then extends downward below said water outlet; b. a first level of water within said cavity at a height below said curvature, wherein said first level of water remains in said cavity and does not flow out of said water outlet; and c. a second level of water within sad cavity at a height greater than said curvature, wherein a siphoning effect occurs and substantially all of the water flows out of said cavity via said water outlet.
- 15. A dispenser for dispensing a use solution from a solid detergent into a washing machine, comprising:a. a solid detergent; b. a water source providing water to the dispenser; c. a chamber including a front portion, a first side portion, a second side portion, a back portion, a bottom portion, a top portion, and an opening, the chamber defining a cavity configured and arranged to receive the solid detergent and the water, the back portion of the chamber further comprising a water inlet proximate the top portion and a water outlet proximate the bottom portion, the water inlet being configured and arranged to receive the water from the water source, whereby the water flows into the cavity from the bottom of the chamber where it contacts the solid detergent and dissolves a portion of the solid detergent to form a use solution, the solid detergent being dispensed completely over more than one flooding of water within the cavity, and whereby the water outlet is configured and arranged to dispense substantially all of the water and the use solution out of the chamber and into the washing machine when the dispenser is not in use; d. an air gap proximate the water inlet to prevent the water from returning to the water source; e. a tunnel proximate the back portion and the second side portion, wherein the water travels from the water inlet, through the tunnel, and into the bottom portion of the chamber; f. a level of the water within the cavity of the chamber contacting the solid detergent, wherein uniform dissolution of the solid detergent occurs thereby maintaining a relatively constant concentration and a relatively constant shape of the solid detergent; and g. a lid connected to the top portion of the chamber, whereby the lid covers the opening of the chamber into the cavity.
- 16. The dispenser for dispensing a use solution from a solid detergent into a washing machine of claim 15, wherein the level of water within the cavity of the chamber is approximately ¼ inch to 3 inches.
- 17. The dispenser for dispensing a use solution from a solid detergent into a washing machine of claim 15, wherein the water has a temperature of approximately 80 to 180° F.
- 18. The dispenser for dispensing a use solution from a solid detergent into a washing machine of claim 13, wherein the water outlet is always open and the water flows into the water inlet at approximately 0.1 to 2 gallons per minute and the water flows out of the water outlet at approximately 0.1 to 1 gallon per minute.
- 19. The dispenser for dispensing a use solution from a solid detergent into a washing machine of claim 15, wherein the use solution from the solid detergent is dispensed into the washing machine having a concentration of 0.1% to 1.5% weight to weight.
- 20. The dispenser for dispensing a use solution from the solid detergent into a washing machine of claim 15, further comprising a tab extending from and operatively connected to said front portion of said chamber and an opening in said lid, wherein said tab extends through said opening when said solid detergent should be added to said dispenser.
- 21. The dispenser for dispensing a use solution from a solid detergent into a washing machine of claim 15, further comprising:a. a hose member operatively connected to said water outlet and having a curvature, wherein said curvature extends in an upward direction at a height greater than said water outlet and then extends downward below said water outlet; b. a first level of water within said cavity at a height below said curvature, wherein said first level of water remains in said cavity and does not flow out of said water outlet; and c. a second level of water within said cavity at a height greater than said curvature, wherein a siphoning effect occurs and substantially all of the water flows out of said cavity via said water outlet.
- 22. A method for dispensing detergent, comprising the steps of:a. placing a detergent with a particular composition into a dispenser having a cavity, a water inlet, and a water outlet, said cavity being configured and arranged to receive and support said detergent; b. supplying water to said water inlet and using a valve to control the amount of water flowing into said water inlet; c. flooding said dispenser with water to a level within said cavity wherein said water contacts said detergent and dissolves a portion of said detergent to form a use solution, the detergent being dispensed completely over more than on flooding of water within the cavity; and d. releasing said use solution through said water outlet, thereby dispensing a particular concentration of said use solution, when in said water outlet is always open, and wherein water is supplied to said water inlet at a rate faster than water is released through said water outlet, thereby allowing the water to contact the detergent and dissolve a portion of said detergent to form said use solution.
- 23. The method for dispensing detergent of claim 22, further comprising flooding said cavity with water to a first level, wherein said first level of water contacts said detergent contained within said cavity to form a use solution, said detergent being dispensed completely over more than one flooding of water within said cavity, and flooding said cavity with water to a second level, wherein said second level of water initiates the flow of substantially all of said use solution out of said water outlet into a washing machine.
- 24. A dispenser for dispensing a use solution from a solid detergent into a washing machine, comprising:a. a solid detergent having a bottom; b. a dispenser including a cavity, a water inlet, and a water outlet, wherein said cavity is configured and arranged to receive and support said solid detergent; c. a conduit connecting said water inlet to a water source; d. a valve operatively connected to said conduit controlling the flow of water from said water source into said water inlet, wherein said cavity is flooded with water to a level within said cavity, wherein water contacts said solid detergent from the bottom of said solid detergent and a uniform dissolution of said solid detergent occurs thereby maintaining a relatively constant concentration and a relatively constant shape of the solid detergent, and wherein a use solution is formed, solid detergent being dispensed completely over more than one flooding of water within the cavity; and e. a hose member connecting said water outlet to a washing machine, wherein substantially all of said use solution is dispensed out of said cavity through said water outlet and into the washing machine via said hose member.
- 25. The dispenser for dispensing a use solution from a solid detergent into a washing machine of claim 24, further comprising:a. a curvature of said hose member, said curvature extending in an upward direction at a height greater than said water outlet and then extending downward below said water outlet; b. a first level of water within said cavity at a height below said curvature, said first level of water remaining in said cavity and not flowing out of said water outlet; and c. a second level of water within said cavity at a height than said curvature, wherein a siphoning effect occurs and substantially all of the water flows out of said cavity via said water outlet.
- 26. A detergent dispenser for use with a washing machine, comprising:a. a dispenser having a chamber including a cavity, a water inlet and a water outlet; b. a solid detergent; c. a conduit connecting said water inlet to a water source; d. a valve operatively connected to said conduit, wherein said valve controls the amount of water flowing from said water source into said water inlet; e. a hose member operatively connected to said water outlet and having a curvature, wherein said curvature extends in an upward direction at a height greater than said water outlet and then extends downward below said water outlet; f. a first level of water within said cavity controlled by said valve to reach a height below said curvature, wherein said first level of water remains in said cavity and does not flow out of said water outlet; and g. a second level of water within said cavity controlled by said valve to reach a height greater than said curvature, wherein a siphoning effect occurs and substantially all of the water flows out of said dispenser via said water outlet, said solid detergent being dispensed completely over more than one flooding of water within said cavity.
- 27. A method of dispensing a use solution from a solid detergent into a washing machine, comprising the steps of:a. placing a solid detergent inside a dispenser having a cavity, a water inlet, a water outlet, and a hose member operatively connected to said water outlet, said hose member having a curvature, wherein said curvature extends in an upward direction at a height greater than said water outlet and then extends downward below said water outlet; b. supplying water to said water inlet, wherein water flows from said water inlet into said cavity; c. controlling the amount of water flowing into said water inlet with a valve; d. flooding said cavity with water to a first level, wherein said first level of water contacts said solid detergent contained within said dispenser to form a use solution; and e. flooding said cavity with water to a second level, wherein said second level of water initiates the flow of substantially all of said use solution out of said water outlet into a washing machine, the solid detergent being dispensed completely over more than one flooding of water within the cavity.
US Referenced Citations (19)