Patent Grant
12043998
The present disclosure relates to waste disposers such as food waste disposers and methods of mounting such waste disposers in relation to other structures such as sinks and, more particularly, to waste disposer assemblies or mounting assemblies of or for such waste disposers, and methods of mounting such waste disposers in relation to other structures such as sinks, by way of such waste disposer assemblies or mounting assemblies.
Food waste disposers are used to comminute food scraps into particles small enough to pass through household drain plumbing. Referring to
Conventional food waste disposers such as the food waste disposer 10 can be installed to a sink in a two-step procedure using a mounting assembly 100, an example of which is shown in
More particularly with respect to the attachment of the disposer assembly 30 to the sink flange assembly 102, it should be understood that the lower mounting flange 118 is placed around the housing 18 that forms the inlet of the food conveying section 12. The mounting gasket 116 is then placed around that inlet as well, above the lower mounting flange 118, in a manner tending to secure the mounting gasket 116 to the inlet, by virtue of a lip at the inlet of the housing 18. Attachment of the disposer assembly 30 including the food waste disposer 10 to the sink flange assembly 102 and thereby to the sink is then particularly achieved by engaging mounting tabs 120 of the lower mounting flange 118 with ramps (or inclined mounting fasteners or edges or ridges) 122 of the upper mounting flange 110 and then rotating the lower mounting flange 118 relative to the upper mounting flange 110 until secure. When the lower mounting flange 118 and upper mounting flange 110 are secured together, the mounting gasket 116 is compressed therebetween, and provides a seal between the sink flange and inlet.
Although food waste disposers have long been successfully installed in relation to sinks in the manner described above (or in similar manners), mounting assemblies such as the mounting assembly 100 are not ideal for all applications because the mounting assemblies establish fixed connections between the food waste disposers and the sinks to which those food waste disposers are attached and consequently can communicate significant amounts of potentially-annoying vibration to the sinks from the food waste disposers when those disposers are operating. In view of this concern, alternate mounting assemblies have been developed that can at least partly isolate, in terms of the communication of vibration, food waste disposers from the sinks in relation to which those disposers are installed. U.S. Pat. No. 5,924,635, which is beneficially assigned to Taisei Corporation and entitled “Vibration Isolation Installation Mechanism For a Disposer”, which is hereby incorporated by reference herein, describes several such embodiments of vibration isolating installation mechanisms by which disposers can be coupled to sinks.
More particularly, in several such conventional mechanisms, a flexible cylinder is employed to link upper and lower cylindrical components of the mechanism/assemblies and additionally, radially outwardly from the flexible cylinder, support rods are provided that also link the upper and lower cylindrical components. Support of the lower cylindrical component relative to the upper cylindrical component is provided by way of the support rods, which are coupled to those cylindrical components by way of elastic bushings or springs in manner that reduces the amount of vibration that can be communicated between the lower and upper cylindrical components. Correspondingly, this reduces the amount of vibration that can be communicated between a disposer supported via the lower cylindrical component and a sink to which the upper cylindrical component is connected. Although support rods are employed in some of these conventional embodiments, in at least one other conventional embodiment the support rods are omitted and the lower and upper cylindrical components are coupled with one another solely by way of the flexible cylinder.
Notwithstanding the availability of such conventional vibration isolating installation mechanisms or mounting assemblies, such conventional mechanisms/assemblies can be disadvantageous in several respects. In particular, conventional mechanisms/assemblies that employ support rods externally of the flexible cylinder can be expensive to manufacture and complicated to install, due to the multiple parts associated with the support rods, elastic bushings or springs, and/or other associated componentry. The conventional mechanisms/assemblies involving the support rods also can entail undesirably-high axial space requirements in terms of the distances between the disposers and sinks, and may not be aesthetically pleasing. Alternatively, the conventional mechanism/assembly employing the flexible cylinder without the external support rods envisions that the flexible cylinder will provide all support of the lower cylindrical component and attached disposer relative to the upper cylindrical component (and sink to which it is attached). Should the flexible cylinder rupture over time (indeed, perhaps partly due to the vibrations experience by the cylinder due to ongoing disposer operation), the disposer could detach from the sink.
Accordingly, it would be desirable if an improved food waste disposer assembly (or other waste disposer assembly), and/or an improved mounting assembly of or for such a food waste disposer assembly (or other waste disposer assembly), and/or an improved method of installing or mounting such a waste disposer assembly or mounting assembly in relation to another structure such as a sink, could be developed that alleviated or addressed one or more of the above-discussed concerns associated with conventional waste disposer assemblies, or alleviated or addressed one or more other concerns or disadvantages, or provided one or more advantages by comparison with conventional arrangements.
In at least some example embodiments, the present disclosure relates to a mounting system for mounting a waste disposer. The mounting system includes a tubular structure extending between first and second ends, and an enclosure structure having an additional end, where the enclosure structure is configured to be able to support, at least indirectly, the waste disposer. Further, the mounting system also includes an elastomeric member extending between the second end and the additional end, where the elastomeric member is coupled to each of the tubular structure and the enclosure structure, and serves to couple the tubular structure and the enclosure structure. Additionally, the mounting system includes a plurality of backup linkage members, where each of the plurality of backup linkage members is coupled at least indirectly to each of the tubular structure and the enclosure structure, and couples at least indirectly the tubular structure and the enclosure structure, and where each of the plurality of backup linkage members is integrally formed or molded with at least one of the tubular structure and the enclosure structure.
Additionally, in at least some example embodiments, the present disclosure relates to a waste disposer assembly that includes a waste disposer and a mounting assembly. The mounting assembly includes a first structure having a first end and a second end, and configured to be coupled at or proximate the first end to a support structure. The mounting assembly also includes a second structure having an additional end, where the waste disposer is at least indirectly attached to and supported by the second structure, and an anti-vibration linking structure extending between and coupling the second end and the additional end. Further, the mounting assembly includes a plurality of supplemental linking structures coupling the first structure and the second structure, where each of the supplemental linking structures is integrally formed or molded with respect to each of the first structure and the second structure. Additionally, the anti-vibration linking structure is overmolded around, so as to substantially encapsulate, each of the supplemental linking structures.
Further, in at least some example embodiments, the present disclosure relates to a method of assembling a mounting system for use in coupling a food waste disposer to a sink. The method includes forming a mounting subassembly including a tubular structure, an enclosure structure, and a plurality of first linking structures, where all of the tubular structure, the enclosure structure, and first linking structures are formed integrally. Also, the method includes applying an elastomeric material to the mounting subassembly, so as to provide an elastomeric formation extending between the tubular structure and the enclosure structure, and so as to couple the enclosure structure with the tubular structure. Further, the elastomeric formation serves as a primary linking structure by which the enclosure structure is supported in relation to the tubular structure, and the first linking structures are backup linking structures, and also the elastomeric formation is configured to prevent or reduce a communication of vibrations between the tubular structure and the enclosure structure.
Embodiments of food waste disposer assemblies (or other waste disposer assemblies), mounting assemblies of or for such waste disposer assemblies, and related methods are disclosed with reference to the accompanying drawings and are for illustrative purposes only. The waste disposer/mounting assembly apparatuses and methods encompassed herein are not limited in their applications to the details of construction, arrangements of components, or other aspects or features illustrated in the drawings, but rather such apparatuses and methods encompassed herein include other embodiments or are capable of being practiced or carried out in other various ways. Like reference numerals are used to indicate like components. In the drawings:
Referring to
In the present embodiment, the improved mounting assembly 208 particularly includes an anti-vibration (AV) tube 210, an enclosure 212, and an overmolded section 214 positioned between and coupling the AV tube with the enclosure. Also, the improved mounting assembly 208 includes coupling components 215, which in the present embodiment include the mounting (or sealing) gasket 116 and lower mounting flange 118 described above with reference to
The enclosure 212, which can also be referred to as a bottom enclosure piece (or grind enclosure or container body), is positioned beneath the AV tube 210 and coupled therewith by way of the overmolded section 214. The enclosure 212 particularly serves to support the disposer assembly 204 including the food waste disposer 206, which is positioned beneath and coupled to that enclosure. Although for purposes of the present disclosure, the sink flange assembly 216 is considered to be a part of the sink 202, alternatively the sink flange assembly (or portions thereof, such as the upper mounting flange 110) can be considered part of the improved mounting assembly 208 (in some such cases, the improved mounting assembly can also be considered an improved sink flange assembly). Likewise, although for purposes of the present disclosure the coupling components 215 are considered to be part of the improved mounting assembly 208, alternatively the coupling components (or portions thereof, such as the lower mounting flange 118) can be considered part of the sink flange assembly.
Although the food waste disposer 206 of
Turning to
Additionally as shown in
Further, the top circumferential lip 306 enables the coupling components 215 to couple the AV tube 210 to the sink flange assembly 216. More particularly, during installation of the improved food waste disposer assembly 200 in relation to the sink 202, the lower mounting flange 118 of the coupling components 215 is positioned so as to extend around the AV tube 210, between the top circumferential lip 306 and bottom circumferential lip 302. Additionally, the mounting gasket 116 is positioned around the top circumferential lip 306. More particularly, the mounting gasket 116 has an internal groove (e.g., a groove along its inner circumference) that captures the top circumferential lip 306. Before installation is complete, the lower mounting flange 118 can rest upon the top surface of the bottom circumferential lip 302. However, to achieve installation, the lower mounting flange 118 of the coupling components 215 is coupled to the upper mounting flange 110 of the sink flange assembly 216, with both the top circumferential lip 306 of the AV tube 210 as well as the mounting gasket 116 being positioned between those two flanges.
Given such an arrangement, a portion (e.g., an annular portion) of the mounting gasket 116 extends below the top circumferential lip 306, and the lower mounting flange 118 particularly contacts this portion of the mounting gasket (e.g., abuts the lower surface or underside of the mounting gasket, which in turn is in contact with the top circumferential lip along its internal groove), such that the top circumferential lip 306 is supported upon the lower mounting flange 118 indirectly by way of the mounting gasket 116 therebetween (that is, the lower mounting flange 118 does not directly contact the top circumferential lip 306 but still nevertheless that lip is supported indirectly by that flange via the mounting gasket). Additionally, given this arrangement, the lower mounting flange 118 compresses the mounting gasket 116 around and in relation to the top circumferential lip 306, so as to create a seal and prevent leakage. Accordingly, the entire AV tube 210—and all of the remaining portions of the improved mounting assembly 208 and improved food waste disposer assembly 200 supported by the AV tube—are supported in relation to the sink 202.
Referring additionally to
More particularly with respect to
Also, in the present embodiment, each of the springs 400 includes a respective first ramp portion 404 and a respective second ramp portion 406 that are integrally connected at a respective junction 408 (which can be implemented without sharp points or be rounded to some extent, to facilitate manufacture and/or extend operational life). More particularly, the respective first ramp portion 404 of each of the respective springs 400 springs extends from a respective circumferential location 410 along the bottom circumferential lip 302 of the AV tube 210 toward the enclosure 212, to the respective junction 408, and the respective second ramp portion 406 of each respective spring extends from the respective junction to a respective circumferential location 412 along the top circumferential lip 304 of the enclosure 212. Additionally as shown, the respective first ramp portion 404 of each of the springs 400 is generally inclined in a first circumferential direction (e.g., clockwise, as one proceeds away from the AV tube 210 toward the enclosure 212) and the respective second ramp portion 406 of each of the springs is generally inclined in a second circumferential direction (e.g., counterclockwise, as one proceeds away from the AV tube toward the enclosure).
Additionally, it should be recognized from
To achieve such an arrangement, the annular elastomeric formation 300 is formed by injecting and overmolding the TPE or other elastomeric material (or other material) used to form that annular elastomeric formation in relation to the integrally-formed assembly of the AV tube 210, enclosure 212, and springs 400. In particular, as illustrated by
Turning to
Additionally, referring to
Notwithstanding the configuration of the springs 400 described above, it should be appreciated that, in other embodiments, the springs can take other forms. For example, the inclination of the ramp portions can vary from that described above (e.g., different ones of the springs can have ramp portions that are inclined in different manners), and/or one or more of the springs can include more than two ramp portions or include other (e.g., non-ramped, or vertical) portions. Also, even though each of the ramp portions 404, 406 in the present example embodiment are generally straight structures, in other embodiments one or more of the ramp portions can be curved. Additionally, although in the present embodiment it is envisioned that there are four of the springs 400, which are circumferentially spaced equidistantly from one another around a center line of the 402 of the improved mounting assembly (and of the AV tube 210 and enclosure 212 thereof), in alternate embodiments the number or relative spacing of the springs 400 can vary from that shown. For example, in some alternate embodiments, there can be two, three, six, or eight springs, and/or certain neighboring ones of the springs can be positioned more closely to one another than other neighboring ones of the springs. Indeed, in general, the geometries and number of springs can be set or iterated to optimize the anti-vibration performance of the spring-overmold mount.
In the present example embodiment, the springs 400 fulfill multiple roles. First, although it is intended that the annular elastomeric formation 300 serve as the primary support structure linking the AV tube 210 and the enclosure 212, the springs 400 can serve a backup support structure. That is, although it is intended that the annular elastomeric formation will serve as the primary weight bearing structure allowing for any weight coupled to the enclosure (e.g., the disposer assembly 204 with the food waste disposer 206) to be borne by the AV tube (and any structure supporting the improved food waste disposer assembly 200 such as the sink 202), the springs 400 can also provide such support. This can be beneficial, for example, if over time the annular elastomeric formation 300 experiences creeping or becomes distended, or if for some reason the annular elastomeric formation itself ceases to fully or substantially couple the AV tube 210 with the enclosure 212 (for example, if adhesive used to link the annular elastomeric formation 300 with the AV tube or enclosure weakens). In short, the springs 400 provide a redundant coupling mechanism by which the AV tube 210 and enclosure 212 are linked, so as to supplement the coupling provided by the annular elastomeric formation 300.
Second, in the present embodiment, the springs 400 also provide a mechanism by which a pre-load (in tension or compression) can be implemented as an aspect of the improved mounting assembly 208. As described further below in regard to
Referring now to
Next, at a second step 806, it is determined whether, and to what extent, a pre-load (in tension or compression) should be applied to the mounting subassembly 600, and particularly to the springs 400 thereof. This determination for example can be made during manufacturing, and in some cases can be made automatically (e.g., by a computer). In at least some circumstances or embodiments, this determination takes into account the expected loading that will be experienced by the improved mounting assembly 208 (e.g., due to the weight of the food waste disposer 206).
Subsequently, at a third step 808, if it is determined at the second step 806 that a pre-load should be applied, then that pre-load is applied to the mounting subassembly 600 (and particularly to the springs 400 thereof) or, alternatively, if it is determined at the second step 806 that no pre-load should be applied, then the mounting subassembly 600 is left in a neutral (e.g., unloaded) state. A preload involving a preset tension can be applied at the step 808, for example, by applying a tension force between the AV tube 210 and the enclosure 212 as represented by first arrows 602 in
Next, at a fourth step 810, an elastomer is applied to the mounting subassembly 600 to form the combination of structures that are comprised by the improved mounting assembly 208. As already described above, this application involves overmolding the elastomer relative to the AV tube 210, the enclosure 212, and the springs 400, especially in a manner so that the elastomer fills in the gaps among these components and couples the AV tube 210 with the enclosure 212, as well as surrounds or encapsulates (or substantially encapsulates) the springs. By virtue of this step, the elastomer forms the annular elastomeric formation 300 and, in combination with the springs 400, forms the overmolded section 214. The elastomer applied at the fourth step 810 can be, as mentioned above, TPE or another elastomeric material (or other material). In at least some embodiments, the elastomer can be applied by way of injection (e.g., during a “neck fill”).
Upon the completion of the fourth step 810, the process of
Although the process represented by the flow chart 800 particularly is intended to relate to the manufacturing or assembling of the improved mounting assembly 208, this process can be understood as also encompassing or extending to encompass additionally the loading of the improved mounting assembly, as represented by a further step 816. Such loading can occur, for example, when a food waste disposer such as the food waste disposer 206 is attached to the enclosure 212 of the improved mounting assembly 208. It should be appreciated that the further step 816 is shown in dashed lines in
Referring still to
More particularly,
It should be appreciated that any arbitrary level or magnitude of tension or compression can be applied at the third step 808. However, the five (5) pre-load scenarios that are shown in the first side-box 818 have been chosen because the scenarios can result in qualitatively different outcomes, in terms of post-overmolding states of the improved mounting assembly 208 and the overall food waste disposer assembly 200. Given these different scenarios in terms of the application (or absence of application) of pre-loading to the mounting subassembly 600/springs 400, the TPE or other elastomeric material (or other elastomer or material) of the overmolded section 214 can experience different levels of tension or compression (or absence thereof) after the overmolding has occurred at the step 810. Additionally, although the TPE or other elastomeric material (or other elastomer or material) can experience such post-overmolding tension or compression subsequent to overmolding even when no weight is applied to the improved mounting assembly 208, such tension or compression that is experienced by the TPE or other elastomeric material (or other elastomer) and by the improved mounting assembly overall can additionally change when a weight such as that due to the food waste disposer 206 is attached to improved mounting assembly 208.
More particularly in this regard, the post-overmold states of the improved mounting assembly shown in the second side-box 820 include five possible pairs of states (A, B, C, D, and E) that respectively correspond to the respective five pre-load scenarios shown in the first side-box 818 (A, B, C, D, and E discussed above), with the correspondence being in shown in
It should be appreciated that there exists correlations between the pre-load scenarios and the post-overmolding states as represented in the side-boxes 818 and 820. In general, if tension is applied to the mounting subassembly 600/springs 400 prior to overmolding, then the springs post-overmolding will tend to return to their natural, unstressed position, and consequently the TPE or other elastomeric material (or other material) applied during overmolding will tend to be compressed. Inversely, if the mounting subassembly 600/springs 400 are compressed prior to overmolding, then the springs post-overmolding will tend to return to their natural, unstressed position, and consequently the TPE or other elastomeric material (or other material) applied during overmolding will tend to experience tension. Further, the application of a load (e.g., due to the attachment of the food waste disposer 206) post-overmolding will tend to add tension or reduce compression within the improved mounting assembly 208. Therefore, the overall tension or compression experienced after a load is applied within the improved mounting assembly 208, and particularly by the springs 400, will depend upon the relative balance between any compression or tension that exists within the improved mounting assembly 208 prior to load being applied, the tension change imparted by the weight of the load itself.
The post-overmold states of the improved mounting assembly 208 shown in
Further, if the pre-load scenario experienced by the mounting subassembly 600/springs 400 involves a preset tension (scenario C, B, or A), then the improved mounting assembly 208 will experience compression as its post-overmold state, as achieved at the fifth step 812 prior to the application of any load. The magnitude of the compression experienced in this state will correspond directly to the level of preset tension that was applied at the third step 808. However, upon the application of a load (e.g., due to the attachment of the food waste disposer 206) at the step 816, the improved mounting assembly 208 (and the springs 400 thereof) can experience any of compression, tension, or neither. It will be appreciated that, if the preset tension is sufficiently small (e.g., in accordance with scenario A of the first side-box 818), even though compression may be experienced by the TPE or other elastomeric material (or other material) initially after overmolding has been completed, any such compression will be superseded by the tension arising from the application of weight to the improved mounting assembly 208. Consequently, as indicated in the second side-box 820, the post-overmold states of the improved mounting assembly 208 associated with scenario A involve compression followed by tension arising due to the weight applied to the improved mounting assembly 208.
Inversely, it will be appreciated that, if the preset tension is sufficiently large (e.g., in accordance with scenario C of the first side-box 818), compression may be experienced by the TPE or other elastomeric material (or other material) initially after overmolding has been completed, and continue to be experienced following the application of the load to the improved mounting assembly 208. In such cases, the load borne by the improved mounting assembly 208 is insufficient to overcome the internal compression experienced by the improved mounting assembly 208 due to the internal action of the springs 400.
Additionally, there also exists the possibility that the application of the pre-load at the third step 808 is set at just an appropriate amount that any internal compression experienced by the improved mounting assembly 208 due to the internal action of the springs 400 can be exactly (or substantially exactly) balanced by the tension generated by a load borne by the improved mounting assembly 208. Thus, as illustrated in
Thus, the various scenarios and states shown in
Further, if pre-loading is applied in accordance with scenario B and the preset was balanced against the effect of unit weight (e.g., the effect of the application of a load corresponding to installation of the food waste disposer), the TPE will experience post-overmold compression due to springs, and further can end up in an equilibrium state (or a state that cycles through tension and compression during operation) upon installation of the food waste disposer. Also, if pre-loading is applied in accordance with scenario C, then TPE will experience post-overmold compression due to springs and, if the preset was large relative to the effect of unit weight, the weight can be offset such that the TPE will remain in a state of compression (or mostly so, during operational cycling). Finally, if pre-loading is applied in accordance with scenario E, then TPE will experience post-overmold tension due to springs, the state of which will be exacerbated by the addition of unit weight upon installation.
Notwithstanding the above description relating to
Similar to the improved mounting assembly 208, the improved mounting assembly 908 particularly includes an anti-vibration (AV) tube 910, an enclosure 912, and an overmolded section 914 positioned between and coupling the AV tube with the enclosure. The AV tube 910 is configured to be mounted or coupled to the sink flange (or strainer flange) 216 of the sink 202 (discussed above). The enclosure 912, which is positioned beneath the AV tube 910 and coupled therewith by way of the overmolded section 914, supports the food waste disposer 206, which is positioned beneath and coupled to that enclosure.
In the view provided by
As with the annular elastomeric formation 300, the annular elastomeric formation 900 can be made, for example, from a thermoplastic elastomer (TPE) or other elastomeric material. Also, as with the annular elastomeric formation 300, the annular elastomeric formation 900 serves an anti-vibration purpose, particularly in terms of eliminating or reducing the amount of vibration that can be communicated from the enclosure 912 to the AV tube 910, and thus in terms of eliminating or reducing the amount of vibration that can be communicated from the food waste disposer 206 of the disposer assembly 204 to the sink 202 when the disposer assembly 204 is coupled to the enclosure 912 and the AV tube 910 is coupled to the sink. However, it will be observed from a comparison of
Referring additionally to
More particularly with respect to
In the present example embodiment, there are two of the living-hinge members 1000, which are at diametrically-opposed locations from one another on the improved mounting assembly 908 (and of the AV tube 910 and enclosure 912 thereof). In alternate embodiments, the number or relative spacing of the living-hinge members 1000 can vary from that shown. For example, in other alternate embodiments, there can be three, four, six, or eight living-hinge members, and/or certain neighboring ones of the living-hinge members (particularly if there are more than two such members) can be positioned more closely to one another than other neighboring ones of the living-hinge members. Also, although it is envisioned that the improved mounting assembly 908 will include only living-hinge members and that the improved mounting assembly 208 will include only springs, in further embodiments it is possible for a given improved mounting assembly to include any combination of one or more springs and one or more living-hinge members.
As is evident particularly from
More particularly, the respective first ramp portion 1104 of each of the respective living-hinge members 1000 extends from a respective circumferential location 1110 along the bottom circumferential lip 902 of the AV tube 910 toward the enclosure 912, to the respective junction 1108, and the respective second ramp portion 406 of each respective spring extends from the respective junction to a respective circumferential location 1112 along the top circumferential lip 904 of the enclosure 912. Additionally as shown, the respective first ramp portion 1104 of each of the living-hinge members 1000 is generally inclined in a first radial direction (e.g., radially outward as one proceeds downward from the AV tube 910 toward the enclosure 912) and the respective second ramp portion 1006 of each of the living-hinge members 1000 is generally inclined in a second radial direction (e.g., radially outward as one proceeds upward from the enclosure 912 toward the AV tube 910).
It should be appreciated that the particular configurations of the living-hinge members 1000 as shown in
Relatedly, it should be appreciated that, if the AV tube 910 and enclosure 912 are retracted apart from one another, the living-hinge members will progressively straighten. Ultimately, when the distance between the AV tube 910 and enclosure 912 increases to equal the full length of the living-hinge members 1000, each of the living-hinge members will have a configuration that is strictly linear between the respective circumferential locations 1110 and 1112 at which the respective living-hinge member is connected to the AV tube and enclosure. That is, in such circumstance, the living-hinge members 1000 will no longer have bending at or proximate to the junctions 1108 and circumferential locations 1110 and 1112, and will not have sloped portions corresponding to the ramped portions 1104 and 1106.
Additionally, it should be recognized from
As with the springs 400, it should be recognized that the living-hinge members 1000 provide a redundant coupling mechanism by which the AV tube 910 and enclosure 912 are linked, so as to supplement the coupling provided by the annular elastomeric formation 900. That is, although it is intended that the annular elastomeric formation 900 serve as the primary support structure linking the AV tube 210 and the enclosure 212 in the improved mounting assembly 908, the living-hinge members 1000 can serve a backup support structure. Consequently, although the annular elastomeric formation 900 will serve as the primary weight bearing structure allowing for any weight coupled to the enclosure 912 (e.g., the disposer assembly 204 with the food waste disposer 206) to be borne by the AV tube 910 (and any structure supporting the improved food wasted disposer assembly 200 such as the sink 202), the springs 1000 can also provide such support. This can be beneficial, for example, if over time the annular elastomeric formation 900 experiences creeping or becomes distended, or if for some reason the annular elastomeric formation itself ceases to fully or substantially couple the AV tube 910 with the enclosure 912 (for example, if adhesive used to link the annular elastomeric formation 900 with the AV tube or enclosure weakens).
The assembly or manufacturing process by which the improved mounting assembly 908 is formed can be similar to that discussed above in regard to
Notwithstanding the above similarities between the assembly processes for the improved mounting assemblies 908 and 208, the steps of
The above-described embodiments relating to
More particularly in this regard,
Similar to the improved mounting assembly 208, the improved mounting assembly 1208 particularly includes an anti-vibration (AV) tube 1210 and an enclosure 1212. Again, the AV tube 1210 is configured to be mounted or coupled to the sink flange (or strainer flange) 216 of the sink 202 (discussed above). Also, the enclosure 1212 is positioned beneath and coupled to the AV tube 1210, and supports the food waste disposer 206, which is positioned beneath and coupled to that enclosure. Additionally, the improved mounting assembly includes an annular elastomeric formation 1200 positioned between and coupling the AV tube 1210 with the enclosure 1210.
Notwithstanding these similarities, improved mounting assembly 1208 differs from the improved mounting assembly 208 in that the annular elastomeric formation 1200 is not overmolded around backup linkages (such as the springs 400 or living-hinge members 1000), but rather is simply an annular elastomer that is coupled to and extends between, and is in tension between, the AV tube 1210 and enclosure 1212. Rather than employing any backup linkages (such as the springs 400 or living-hinge members 1000) that are positioned within or substantially encapsulated within the annular elastomeric formation 1200, instead the improved mounting assembly 1208 includes two suspenders (or suspender extensions) 1214 on the AV tube 1210 and two complementary features 1216 on the enclosure 1212.
As shown, the suspenders 1214 particularly are extensions that are integrally formed or molded as part of the AV tube 1210, and coupled to the AV tube at locations along an outer circumference 1218 of the AV tube (in this example embodiment, along a bottom rim of the AV tube to which the annular elastomeric formation 1200 is coupled). The suspenders 1214 particularly extend downward from the AV tube 1210, in a manner substantially parallel to (in this example, tapered slightly relative to) a central axis 1202 of the improved mounting assembly 1208 and alongside the outer circumference of the annular elastomeric formation 1200, to the complementary features 1216 of the enclosure 1212. The complementary features 1216 and suspenders 1214 are configured so that the suspenders 1214 can be secured or attached to the complementary features 1216 during assembly of the improved mounting assembly 1208.
In the present embodiment, the complementary features 1216 particularly include orifices into which and through which the suspenders 1214 are positioned during assembly of the improved mounting assembly 1208. All of the AV tube 1210, suspenders 1214, enclosures 1212, and complementary features 1216 are made of a common, meltable material (e.g., polymer plastic). Given this to be the case, the suspenders 1214 can be coupled to or locked in relation to the complementary features 1216 by way of heating, melting, and cooling the suspenders and complementary features, or heat staking the suspenders and complementary features relative to one another. In alternate embodiments, other locking features (e.g., complementary teeth) can be provided on the suspenders and complementary features such that the suspenders become locked in place relative to the complementary features upon being inserted therein. Regardless of the manner in which suspenders are coupled to complementary features, the coupling of the suspenders with the complementary features should be performed in a manner that leaves some slack in the suspenders, so as to avoid overly restricting (e.g., in terms of extension) the annular elastomeric formation 1200.
The process of assembling the improved mounting assembly 1208 can particularly involve two steps, namely, the applying of an elastomer in relation to the AV tube 1210 and enclosure 1212 so as to couple those structures, and coupling the suspenders 1214 to the complementary features 1216, with those two steps being performable in a simultaneous or sequential (in either order) manner. Although not shown, for aesthetic purposes, the improved mounting assembly 1208 can be further supplemented with an additional cylindrical (or substantially cylindrical) trim shell component or skirt that is slipped over the AV tube 1210 and positioned so as to surround and cover over the suspenders 1214 and complementary features 1216. Implementation of such a trim shell component can be considered an additional step of assembly.
Also, notwithstanding the above description concerning the embodiment of
In view of the above description, it should be appreciated that the present disclosure is intended to encompass numerous embodiments of improved mounting assemblies for implementation in food waste disposer assemblies or other disposer assemblies. In at least some embodiments encompassed herein, the improved mounting assemblies allow for the grind chamber of the waste disposer, or associated enclosure, to be isolated from the sink by the use of an intermediate band of material (such as rubber or a thermoplastic elastomer) at or immediately below the neck or tube which connects to the mounting assembly (e.g., the AV tube). By employing the intermediate band of material, the improved mounting assemblies provide an anti-vibration (AV) feature with a tensile load. In addition, the improved mounting assemblies include backup linkages such as, for example, springs, living-hinge members, or suspenders, that serve to support the waste disposer, and/or associated enclosure, relative to the AV tube and sink to which it is mounted. Thus, an AV tension mount can be achieved by providing substrate support that reduces, adjusts, or offsets the tensile loading on the elastomeric component of the mount, and/or provides back-up support.
In at least some such embodiments, the improved mounting assemblies can be considered spring overmold-mount assemblies that (a) employ spring members to join the AV tube and enclosure to act with an overmold as a spring-and-elastomer suspension and damping system, and (b) optionally also involve pre-loading during the overmolding process to achieve an optimized in-service loading for the mount. That is, in at least some embodiments, a set of integral springs connects, and is molded together with, the AV tube and the enclosure. This mounting subassembly or substrate structure is then overmolded together with an elastomeric material (or other material), such as a thermoplastic elastomer (TPE). The springs provide backup support in terms of the coupling of the enclosure—and structure(s) attached thereto, such as a food waste disposer—to the AV tube (and therefore to the sink or any other structure to which the AV tube is attached). The substrate springs would optionally allow a pre-load (in tension or compression) to be applied at the time of the overmolding process. This permits the TPE or other overmold material to be influenced with regard to its loading during post-installation service, with the potential to offset at least some of a food waste disposer or other unit's weight or achieve an optimal state for performance and structural integrity. Depending upon the embodiment, the geometries and number of springs can be set or iterated to optimize the anti-vibration performance of the spring-overmold mount.
Also, in at least some other embodiments, multiple sets of living-hinge members (or living hinges with reduced thickness) and rigid member pairs connect, and are molded together with, the AV tube and the enclosure. That combined subassembly (and particularly the living-hinge members) are then overmolded with an elastomeric material or other material (such as TPE). The overmolding is performed in a manner such that the living-hinge members are not significantly loaded in tension and will not transmit a significant amount of vibration, yet provide back-up support for the AV mount to reduce or eliminate disadvantages that can arise if the elastomeric material creeps in tension. Again, the geometry of these living-hinge members (as with the springs discussed above or other substrate members), including their orientation/loading during the overmolding process, or both, can be iterated or adjusted to optimize the AV performance and the forces acting on the elastomeric mount feature.
Further, in at least some additional embodiments, the improved mounting assemblies employ external-support alternatives. Such improved mounting assemblies again can include an annular elastomeric formation or other structure that links the AV tube and enclosure and is intended to prevent or reduce the amount of vibration communicated between the AV tube and enclosure, and can again include backup linking structures that couple, and are integrally formed or molded in relation to, one or both of the AV tube and enclosure. However in contrast to embodiments in which springs, living hinges, or other backup linking structures connecting the AV tube and enclosure are positioned or substantially encapsulated within an overmolded structure, the backup linking structures in such external-support alternatives are positioned radially outward and/or radially inward (or otherwise externally) from the location of any annular elastomeric formation or other structure formed from an elastomeric (or other) material that links the AV tube and the enclosure. For example, such external-support alternatives can employ, as the backup linking components (or backup support linkages), suspenders (and possibly complementary features) that are integrally formed in relation to one or both of the AV tube and the enclosure. Also for example, depending upon the embodiment, the backup linking structures can be offset relative to, or in-line with, areas where a substrate wall is already produced by existing tooling.
As already discussed in regard to
Additionally, the present disclosure is also intended to encompass other embodiments employing one or more other types of linking structures for coupling an AV tube and enclosure that are positioned externally of an annular elastomeric formation or similar structure serving as an anti-vibration link between the AV tube and enclosure, including for example, springs or rods. Such additional linking structures can for example be employed in combination with any of the suspenders, springs, living hinges, or other backup linking structures described above. For example, in some embodiments encompassed herein, an AV tube and enclosure are coupled by one or more backup linking structures that are overmolded (such as the springs 400 or living-hinge members 1000) and additionally by one or more other backup linking structures that are externally positioned relative to any annular elastomeric formation or other anti-vibration coupling structure.
In view of above description, it should be appreciated that one or more of the embodiments of improved mounting assemblies or food waste disposer assemblies disclosed or encompassed herein can be advantageous in one or more respects. For example, in at least some embodiments encompassed herein, backup linkages linking an AV tube and enclosure (or linking top and bottom enclosure pieces) can support the weight of a food waste disposer or other unit or structure attached (at least indirectly) to the enclosure, without having to entirely rely on the performance or creep resistance of any anti-vibration structure(s) (e.g., an annular elastomeric formation or other structure formed from TPE or other elastomeric material) that are normally employed (in tension) to couple the AV tube and enclosure. Further, in at least some embodiments encompassed herein, the backup linkages are integrally formed or molded in relation to one or both of the AV tube and enclosure, so as to form a one-piece substrate. The primary linkage(s) between the AV tube and enclosure, which are intended to be formed from TPE or another elastomeric material (or other material suitable for providing an anti-vibration link), can be formed by a separate molding, casting, injection, or overmolding step.
Formation of the backup linkages in this manner can the facilitate manufacture of the improved mounting assembly, through the reduction of parts count or processing steps. Among other things, these manners of forming improved mounting assemblies can reduce or minimize the number of enclosure molds required for the project (e.g., by avoiding part-specific back-up tooling), can serve to enhance or maximize the flexibility to meet manufacturing/production shifts in a “mix” of products (since any mold can produce enclosures of a variety of types), and can generally serve to maximize an opportunity for there being commonality (in terms of a common manufacturing platform or process setup) at an as-molded stage.
Also, in at least some embodiments encompassed herein, the anti-vibration structure(s) employed to couple the AV tube and enclosure can be implemented by way of an overmolding process, such as through the overmolding of TPE or another elastomeric material (or other material suitable for providing an anti-vibration link), where the anti-vibration structure(s) are overmolded around one or more of the backup linkages. Such overmolded embodiments can be advantageous in one or more respects, including that the primary, anti-vibration linkage and the backup linkage structure(s) form an integrated package that is simple, elegant, and can avoid the interposition of debris between the different linkage structures.
Also, in at least some embodiments, such as where the backup linkages are springs, the backup linkages can be formed in a manner that introduces pre-loading, which can in some circumstances or embodiments introduced added or reduced levels of tension or compression to the overall overmolded structure after overmolding has occurred. Such added or reduced levels of tension or compression are configurable based upon the pre-loading, and can be introduced in a variety of manners that are intended to foster desired behavior, or enhance the longevity of operation, of the improved mounting assembly or portions thereof (e.g., to reduce the progression of creeping of the primary, ant-vibration linkage structure(s)), or to permit additional support for unit(s)/structure(s) (e.g., food waste disposers) that will be supported by the mounting assembly.
Indeed, in at least some such embodiments, the substrate springs can allow some degree of pre-loaded tension or compression to be applied at the time of the overmolding process, if desired. Such pre-loading will result in an interim post-overmolding state to which the TPE or other such damping material is subjected when the preload is relaxed, and another state once the system is permanently loaded by the unit weight upon installation and during its service life. If a desired state of in-service overmold tension or compression can be identified (e.g., based on analysis and/or the testing of different iterations), then—taking the unit's weight into account—the corresponding preload to attain that state can be calculated and designed into the overmold tooling/process. Further, even if processing or other limitations may make it difficult, in practice, to achieve or closely hold a particular desired state, it may be possible to use a degree of preloading during overmolding to at least hedge against an undesirable in-service state.
Also, at least some embodiments encompassed by the present disclosure can be advantageous in terms of the configurability of the mounting assemblies that is permitted, and/or the relevant simplicity with which the mounting assemblies can be manufactured, and/or the extent to which the same or substantially similar manufacturing machinery, tooling, or processing can be employed to manufacture/assemble a variety of different types or configurations of mounting assemblies. For example, in at least some embodiments in which the AV tube (or neck section of the substrate) can attach to the enclosure (or container body portion of the substrate) via a set of integral springs, such embodiments can be advantageous in that there are easy-to-implement manners of producing opposing pairs of springs (each pair by a different mechanism, due to the action of the tooling)—further for example, up to four essentially-similar springs in total. The cross-section of the springs can be configured to allow overmolding material (e.g., TPE) to flow into and fill the AV tube (or neck area of the part), during overmolding.
Some such arrangements are further advantageous in that the mounting assemblies can be manufactured/assembled using one or more manufacturing machines or techniques that are common both to such mounting assemblies employing anti-vibration linkage(s) and possibly other types of mounting assemblies. For example, a manner of manufacturing an improved mounting assembly with anti-vibration linkage(s) in combination with springs allows for a common gating system to be employed during manufacture, where the common gating system can be employed both for manufacturing the improved mounting assemblies with the anti-vibration linkage(s) (AV-mount mounting assemblies) and also for manufacturing other mounting assemblies that do not include such anti-vibration linkage(s) and can be considered rigid mounting assemblies.
Also, in at least some embodiments, the width or other geometrical attributes of the springs can be iterated (e.g., in prototype production and testing) in order to adjust the overall stiffness or system performance). Additionally, such an arrangement can be advantageous in that it is adaptable, and particularly is consistent with the addition of other substrate features in this area (e.g., between the AV tube and enclosure) as can be appropriate in certain embodiments or circumstances. For example, in a circumstance where a reduced number of springs, or springs of significantly reduced width or cross-section, would be appropriate to achieve desired system stiffness/AV performance—or if a fill analysis determined additional flow was needed—then temporary bridges could be molded in place to augment the flow and then subsequently removed. The overmold would then be applied around, outside, and/or between the springs to seal off the remaining gap area. The molder's production transition from the AV-mount (substrate) version to the rigid version (non-overmolded) would require only an insert or slide change. The overmolding step can be varied according to the requirements of the design.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.
| Filing Document | Filing Date | Country | Kind |
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| WO2020/237091 | 11/26/2020 | WO | A |
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