Patent Application
20240247798
The present application relates to electric steam generating devices for use in a shower, a spa, or a bath.
Many residential steam generators are non-pressurized boilers that are similar in operation to a tea kettle. These residential steam generators are used to heat shower spaces and provide a therapeutic environment. These residential steam generators may include an internal construction having water vessel containing water, an electric heating element immersed in the water, a water level float, a safety valve to release pressure, one or more solenoid valves and one or more sensors for controls.
The most common limitation of durability of these residential steam generators is scale buildup. As water is boiled, the dissolved minerals and salts remain in the kettle. This increasing concentration accelerates the formation of deposits on the internal components and eventually results in device failure.
Another limitation of the boiler is the startup time. Some devices continuously heat the water reservoir to reduce the time to steam when demanded. This method consumes power when not in use and can also accelerate scale formation.
The following embodiments improve durability through the reduction of scale build up, provide fast start, and reduce power consumption.
Exemplary embodiments are described herein with reference to the following drawings, according to an exemplary embodiment.
The following embodiments isolate the fluid flow path through a steam generator. In this way, the fluid flow path does not directly contact the heating element. In addition, the water reservoir is eliminated, which overcomes problems of buildup in the water reservoir. Through these techniques, the steam generators of the following embodiments improve durability through the reduction of scale build up, provide fast start, and reduce power consumption.
A solid cast device transfers heat from the electric element to the metal fluid passage. The fluid remains isolated in the tube and does not contact the heating element. The tube may include two stages. Water enters into the first stage and is heated nearly to the boiling point. After it flows into the second stage, the water changes phase into steam and exits the tube. The water flows by gravity feed and no standing water remains in the tube. The first stage tube diameter/size is designed to heat the water rapidly in a small space. The second stage larger diameter/size provides expansion volume and allows for scale buildup without plugging the flow passage. The device can be sized incrementally to produce discreet steam flow rates at given power levels.
Referring generally to the following embodiments, a shower and a shower control system are described and illustrated. Similar components and features may be applied to a bath or bathtub and bath control system, as well as a spa, hot tub, or spa control system. The shower may include a shower enclosure and several shower subsystems (i.e., a water subsystem, an audio subsystem, a steam subsystem, a lighting subsystem, etc.). Each of the shower subsystems has output devices (e.g., shower outlets, flow control valves, temperature control valves, solenoids associated with the valves, lighting devices, audio output systems, steam outlets, etc.) configured to provide a user of the shower with an enhanced showering experience.
The shower control system is provided for receiving and processing user inputs, displaying a graphical user interface on the electronic display, and controlling outputs of the various output devices. Settings and combinations of settings may be saved in the shower control system (e.g., a controller of the system) for later playback (e.g., execution) by a controller of the shower control system. Such playback or execution causes actuation, adjustment, or another state change of one or a plurality of the shower output devices.
The water subsystem may include one or more analog or digital valves. Valves of the system may be configured to allow for an electronically controlled mixing of hot and cold water. Such mixing can allow control systems and methods described herein to achieve or approach certain target temperatures. Valves of the system may also be configured to allow for electronically controlled or selected shower outlet water flow. The electronically controlled valves (e.g., solenoids for actuating the hydraulic valves) are controlled via control signals from one or more controllers of the shower control systems.
The shower 110 includes a steam subsystem. The steam subsystem includes steam outlets that receive steam from the steam generator 100 in fluid communication with steam outlets. The steam generator is disposed between, and coupled via conduit (e.g., piping or tubing), to steam outlets and a water supply. The steam generator 100 heats the water, turning it into steam that is then communicated into shower enclosure through steam outlets. The steam generator 100 is controlled via control signals from one or more controllers of the shower control systems.
The heating element 103 is electric and includes connectors or terminal for connecting a power source. The connectors may include en electrical connection to which wires or other electrical connectors are coupled and then covered by end caps. The heating element 103 includes an electric resistance that converts the electrical energy to heat. The heating element 103 is at least partially surrounded by the cast body 104.
The cast body 104 may be formed of a cast metal with high heat transfer coefficient or other heat transfer characteristics, such as aluminum. During casting of the cast body 104, the heating element 103 is placed inside the cavity should that the cast body 104 forms around the heating element 103. During casting of the cast body 104, a fluid passage is placed inside the cavity so that the cast body 104 forms around the fluid passage. The fluid passage begins at inlet 105, extends through the cast body 104, and ends at the outlet 106.
The fluid passage is spaced apart from the heating element (e.g., not touching). The spacing may be approximately 1-5 centimeters depending on the size of the cast body 104. The cast body 104 transfers heat from the heating element 103 to the fluid passage through the spacing in the cast 104 between the heating element 103 and the fluid passage.
A solid cast device transfers heat from the electric element to the metal fluid passage. The fluid remains isolated in the tube, and does not contact the heating element. Water enters into the first stage, and is heated nearly to the boiling point. After it flows into the second stage, the water changes phase into steam and exits the tube. The water flows by gravity feed and no standing water remains in the tube. The first stage tube diameter is designed to heat the water rapidly in a small space. The second stage larger diameter provides expansion volume and allows for scale buildup without plugging the flow passage. The device can be sized incrementally to produce discreet steam flow rates at given power levels.
In some examples, the first portion 115 and the second portion 116 have different sizes. As shown in
As shown, the junction 107 may include a plate that blocks the inlet to the larger of the two portions (e.g., second portion 116) and includes an opening adapted to connect to the smaller of the two portions (e.g., first portion 115). This orientation prevents standing water and facilitates rapid flushing. The junction 107 may include a passage adapter that allows the first portion 115 and the second portion 116 to be connected. The junction 107 may be tapered and include a gradually increasing/decreasing diameter in order to mate the first portion 115 and the second portion 116.
The two-stage coil or fluid passage improves heat transfer, temperature uniformity and reduces the overall size of the steam generator 100. In the first stage (first portion 115) the water is heated to within a range of boiling. Example ranges may include 2-5 degrees Celsius or Fahrenheit to the boiling point of water. Impurities in the water may affect the boiling temperature. A smaller passage increases the proportion of the water that is in contact with the tube. By reducing the size of the tube, the water can be heated in a compact form and the heat up or startup time to steam is reduced. The second stage continues to add heat energy until the phase changes to vapor, and thus (second portion 116) provides a larger area for expansion. In addition, more spaces allows for scale buildup and eliminates plugging.
The outlet 106 may be connected to a plenum before the shower 110. The plenum prevents standing water in the steam generator 100. The plenum separates steam from condensate. The plenum may collect debris.
In this example of the second embodiment, the fluid passage has a helical shape overall. Rather than the circular cross section of the first embodiment, the second embodiment includes a flattened circular cross section or rounded rectangle. As shown in
The junction 107 may also be included in the second embodiment as a plate that blocks the inlet to the larger of the two portions and includes an opening adapted to connect to the smaller of the two portions. The junction 107 may include a passage adapter that allows the first portion and the second portion to be connected through a tapered connector or another technique.
In other examples, the first portion and the second portion may have cross sections of different shapes. The first shape of the first portion may have circular cross section and the second shape of the second portion may have a rounded rectangular cross section. Other shapes that may be used for either portion include, square, rectangular, oval, or star. The cross sections may include fins to increase the surface area of contact between the fluid passage and the cast body 104. In one example, the first shape of the first portion has circular cross section, and the second shape of the second portion has a rounded rectangular cross section (or oval cross section).
Upon completion of the steam cycle, the metering loop 211 is closed and the flush loop 212 is opened for the flush cycle, including a flow which is considerably higher (e.g., up to 100 times the flow rate). This operation mode cleans the fluid path inside the steam generator 100 to remove mineral buildup particularly in the region of phase change.
The metering loop (path) 211 includes the supply valve 213 and provides the water from which the steam generator 100 generates a steam. The flush loop (path) 212 provides water for flushing the steam generator 100 and includes a flushing valve 214 operated according to a flush cycle. The control system 210 includes a flow sensor 215 (flow meter) in line with the metering loop 211 configured to measure the flow through the metering loop 211 and a temperature sensor 222 configured to measure a temperature associated with the steam generator 100. A heater control portion or module 221 may be included in the controller 101 or operate independently of the controller 101. The controller 101 may receive data feedback from the flow sensor 215 and/or temperature sensor 222 and generate commands for the heater control 221, supply valve 213, and/or flushing valve 214. Additional, different, or fewer components may be included in the control system 210. The control system 210 may be enclosed in a housing. That is, a single housing may include the steam generator, the metering loop 211, the flush loop, the supply valve 213, the flushing valve 214, and the controller 101. The housing may include a single inlet and a single outlet. The housing may include a power source (e.g., battery) or an external power source may be connected.
The controller 101 may determine when to start or end a steam cycle based on user input (e.g., received graphical user interfaces to be presented via the display 102). That is, the user may press a button to start the steam cycle. Likewise, the controller 101 may end the steam cycle based on another user input. Alternatively, the controller 101 may determine the end of the steam cycle based on a timer configured to measure operation time of the steam generator or the metering loop supplying the steam generator. The controller 101 is configured to operate the supply valve 213 (turn off) and/or the flushing valve 214 (turn on) in response to the operation time.
Alternatively or additionally, the controller 101 operates the control system 210 based on the data feedback and/or a steam cycle operation timing. The controller 101 may begin or initiate operation of the steam generator 100 by opening the metering loop 211 through actuation of the supply valve 213. The supply valve 213 may be configured to supply a predetermined flow rate of water through the metering loop 211 to the steam generator 100. For example, a small orifice (e.g., having a predetermined diameter) in the supply valve 213 may determine the metering flow rate. The supply valve 213 may include multiple settings so that the controller 101 can set a specific metering flow rate of water through the metering loop 211 to the steam generator 100. In this example, the small orifice is variable and set by the controller 101. In one particular example, for a specific heating element size (e.g., 6 KW), the metering flow rate may be 130 milliliters per minute (ml/min) or in the range of 100-150 ml/min.
The controller 101 may operate the supply valve 213 to a target flow rate based on the feedback data provided by the flow sensor 215. When the flow sensor 215 detects a flow rate greater or less than the target flow rate, the controller 101 adjusts the supply valve 213 until the target flow rate is achieved.
The target flow rate may be selected based on a variety of factors. The maximum steam production can be achieved by metering the water inlet flow to a rate that results in constant temperature of the heater with continuous power input. In this configuration, all the water input can be converted to steam. As water flow rate is increased further, the heater temperature decreases, and some liquid water will exit with steam. It is preferred to control the water flow rate below the maximum and allow the heater control to maintain steady temperature by cycling power input. This operation allows selection of steady state temperature that creates uniform steam output.
The dimensions or volume of the fluid passage and the steam generator 100 power rating may impact the target flow rate. The target flow rate may be selected so that substantially all of the water metered into the fluid passage by the target flow rate is converted from water to steam. The target flow rate may be selected so that the heater does not turn on and off during the heat cycle. If the flow rate through the heater is too low, the heater temperature will rise. When the heater temperature exceeds a target temperature, the controller 101 turns off the heater.
The flush cycle allows a high volume of water to be provided to or pushed through the steam generator 100 to remove minerals scale or debris from the fluid passage. The controller 101 may initiate the flush cycle and open the flush valve 214 according to one or more triggers. In one example, the trigger for the flush cycle is a predetermined time of day. That is the flush cycle may be operated at a certain time of day. In another example, the trigger for the flush cycle may be after a certain number of steam cycles. The controller 101 may count steam cycles (e.g., times the heating element is turned on or times the supply valve 213 is opened). The controller 101 may initiate the flush cycle after the certain number of steam cycles is reached. In another example, the trigger for the flush cycle may be a set time after a steam cycle. The flush cycle may be started after the set time for each steam cycle or after the set time after the certain number of steam cycles.
In another example, the trigger for the flush cycle may be in response to sensor data indicative of a blockage in the fluid passage. A sensor in the fluid passage may detect block or buildup in the fluid passage. In a similar fashion, the trigger for the flush cycle may be in response to sensor data from the flow sensor 215. The controller 101 may determine a cumulative flow of water through the steam generator 100 in one or more steam cycles and initiate the flush cycle when the cumulative flow of water exceeds a predetermined quantity of water.
The controller 101 may transition the control system 201 for the steam generator 100 from the steam cycle (feedback control of the supply valve 213) to a flush cycle. During the flush cycle, the controller 101 open opens the flushing valve 214.
The controller 201 may determine when to start or end a flush cycle based on user input (e.g., received graphical user interfaces to be presented via the display 102). That is, the user may press a button to start the flush cycle. Likewise, the controller 101 may end the flush cycle based on another user input. Alternatively, the controller 101 may determine the end of the flush cycle based on a timer configured to measure operation time of the steam generator 100 or the flush loop supplying the steam generator. The controller 101 is configured to operate the supply valve 213 (turn off) and/or the flushing valve 214 (turn on) in response to the operation time.
At act S101, the controller 101 generates a command to connect a heating element of the steam generator to a power source. The command may originate with a user input. The user input may be a signal received from a switch, a button or lever that operates mechanically. The user input may be derived from data received at a touchscreen. The user input may be based on a wirelessly transmitted communication over a network or wireless protocol from a mobile (e.g., a mobile phone or a tablet).
The command may originate with sensor data. The sensor data may be part of a feedback system measuring temperature, a water flow, or other characteristic of the steam generated or an associated appliance (e.g., shower, bathtub, chamber, or spa). The sensor data may be based on a proximity sensor that detects a user near the steam generator or associated appliance. The sensor data may be image data for identification of a user near the steam generator or associated appliance. Authorized users only may trigger the command to connect the steam generator to the power source.
At act S103, the controller 101 generates a command to open a first valve between a water inlet and the steam generator on a metering loop during a steam cycle. The first valve and the metering loop may provide steam to the connected appliance.
At act S105, the controller 101 generates a command to close the first valve. The command to close the first valve may occur after a predetermined time period. The command to close the first valve may occur in response a predetermined steam cycle having a duty cycle. At act S107, the controller 101 generates a command to disconnect the heating element from the power source for the end of the steam cycle.
At act S109, the controller 101 generates a command to open a second valve between the water inlet and the steam generator on a flush loop coupled to the water inlet and the steam generator during a flush cycle. The flush cycle may have a flow rate greater than the flow rate of the metering loop.
The controller 101 may also receive sensor data for the steam generator 100 or the metering loop 211. The steam cycle is started, the flush cycle is started, or the heating element is disconnected in response to the sensor data. In some examples, the sensor data describes a flow of water through the steam generator 100. In some examples, the sensor data describes a temperature of the steam generator 100.
Optionally, the control system may include an input device 355 and/or a sensing circuit 356 in communication with any of the sensors. The sensing circuit receives sensor measurements from sensors as described above. The input device may include any of the user inputs such as buttons, touchscreen, a keyboard, a microphone for voice inputs, a camera for gesture inputs, and/or another mechanism.
Optionally, the control system may include a drive unit 340 for receiving and reading non-transitory computer media 341 having instructions 342. Additional, different, or fewer components may be included. The processor 300 is configured to perform instructions 342 stored in memory 352 for executing the algorithms described herein. A display 350 may be an indicator or other screen output device. The display 350 may be combined with the user input device 355.
Processor 300 may be a general purpose or specific purpose processor, an application specific integrated circuit (ASIC), one or more programmable logic controllers (PLCs), one or more field programmable gate arrays (FPGAs), a group of processing components, or other suitable processing components. Processor 300 is configured to execute computer code or instructions stored in memory 352 or received from other computer readable media (e.g., embedded flash memory, local hard disk storage, local ROM, network storage, a remote server, etc.). The processor 300 may be a single device or combinations of devices, such as associated with a network, distributed processing, or cloud computing.
Memory 352 may include one or more devices (e.g., memory units, memory devices, storage devices, etc.) for storing data and/or computer code for completing and/or facilitating the various processes described in the present disclosure. Memory 352 may include random access memory (RAM), read-only memory (ROM), hard drive storage, temporary storage, non-volatile memory, flash memory, optical memory, or any other suitable memory for storing software objects and/or computer instructions. Memory 352 may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. Memory 352 may be communicably connected to processor 300 via a processing circuit and may include computer code for executing (e.g., by processor 300) one or more processes described herein. For example, the memory 352 may include graphics, web pages, HTML files, XML files, script code, shower configuration files, or other resources for use in generating graphical user interfaces for display and/or for use in interpreting user interface inputs to make command, control, or communication decisions.
In addition to ingress ports and egress ports, the communication interface 353 may include any operable connection. An operable connection may be one in which signals, physical communications, and/or logical communications may be sent and/or received. An operable connection may include a physical interface, an electrical interface, and/or a data interface. The communication interface 353 may be connected to a network. The network may include wired networks (e.g., Ethernet), wireless networks, or combinations thereof. The wireless network may be a cellular telephone network, an 802.11, 802.16, 802.20, or WiMax network, a Bluetooth pairing of devices, or a Bluetooth mesh network. Further, the network may be a public network, such as the Internet, a private network, such as an intranet, or combinations thereof, and may utilize a variety of networking protocols now available or later developed including, but not limited to TCP/IP based networking protocols.
While the computer-readable medium (e.g., memory 352) is shown to be a single medium, the term “computer-readable medium” includes a single medium or multiple media, such as a centralized or distributed database, and/or associated caches and servers that store one or more sets of instructions. The term “computer-readable medium” shall also include any medium that is capable of storing, encoding or carrying a set of instructions for execution by a processor or that cause a computer system to perform any one or more of the methods or operations disclosed herein.
In a particular non-limiting, exemplary embodiment, the computer-readable medium can include a solid-state memory such as a memory card or other package that houses one or more non-volatile read-only memories. Further, the computer-readable medium can be a random access memory or other volatile re-writable memory. Additionally, the computer-readable medium can include a magneto-optical or optical medium, such as a disk or tapes or other storage device to capture carrier wave signals such as a signal communicated over a transmission medium. A digital file attachment to an e-mail or other self-contained information archive or set of archives may be considered a distribution medium that is a tangible storage medium. Accordingly, the disclosure is considered to include any one or more of a computer-readable medium or a distribution medium and other equivalents and successor media, in which data or instructions may be stored. The computer-readable medium may be non-transitory, which includes all tangible computer-readable media.
In an alternative embodiment, dedicated hardware implementations, such as application specific integrated circuits, programmable logic arrays and other hardware devices, can be constructed to implement one or more of the methods described herein. Applications that may include the apparatus and systems of various embodiments can broadly include a variety of electronic and computer systems. One or more embodiments described herein may implement functions using two or more specific interconnected hardware modules or devices with related control and data signals that can be communicated between and through the modules, or as portions of an application-specific integrated circuit. Accordingly, the present system encompasses software, firmware, and hardware implementations. Herein, the phrase “coupled with” or “coupled to” is defined to mean directly connected to or indirectly connected through one or more intermediate components. Such intermediate components may include both hardware and software based components. Further, to clarify the use in the pending claims and to hereby provide notice to the public, the phrases “at least one of <A>, <B>, . . . and <N>” or “at least one of <A>, <B>, . . . <N>, or combinations thereof” are defined by the Applicant in the broadest sense, superseding any other implied definitions here before or hereinafter unless expressly asserted by the Applicant to the contrary, to mean one or more elements selected from the group comprising A, B, . . . and N, that is to say, any combination of one or more of the elements A, B, . . . or N including any one element alone or in combination with one or more of the other elements which may also include, in combination, additional elements not listed. Furthermore, to the extent that the term “or” is employed (e.g., <A> or <B>) it is intended to mean “<A> or <B> or both.” When the intent is to indicate “only A or B but not both” then the term “only A or B but not both” will be employed.
The illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The illustrations are not intended to serve as a complete description of all of the elements and features of apparatus and systems that utilize the structures or methods described herein. Many other embodiments may be apparent to those of skill in the art upon reviewing the disclosure. Other embodiments may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure. Additionally, the illustrations are merely representational and may not be drawn to scale. Certain proportions within the illustrations may be exaggerated, while other proportions may be minimized. Accordingly, the disclosure and the figures are to be regarded as illustrative rather than restrictive.
While this specification contains many specifics, these should not be construed as limitations on the scope of the invention or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the invention. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
One or more embodiments of the disclosure may be referred to herein, individually and/or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any particular invention or inventive concept. Moreover, although specific embodiments have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.
It is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is understood that the following claims including all equivalents are intended to define the scope of the invention. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents thereto are claimed as the invention.
This application claims priority benefit of Provisional application No. 63/440,199 filed Jan. 20, 2023, which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63440199 | Jan 2023 | US |
