Patent Application
20190159654
The present disclosure relates generally to dishwasher appliances, and more particularly to features for cleaning filters within dishwasher appliances.
Dishwasher appliances generally include a tub that defines a wash chamber. Rack assemblies can be mounted within the wash chamber of the tub for receipt of articles for washing. Wash fluid (e.g., various combinations of water and detergent along with optional additives) may be introduced into the tub where it collects in a sump space at the bottom of the wash chamber. During wash and rinse cycles, a pump may be used to circulate wash fluid to spray assemblies within the wash chamber that can apply or direct wash fluid towards articles disposed within the rack assemblies in order to clean such articles. During a drain cycle, a pump may periodically discharge soiled wash fluid that collects in the sump space and the process may be repeated.
Conventional dishwasher appliances use a filter to remove food particles, soil, and other contaminants from the wash fluid before recirculating the wash fluid through the pump and to the spray assemblies. The collected soil must be periodically removed from the filter to decrease flow resistance and improve the cleaning performance of the dishwasher appliance. Therefore, certain conventional dishwasher appliances include one or more filter cleaning ports defined on a bottom surface of the lower spray arm. The filter cleaning ports are configured for directing a stream of wash fluid onto the filter to dislodge food particles and soil to allow them to fall to the bottom of the sump for discharge during a drain cycle. However, in order to support operation of both the lower spray arm cleaning ports and the filter cleaning ports, a large pump is needed to generate sufficient wash fluid pressure. In addition, the filter cleaning ports are positioned far away from the filter, are directed at an angle relative to the filter, and often cannot directly spray all surfaces of the filter, resulting in less effective cleaning.
Accordingly, a dishwasher appliance that utilizes an improved filter cleaning assembly would be useful. More specifically, a filter cleaning assembly that effectively cleans a filter of the dishwasher appliance without requiring a larger pump or complicated fluid supply systems would be particularly beneficial.
The present subject matter provides a dishwasher appliance including a filter screen positioned within a sump for removing soil from recirculated wash fluid. A wash pump assembly includes a wash pump impeller for drawing wash fluid through the filter screen and pumping it through a supply conduit. A filter cleaning assembly includes a filter cleaning manifold positioned proximate the filter screen and defining a wash fluid plenum in fluid communication with the supply conduit. A plurality of cleaning ports are defined by the filter cleaning manifold and are in fluid communication with the wash fluid plenum, the cleaning ports being positioned and oriented for directing wash fluid toward the filter screen. Additional aspects and advantages of the invention will be set forth in part in the following description, may be apparent from the description, or may be learned through practice of the invention.
In accordance with one exemplary embodiment of the present disclosure, a dishwasher appliance defining a vertical direction is provided. The dishwasher appliance includes a wash tub that defines a wash chamber and a sump for collecting wash fluid. A filter screen is positioned within the sump, the filter screen defining a filtered region and an unfiltered region. A wash pump assembly includes a wash pump impeller and a supply conduit, the wash pump impeller being configured for urging wash fluid through the filter screen and into the supply conduit. A filter cleaning assembly includes a filter cleaning manifold positioned proximate the filter screen, the filter cleaning manifold defining a wash fluid plenum in fluid communication with the supply conduit. A plurality of cleaning ports are defined by the filter cleaning manifold and are in fluid communication with the wash fluid plenum, the cleaning ports being positioned and oriented for directing wash fluid toward the filter screen.
In accordance with another exemplary embodiment of the present disclosure, a filter cleaning assembly for a dishwasher appliance is provided. The dishwasher appliance includes a filter screen positioned within a sump and a wash pump assembly for urging wash fluid through a supply conduit. The filter cleaning assembly includes a filter cleaning manifold positioned proximate the filter screen, the filter cleaning manifold defining a wash fluid plenum in fluid communication with the supply conduit. A plurality of cleaning ports are defined by the filter cleaning manifold and are in fluid communication with the wash fluid plenum, the cleaning ports being positioned and oriented for directing wash fluid toward the filter screen.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
As used herein, the term “article” may refer to, but need not be limited to dishes, pots, pans, silverware, and other cooking utensils and items that can be cleaned in a dishwashing appliance. The term “wash cycle” is intended to refer to one or more periods of time during which a dishwashing appliance operates while containing the articles to be washed and uses a detergent and water, preferably with agitation, to e.g., remove soil particles including food and other undesirable elements from the articles. The term “rinse cycle” is intended to refer to one or more periods of time during which the dishwashing appliance operates to remove residual soil, detergents, and other undesirable elements that were retained by the articles after completion of the wash cycle. The term “drain cycle” is intended to refer to one or more periods of time during which the dishwashing appliance operates to discharge soiled water from the dishwashing appliance. The term “wash fluid” refers to a liquid used for washing and/or rinsing the articles and is typically made up of water that may include other additives such as detergent or other treatments. Furthermore, as used herein, terms of approximation, such as “approximately,” “substantially,” or “about,” refer to being within a ten percent margin of error.
The tub 104 includes a front opening 114 and a door 116 hinged at its bottom for movement between a normally closed vertical position (shown in
As best illustrated in
Some or all of the rack assemblies 122, 124, 126 are fabricated into lattice structures including a plurality of wires or elongated members 130 (for clarity of illustration, not all elongated members making up rack assemblies 122, 124, 126 are shown in
Dishwasher 100 further includes a plurality of spray assemblies for urging a flow of water or wash fluid onto the articles placed within wash chamber 106. More specifically, as illustrated in
The various spray assemblies and manifolds described herein may be part of a fluid distribution system or fluid circulation assembly 150 for circulating water and wash fluid in the tub 104. More specifically, fluid circulation assembly 150 includes a pump 152 for circulating water and wash fluid (e.g., detergent, water, and/or rinse aid) in the tub 104. Pump 152 may be located within sump 138 or within a machinery compartment located below sump 138 of tub 104, as generally recognized in the art. Fluid circulation assembly 150 may include one or more fluid conduits or circulation piping for directing water and/or wash fluid from pump 152 to the various spray assemblies and manifolds. For example, as illustrated in
As illustrated, primary supply conduit 154 is used to supply wash fluid to one or more spray assemblies, e.g., to mid-level spray arm assembly 140 and upper spray assembly 142. However, it should be appreciated that according to alternative embodiments, any other suitable plumbing configuration may be used to supply wash fluid throughout the various spray manifolds and assemblies described herein. For example, according to another exemplary embodiment, primary supply conduit 154 could be used to provide wash fluid to mid-level spray arm assembly 140 and a dedicated secondary supply conduit (not shown) could be utilized to provide wash fluid to upper spray assembly 142. Other plumbing configurations may be used for providing wash fluid to the various spray devices and manifolds at any location within dishwasher appliance 100.
Each spray arm assembly 134, 140, 142, integral spray manifold 144, or other spray device may include an arrangement of discharge ports or orifices for directing wash fluid received from pump 152 onto dishes or other articles located in wash chamber 106. The arrangement of the discharge ports, also referred to as jets, apertures, or orifices, may provide a rotational force by virtue of wash fluid flowing through the discharge ports. Alternatively, spray arm assemblies 134, 140, 142 may be motor-driven, or may operate using any other suitable drive mechanism. Spray manifolds and assemblies may also be stationary. The resultant movement of the spray arm assemblies 134, 140, 142 and the spray from fixed manifolds provides coverage of dishes and other dishwasher contents with a washing spray. Other configurations of spray assemblies may be used as well. For example, dishwasher 100 may have additional spray assemblies for cleaning silverware, for scouring casserole dishes, for spraying pots and pans, for cleaning bottles, etc. One skilled in the art will appreciate that the embodiments discussed herein are used for the purpose of explanation only, and are not limitations of the present subject matter.
In operation, pump 152 draws wash fluid in from sump 138 and pumps it to a diverter assembly 156, e.g., which is positioned within sump 138 of dishwasher appliance. Diverter assembly 156 may include a diverter disk (not shown) disposed within a diverter chamber 158 for selectively distributing the wash fluid to the spray arm assemblies 134, 140, 142 and/or other spray manifolds or devices. For example, the diverter disk may have a plurality of apertures that are configured to align with one or more outlet ports (not shown) at the top of diverter chamber 158. In this manner, the diverter disk may be selectively rotated to provide wash fluid to the desired spray device.
According to an exemplary embodiment, diverter assembly 156 is configured for selectively distributing the flow of wash fluid from pump 152 to various fluid supply conduits, only some of which are illustrated in
The dishwasher 100 is further equipped with a controller 160 to regulate operation of the dishwasher 100. The controller 160 may include one or more memory devices and one or more microprocessors, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with a cleaning cycle. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 160 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.
The controller 160 may be positioned in a variety of locations throughout dishwasher 100. In the illustrated embodiment, the controller 160 may be located within a control panel area 162 of door 116 as shown in
It should be appreciated that the invention is not limited to any particular style, model, or configuration of dishwasher 100. The exemplary embodiment depicted in
Referring now generally to
According to an example embodiment, drive motor 170 may be a variable speed motor. In this regard, drive motor 170 may be operated at various speeds depending on the current operating cycle of the dishwasher. For example, according to an exemplary embodiment, drive motor 170 may be configured to operate at any speed between a minimum speed, e.g., 1500 revolutions per minute (RPM), to a maximum rated speed, e.g., 4500 RPM. In this manner, use of a variable speed drive motor 170 enables efficient operation of dishwasher 100 in any operating mode. Thus, for example, the drain cycle may require a lower rotational speed than a wash cycle and/or rinse cycle. A variable speed drive motor 170 allows impeller rotation at the desired speeds while minimizing energy usage and unnecessary noise when drive motor 170 does not need to operate at full speed.
According to an exemplary embodiment, drive motor 170 and all its components may be potted. In this manner, drive motor 170 may be shock-resistant, submersible, and generally more reliable. Notably, because drive motor 170 is mounted inside wash chamber 106 and is completely submersible, no seals are required and the likelihood of leaks is reduced. In addition, because drive motor 170 is mounted in the normally unused space between lower spray arm assembly 134 and a bottom wall of sump 138, instead of beneath the sump 138, this design is inherently more compact than conventional designs.
According to an exemplary embodiment, fluid circulation assembly 150 may be vertically mounted within sump 138 of wash chamber 106. More particularly, drive motor 170 of fluid circulation assembly 150 may be mounted such that drive shaft 176 is oriented along vertical direction V of dishwasher 100. More particularly, drive shaft 176 may define an axial direction A, a radial direction R, and a circumferential direction C (
Referring now to
Referring still to
As shown in
As illustrated in
As illustrated, filter 196 is a cylindrical and conical fine mesh filter constructed from a perforated stainless steel plate. Filter 196 may include a plurality of perforated holes, e.g., approximately 15/1000 of an inch in diameter, such that wash fluid may pass through filter 196, but food particles entrained in the wash fluid do not pass through filter 196. However, according to alternative embodiments, filter 196 may be any structure suitable for filtering food particles from wash fluid passing through filter 196. For example, filter 196 may be constructed from any suitably rigid material, may be formed into any suitable shape, and may include apertures of any suitable size for capturing particulates.
According to the illustrated exemplary embodiment, filter 196 defines an aperture through which drive shaft 176 extends. Wash pump impeller 182 is coupled to drive shaft 176 above filter 196 and a drain pump assembly (e.g., as described below) is coupled to drive shaft 176 below filter 196 along the vertical direction V. Fluid circulation assembly 150 may further include an inlet guide assembly 199 which is configured for accurately locating and securing filter 196 while allowing drive shaft 176 to pass through aperture and minimizing leaks between the filtered and unfiltered regions 197, 198 of sump 138. More specifically, as best illustrated in
Referring again to
Drain pump assembly 200 may include a drain pump impeller 202 coupled to a bottom portion of drive shaft 176 and positioned within a drain volute 204 below filter 196. More specifically, drain volute 204 is defined by a drain basin 206 of sump 144 and a drain cover 208 that positioned over drain basin 206 and forms a fluid tight seal with drain basin 206, e.g., by using an O-ring 210 or any other suitable sealing mechanism. According to the illustrated embodiment, the bottom of sump 138 and drain cover 208 define a seamless transition and are cone-shaped to help funnel food particles toward drain volute 202. For example, as illustrated, sump 138 and drain cover 208 define a frustum of a cone above drain basin 206.
As best shown in
Notably, drain pump impeller 202 is coupled to the bottom portion of drive shaft 176 using a one-way clutch 226. In this regard, during a wash/rinse cycle, drive motor 170 rotates in one direction, pumping filtered wash fluid using wash pump impeller 182. However, one-way clutch 226 is disengaged, so drain pump impeller 202 does not rotate at the same speed. Instead, drain pump impeller 202 may rotate at a decreased speed, e.g., due to some friction between one-way clutch 226 and drive shaft 176. According to alternative embodiments, drain pump impeller 202 may remain stationary during the wash cycle or may rotate at the same speed as wash pump impeller 182. In both cases, soil and food particles will have a tendency to collect within drain volute 204, as described herein. By contrast, during a drain cycle, drive motor 170 rotates in the opposite direction, thereby engaging one-way clutch 226 and causing drain pump impeller 202 to rotate and discharge wash fluid.
As illustrated, drain inlet 220 is positioned at a center of drain cover 208 and is sized such that wash fluid and large food particles may pass into drain volute 204. However, drain cover 208 also acts as a barrier to prevent soil that collects around a perimeter of drain volute 204 from escaping drain volute 204, e.g., along the vertical direction V. In this manner, as drain pump impeller 202 rotates, soil and food particles are urged radially outward within drain basin 206 where they are trapped and collect until a drain cycle is initiated. When drive shaft 176 is rotated in the drain direction, wash fluid and soils collected in drain volute 204 are quickly and efficiently expelled through discharge conduit 216.
Drain pump volute 202 and discharge conduit 216 are both positioned at the very bottom of sump 138, at the lowest portion of fluid circulation assembly 150, providing several operational advantages. Specifically, heavier soil tends to fall toward drain volute 204 where wash fluid and food particles are collected. During a drain cycle, drain pump impeller 202 is rotated and soiled wash fluid is discharged from dishwasher 100 through a discharge conduit 216 such that complete draining of soiled wash fluid may be achieved. After some or all of the soiled wash fluid is discharged, fresh water and/or wash additives may be added and the wash or rinse cycle may be repeated.
It should be appreciated that drain pump assembly 200 is used only for the purpose of explaining aspects of the present subject matter. Modifications and variations may be made to drain pump assembly 200 while remaining within the scope of the present subject matter. For example, the number, size, spacing, and configuration of vanes of drain pump impeller 202 may be adjusted while remaining within the scope of the present subject matter.
Drain pump assembly 200 as described above enables both wash pump impeller 182 and drain pump impeller 202 of fluid circulation system 150 to be placed on a single drive shaft 176. In this manner, a single, reversible drive motor 170 can rotate drive shaft 176 in a first direction for wash/rinse cycles and in the opposite direction for drain cycles. More specifically, according to the illustrated embodiment, drive motor 170 and wash pump assembly 180 are positioned within filtered region 198, while drain pump assembly 200 is positioned within unfiltered region 197. Furthermore, because drain pump impeller 202 rotates relatively slowly during the wash cycle, drain pump impeller 202 draws food particles and soil into drain volute 204 and urges them radially outward to trap them in drain volute 204. In this manner, wash fluid circulated within wash chamber 106 has a lower soil content and can facilitate more effective cleaning of articles placing in the dishwashing racks. In addition, the soil is trapped or contained proximate discharge conduit 216 for effective discharge when drain pump impeller 202 is rotated in the drain direction.
Referring now generally to
According to the illustrated embodiment, filter cleaning assembly 250 includes a filter cleaning manifold 252 that is positioned proximate filter screen 196. Filter cleaning manifold 252 defines a wash fluid plenum 254 that is in fluid communication with supply conduit 188 through diverter chamber 194. In addition, filter cleaning assembly 250 includes a plurality of cleaning ports 256 that are in fluid communication with wash fluid plenum 204. In this manner, filter cleaning manifold 252 is generally configured for receiving a flow of wash fluid when diverter disc 192 is positioned such that wash fluid plenum 254 is in fluid communication with diverter chamber 194.
As shown, filter cleaning manifold 252 is a circular manifold positioned all the way around the top of cylindrical filter screen 196. In this manner, wash fluid plenum 254 is generally an annular chamber that distributes the flow of wash fluid around an entire circumference of filter screen 196. In addition, according to the illustrated embodiment, cleaning ports 256 are defined at least in part by filter cleaning manifold 252. More specifically, according to an exemplary embodiment, filter cleaning manifold is positioned above the filter screen 196 along the vertical direction V and cleaning ports 256 are defined on a bottom of filter cleaning manifold 252.
In addition, according to one embodiment, filter cleaning manifold 252 defines a circular slot 260 having a diameter substantially equivalent to the diameter of filter screen 196. As best shown in
According to the illustrated embodiment, filter screen 196 is received within slot 260 defined by filter cleaning manifold 252. Thus filter screen 116 may generally be compression fit within slot 260. However, it should be appreciated that filter screen 196 may be mounted to the filter cleaning manifold 252 using one or more mechanical fasteners, such as screws, bolts, rivets, etc. Alternatively, glue, welding, snap-fit mechanisms, interference-fit mechanisms, or any suitable combination thereof may secure filter screen 196 to filter cleaning manifold 252.
Cleaning ports 256 may generally be positioned and oriented for directing wash fluid toward filter screen 196. As explained briefly above, cleaning ports 256 may be defined by filter cleaning manifold 252 which is positioned vertically above filter screen 196. In this manner cleaning ports 256 may be directed downward along the vertical direction V, e.g., substantially parallel to the filter screen 196. In this manner, more effective cleaning of filter screen 196 may be achieved as compared to directing a stream of wash fluid at an angle relative to the filter screen 196.
Notably, most if not all of filter cleaning assembly 250 is positioned within sump 138 of dishwasher 100. In this manner, cleaning ports 256 may be defined proximate, immediately adjacent, or even be defined in part by filter screen 196. This enables high pressure wash fluid to be directed immediately onto filter screen 196 for maximum cleaning effect. For example, according to the illustrated embodiment, filter cleaning manifold 252 is positioned below the lower spray arm assembly 134 and at least partially within sump 138. Moreover, lower spray arm assembly 134 is connected to diverter assembly 200 using a different outlet defined on diverter chamber 194 than the outlet fluidly coupling diverter chamber 194 to wash fluid plenum 254. In this manner, lower spray arm assembly 134 and filter cleaning assembly 250 define two separate fluid circuits that may operate independently of each other. In this manner, when wash pump impeller 182 is pumping wash fluid, filter cleaning assembly 250 may utilize the full flow and pressure of wash fluid to clean filter screen 196. Thus, more effective cleaning may be achieved and a smaller drive motor 170 may be utilized than if wash pump impeller 182 were providing flow to both filter cleaning assembly 250 and lower spray arm assembly 134.
During operation, when drive motor 170 is rotating in a wash direction, wash impeller 182 spins in a direction where it is designed to be most efficient in urging a flow of wash fluid through supply conduit 188. Notably, because drain pump impeller 202 is coupled to drive shaft 176 using a one-way clutch 226, drain pump assembly 200 pumps little or no wash fluid through discharge conduit 216 during the wash cycle.
It may be desirable to intermittently flush filter screen 196 during the wash cycle. To achieve such filter cleaning, controller 160 may be programmed to rotate diverter disc 192 to a filter cleaning position where an aperture defined in diverter disc 192 directs the flow of wash fluid from diverter chamber 194 into wash fluid plenum 254. The wash fluid is then distributed circumferentially throughout wash fluid plenum 254 and discharged out cleaning ports 256 down along filter screen 196. This cleaning process may be repeated intermittently throughout a wash cycle, e.g., by alternating between providing wash fluid to the spray arm assemblies and the filter cleaning assembly 250. Alternatively, this cleaning process may be performed once at the end of a wash cycle, once at the beginning of a wash cycle, etc.
By contrast, when drive motor 170 reverses direction during a drain cycle, one-way clutch 226 engages driveshaft 176 such that drain pump impeller 202 begins discharging wash fluid through discharge conduit 216. Notably, during a drain cycle, wash pump impeller 182 also rotates with driveshaft 176 (e.g., because it is directly coupled to drive shaft 176). Because impellers have the tendency to pump fluid even when rotated in the reverse direction (albeit less efficiently), wash pump impeller 182 generates pressure within supply conduit 188 even during a drain cycle. To harness the pumping effect of the wash pump impeller 182 during a drain cycle, the diverter disk 192 may be rotated to provide fluid communication between diverter chamber 194 and wash fluid plenum 254 during a drain cycle. In this manner, as wash fluid is being discharged through discharge conduit 216 and level of wash fluid within sump 138 is dropping, filter cleaning assembly 250 flushes filter screen 196 with wash fluid until the wash fluid level drops below pump intake 186, at which time most or all food particles and soil have entered drain basin 206.
It should be appreciated that filter cleaning assembly 250 is described herein only for the purpose of explaining aspects of the present subject matter. Modifications and variations may be made to filter cleaning assembly 250 while remaining within the scope of the present subject matter. For example, the size, configuration, position, and orientation of cleaning ports 256 may vary. In addition, controller 160 may be programmed in any suitable manner for controlling drive motor 170 and diverter disc 192 to cleaning filter screen 196 at any suitable time and in any suitable manner. Thus, filter cleaning assembly 250 as described above provides a simple and effective means for cleaning filter screen 196 without requiring complicated plumbing systems or a larger drive motor or pump assembly. In addition, filter cleaning assembly 250 is generally more effective at cleaning filter screen 196 due to the proximity and angle of attack of cleaning ports 256. Moreover, energy usage may be reduced because a smaller drive motor 170 is needed and filter cleaning assembly 250 utilizes pumped wash fluid that would otherwise simply be recirculated in wash chamber to flush filter screen 196. Other configurations and benefits will be apparent to those of skill in the art.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
