The present disclosure relates to dishwashers and more particularly to structures and methods configured to attenuate and reduce sound generated from use of dishwashers and improve energy efficiency while reducing environmental impact.
One issue of interest in the field of dishwashers is to reduce the externally perceptible noise generated by the dishwasher when the dishwasher is in use. Due to the number of mechanical devices cooperating to circulate the water to clean and rinse the dishware within the dishwasher, the sources and conduits of sound are numerous and determining ways to reduce the noise may be challenging.
Further, another issue of interest is the reduction of energy usage required to operate dishwashers. In this regard, water may be heated in order to clean dishes. When the dishwasher is designed to reduce heat losses to the external environment around the dishwasher, the energy expended to heat the water may be reduced.
One material which has been employed in an attempt to reduce noise emissions from dishwashers and insulate against heat loss therefrom is that of mastic materials. Mastic materials, which may also be referred to as bitumen materials, are presently used in dishwashers because they are believed to absorb sound and insulate the dishwashers. However, mastic materials may have certain disadvantages.
Embodiments of a mastic-less dishwasher are provided herein. In one embodiment, the mastic-less dishwasher includes a recyclable and/or reclaimable tub comprising a plurality of walls defining a washing chamber configured to receive and hold a plurality of dishware and an opening. Further, the mastic-less dishwasher includes a door movable between an open position configured to provide access to the washing chamber through the opening, and a closed position configured to substantially close the opening and a mastic-less material coupled to at least one of the door and the walls of the recyclable and/or reclaimable tub external to the washing chamber. The mastic-less material may be non-expandable, and the dishwasher may be free of a mastic material such that during operation the mastic-less material does not expand and the dishwasher is configured to provide greater energy efficiency than a dishwasher comprising a mastic material.
In some embodiments, the mastic-less material may comprise a composite acoustic membrane including a layer of an acoustic tape, the acoustic tape comprising a plurality of first fibers extending in a first direction and a plurality of second fibers extending in a second direction, the first and second directions perpendicular to each other form a grid-like pattern, wherein the acoustic tape is positioned and configured to convert at least a portion of a sound power level generated by the dishwasher into heat such that the sound power level outside the dishwasher is reduced. Further, the composite acoustic membrane may include a first foam layer configured to absorb at least a portion of the sound power level and to reduce the speed of the sound power level prior to the sound power level reaching the acoustic tape. Also, the composite acoustic membrane may include a second foam layer and a vinyl layer between the first and second foam layers, the vinyl layer being configured to convert at least a portion of the sound power level into heat.
According to additional embodiments, the mastic-less material may comprise a laminated structure positioned and configured to attenuate a sound power level generated by the dishwasher, the laminated structure including a layer of an acoustic tape, the acoustic tape comprising a non-fibrous layer and a plurality of fibers mounted thereon, and wherein the plurality of fibers is configured to convert at least a portion of a sound power level generated by the dishwasher into heat such that the sound power level outside the dishwasher is reduced. Further, at least one of the door and the walls of the recyclable and/or reclaimable tub may define an inner wall that is exposed to the washing chamber, wherein an air gap is defined between the inner wall and the mastic-less material. At least one of the door and the walls of the recyclable and/or reclaimable tub may further define an intermediate wall defined between the inner wall and the mastic-less material. Also, at least one of the door and the walls of the recyclable and/or reclaimable tub may further define an outer wall configured to be exposed to an outside environment, wherein the mastic-less material is positioned between the intermediate wall and the outer wall and configured to contact both the intermediate wall and the outer wall. Further, the mastic-less material may comprise a composite cellular membrane comprising a cell layer positioned between a first reflective layer and a second reflective layer.
In some embodiments, the door and the walls of the recyclable and/or reclaimable tub include a plurality of stainless steel panels. A base tray may be configured to manage and control thermo-acoustic waves associated with noise generated by the dishwasher in an operational state, wherein the thermo-acoustic waves comprise vibrations and/or sound waves. The base tray may comprise a major surface and an array of thermo-acoustic nodes disposed on the major surface and defined by a plurality of rows and a plurality of columns, at least two of the thermo-acoustic nodes being interconnected and configured to channel the thermo-acoustic waves therebetween so as to control and manage the thermo-acoustic waves, thereby attenuating the noise associated with the thermo-acoustic waves.
In another embodiment, the mastic-less dishwasher further includes a water conduit and a fluid inlet in communication with the washing chamber and the water conduit, the fluid inlet comprising a nozzle defining a combination of a first plurality of orifices and a second plurality of orifices that define a diameter that is relatively larger than the diameter of the first plurality of orifices, wherein, during a filling cycle of the dishwasher, water is transmitted along the water conduit through the nozzle to the washing chamber. Each of the first plurality of orifices and the second plurality of orifices may define a constant cross-section in a water inflow direction. Further, the nozzle may comprise an inner surface and an outer surface, wherein each of the first plurality of orifices extends from the inner surface to the outer surface and defines a constant cross-section there along, and wherein each of the second plurality of orifices extends from the inner surface to the outer surface and defines a diverging cross-section there along. Additionally, the mastic-less material may be coupled directly to a bare structure of at least one of the door and the walls of the recyclable and/or reclaimable tub external to the washing chamber.
In an additional embodiment, a mastic-less dishwasher includes a recyclable and/or reclaimable tub comprising a plurality of walls defining a washing chamber configured to receive and hold a plurality of dishware and an opening. A door may be moveable between an open position configured to provide access to the washing chamber through the opening, and a closed position configured to substantially close the opening. A mass dampener material may be coupled to at least one of the door and the walls of the recyclable and/or reclaimable tub, wherein the mass dampener material comprises a mastic-less material, and wherein the dishwasher is free of a mastic material such that during operation the dishwasher is configured to provide greater energy efficiency than a dishwasher comprising a mastic material. For example, the mass dampener material may includes a vinyl layer configured to convert at least a portion of a sound power level generated by the dishwasher into heat such that the sound power level outside the dishwasher is reduced.
In another embodiment, a method for assembling a mastic-less dishwasher is provided. The method may include providing a recyclable and/or reclaimable tub comprising a plurality of walls defining a washing chamber configured to receive and hold a plurality of dishware and an opening. Further, the method may include providing a door movable between an open position configured to provide access to the washing chamber through the opening, and a closed position configured to substantially close the opening. Additionally, the method may comprise coupling a mastic-less material to at least one of the door and the walls of the recyclable and/or reclaimable tub external to the washing chamber, wherein the mastic-less material is non-expandable, and wherein the dishwasher is free of a mastic material such that during operation the dishwasher is configured to provide greater energy efficiency than a dishwasher comprising a mastic material.
In some embodiments, coupling the mastic-less material may comprise coupling the mastic-less material without causing the mastic-less material to be compressed by the walls of the recyclable and/or reclaimable tub or the door. Further, coupling the mastic-less material may comprise placing a composite acoustic membrane in a position external to the washing chamber, the composite acoustic membrane configured to convert at least a portion of the sound generated by the dishwasher into heat, the composite acoustic membrane comprising a layer of an acoustic tape, the acoustic tape including a plurality of first fibers extending in a first direction and a plurality of second fibers extending in a second direction. The method may also include providing a base tray comprising a major surface and an array of thermo-acoustic nodes disposed on the major surface and defined by a plurality of rows and a plurality of columns, at least two of the thermo-acoustic nodes being interconnected, wherein the base tray is configured to channel a plurality of thermo-acoustic waves associated with noise generated by the dishwasher in an operational state between the thermo-acoustic nodes so as to control and manage the thermo-acoustic waves and to thereby attenuate the noise associated with the thermo-acoustic waves. Further, the method may include providing a water conduit and providing a fluid inlet in communication with the washing chamber and the water conduit, the fluid inlet comprising a nozzle defining a combination of a plurality of relatively small-diameter orifices and a plurality of relatively large-diameter orifices, the water conduit configured to transmit water to the washing chamber through the nozzle during a filling cycle. Additionally, coupling the mastic-less material to at least one of the door and the walls of the recyclable and/or reclaimable tub external to the washing chamber may comprise coupling the mastic-less material directly to a bare structure of at least one of the door and the walls of the recyclable and/or reclaimable tub external to the washing chamber.
As such, aspects of the present disclosure may provide significant advantages as otherwise detailed herein.
Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
Applicant has identified certain disadvantages associated with the conventional use of mastic materials, also known as bitumen, in dishwashers. In this regard, sheets of mastic materials may be applied externally to dishwashers and/or inserted within the door and/or wall cavities of the dishwasher in an attempt to reduce noise emissions from the dishwasher. However, mastic materials may have the undesirable characteristic that they may be rigid, particularly before they warm sufficiently, and hence mastic materials may tend to vibrate and transmit sound. In addition, the present application further demonstrates that mastic materials tend to act as a heat sink. In this regard, as the dishwasher warms during use, heat is absorbed into the mastic material, removing this heat from a washing chamber of the dishwasher. Therefore, production of additional heat may be required to operate the dishwasher, thereby adversely affecting energy efficiency. Additionally, use of a mastic material may complicate recycling of dishwashers once the dishwashers are removed from service. In this regard, mastic materials may be bonded to the dishwashers in a manner such that removal of the mastic materials involves significant labor and/or expense. Thus, elimination of mastic materials may reduce material and labor costs associated with assembly and disassembly of the dishwashers. Accordingly, embodiments of a dishwasher configured to avoid the problems associated with use of mastic materials are provided herein.
In this regard,
The tub 13 may also define an opening, generally designated as 16, through which the dishware may be inserted into and removed from the washing chamber 11. A door 50 may be configurable between an open position configured to provide access to the washing chamber 11 through the opening 16, and a closed position configured to substantially close the opening. In
The dishwasher 10 may also include slidable lower and/or upper racks (not shown) for holding the dishware to be washed. The tub 13 may define a sump, generally designated as 14, in which wash water or rinse water is collected, for example, under the influence of gravity. The wash/rinse water may be pumped by a pump 15 out of the sump 14 to various spray arms 20 mounted in the interior of the tub 13 for spraying the wash/rinse water, under pressure, onto the dishes, utensils, and other dishware contained therein.
The pump 15 and/or other mechanical devices (e.g., a circulation pump, a drain pump, water valve(s)) that provide operational functions for the dishwasher 10 may be housed, disposed, or otherwise positioned within a base 22 positioned beneath the tub 13, wherein the base receives and supports a lower end 18 of the tub 13. In some instances, the base 22 may be a separate component with respect to the tub 13, such as, for example, a molded polymer component, while in other instances the base may be integral with the tub such that the side walls forming the tub also at least partially form the base.
The door 50 may be pivotably engaged with the tub 13 about the lower end 18 of the tub so as to selectively permit access to the washing chamber 11. That is, a lower edge 26 of the door 50 may be pivotably engaged (e.g., hinged) with the lower end 18 of the tub 13 such that the door is pivotable about the lower edge thereof to cover and seal the opening 16 in the closed position when the dishwasher 10 is in operation, and to provide access to the interior of the tub through the opening when the door is pivoted from the closed position to the open position. In some instances, the door 50 may comprise an inner wall 60 and an outer wall 70. The door 50 may include a handle member 24 disposed on an outer surface 72 of the outer wall 70 to provide the user with a grasp portion.
As noted above, Applicant has identified a number of disadvantages associated with use of a mastic material. Accordingly, embodiments of the present disclosure are generally directed to dishwashers that are free of a mastic material, which may be referred to herein as mastic-less dishwashers. For example, the dishwasher 10 described above may not include a mastic material. Accordingly, in one embodiment the dishwasher 10 may be free of an insulating material coupled to the walls 12 of the tub 13. For example,
Further, the tub 13 may be recyclable and/or reclaimable. For example, the material forming the tub 13 may be recycled or otherwise processed into a new object, or reclaimed for reuse as a tub in a new dishwasher. In this regard, by avoiding use of a mastic material, issues with respect to removing a mastic material from the tub may be avoided. Thus, the tub 13 provided herein may be considered recyclable and/or reclaimable, whereas the tub of a dishwasher including mastic materials coupled thereto may not be considered recyclable and/or reclaimable because of the cost and/or effort associated with removing the mastic material from the tub.
In a further embodiment, the dishwasher 10 may include a mastic-less material (i.e., an insulting material or emission reduction material that does not include a mastic material) coupled to at least one of the door 50 and the walls 12 of the tub 13, or other portion of the dishwasher. In some embodiments the mastic-less material may be directly coupled to a bare structure of the door, walls, or other portion of the dishwasher 10. For example, the mastic-less material may be adhered thereto through use of glue or other adhesive. Further, in some embodiments the mastic-less material may be installed without requiring use of a heat source. For example, some insulating materials may require heat to expand the material to fit a desired space during use of the dishwasher, while materials such as mastic are baked onto the dishwasher, whereas the mastic-less materials described herein need not necessarily require heat for installation or effectiveness. Accordingly, the door 50 and/or one or more of the walls 12 of the tub 13 of the dishwasher 10 may be insulated by mastic-less materials. Various embodiments of mastic-less materials may be employed, such as the embodiments of mastic-less materials disclosed in U.S. patent application Ser. No. 12/360,600.
As illustrated in
Although a mass loaded vinyl layer 220 is generally described herein, various other embodiments of mass dampener materials may be employed in other embodiments. In this regard, other examples of mass dampeners may include viscoelastic composite cushions (single or multilayer), brush seal material, elastometers, gaskets (e.g., die cut), fabric over foam, foam cushions, closed and/or open cell foam, felt, cork, rubber (natural or synthetic), a combination of rubber and vinyl, polyurethane, micro-cellular rubber, polyfoam, neoprene, crosslinked polymer, silicone, solid nitrile and other mastic-less emission reduction materials or combinations thereof. Mass dampener materials, as used herein, refer to materials of relatively high density that are configured to absorb sound and vibrations. Accordingly, use of mass dampener materials in the composite acoustic membrane 200 may reduce noise emissions from the dishwasher 10.
In some embodiments the acoustic tape 240 may be aluminum foil, metallized biaxially-oriented polyethylene terephthalate, or other foil material, with an adhesive backing. The adhesive backing may be used to adhere the acoustic tape 240 to one of the foam layers (e.g., the second foam layer 230, as shown). As illustrated in
The thickness of any of the individual layers of the composite acoustic membrane may vary. For example, the thickness of the layers may be configured such that collectively the thickness of the layers provided an overall thickness such that the composite acoustic membrane occupies a particular cavity or opening of the dishwasher. As another example, the relative thickness of the foam layers may vary depending on the application. In general, each of the foam layers may absorb and decelerate a portion of the sound transmitted through the layer regardless on the direction of the sound. The foam layer on either side of the vinyl layer may absorb and decelerate the sound before it reaches the vinyl layer regardless of the direction of the sound, which may increase the overall effectiveness of the composite acoustic membrane.
In some applications, the sound coming from a particular side of the vinyl layer may be relatively minimal and in such case, the foam layer on that particular side may be relatively thinner than the other foam layer. It should be noted that, in some applications, it is believed that it is beneficial to manage not only the sound transmitted from inside the dishwasher to outside the dishwasher but also the sound transmitted from outside the dishwasher to the inside the dishwasher as well. Sound transmitted from outside the dishwasher to inside the dishwasher may eventually reflect back or otherwise contribute to the level of sound transmitted from the inside the dishwasher to the outside of the dishwasher.
It is believed that the mass loaded vinyl layer 220 of the composite acoustic membrane 200 is effective at absorbing sound at a low frequency (30-300 kilohertz) and the first 210 and second 230 open cell foam layers 210, 230 is effective at absorbing sound at a medium frequency (300-3000 kilohertz). It is also believed that the excess at a high frequency (3-30 megahertz) is transformed into heat which dissipates in two directions along the bi-directional polymer fibers 244 of the acoustic tape 240 and excess noise is attenuated at the intersections of the fibers.
As noted above, the mastic-less material may be configured in a variety of positions in or around the dishwasher 10. In this regard,
As noted above, in some embodiments the dishwasher 10 may be free of an insulating material coupled to the door 50, and hence the cavities 462, 468 of the door may be free of an insulating material in some embodiments. However, in embodiments employing an insulating material, the door 50 may include a panel of the composite acoustic membrane 200 positioned within one or both of the cavities 462, 468. For a more specific example and according to the illustrated embodiment of
The composite acoustic membrane 200 may be shaped and sized that the composite acoustic membrane substantially occupies the entire cavity 468. In embodiments in which the second cavity 468 contains additional components such as a drying system or a dispenser, the composite acoustic membrane 200 may be configured to define openings or shapes such that the composite acoustic membrane extends at least partially around such components or otherwise provides space for the components. Although the composite acoustic membrane 200 may be configured to substantially entirely occupy a cavity within the door 50, the composite acoustic membrane may be configured so as to not be compressed against the walls of the tub or the door. In this regard, by configuring the composite acoustic membrane 200 so as to not be compressed, the tendency of the composite acoustic membrane to transmit vibrations may be reduced. For example, if the composite acoustic membrane were to be compressed between inner and outer walls of a door or a tub, the composite acoustic membrane may transmit vibrations to the outer wall of the door or tub, which could transmit noise to the environment around the dishwasher.
The composite acoustic membrane 200 and other embodiments of mastic-less materials described herein may be non-expandable. Non-expandable insulating materials, as used herein, refer to insulating materials that are not configured to expand or swell during the operation of the dishwasher or during installation therein. In this regard, the mastic-less materials provided herein may not be configured to act as spring dampeners that expand into contact with one or more surfaces, such as to bridge a gap between a dishwasher and an adjacent cabinet. Instead, the mastic-less materials may be configured to reduce noise emissions through other modes of operation as described herein. While some expansion may inherently occur as a result of changes in temperature during operation of the dishwasher, non-expandable insulating materials are not configured or required to expand into contact with one or more surfaces in order to provide noise abatement or other functionality.
According to the illustrated embodiment of
The sound power not absorbed or converted into heat by the first open cell foam layer 210, mass loaded vinyl layer 220, and the second open cell foam layer 230 may be transmitted onto the fibers of the acoustic tape 240. In particular, the composite acoustic membrane 200 may include the acoustic tape 240 as a fourth layer including the bi-directional polymer fibers 244 (see, e.g.,
The composite acoustic membrane 200 may have a first orientation within the door 50. For example, according to the illustrated embodiment, the acoustic tape layer 240 may be adjacent the outer panel 70 such that the acoustic tape is considered to be facing the outside environment of the dishwasher 10. As another example (not illustrated), in a second orientation, the acoustic tape layer 240 may be adjacent the intermediate panel 465 such that the acoustic tape is considered to be facing the washing chamber 11. In both the first and second orientation, the composite acoustic membrane 200 may include an adhesive, such as a pressure-sensitive adhesive, for adhering the first open cell foam layer 210 to either the outer panel 70 or the intermediate panel 465.
The door 50 may include an additional composite acoustic membrane that is positioned within the first cavity between the inner panel 60 and the intermediate panel 465. In other embodiments, the door 50 may include a panel of expanded polystyrene positioned within the first cavity to further help to insulate the door or to provide additional support or stiffening of the door.
Further, in an additional embodiment, the walls 12 of the dishwasher 10 may comprise two or more walls, for example, the walls 12 defining the tub 13 may include an inner wall and an outer wall. Further, the walls may include an intermediate wall. Thus, the walls 12 may be configured as described above with respect to the door 50 in some embodiments. For example, an air gap may be defined between the inner wall and the intermediate wall. Further, the composite acoustic membrane 200 may be positioned between the intermediate wall and the outer wall as described above. Accordingly, in some embodiments the above-described configuration of the walls and the composite acoustic membrane with respect to the door 50 may additionally or alternatively apply to the walls 12 of the tub 13. Thus, the dishwasher 10 may in some embodiments incorporate a mastic-less material, for example, in accordance with the disclosure of U.S. patent application Ser. No. 12/360,700.
By way of further example,
The composite cellular membrane 250 may attach to the walls and/or the door of the dishwasher 10. For example,
The dishwasher 10 may in some embodiments additionally or alternatively include a base tray, for example, as disclosed in U.S. patent application Ser. No. 12/841,883. In this regard,
The base 22 may be molded to receive a base tray 25 (see, e.g.,
One embodiment of a base tray 25 (shown in
As illustrated, the array 30 of thermo-acoustic nodes 40 may also comprise clusters 100 of thermo-acoustic nodes (circled regions). Clusters 100 comprise adjacent thermo-acoustic nodes 40 or the interconnection of at least two thermo-acoustic nodes, such as by sharing a common outer wall member 42 (i.e., common sides) or having otherwise interconnected wall members. The clusters of the thermo-acoustic nodes 40 encourage sound waves to bounce back and forth between the thermo-acoustic nodes inside the cluster 100 in an effort to control them and eventually cancel out the sound being emitted. In the depicted embodiment, the thermo-acoustic nodes 40 generally form a plurality of rows and a plurality of columns across the array 30. As such, a cluster 100 can occur at any interconnection between at least two thermo-acoustic nodes 40 across either a row or a column.
Furthermore, clusters 100 can occur between any combination of thermo-acoustic nodes 40 in the array. For example, in the depicted embodiments, some but not all clusters 100 are shown in
The dishwasher 10 may in some embodiments additionally or alternatively include a fluid inlet, for example, as disclosed in U.S. patent application Ser. No. 12/362,262. In this regard, one or more embodiments of the dishwasher 10 are directed to attenuating acoustic emissions transmitted through a fluid inlet. As illustrated in
The fluid inlet 400 may include a nozzle 520 defining a plurality of orifices 522, 524. The relative sizes and shapes of the orifices 522, 524 may be configured to reduce or manage the acoustic emissions transmitted through or by the nozzle 520. As explained above, the sources of the acoustic emissions may vary internally and externally, e.g., the splashing and transmission of water and the pumps, motors, valves, and other components of the dishwasher 10 and devices and the environment external of the dishwasher. According to the illustrated embodiment of
Water is discharged through the relatively small-diameter orifices 522 and the relatively large-diameter orifices 524 into the tub. Also, the fluid inlet 400 may further function as vent such that air may travel through the relatively small 522 and large 524 orifices into and out of the washing chamber 11. “Relatively,” as used in reference to the orifices, describes the relative sizes of the different size holes to each other, i.e., the orifices of the first plurality of orifices are smaller than the orifices of the second plurality of orifices and thus may be referred to herein as relatively small-diameter orifices 522. Likewise, the orifices of the second plurality of orifices may be referred to herein as relatively large-diameter orifices 524 because the orifices of the second plurality are larger than the orifices of the first plurality.
As shown in
As illustrated in
Accordingly, the dishwasher 10 may include various embodiments of features configured to reduce sound emissions therefrom. In various combinations, the above-described embodiments of the dishwasher 10 may synergistically contribute to reduced sounds emissions. In this regard, for example, the combination of a mastic-less dishwasher with a mastic-less material in accordance with U.S. patent application Ser. No. 12/360,600, a base tray in accordance with U.S. patent application Ser. No. 12/360,700, and/or a fluid inlet in accordance with U.S. patent application Ser. No. 12/362,262 may reduce the sound emissions further than may occur without inclusion of one or more of these optional embodiments. Accordingly, the dishwasher 10 may benefit from various combinations of the embodiments disclosed herein.
In this regard, Applicants have tested embodiments of the mastic-less dishwasher 10 under the acoustic standards within the International Electrotechnical Commission (IEC) sections 607.04-2, 3, 4 and compared them to embodiments of dishwashers including mastic materials. The test results indicate that the sound intensity of the mastic-less dishwasher 10 may be within one decibel of a dishwasher employing a mastic material through the one kilohertz to 4 kilohertz frequency range. Further, Applicants have found that peak sound intensity of embodiments of the mastic-less dishwasher 10 may be within four decibels of a dishwasher incorporating a mastic material. Accordingly, the mastic-less dishwasher 10 may emit substantially similar intensities of noise as compared to a dishwasher incorporating a mastic material while realizing various benefits as discussed herein.
As illustrated, Dishwasher A has the lowest expected annual power usage. In particular, Dishwasher A has an expected annual power usage of 264 kilowatt hours/year, whereas Dishwashers B-E have an expected annual power usage of 299 kilowatt hours/year and Dishwasher F has an expected annual power usage of 303 kilowatt hours/year. Accordingly, Dishwasher A has an expected annual power usage that is 35 kilowatt hours/year less than the lowest expected annual power usage of the remaining tested dishwashers. In this regard, Dishwasher A, which does not comprise a mastic material, is expected to use over eleven percent less energy over the course of a year. Accordingly, embodiments of the mastic-less dishwasher 10 provide unexpected results in terms of energy efficiency gains in comparison to dishwashers employing mastic materials.
Further, the mastic-less dishwasher 10 may provide benefits in terms of improved drying performance. In this regard, more heat may be retained in the mastic-less dishwasher as a result of not employing a mastic material, which may act as a heat sink as described above. In this regard Applicant has performed drying performance tests on embodiments of the mastic-less dishwasher 10. The test results yielded dry performance scores between 49 and 71 percent, whereas an embodiment of a dishwasher employing a mastic material yielded a dry performance score of 43 percent. These values are calculated based on performance tests whereby dust is applied to dishware in the dishwashers after completion of a wash cycle, and the amount of dust remaining on the dishware after completion of the dry cycle is measured. Accordingly, the mastic-less dishwasher 10 also provides unexpected results in terms of improved drying performance, which may enable the mastic-less dishwasher 10 to dry dishes more quickly than may occur in embodiments of dishwashers employing mastic materials.
In a further embodiment a method for assembling a mastic-less dishwasher is provided. In some embodiments the dishwasher may comprise an embodiment of the above described dishwasher 10. As illustrated in
In some embodiments, certain ones of the above-described operations (as illustrated in solid lines in
For example, the method may further comprise the step of providing a base tray comprising a major surface and an array of thermo-acoustic nodes disposed on the major surface and defined by a plurality of rows and a plurality of columns, at least two of the thermo-acoustic nodes being interconnected at operation 1006. The base tray may be configured to channel a plurality of thermo-acoustic waves associated with noise generated by the dishwasher in an operational state between the thermo-acoustic nodes so as to control and manage the thermo-acoustic waves and to thereby attenuate the noise associated with the thermo-acoustic waves in some embodiments of the method.
Additionally, the method may include the step of providing a water conduit at operation 1008. Also, the method may include the step of providing a fluid inlet in communication with the washing chamber and the water conduit, the fluid inlet comprising a nozzle defining a combination of a plurality of relatively small-diameter orifices and a plurality of relatively large-diameter orifices, the water conduit configured to transmit water to the washing chamber through the nozzle during a filling cycle at operation 1010. Further, in some embodiments the step of coupling the mastic-less material at operation 1004 may comprise the step of coupling the mastic-less material comprises coupling the mastic-less material without causing the mastic-less material to be compressed by the walls of the tub or the door at operation 1012. Also, in some embodiments the step of coupling the mastic-less material at operation 1004 may comprise the step of placing a composite acoustic membrane in a position external to the washing chamber, the composite acoustic membrane configured to convert at least a portion of the sound generated by the dishwasher into heat, the composite acoustic membrane comprising a layer of an acoustic tape, the acoustic tape including a plurality of first fibers extending in a first direction and a plurality of second fibers extending in a second direction at operation 1014. Further, the step of coupling the mastic-less material at operation 1004 may comprise the step of coupling the mastic-less material directly to a bare structure of at least one of the door and the walls of the recyclable and/or reclaimable tub external to the washing chamber at operation 1016.
Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
This application is a continuation-in-part of U.S. patent application Ser. No. 12/360,700, filed Jan. 27, 2009, U.S. patent application Ser. No. 12/362,262, filed Jan. 29, 2009, and U.S. patent application Ser. No. 12/841,883, filed Jan. 22, 2010, all of which are hereby incorporated herein in their entirety by reference.
Number | Date | Country | |
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Parent | 12360700 | Jan 2009 | US |
Child | 13153768 | US | |
Parent | 12362262 | Jan 2009 | US |
Child | 12360700 | US | |
Parent | 12841883 | Jul 2010 | US |
Child | 12362262 | US |