The present disclosure relates to waste disposers such as food waste disposers and, more particularly, to systems and methods for implementing and supporting motors within such waste disposers.
Food waste disposers are used to comminute food scraps into particles small enough to pass through household drain plumbing. A food waste disposer typically includes a primary inlet along the top of the food waste disposer at which the food waste disposer receives water and food scraps from a sink, and also a primary outlet at which food waste and water are output from the food waste disposer. A food waste disposer can be understood as including a food conveying section, a motor section, and a grinding section. The motor section includes a motor, such as an inductive motor or permanent magnet motor, which operates to impart rotational movement to a motor shaft to operate the grinding section.
In general, to save on manufacturing costs, it is desirable to reduce the complexity of the manufacturing process. Also in general, the complexity of the manufacturing process for a given system is directly correlated with the number of components of the system being manufactured. More particularly with respect to food waste disposers, the motor section of a food waste disposer can include a high number of components. Given this to be the case, the motor sections of many conventional food waste disposers may be undesirably complex and costly to implement.
For at least one or more of these reasons, or one or more other reasons, it would therefore be advantageous if improved waste disposers such as improved food waste disposers, and/or improved motor sections or portions of such waste disposers, and/or improved methods of implementation, manufacturing, assembly, and/or operation of such waste disposers or sections or portions thereof, could be developed, so as to address any one or more of the concerns discussed above or to address one or more other concerns or provide one or more benefits.
In at least some example embodiments, the present disclosure relates to a food waste disposer. The food waste disposer includes a housing including a primary inlet and a primary outlet. Also, the food waste disposer includes a food conveying section, a motor section, and a grinding section between the food conveying section and the motor section, where each of the food conveying section, motor section, and grinding section is at least partly supported by or within the housing. Further, the motor section includes a motor, a motor shaft, a first bearing, a second bearing, and a frame portion that least partly extends above or around the motor. Additionally, the frame portion includes each of a first cylindrical wall defining a first central orifice that extends around a central axis, a bottom annular lip extending radially inwardly toward the central axis from a bottom portion of the first cylindrical wall, and a plurality of upwardly-extending tabs extending upward from the first cylindrical wall. Further, the first bearing is supported by the frame portion within the first cylindrical wall, and tips of the upwardly-extending tabs are bent at least partly radially inwardly toward the central axis so that the first bearing is retained by the frame portion by the first cylindrical wall, the bottom annular lip, and the upwardly-extending tabs.
Also, in at least some example embodiments, the present disclosure relates to a method of assembling a motor section of a food waste disposer. The method includes forming a frame portion for the motor section, where the frame portion includes each of an annular top surface extending outward from a central axis toward an outer rim and having a radially inward edge portion defining a first central orifice about the central axis, a radially inwardly extending annular shelf, a first cylindrical wall that extends axially downward from the radially inward edge portion of the annular top surface to the radially inwardly extending annular shelf, and a second cylindrical wall that extends axially downward from an annular ridge provided at a radially inward portion of the radially inwardly extending annular shelf. Further, the frame portion also includes a plurality of upwardly-extending tabs extending upward from the second cylindrical wall. Additionally, the method includes placing a bearing within a second central orifice defined by the second cylindrical wall so that the bearing is supported by the frame portion, deforming at least some portions of the upwardly-extending tabs in a radially-inward manner toward the central axis so that the bearing is captured within the frame portion.
Additionally, in at least some further example embodiments, the present disclosure relates to a motor assembly. The motor assembly includes a motor, a motor shaft, a first bearing, a second bearing, and a frame portion that least partly extends above or around the motor. The frame portion includes each of a first cylindrical wall defining a first central orifice that extends around a central axis, a bottom annular lip extending radially inwardly toward the central axis from a bottom portion of the first cylindrical wall, and a plurality of upwardly-extending tabs extending upward from the first cylindrical wall. Additionally, the first bearing is supported by the frame portion within the first cylindrical wall, and tips of the upwardly-extending tabs are bent at least partly radially inwardly toward the central axis so that the first bearing is retained by the frame portion by the first cylindrical wall, the bottom annular lip, and the upwardly-extending tabs.
Embodiments of waste disposers such as food waste disposers (or systems including waste disposers), motor sections or portions of such waste disposers, and/or related methods, are disclosed with reference to the accompanying drawings and are for illustrative purposes only. The systems and methods encompassed herein are not limited in their applications to the details of construction, arrangements of components, or other aspects or features illustrated in the drawings, but rather such systems and methods encompassed herein include other embodiments or are capable of being practiced or carried out in other various ways. Like reference numerals are used to indicate like components. In the drawings:
Referring to
Further as shown, the food waste disposer 100 includes a primary input port or inlet 114 and a primary output port or outlet 116. The primary inlet 114 is positioned along or proximate to a top end 118 of the food waste disposer 100, and is configured to receive water and food scraps from a sink (not shown) to which the food waste disposer is mounted during operation of the food waste disposer. The primary outlet 116 is formed along a first sidewall portion 120 of the enclosure 104, proximate a junction 122 between the enclosure 104 and the bottom housing portion 106, and is configured to allow for food waste and water to pass from the grinding section 112 out from the food waste disposer 100 during operation. The food waste disposer 100 also includes a dishwasher inlet 124 that is an auxiliary port of the food waste disposer and that also is formed along, and as part of, the first sidewall portion 120.
Referring to
Further, the grinding section 112 in the present embodiment employs a rotating plate 234, lugs 236, and a stationary shredder ring 238. More particularly, the stationary shredder ring 238 generally takes the form of a cylindrical wall that is supported (at least indirectly) and fixed in position relative to the housing 102. The stationary shredder ring 238 circumferentially surrounds, and generally extends upward from the outer circumference of, the rotating plate 234. The rotating plate 234 is coupled to the motor shaft 228 of the motor section 110 so as to rotate in response to rotation of the motor 226, and the lugs 236 mounted on the rotating plate rotate along with rotation of the rotating plate. Centrifugal forces associated with rotation of the rotating plate 234, along with forces imparted by the lugs 236, tend to cause food scraps to be directed or projected radially outward toward the stationary shredder ring 238.
It should be appreciated that, upon impacting and contacting teeth (not shown) formed along the stationary shredder ring 238, food scraps (not shown) received into the food waste disposer 100 via the primary inlet 114 are comminuted into particles of the desired small size. The particles then pass through gaps (not shown) between the teeth (not shown) of the stationary shredder ring 238. In the present embodiment, after passing through the gaps, the particles (and associated water or other fluids) proceed downward toward an upper surface 244 of an upper end frame (UEF) 250 of the motor section 110, and further proceed circumferentially and radially outward so as to reach the primary outlet 116, by which those particles (and associated water or other fluids) exit the food waste disposer 100. As described further below, among other things, in the present embodiment the UEF 250 is a top enclosure of the motor 226 and serves to support the upper motor bearing 230.
Turning to
Further, referring to
The radially inwardly extending annular shelf 410 extends from the first cylindrical wall 404, toward the central axis 406, to an annular ridge 412. As the radially inwardly extending annular shelf 410 extends toward the annular ridge 412, that shelf also extends somewhat downwardly (away from the raised annular lip 402). Further, at the annular ridge 412, the radially inwardly extending annular shelf 410 transitions to become a second cylindrical wall 414. The second cylindrical wall 414 extends axially downward from the annular ridge 412 (also away from the raised annular lip 402), in a manner that is substantially parallel to the central axis 406, and defines a second central orifice 416 that is smaller in diameter than the first central orifice 304.
As illustrated, the second cylindrical wall 414 does not take the exact form of a cylinder, but rather has an aspherical contour such that the diameter of the second cylindrical wall varies somewhat as one proceeds along the second cylindrical wall in a direction substantially parallel to the central axis 406. In particular, as one proceeds along the second cylindrical wall 414 from the annular ridge 412 downward toward a bottom annular edge portion 418 of the second cylindrical wall, the diameter of the second cylindrical wall becomes smaller as one approaches the bottom edge portion, such that the UEF 250 and particularly the second cylindrical wall thereof forms an aspherical bearing pocket. Further, a radially inwardly extending annular bottom lip 420 is additionally formed at the bottom edge portion 418 of the second cylindrical wall 414. The annular bottom lip 420 is integrally formed with, and extends radially inwardly from, the second cylindrical wall 414 toward the central axis 406 and defines a third central orifice 422. Thus, in the present embodiment, the first central orifice 304 has a first diameter that is larger than a second diameter of the second central orifice 416, and the second diameter of the second central orifice is larger than a third diameter of the third central orifice 422.
Further with respect to
Thus, the upwardly-extending tabs 424 are integrally formed with annular ridge 412 and with the UEF 250. Although characterized as upwardly-extending, the upwardly-extending tabs can be tabs that extend only slightly upward on a slant rather than directly vertically upward, and in some embodiments need not be upwardly-extending when initially formed (rather, in some such embodiments, the tabs can simply be defined tab structures that are at least partly distinct from the annular shelf 410 or other portion(s) of the UEF 250.
Turning to
Referring to
Due to the bent posture of the upwardly-extending tabs 424 and the upper tips 602 thereof, the upwardly-extending tabs and upper tips thereof extend over portions of the upper motor bearing 230. Consequently, the upper motor bearing 230 is physically captured and retained, or staked, in place relative to the UEF 250 by the UEF, and particularly by the upwardly-extending tabs 424 and upper tips 602 thereof in combination with the radially inwardly extending annular bottom lip 420 and second cylindrical wall 414. Although physically captured and retained in place relative to the UEF 250, it should be appreciated that the upper motor bearing 230 is still capable of limited movement within and relative to the UEF 250, including rotational movement about the central axis 406 and possibly some limited axial movement upward or downward along the central axis.
Further, it should be appreciated from
In this manner, the upper motor bearing 230, as supported by and retained within the UEF 250, is able to support and guide movement of the motor shaft 228 during operation of the motor 226. More generally, the upper motor bearing 230 as supported by the UEF 250, in combination with the lower motor bearing 232, are configured to allow for the motor shaft 228 of the motor 226 to rotate relative to other portions of the food waste disposer 100 (such as the housing 102) and to cause movement within the food waste disposer of other components such as the rotating plate 234 (and the lugs 236 supported thereon) of the grinding section 112.
Notwithstanding the description provided above, the present disclosure encompasses numerous additional or alternate embodiments in addition to or differing from what is described above. For example, the UEF 250 can have one or more physical or structural features that are in addition to or different from one or more of the physical or structural features described above. Further for example, in one alternate embodiment, the UEF 250 does not include the raised annular lip 402. Also for example, although there are three of the upwardly-extending tabs of the plurality of upwardly-extending tabs 424 that are spaced apart from one another by 120 (or substantially 120) degrees about the annular ridge 412 in the present embodiment, the present disclosure also encompasses alternate embodiments in which the plurality of upwardly-extending tabs includes other numbers of tabs (e.g., four or five tabs) and/or in which the tabs of the plurality of upwardly-extending tabs are spaced apart from one another by other amounts or in other manners, including manners in which the spacing between different pairs of the tabs is not consistent among different pairs of the tabs.
Further for example, although at least some embodiments encompassed herein relate to an UEF that is configured to support an upper motor bearing that is intended to support a motor shaft of a motor section or assembly that in turn is coupled to a rotating plate of a food waste disposer, the present disclosure also encompasses numerous other embodiments. For example, the present disclosure also encompasses embodiments in which the motor bearing that is supported is another motor bearing, such as a lower motor bearing, and/or embodiments in which the structure that supports or retains the bearing is another type of structural frame component associated with a motor section or assembly other than an UEF. Additionally for example, the present disclosure further encompasses embodiments in which the motor section including the motor bearing is implemented in another type of waste disposer other than a food waste disposer, and/or embodiments in which the motor section including the motor bearing is implemented in another type of device or system other than a waste disposer.
One or more of the embodiments encompassed herein can be advantageous in one or more respects. In particular, in at least some embodiments encompassed herein, the upper motor bearing is staked into the UEF (or the upper motor frame or a portion thereof) and the bearing is staked with material of the UEF. Given such an arrangement, no bearing retainer is employed at the location of the upper motor bearing for implementing the upper motor bearing. By avoiding the use of a bearing retainer at the location of the upper motor bearing, one less part is employed in assembling the motor section or assembly and the overall food waste disposer by comparison with the assembling of at least some conventional embodiments. The upper motor bearing can be formed simply in three steps by (1) initially stamping an UEF component (e.g., a single UEF component) including an aspherical bearing pocket surrounded by three formed tabs, (2) during the production assembly process, placing a spherical bearing in the aspherical bearing pocket, and (3) deforming the three tabs to secure or capture the bearing in the pocket formed within the UEF.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.
| Number | Date | Country | |
|---|---|---|---|
| 63536568 | Sep 2023 | US |