Patent Application
20240170234
The present disclosure relates to waste disposers such as food waste disposers and, more particularly, to control systems for use in or in conjunction with such waste disposers or associated devices, as well as to waste disposers comprising such control systems, and to methods of assembling and/or operating control systems in relation to waste disposers or associated devices.
Food waste disposers are used to comminute food scraps into particles small enough to pass through household drain plumbing. Such food waste disposers can be powered in several manners depending upon the embodiment or environment. Most older homes (pre-1970's) have a Romex/BX cable extending from a wall of the home, which can be coupled and terminated directly to the disposer in a hardwired manner. However, most newer homes have a standard electric power outlet (e.g., a wall outlet) near the disposer, to which the disposer can be coupled by way of a power cord and associated plug so as to receive power. Out of all homes, it is estimated that 60% of homes with a disposer have hardwiring and that the remaining 40% use a power outlet located in the sink cabinet.
In many installations of food waste disposers, whether power is provided to the disposer (or whether the disposer is switched on or off) can be determined by way of a built-in wall switch. Such installations can include ones in which the disposers are installed via hardwiring including a Romex/BX cable as well as ones in which the disposers are coupled to an electrical power outlet by way of a power cord and associated plug. In such installations, whether power is made available to the food waste disposer, via the Romex/BX cable or via the electrical power outlet and power cord and plug as the case may be, is determined based upon the status of the wall switch.
However, in other installations, whether power is provided to the disposer (or whether the disposer is switched on or off) is determined by way of an additional operator-controllable switching mechanism other than (or in addition to) a built-in wall switch. In some such embodiments, a food waste disposer is implemented in conjunction with an aftermarket air switch power control device by which an operator can control the provision of power to the disposer (or whether the disposer is switched on or off). The air switch power control device includes a power control module linked to an operator-actuatable push button by way of an air conduction tube. The power control module has an electrical power outlet into which the plug of a power cord of the disposer can be plugged. Further, the air switch power control device also includes a power cord extending between the power control module and an associated plug, which can be plugged into another electrical power outlet such as a wall outlet.
Such an air switch power control device is configured to have two operational states. In a first one of the operational states, the electric power received via the power cord of the air switch power control device, which is coupled to the wall outlet, is in turn communicated to the electrical power outlet of the power control module itself. In this first operational state, any food waste disposer coupled to the electrical power outlet of the power control module (e.g., coupled by way of a power cord of the disposer itself) can receive electric power and be switched on. Also, in a second one of the operational states, the electrical power outlet of the power control module is decoupled electrically from the power cord of the air switch power control device. In this second operational state, no power from the wall outlet is provided at the electrical power outlet of the power control module, and thus any food waste disposer coupled to the electrical power outlet of the power control module cannot receive power and is switched off.
Whether the air switch power control device is in the first operational state or in the second operational state depends upon operator actuation of the operator-actuatable push button. More particularly, upon being pressed by an operator, the operator-actuatable push button causes air to be forced away from the push button through the air conduction tube to a diaphragm in the power control module, which moves in response to change in air pressure (or the received air flow). The position of the diaphragm in turn controls the state of an electric switch that governs whether electric power received at the power control module from the wall outlet is provided to the electrical power outlet of the power control module and thus provided to power any disposer coupled to that electrical power outlet. For example, if the push button is depressed and causes air flow to proceed toward the diaphragm, then in turn movement of the diaphragm can occur that causes the electrical switch to be closed and results in electric power being communicated to the disposer. Further, if the push button is released such that air flow moves toward the push button, then in turn corresponding movement of the diaphragm can occur that causes the electrical switch to be open-circuited and results in the disposer no longer receiving electric power.
Although such an air switch power control device enables an operator to control the provision of power from a wall outlet to a food waste disposer coupled to that air switch power control device without the presence of a wall switch, there are several disadvantages associated with installations involving such an air switch power control device. In particular, implementation of such an air switch power control device can be unwieldy or awkward given the number of connections/linkages involved, including not only the power cord of the food waste disposer itself but also the power cord of the air switch power control device, in addition to the air conduction tube, and also insofar as it may be difficult to find a location (e.g., under a kitchen sink) at which the power control module can be situated/supported in a manner that accommodates these connections/linkages.
For at least one or more of these reasons, or one or more other reasons, it would therefore be advantageous if improved control mechanisms or systems for use in or in conjunction with food waste disposers or other disposers and/or associated devices could be developed, and/or if improved food waste disposers or other disposers having or operating in conjunction with such improved control mechanisms or systems could be developed, and/or if improved methods of assembling and/or operating such mechanisms, systems, or disposers 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 one example embodiment, the present disclosure relates to a food waste disposer system. The food waste disposer system includes a housing including a bottom housing portion and a top housing portion, and a power control module supported at least partly within the housing. Also, the food waste disposer system includes a motor supported within the housing and coupled electrically, at least indirectly, to the power control module. Further, the food waste disposer system includes an actuator positioned externally of the housing, and an air conduction tube connecting the actuator at least indirectly with the power control module. Additionally, the food waste disposer system includes a power link extending outward from the power control module and the housing, so that the power control module can be coupled electrically, at least indirectly, to a power source. The power control module is configured to switch between having a first operational status and having a second operational status in response to a pressure change communicated through the air conduction tube as a result of an actuation of the actuator. Further, electric power received at the power link from the power source is communicated to the motor from the power link at least indirectly via the power control module when the power control module has the first operational status, but is not communicated to the motor when the power control module has the second operational status.
Additionally, in at least one example embodiment, the present disclosure relates to a method. The method includes providing a waste disposer system including a housing including a bottom housing portion and a top housing portion, a power control module supported at least partly within the housing, a motor supported within the housing and coupled electrically, at least indirectly, to the power control module, an actuator positioned externally of the housing, an air conduction tube connecting the actuator at least indirectly with the power control module, and a power link extending outward from the power control module and the housing, so that the power control module can be coupled electrically, at least indirectly, to a power source. Further, the method includes receiving electric power at the power control module at least indirectly via the power link, and transmitting a pressure change through the air conduction tube to the power control module in response to an actuation of the actuator. Additionally, the method includes switching from a first operational status of the power control module to a second operational status of the power control module in response to the pressure change, and communicating the electric power received via the power link to the motor from the power link at least indirectly via the power control module when the power control module has the first operational status. Further, the method includes additionally switching from the second operational status to the first operational status in response to an additional pressure change, and ceasing the communicating of the electric power to the motor when the power control module has the second operational status.
Further, in at least one example embodiment, the present disclosure relates to an air switch assembly for implementation in combination with a waste disposer in an integrated manner so as to provide air switch control of operation of the waste disposer. The air switch assembly includes a power control module including a base plate and also a switching mechanism and a terminal assembly that are each supported upon the base plate, where the base plate includes at least one feature that enables, at least in part, the base plate to be secured to the waste disposer. Additionally, the air switch assembly includes a power link extending outward from the power control module, where the power link includes a plug at an end apart from the power control module that is configured for being coupled to a wall outlet. Further, the air switch assembly includes an air switch mechanism including an actuator and an air conduction tube linking the actuator with the power control module, where the switching mechanism includes a diaphragm structure at least indirectly in communication with an electrical switch. Also, the diaphragm structure is configured to be moved in response to pressure changes communicated via the air conduction tube in response to actuations of the actuator, and the switching mechanism is configured so that the electrical switch changes switch states in response to movements of the diaphragm structure. Further, the terminal assembly includes a plurality of first electrical contacts that are configured to engage a plurality of second electrical contacts formed along an interior of the waste disposer, so as to allow for a direct physical connection and a direct electrical connection to be formed between the power control module and the plurality of second electrical contacts.
Embodiments of waste disposer systems (e.g., food waste disposer systems), waste disposers (e.g., food waste disposers), control systems for integration or implementation in combination with such disposer systems or disposers, combination systems including associated or auxiliary devices in addition to such disposer systems or 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:
The present disclosure relates to waste disposer systems such as food waste disposer systems, and more particularly to such waste disposer systems having control systems included therewithin or integrated or utilized in conjunction with waste disposers thereof, as well as to such control systems for use in conjunction with or as part of such waste disposer systems, and also to methods of operating and implementing such waste disposer systems and waste disposers and control systems thereof.
More particularly in this regard, the present inventors have recognized that an improved food waste disposer system in at least some embodiments will include an air switch power control device or arrangement (or simply air switch assembly) that is integrated with a food waste disposer of the food waste disposer system, where such integration particularly involves positioning a power control module of the air switch arrangement within (or as part of) the food waste disposer of the food waste disposer system. Given such an arrangement, control over whether power is provided to the food waste disposer, or whether the food waste disposer is actuated, can be governed by actuation of an air switch actuator (e.g., button) that is coupled to the power control module within the food waste disposer by an air conduction tube. By employing such an arrangement, control over the food waste disposer as governed by actuation of the air switch actuator can be achieved without any additional power links or cords being employed externally of the food waste disposer to couple the power control module to the food waste disposer.
Referring to
The motor section includes a motor 204 (see
As further shown in
Additionally as shown in
It should be understood that the sink 170, even though coupled to the food waste disposer system 10, is distinct from and not part of the food waste disposer system in the present embodiment. Also, although in the present description the air switch assembly 121 including the air switch mechanism 120 and power link 106 is considered to be distinct from the food waste disposer 100, in other embodiments or contexts one or more of the air switch assembly 121, the air switch mechanism 120, and the power link 106 can be considered to form a part of the food waste disposer 100 itself.
Turning to
Further as illustrated, the power control module 202 particularly includes a diaphragm structure (or simply diaphragm) 210 that serves as an air pressure (or vacuum, or air flow) sensor, and that is coupled to the actuator 122 by the air conduction tube 124. Also, the power control module 202 includes a switch actuator 212 and a single throw switch 214. As shown, the diaphragm structure 210 is connected or coupled, within the power control module 202 as represented figuratively by the switch actuator 212, to the single throw switch 214. An input terminal 216 of the single throw switch 214 is coupled by a first electrical connector 218 to the power terminal 208. The first electrical connector 218 in the present embodiment includes three wires or connections, namely, a neutral wire 230, a ground wire 232, and a live (or hot) wire 234. Each of the power terminal 208 and the first electrical connector 218 can be considered to be parts of the power control module.
Additionally, a first output terminal 220 of the single throw switch 214 is coupled by a second electrical connector 222 to the motor 204. For purposes of the present description, the motor 204 and the second electrical connector 222 can be considered to be parts of the food waste disposer 100 rather than parts of the power control module 202, air switch mechanism 120, or air switch assembly 121. As with the first electrical connector 218, the second electrical connector 222 also includes three wires or connections, namely, a neutral wire 240, a ground wire 242, and a live (or hot) wire 244. The single throw switch 214 is coupled between the first electrical connector 218 and the second electrical connector 222 such that the neutral wire 230 is directly coupled to the neutral wire 240, the ground wire 232 is directly coupled to the ground wire 242, and the live wire 234 can be coupled directly to or decoupled from the live wire 244 based upon the open or closed status of the single throw switch 214, as governed by the switch actuator 212 in response to movement of the diaphragm structure 210.
In the present embodiment, the power terminal 208 is an internal node associated with the power control module 202 (relatedly, the first electrical connector 218 also can be considered to be a part of the power control module). As already noted in regard to
In the present embodiment, the status of the single throw switch 214 is governed by the diaphragm structure 210, due to at least indirect physical contact between the diaphragm structure and the single throw switch as represented by the switch actuator 212. By virtue of the switch actuator 212, movement of the diaphragm structure 210 causes switching of the single throw switch 214 (thus, the switch actuator 212 can also be considered an actuation linkage between the diaphragm structure 210 and the single throw switch 214). The arrangement of the diaphragm structure 210 and single throw switch 214 can take the form, for example, of the pneumatic activated switch described in U.S. Pat. No. 6,418,870 issued on Jun. 25, 2002 and titled “Pneumatic Activated Switch,” the contents of which are hereby incorporated by reference herein.
When the diaphragm structure 210 experiences a sufficient increase in air pressure (or vacuum pressure, or in air flow), which can occur when air flows through the air conduction tube 124 toward the diaphragm structure due to actuation (e.g., depressing) of the actuator 122, the diaphragm structure by way of the switch actuator 212 impacts the single throw switch 214 in a manner causing the switch to change from being in a first operational state (or operating in a first operational mode) to being in a second operational state (or operating in a second operational mode). This can also be considered a first operational status of the power control module 202. Alternatively, when the diaphragm structure 210 experiences a sufficient decrease in air pressure (or vacuum pressure, or in air flow), which can occur when air flows through the air conduction tube 124 away from the diaphragm structure due to releasing of the actuator 122, the diaphragm structure impacts the single throw switch 214 in a manner causing the switch to change from being in the second operational state (or operating in the second operational mode) to being in the first operational state (or operating in the first operational mode). This can also be considered a second operational status of the power control module 202.
Additionally, in the present example embodiment, the first operational state of the single throw switch 214 can be a closed state. Accordingly, when the single throw switch 214 is in the first operational state, input power received at the input terminal 216 from the power terminal 208 (assuming that the power terminal 208 is coupled to an external power source) is communicated through the single throw switch to the first output terminal 220 and further to the motor 204 by the second electrical connector 222. Thus, in the present embodiment, the first operational state of the single throw switch 214 (and first operational status of the power control module 202) results in or corresponds to actuation of the motor 204. Alternatively, the second operational state of the single throw switch 214 can be an open state. Accordingly, when the single throw switch 214 is in the second operational state, input power received at the input terminal 216 from the power terminal 208 (assuming that the power terminal 208 is coupled to an external power source) is precluded from being communicated through the single throw switch to the first output terminal 220 or to the motor 204. Thus, in the present embodiment, the second operational state of the single throw switch 214 (and second operational status of the power control module 202) results in or corresponds to deactivation of the motor 204.
In at least one embodiment, the single throw switch 214 can be a normally-open switch that is biased (e.g., by a spring) to be in the second operational state. However, in other embodiments, the single throw switch 214 can be a normally-closed switch (e.g., biased by a spring to be in the first operational state) or need not be biased in any manner. Further, notwithstanding the above description of how the power control module 202 can operate in response to actuation signals communicated from the actuator 122 via the air conduction tube 124, the power control module 202 in other embodiments can be configured to operate in other manners. For example, in one additional embodiment, a toggle switch can be substituted for the single throw switch 214.
Referring additionally to
Turning next to
The terminal assembly 402 corresponds to the first output terminal 220 shown in
Referring further to
In the present embodiment, during installation, the power control module 202 is aligned relative to the orifice 308. Then the power control module can be moved toward and at least partly into the orifice, so that the switching mechanism 400 and terminal assembly 402 are inserted through the orifice and at least partly into an interior of the food waste disposer, and so that the base plate 404 comes into contact with the LEF 306. Next, the base plate 404 of the air switch assembly 121 is slid relative to the LEF 306 in a direction corresponding to an arrow 608 shown in
Further, the retaining screw 604 precludes the base plate 404 from sliding relative to the LEF 306 in a manner that the first end edge portion 600 passes out from the retaining lip 602 (e.g., in a direction opposite the direction indicated by the arrow 608 of
The present disclosure is also intended to encompass further embodiments and modified versions of the above-described embodiments in addition to the embodiments specifically described above. Among other things, although the above description relates to food waste disposers, the present disclosure is also intended to encompass embodiments relating to other types of waste disposers. Also, notwithstanding the description above, the present disclosure is intended to encompass any of a variety of other types of arrangements by which a food waste disposer of a food waste disposer system (or a waste disposer of another type of waste disposer system) is coupled to an external power source to receive electric power. Also, the present disclosure is intended to encompass any of a variety of different types of food waste disposers or other waste disposers employing any of a variety of types of motors, for example, including permanent magnet motors in addition to induction motors.
Further, the present disclosure is intended to encompass any of a variety of types of terminals, sockets, plugs, connectors, fasteners, and other features allowing for various components, structures, and devices to be coupled or in communication with one another, either electrically or pneumatically. For example, depending upon the embodiment, any of a variety of wire joiner connectors, standard wire nuts, or other connectors can be employed to join various conductors or structures. Any one or more of such components can be considered, in at least some embodiments, to form part of a terminal or power terminal such as the power terminal 208. Also, the present disclosure is intended to encompass other types of fasteners instead of or in addition to the fastening devices described herein such as the retaining screw 604. Additionally for example, although the orifice 308 into which is positioned the air switch assembly 121 is shown to be positioned on the LEF 306 in
Also, although the present disclosure envisions embodiments in which a food waste disposer assembly is coupled to a wall outlet by way of a power cord having a plug such as a NEMA 5-15 plug, the present disclosure is also intended to encompass other embodiments that include or operate in conjunction with other types of connectors, plugs, and adapters, including for example C-13 or C14 sockets or plugs. Further, the present disclosure also includes a variety of different manners of operation and control as determined by a power control module such as (but not limited to) the power control module 202, at least in part as determined by an air switch mechanism such as the air switch mechanism 120.
Additionally, the present disclosure is intended to encompass other types of air switch mechanisms that involve other components and/or different manners of operation than the air switch mechanisms such as the air switch mechanism 120 described above. For example, in some embodiments, a power control module can have a normal state and an actuated state, and signals communicated by the air switch mechanism in response to user actuation of an actuator can cause the power control module to switch from the normal state to the actuated state and/or back again to the normal state. Also, the present disclosure is intended to encompass numerous different types of air switch mechanisms having any of a variety of types of actuators or actuation mechanisms.
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.
