Abstract:
A dishwasher appliance is provided with a spray arm assembly. The spray arm assembly defines an orifice for directing liquid out of the spray arm assembly. The orifice can selectively receive a nozzle with a particular outlet geometry. By selectively receiving the nozzle, a spray pattern of liquid exiting the orifice can be changed by replacing or modifying the nozzle without remanufacturing or replacing the spray arm assembly.

Description:
FIELD OF THE INVENTION 
       [0001]    The present subject matter relates generally to spray arms for dishwasher appliances. 
       BACKGROUND OF THE INVENTION 
       [0002]    Dishwasher appliances generally include a tub that defines a wash compartment. A rack assembly can be slidably mounted within the wash compartment and configured for receipt of articles for washing. In addition, dishwasher appliances can include spray arm assemblies for applying wash fluid to articles in the rack assembly. 
         [0003]    Spray arm assemblies for dishwasher appliances generally include a housing that defines a cavity. The cavity can receive wash fluid during operation of the dishwasher appliance. The cavity directs such wash fluid to a plurality of orifices defined by the housing. The wash fluid exits the cavity through the orifices and can be directed towards articles within the rack assembly. 
         [0004]    Each of the plurality of orifices can have any of a variety of outlet geometries or configurations. For example, a particular one of the plurality of orifices can have a pencil jet geometry or configuration. Conversely, another of the plurality of orifices can have a fan jet geometry or configuration. Various arrangements of outlet geometries can be selected to adjust the spray pattern of the spray arm assembly. For example, pencils jets direct a concentrated stream of wash fluid adapted, e.g., to removing food particles and stains from articles in the rack assembly during a wash cycle. On the other hand, fan jets direct a mist of wash fluid adapted, e.g., to rinsing wash fluid from articles in the rack assembly during a rinse cycle. Accordingly, a dishwasher designer can select outlet geometries in order to generate a particular spray pattern for the spray arm assembly. By carefully selecting the spray pattern, the designer can improve performance of the dishwasher appliance. 
         [0005]    In certain dishwasher appliance, the spray arm assembly is molded from single piece of material. Accordingly, during the molding process, the outlet geometries of the plurality of orifices are determined by the mold used to construct the spray arm assembly. Thus, in the event of a design change involving the outlet geometries of the plurality of orifices, the entire mold is modified or replaced. For example, if the designer desires to change the direction of a pencil jet, the entire mold used to construct the spray arm assembly may require replacement or modification. 
         [0006]    Replacing or modifying the entire mold can be a time intensive and expensive process. Accordingly, a spray arm assembly with features for more easily modifying an outlet geometry of an orifice would be useful. In particular, a spray arm assembly with features for modifying an outlet geometry of an orifice without requiring modification or remanufacture of the remainder of the spray arm assembly would be useful. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0007]    A dishwasher appliance is provided with a spray arm assembly. The spray arm assembly defines an orifice for directing liquid out of the spray arm assembly. The orifice can selectively receive a nozzle with a particular outlet geometry. By selectively receiving the nozzle, a spray pattern of liquid exiting the orifice can be changed by replacing or modifying the nozzle without remanufacturing or replacing the spray arm assembly. Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention. 
         [0008]    In a first exemplary embodiment, a spray assembly for a dishwasher appliance is provided. The spray assembly includes a spray arm that defines a chamber configured for receipt of a wash fluid. The spray arm further defines a plurality of orifices. A first nozzle is inserted within one of the plurality of orifices. The first nozzle has a first outlet geometry. A second nozzle is inserted within another one of the plurality of orifices. The second nozzle has a second outlet geometry. The second outlet geometry is different from the first outlet geometry. The first and second nozzles are configured for directing wash fluid out of the chamber of the spray arm. 
         [0009]    In a second exemplary embodiment, a dishwasher appliance is provided. The dishwasher appliance has a tub that defines a wash compartment. A rack assembly is received within the wash compartment. The rack assembly is configured for receipt of articles for washing. A spray assembly is configured for applying wash fluid to articles in the rack assembly. The spray assembly includes a spray arm that defines a chamber configured for receipt of a wash fluid. The spray arm further defines a plurality of orifices. A first nozzle is inserted within one of the plurality of orifices. The first nozzle has a first outlet geometry. A second nozzle is inserted within another one of the plurality of orifices. The second nozzle has a second outlet geometry. The second outlet geometry is different from the first outlet geometry. The first and second nozzles are configured for directing wash fluid out of the chamber of the spray arm. 
         [0010]    In a third exemplary embodiment, an intermediary component for a spray arm is provided. The intermediary component includes a first nozzle. The first nozzle has a first outlet geometry. A second nozzle has a second outlet geometry. The second outlet geometry is different than the first outlet geometry. A web extends between and connects the first nozzle and the second nozzle. 
         [0011]    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 exemplary embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    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, in which: 
           [0013]      FIG. 1  provides a partial, cross-sectional side view of a dishwasher appliance according to an exemplary embodiment of the present subject matter. 
           [0014]      FIG. 2  illustrates a top, perspective view of an exemplary embodiment of a spray arm assembly as may be used in the dishwasher appliance of  FIG. 1  and, in particular, illustrates a first plurality of exemplary nozzles and a second plurality of exemplary nozzles of the spray arm assembly. 
           [0015]      FIG. 3  illustrates an exploded, perspective view of the spray arm assembly of  FIG. 2 . 
           [0016]      FIG. 4  provides a bottom cross-section view of the spray arm assembly of  FIG. 2  taken along line  4 - 4  of  FIG. 2 . 
           [0017]      FIG. 5  provides a side cross-section view of the spray arm assembly of  FIG. 2  taken along line  5 - 5  of  FIG. 2 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0018]    Reference now will be made in detail to exemplary 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. 
         [0019]      FIG. 1  is a side view of an exemplary domestic dishwasher system  100  shown in partial cut-away and is representative of a type of a dishwasher that may incorporate aspects of the present subject matter. It is contemplated, however, that the present subject matter may be practiced in other types of dishwashers and dishwasher systems beyond dishwasher system  100  described and illustrated herein. Accordingly, the following description is for illustrative purposes only, and the present subject matter is in no way limited to use in a particular type of dishwasher system, such as dishwasher system  100 . 
         [0020]    Dishwasher  100  includes a cabinet  102  having a tub  104  therein that defines a wash compartment  106 . The tub  104  includes a front opening (not shown in  FIG. 1 ) and a door  120  hinged at its bottom  122  for movement between a normally closed vertical position (shown in  FIG. 1 ) wherein the wash compartment  106  is sealed shut for washing operation, and a horizontal open position (not shown) for loading and unloading of dishwasher contents. 
         [0021]    Upper and lower guide rails  124 ,  126  are mounted on tub side walls  128  and accommodate upper and lower roller-equipped racks  130 ,  132 , respectively. Each of upper and lower racks  130 ,  132  is fabricated from known materials into lattice structures including a plurality of elongate members  134 , and each rack  130 ,  132  is adapted for movement between an extended loading position (not shown) in which the rack is substantially positioned outside the wash compartment  106 , and a retracted position (shown in  FIG. 1 ) in which the rack is located inside wash compartment  106 . Conventionally, a silverware basket (not shown) is removably attached to the lower rack  132  for placement of silverware, utensils, and the like that are too small to be accommodated by upper and lower racks  130 ,  132 . 
         [0022]    A control input selector  136  is mounted at a convenient location on an outer face of the door  120  and is coupled to control circuitry and control mechanisms for operating a fluid circulation assembly (not shown) to circulate water and dishwasher fluid in the dishwasher tub  104 . The fluid circulation assembly is located in a machinery compartment  140  located below a bottom sump portion  142  of the tub  104 . 
         [0023]    A lower spray assembly  144  is mounted within a lower region  146  of the wash compartment  106  and above tub sump portion  142 . A mid-level spray assembly  148  is located in an upper region of the wash compartment  106  and is located in close proximity to the upper rack  130  and at a sufficient height above lower rack  132  to accommodate larger items, such as a dish or platter. In a further exemplary embodiment, an upper spray assembly (not shown) may be located above the upper rack  130  at a sufficient height to accommodate taller items, such as a glass of a selected height. 
         [0024]    Lower and mid-level spray assemblies  144 ,  148  and the upper spray assembly are fed by the fluid circulation assembly and include an arrangement of discharge ports or nozzles for directing washing liquid onto dishes located in the upper and lower racks  130 ,  132 , respectively. Lower and mid-level spray assemblies  144 ,  148  may include spray arms such that the assemblies  144 ,  148  rotate during application of washing liquid. For example, the arrangement of the discharge ports in the lower and mid-level spray assemblies  144 ,  148  induces a rotational torque by virtue of the angle and force of the water exiting the discharge ports. The resultant rotation of the lower and mid-level spray assemblies  144 ,  148  provides coverage of dishes and other articles with a washing spray. Thus, it should be appreciated that one or all of the spray arm assemblies may be rotatably mounted and configured to generate a swirling spray pattern within the wash compartment  106  when the fluid circulation assembly is activated. 
         [0025]      FIG. 2  illustrates a perspective view of an exemplary embodiment of a spray arm assembly  200  that, e.g., may be used in dishwasher appliance  100  as lower, and/or mid-level spray assemblies  144 ,  148 . Spray arm assembly  200  includes an upper housing  210 . Upper housing  210  is configured for directing washing fluid during operation of dishwasher appliance  100  ( FIG. 1 ) as described in greater detail below. Upper housing  210  may be constructed of metal, plastic, and/or any suitable material or combination of materials. 
         [0026]    Upper housing  210  includes a first pair of arms  214  and a second pair of arms  216 . First and second pair of arms  214 ,  216  are configured for rotation about an axis of rotation A, e.g., during operation of dishwasher appliance  100 . In  FIG. 2 , first and second pairs of arms  214 ,  216  extend away from axis of rotation A arcuately. However, it should be understood that spray arm assembly  200  is provided an example only and is not intended to be limiting. Thus, spray arm assembly  200  may have any suitable configuration. For example, first and second pairs of arms  214 ,  216  may be substantially linear or have any other suitable shape. Similarly, spray arm assembly  200  may include only first or second pairs of arms  214 ,  216  or may contain any suitable number of additional arms. 
         [0027]    Upper housing  210  supports a first plurality of inserts or nozzles  230  on first pair of arms  214  and a second plurality of inserts or nozzles  240  on second pair of arms  216 . First and second pluralities of nozzles  230 ,  240  direct liquid from within spray arm assembly  200  out of spray arm assembly  200  as discussed in greater detail below. First and second pluralities of nozzles  230 ,  240  define various exit or outlet geometries. For example, first and second pluralities of nozzles  230 ,  240  include nozzles with various pencil jet outlet geometries  250  and other nozzles with various fan jet outlet geometries  252 . 
         [0028]    Pencil jet geometries  250  direct a substantially columnar jet of liquid out of upper housing  210 . Pencil jet geometries  250  may have varying circumferences in order to direct jets of liquid with various circumferences out of upper housing  210 . Also, pencil jet geometries  250  may be directed in various directions to provide particular spray patterns. Nozzles  230 ,  240  with pencil jet geometries  250  may, e.g., be suitable for removing or urging food particles off of articles within dishwasher appliance  100  ( FIG. 1 ). Conversely, fan jet geometries  252 , e.g., direct a substantially conic or triangular jet of liquid out of upper housing  210 . Nozzles  230 ,  240  with fan jet geometries  252  may, e.g., be suitable for rinsing or soaking articles within dishwasher appliance  100 . 
         [0029]    Thus, for example, first and second pluralities of nozzles  230  and  240  may include a first pencil jet geometry  250  with a first diameter and a second pencil jet geometry  250  with a second diameter. As another example, first and second pluralities of nozzles  230  and  240  may include a first pencil jet geometry  250  that directs wash fluid in a first direction and a second pencil jet geometry  250  that directs wash fluid in a second direction. As a further example, first and second pluralities of nozzles  230  and  240  may include a pencil jet geometry  250  and a fan jet geometry  252 . However, it should be understood that first and second pluralities of nozzles  230 ,  240  may have any other suitable outlet geometry or combination of geometries. Thus, the examples of outlet geometries disclosed herein are not intended to be limiting. 
         [0030]    First and second pluralities of nozzles  230 ,  240  may be constructed of any suitable material. For example, first and second pluralities of nozzles  230 ,  240  may be constructed of a plastic. In addition, first and second pluralities of nozzles  230 ,  240  may be constructed of a substantially rigid material, e.g., polyethylene, polypropylene, polystyrene, polyvinyl chloride, or any other suitable substantially rigid plastic or material. Alternatively, first and second pluralities of nozzles  230 ,  240  may be constructed of a substantially elastic material, e.g., an elastomer or any other suitable substantially elastic material. 
         [0031]      FIG. 3  illustrates an exploded view of spray arm assembly  200 . As may be seen in  FIG. 3 , upper housing  210  defines a plurality of orifices  220 . Orifices  220  receive first and second pluralities of nozzles  230 ,  240  as may be seen in  FIG. 2 . Thus, first and second pluralities of nozzles  230 ,  240  are inserted into orifices  220 . Orifices  220  are substantially uniformly distributed on first and second pairs of arms  214 ,  216 . However, orifices  220  may be distributed in any suitable manner, e.g., non-uniformly. 
         [0032]    In  FIG. 3 , first and second pluralities of nozzles  230 ,  240  both include a web or sheet  260  that connects the various nozzles of first and second pluralities of nozzles  230 ,  240 . Thus, for example, sheet  260  extends between the nozzles of first plurality of nozzles  230  and couples or secures the nozzles together. However, it should be understood that in alternative exemplary embodiments, first and second pluralities of nozzles  230 ,  240  need not include sheets  260 . For example, each nozzle of first and second pluralities of nozzles  230 ,  240  may be independently inserted into a particular one of the orifices  220 . Thus, the nozzles of first and second pluralities of nozzles  230 ,  240  need not be coupled or secured together. As may be seen in  FIG. 4 , sheet  260  is disposed within upper housing  210 , e.g., within a chamber  212  ( FIG. 5 ), when spray arm assembly  200  is assembled. 
         [0033]    First and second pluralities of nozzles  230 ,  240  may be secured to upper housing  210  and within orifices  220  in a variety of ways. For example, first and second pluralities of nozzles  230 ,  240  may be secured within orifices  220 , e.g., using heat staking, ultrasonic welding, co-molding, over-molding, and/or any other suitable method or combination of methods. Such methods may be used when first and second pluralities of nozzles  230 ,  240  are substantially rigid. 
         [0034]    Conversely, first and second pluralities of nozzles  230 ,  240  may simply be inserted into orifices  220  and mechanically secured therein. For example, a complementary snap-fit or interference fit may be used to secure first and second pluralities of nozzles  230 ,  240  within orifices  220 . By way of additional example, the first and second pluralities of nozzles  230 ,  240  can deform during insertion through orifices  220 . After insertion and when first and second pluralities of nozzles  230 ,  240  are properly positioned within orifices as shown in  FIG. 2 , first and second pluralities of nozzles  230 ,  240  may be held in place by portions of first and second pluralities of nozzles  230 ,  240  with a diameter greater than a diameter of orifices  220 . Such methods may be used, for example, when first and second pluralities of nozzles  230 ,  240  are substantially elastic. 
         [0035]    A bottom housing  270  is shaped to fit upper housing  210 . Thus, bottom housing  270  mounts to upper housing  210  in order to form spray arm assembly  200 . Bottom housing  270  cooperates with upper housing  210  to direct wash fluid during operation of dishwasher appliance  100  as described in greater detail below. In  FIG. 3 , bottom housing  270  does not define additional orifices  220 . However, in alternative exemplary embodiments, bottom housing  270  may define additional orifices that receive nozzles and direct wash fluid into wash chamber  106 . Bottom housing  270  may be constructed of metal, plastic, and/or any suitable material or combination of materials. 
         [0036]      FIG. 4  provides a bottom cross-section view of spray arm assembly  200  taken along the line  4 - 4  of  FIG. 2 .  FIG. 5  provides a side cross-section view of spray arm assembly  200  taken along the line  5 - 5  of  FIG. 2 . As shown in  FIG. 5 , upper housing  210  and bottom housing  270  define a chamber  212  for receipt of wash fluid (e.g., water and/or detergent) during operation of dishwasher appliance  100  ( FIG. 1 ). Chamber  212  is in fluid communication with the fluid circulation assembly (not shown) described above. 
         [0037]    First and second pluralities of nozzles  230 ,  240  are disposed within orifices  220  ( FIG. 3 ). Thus, during operation of dishwasher appliance  100 , wash fluid flows through chamber  212  of spray arm assembly  200  and exits chamber  212  through first and second pluralities of nozzles  230 ,  240 . As may be seen in  FIG. 5 , wash fluid may be directed in various directions by nozzles  230 . 
         [0038]    It should be understood that, by providing first and second pluralities of nozzles  230 ,  240  that are received within orifices  220 , a spray pattern for liquid emitted from spray arm assembly  200  may be modified or customized. For example, nozzles with various outlet geometries may be inserted into any particular one of the orifices  220 . Thus, as will be understood by those skilled in the art, nozzles may be selected to customize and/or improve the spray pattern of spray arm assembly  200 , e.g., while still using a single model of upper housing  210  and/or bottom housing  270 . 
         [0039]    In various exemplary embodiments, first plurality of nozzles  230  may be a first color (e.g., blue). Conversely, second plurality of nozzles  240  may be a second color (e.g., green). Thus, the first and second pluralities of nozzles  230 ,  240  may be different colors. In particular, first and second pluralities of nozzles  230 ,  240  may contain dyes or pigments for providing the first and second colors respectively. 
         [0040]    Upper housing  210  may be a third color (e.g., red). Thus, upper housing  210  and first and second pluralities of nozzles  230 ,  240  may each be a different color. However, it should be understood that upper housing  210  and first and second pluralities of nozzles  230 ,  240  may be the same color or have any suitable combination of colors. Varying colors between upper housing  210  and first and second pluralities of nozzles  230 ,  240  may, e.g., permit product differentiation or provide marketing advantages as well as provide ready identification of parts during assembly. 
         [0041]    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 languages of the claims.