Heating appliance

An iron generally includes a water tank and a steam generator in flow communication with the water tank. The steam generator includes a thin-film heater tube that receives water from the water tank to generate steam inside the heater tube.

BACKGROUND

The present invention relates generally to heating appliances and, more particularly, to an appliance for ironing cloth-like materials.

Conventional clothing irons include a housing, a sole plate attached to the housing, and a heating device contained within the housing for heating the sole plate. When the heated sole plate is pressed against a wrinkled article of clothing, the heated sole plate facilitates removing the wrinkles. Many conventional clothing irons also include a steaming device for moistening the article of clothing to ease the wrinkle removal process.

However, conventional irons tend to be heavier than desired, tend to have a slower than desirable heat-up time, and tend to have a less than desirable steaming capability. Moreover, conventional irons often have a power cord that makes the iron difficult to store, in addition to limiting the user to ironing near an external power supply (e.g., a wall-mounted plug socket).

There is a need, therefore, for an iron that is lighter, is quicker to heat-up, has an improved steaming capability, and/or is usable in places where an external power supply is not readily accessible.

SUMMARY

In one embodiment, an iron generally comprises a water tank and a steam generator in flow communication with the water tank. The steam generator includes a thin-film heater tube that receives water from the water tank to generate steam inside the heater tube.

In another embodiment, an iron generally comprises a water tank and a sole plate unit. The sole plate unit includes a sole plate and a thin-film heater plate that heats the sole plate, and the sole plate unit has a plurality of holes. The iron also includes a plurality of steam generator devices each coupled in flow communication between the water tank and one of the holes of the sole plate unit.

In yet another embodiment, a cordless iron generally comprises a sole plate, a thin-film heater plate that heats the sole plate, and a battery that supplies the thin-film heater plate with electrical current. The iron also comprises a dampening mechanism with a biasing element that biases the sole plate away from the heater plate.

DETAILED DESCRIPTION

Referring to the drawings, and in particular toFIG. 1, a heating appliance is illustrated in the form of a clothing iron (indicated generally by the reference numeral100). The iron100includes a housing102, a handle104mounted on the top of the housing102, and a heating device (indicated generally by the reference numeral106) mounted on the bottom of the housing102. In other contemplated embodiments, the handle104may be positioned at any suitable location on the housing102.

With reference now toFIGS. 2 and 3, the housing102defines an interior compartment108in which at least one battery pack110is contained, and the interior compartment108is covered by a panel112with which the handle104is integrally formed. As such, when access to the battery pack110is desired, the panel112and the handle104are conjointly detachable from the housing102to expose the interior compartment108to the user. In other contemplated embodiments, however, the handle104may not be detachable from the housing102(e.g., the handle104may be integrally molded with the housing102), in which case the handle-less panel112would nonetheless be detachable from the housing102for exposing the interior compartment108to the user.

The illustrated battery pack110is removable from the interior compartment108for replacement such as, for example, when the battery back110is in need of charging. In this manner, the iron100is said to be cordless (i.e., the iron100is usable without a power cord connecting the iron100to a plug socket which provides access to an external power supply). While the iron100is cordless in the illustrated embodiment, it is contemplated that, in other embodiments, the iron100may have a suitable power cord in lieu of, or in addition to, the battery pack110.

In accordance with its cordless configuration, the illustrated iron100is provided in a kit along with a docking station and, optionally, at least one alternate battery pack. In one embodiment, the docking station may be suitably configured to receive only the battery pack110(and not the entire iron100) for charging the battery pack110after the battery pack110has been removed from the interior compartment108. In the embodiments set forth below, however, the docking station is configured to receive the entire iron100for charging the battery pack110while the battery pack110remains within the interior compartment108of the housing102.

Suitably, the battery pack110, and/or the iron100generally, are fitted with at least one electrical contact for interfacing with a corresponding electrical contact of the docking station to electrically connect the battery pack110to the docking station. Because the docking station has a power cord electrically connecting the docking station to an external power supply (via a plug socket mounted on a wall, for example), the battery pack110is supplied with electrical power and is thereby charged when the battery pack110, and/or the entire iron100, is seated on the docking station. In one contemplated embodiment, when heating the iron100to a preset temperature upon initial power-up, the iron100is to be provided with electrical power from the external power source via the docking station if the iron100is seated on the docking station. As such, the iron100essentially uses the battery pack110as back-up power for maintaining the iron100at the preset temperature after the iron100has been removed from the docking station.

Also contained within the interior compartment108of the housing102is a suitable control unit (not shown) having at least a microcontroller and a memory for storing instructions to be executed by the microcontroller, wherein the instructions enable the microcontroller to operate the iron100(e.g., the heating device106) in the manner set forth below. A suitable user interface (e.g., a keypad and a display) is also provided on the housing102to enable user interaction with the control unit when operating the iron100. Optionally, the control unit may be configured for wireless user interaction via a remote user interface provided on a handheld device, such as a smartphone for example.

In the illustrated embodiment, the heating device106includes a water tank body114, a water tank cover116mounted inside the water tank body114to define a water tank117, and a steam generator (indicated generally by reference numeral118) attached to the bottom of the water tank cover116. The water tank body114has an inlet port120that permits a user to pour water into the water tank117, and the water tank cover116has a pair of outlet ports122that permit releasing water from the water tank117into the steam generator118. While the water tank cover116is suitably mounted inside the water tank body114in the illustrated embodiment, it is contemplated that the water tank cover116may be integrally formed with the water tank body114in other embodiments.

The illustrated steam generator118has a thin-film heater tube124that has a serpentine profile, with an inlet valve126(e.g., a one-way valve) coupled to one end of the heater tube124, a relief valve128(e.g., a one-way valve) coupled to the other end of the heater tube124, and an outlet conduit130adjacent the relief valve128. The inlet valve126and the relief valve128are each connected to one of the outlet ports122of the water tank cover116so as to be in flow communication with the water tank117. The inlet valve126is configured to selectively permit water entry into the heater tube124from the water tank117, and the outlet conduit130is configured to exhaust steam from the heater tube124for use in an ironing operation, as set forth in more detail below. The relief valve128is configured to release water/steam back into the water tank117in the event of an overflow or overpressure condition within the heater tube124. Notably, in some embodiments, the inlet valve126may be self-actuating in response to pressure within the heater tube124; and, in other embodiments, the inlet valve126may be selectively actuated by the control unit (e.g., the control unit may be in communication with a suitable sensor that indicates the amount of pressure within the heater tube124).

The heating device106further includes a sole plate unit (indicated generally by reference numeral132) suitably attached near the bottom of the water tank body114beneath the water tank cover116in spaced relation, thereby defining a chamber134in which the steam generator118is housed. The sole plate unit132includes a sole plate136, an insulator138, and a thin-film heater plate140sandwiched between the sole plate136and the insulator138. The insulator138and the heater plate140are attached to the sole plate136via a plurality of fasteners (e.g., screws142). Optionally, the sole plate136may be made of aluminum, or any other suitable material.

Because the steam generator118is contained within the chamber134between the sole plate unit132and the water tank cover116, steam exhausted from the outlet conduit130of the steam generator118flows into the chamber134. The steam then circulates within the chamber134and is permitted to exit the chamber134via a plurality of holes144through the sole plate unit132to facilitate applying the steam to a clothing article that is in contact with the sole plate136during an ironing operation. The sole plate unit132may have any suitable number of holes144arranged in any suitable manner that facilitates enabling the iron100to function as described herein.

In the illustrated embodiment, the heater tube124and the heater plate140are both said to be of the “thin-film” type in the sense that each has a substrate (e.g., a glass, glass-ceramic, or non-glass ceramic substrate) and an electrically conductive material (e.g., a metal oxide material such as tin oxide or aluminum oxide) deposited on the substrate, wherein the substrate and the electrically conductive material have a collective thickness that is only marginally greater than the thickness of the substrate itself (i.e., the electrically conductive material forms a thin film on the substrate). Suitably, it is contemplated that any number of barrier layers may be attached to the faces of the substrate to cover and protect the substrate and/or the electrically conductive material from damage, and the addition of such barrier layers would not, in and of itself, make the heater tube124and/or the heater plate140not be of the “thin-film” type.

The heater tube124and the heater plate140are heated by the control unit supplying electrical current to the electrically conductive material deposited on their respective substrates. Because the electrically conductive material naturally resists the flow of current therethrough, the electrically conductive material heats up as a result. Such heating of the electrically conductive material causes the respective substrates to be heated by virtue of being in conductive heat transfer with the electrically conductive material. Thus, in terms of the heater tube124, electrical current supplied to the electrically conductive material of the heater tube124causes at least a radially inner segment of the heater tube124to be heated, which in turn causes water within the heater tube124to be heated for generating steam within the heater tube124. In terms of the heater plate140, electrical current supplied the electrically conductive material of the heater plate140causes at least the outer face of the heater plate140(i.e., the face oriented toward the sole plate136) to be heated, which in turn causes the sole plate136to be heated.

Because electrical current is supplied from the battery pack110to the electrically conductive material of the heater tube124and to the electrically conductive material of the heater plate140by the control unit, the control unit may be suitably configured to modulate the flow of electrical current from the battery pack110to the electrically conductive material to facilitate regulating the temperature of the substrates of the heater tube124and/or the heater plate140independent of one another (and, hence, the quantity of steam generated by the heater tube124and/or the temperature of the sole plate136independent of one another). In one example, the control unit may be operatively connected to a suitable temperature sensor for regulating a temperature of the heater tube124to facilitate preventing the heater tube124from overheating in the event that little or no water is present within the heater tube124. In some instances, a typical temperature difference between the substrate of the heater plate140and the ironing surface of the sole plate136may be about 70° C., for example.

Generally speaking, the number of battery packs110, and the size and quantity of batteries per battery pack110, is selected to facilitate supplying the instantaneous current needs of the heater tube124and the heater plate140when the iron100is operated away from the docking station in a cordless manner. In one particular embodiment, for example, the quantity of batteries in the battery pack110depends at least in part upon the voltage/current that is to be supplied to the heater tube124and/or the heater plate140. In that regard, the electrical properties (e.g., the supply voltage and resistance) of the heater tube124and the heater plate140are selected such that their instantaneous current needs are met by the battery pack110alone, using, for example, a DC-DC converter topology or by connecting the DC battery voltage directly to the heater tube124and the heater plate140using power path switches. Optionally, an active cell balancing circuit may be provided for increased battery pack sizes and/or quantities. Moreover, the control unit may be configured to monitor the battery pack110while the battery pack110is charging and/or discharging to facilitate identifying over voltage, under voltage, over current, and over temperature events.

Referring now toFIGS. 4 and 5, an alternative embodiment of a heating device (indicated generally by the reference numeral148) may be used in place of the heating device106. The heating device148has a water tank cover150with a plurality of outlet ports152to each of which is coupled a steam generator device (e.g., a piezo atomizer device154) in flow communication with the water tank. In this manner, the piezo atomizer devices154may be selectively actuated by the control unit to generate steam that is exhausted from the iron100through corresponding holes144formed in the sole plate unit132to facilitate applying the steam to a clothing article in contact with the sole plate136during an ironing operation. Any suitable quantity of the piezo atomizer devices154may be utilized in the heating device148, and the sole plate136may have any quantity of corresponding holes144to suit. Moreover, the control unit may be suitably configured to operate the heating device148using a process156represented in the chart ofFIG. 6, for example.

Optionally, to facilitate applying steam to a clothing article in a desired quantity and/or profile, the control unit may be suitably configured to selectively actuate only a subset of the piezo atomizer devices154, as opposed to actuating all of the piezo atomizer devices154simultaneously. In that regard, the control unit may be further configured to permit the user to select a steam setting (e.g., a quantity and/or profile of steam output) from a plurality of optional steam settings (e.g., a plurality of optional steam quantities and/or profiles), wherein the user may be permitted to select (via the user interface) whether all or a subset (and which particular subset) of the piezo atomizer devices154are to be used when generating steam.

Referring now toFIG. 7, the sole plate unit132of the illustrated embodiment may further include a dampening mechanism (generally indicated by reference numeral158) that facilitates mechanically isolating the heater plate140from the sole plate136when the iron100is handled by the user (e.g., when the user is transporting the iron100from the docking station to the clothing article, and vice versa). The illustrated dampening mechanism158includes a plurality of first attractive members (e.g., electromagnets160) coupled to the sole plate136, and a plurality of second attractive members (e.g., metal elements162) coupled to the heater plate140. A suitable biasing element (e.g., a coil spring164) extends between each electromagnet160and an associated one of the metal elements162.

In this manner, when the iron100is seated on the docking station, the control unit energizes the electromagnets160to draw the electromagnets160into contact with their respective metal elements162against the bias of the coil springs164. A thermally conductive path is thus established between the sole plate136and the heater plate140through the electromagnets160and the metal elements162for heating the sole plate136to a preset temperature when the iron100is seated on the docking station.

Once the user removes the iron100from the docking station (e.g., after the preset temperature has been reached), the control unit de-energizes the electromagnets160such that the coil springs164are permitted to decompress and push the sole plate136away from the heater plate140in preparation of the iron100being transported to the clothing article. Then, when the sole plate136is pressed against the clothing article, the sole plate136is displaced toward the heater plate140, thereby bringing the electromagnets160back into contact with their respective metal elements162to again establish a thermally conductive path from the heater plate140to the sole plate136for heating the sole plate136while the clothing article is being ironed. Subsequently, when the sole plate136is no longer pressed against the clothing article (e.g., after the ironing operation has been completed), the coil springs164are again permitted to decompress and push the sole plate136away from the heater plate140in preparation of the iron100being transported back to the docking station.

The dampening mechanism158thereby facilitates spacing the sole plate136away from the heater plate140in situations when the iron100is not docked or the sole plate136is not pressed against a clothing article. In this manner, if the iron100was to be dropped during transport, the coil springs164would dampen (or slow) the inward displacement of the sole plate136toward the heater plate140, thereby reducing the impact of the sole plate136against the heater plate140and minimizing associated damage to the heater plate140that could have otherwise resulted had the sole plate136been in contact with (or in closer proximity to) the heater plate140when the iron100was dropped (e.g., the dampening mechanism158facilitates preventing fracture of the heater plate140if the iron100is dropped).

In one contemplated embodiment, the dampening mechanism158may not include the attractive members (e.g., the electromagnets160and the metal elements162), such that the coil springs164bias the sole plate136away from the heater plate140even when the iron100is seated on the docking station. In such an embodiment, the coil springs164may themselves provide a thermally conductive path between the sole plate136and the heater plate140when the sole plate136is being heated to a preset temperature on the docking station. Such an embodiment may also have a plurality of collapsible members (e.g., telescoping posts) that provide a thermally conductive path from the sole plate136to the heater plate140when the coil springs164are in their decompressed state, such that the collapsible members collapse when the sole plate136is displaced toward the heater plate140(e.g., when the sole plate136is pressed against a clothing article, or when the sole plate136impacts an object upon dropping the iron100during transport).

Optionally, in another contemplated embodiment, the iron100may also include (in conjunction with, or in lieu of, the dampening mechanism158) a plurality of actively extendable, mechanical limbs that facilitate actively pulling the sole plate136inward and actively pushing the sole plate136outward with the user's press of a button disposed on the housing102of the iron100. Alternatively, the user may not need to press a button to actuate the limbs but, rather, the limbs may be automatically actuated by the control unit in response to the position of the iron100(e.g., in response to seating of the iron100on the docking station, or contact of the sole plate136with a clothing article using suitable sensors). Moreover, the limbs may not actively push or pull the sole plate136in some contemplated embodiments but, rather, the limbs may instead function to facilitate guiding the inward displacement and restricting the outward displacement of the sole plate136as caused by the dampening mechanism158.

As shown inFIGS. 8-11, various alternative embodiments of the sole plate unit132are contemplated. Notably, in each of these alternative embodiments of the sole plate unit132, holes165are provided for receiving steam from the steam generator118or the piezo atomizer devices154in the manner set forth above.

As shown inFIG. 8, one embodiment of a sole plate unit (indicated generally by reference numeral166) has a sole plate cover168, at least one metal (e.g., aluminum) foam layer (or pad)170, and an insulator172between which a thin-film heater plate174is sandwiched, such that the metal foam layer170provides a thermally conductive path from the heater plate174to the sole plate cover168, while also cushioning the heater plate174on the sole plate cover168to facilitate minimizing damage to the heater plate174if the iron100is dropped.

As shown inFIG. 9, another embodiment of a sole plate unit (indicated generally by reference numeral176) may be configured to perform a front vapor burst function. More specifically, the sole plate unit176has a sole plate cover178, a sole plate180, and an insulator182between which a thin-film heater plate184is sandwiched. The sole plate180has an isolated front cavity186with a plurality of smaller holes in communication with smaller holes188of the sole plate cover178for applying a burst of steam to the clothing unit being ironed.

As shown inFIG. 10, another embodiment of a sole plate unit (indicated generally by reference numeral190) may also be configured to perform a front vapor burst function. More specifically, the sole plate unit190has a sole plate cover192, a sole plate194, and an insulator196between which a thin-film heater plate198is sandwiched. The sole plate194has an isolated front cavity200having a plurality of smaller holes202in communication with similarly sized holes204of the sole plate cover192. Notably, the heater plate198is sized to cover and heat only back and middle segments of the sole plate194, while the front cavity200of the sole plate194is heated by a thin-film heater strip206. The heater strip206is disposed within the front cavity200and is inverted relative to the heater plate198(i.e., the heater strip206has its outward face covered by an insulator strip208, leaving its inward face exposed) such that water droplets falling onto the inward face of the heater strip206generate a burst of steam that flows through the holes202,204and onto the clothing article being ironed. A suitable cover210is provided over the front cavity200and the heater strip206to facilitate keeping the steam burst from exiting the front cavity200other than through the holes202,204.

As shown inFIG. 11, another embodiment of a sole plate unit (indicated generally by reference numeral212) has a sole plate cover214and a sole plate216. Notably, the sole plate unit212does not have a thin-film heater plate that covers a majority segment of the sole plate216but, instead, has a plurality of spaced-apart, thin-film heater strips218for heating the sole plate216. The heater strips218may be sized and arranged in any suitable manner, and each heater strip218is sandwiched between the sole plate216and a dedicated insulator strip220. Optionally, as illustrated, this embodiment may be suitably configured to perform a front steam burst function.

Referring now toFIG. 12, an alternative embodiment of an iron300is illustrated and includes only a sole plate unit (indicated generally by reference numeral302) and a handle304suitably coupled to the sole plate unit302. The iron300is cordless (e.g., is battery powered) and has a wattage of between about 2000 W and about 2400 W, for example. Notably, the sole plate unit302has only two layers, namely a thin-film heater plate306and a sole plate308, both of which are substantially transparent. For instance, the sole plate308may be made of glass, while the substrate of the heater plate306(and any associated barrier layers coupled to the heater plate306) are also made of glass. In this manner, the entire iron300(other than the handle304) is substantially transparent to facilitate viewing the clothing article through the iron300. Moreover, the handle304contains a suitable battery and control unit for operating the heater plate306(i.e., for supplying electrical current to the electrically conductive material of the heater plate306, which is sandwiched between the sole plate308and the substrate of the heater plate306). Along these same lines, in the embodiments of the iron100set forth above forFIGS. 1-11, any suitable component of the iron100(e.g., the housing, the heater plate(s) (or heater strip(s)), the sole plate, etc.) may be substantially transparent to facilitate viewing the clothing article through the iron100.

In accordance with the embodiments set forth above, and due at least in part to the efficiencies associated with thin-film heating elements (e.g., the weight savings, the quicker heat-up time, the lower energy consumption, the more precise temperature regulation, etc.), the irons100and/or300are configured to be lighter, to be quicker to heat-up, to have an improved steaming capability, and/or to be powered by a battery (and thereby made cordless) for use in places where an external power supply is not readily accessible. The irons100,300are, therefore, an improvement over at least some conventional irons.