Steam system and method

A steam generator for a shower steam system includes a first chamber, a second chamber, and an intermediate heat transfer member. The first chamber is configured to receive water. The second chamber is configured to receive a flow of air. The intermediate heat transfer member fluidly separates the first chamber from the second chamber. The intermediate heat transfer member includes a heating element configured to generate heat energy. The intermediate heat transfer member is configured to transfer heat energy generated by the heating element to the first chamber to generate steam in the first chamber, and transfer heat energy generated by the heating element to the flow of air in the second chamber.

BACKGROUND

The present disclosure relates generally to steam systems and, more specifically, to steam generators for controlling temperature and humidity in a sauna or a shower environment.

In a conventional steam generator, a heating element is typically submerged in a tank filled with water. The heating element can be operated to heat the water until the water boils to generate steam for use in, for example, a sauna or a shower environment. This arrangement typically requires a significant amount of heat to increase the temperature of the water in the tank before any steam is generated, which can result in relatively long startup times. Furthermore, the direct contact between the heating element and the water can result in a gradual deposit of calcium on the heating element, which can reduce the lifespan of the heating element.

In addition, the heating element in a conventional steam generator typically cycles on and off to maintain an average temperature in an environment, which can lead to temperature fluctuations in the water and difficulty in precisely controlling the level of humidity downstream of the steam generator.

It would be advantageous to provide a steam generator that addresses one or more of the above noted deficiencies associated with conventional steam generators. These and other advantageous features will become apparent to those reviewing the present disclosure.

SUMMARY

At least one embodiment relates to a steam generator for a shower steam system. The steam generator includes a first chamber, a second chamber, and an intermediate heat transfer member. The first chamber is configured to receive water. The second chamber is configured to receive a flow of air. The intermediate heat transfer member fluidly separates the first chamber from the second chamber. The intermediate heat transfer member includes a heating element configured to generate heat energy. The intermediate heat transfer member is configured to transfer heat energy generated by the heating element to the first chamber to generate steam in the first chamber, and transfer heat energy generated by the heating element to the flow of air in the second chamber.

Another embodiment relates to a shower steam system. The shower steam system includes a steam generator, a spray nozzle, and a blower. The steam generator includes a first chamber, a second chamber, and an intermediate heat transfer member fluidly separating the first chamber from the second chamber. The intermediate heat transfer member includes a heating element configured to generate heat energy. The spray nozzle is in fluid communication with the first chamber, and is configured to provide an atomized spray of water to the first chamber. The blower is in fluid communication with the second chamber, and is configured to provide a flow of air to the second chamber. The intermediate heat transfer member is configured to transfer heat energy generated by the heating element to the atomized spray of water in the first chamber to generate steam, and transfer heat energy generated by the heating element to the flow of air in the second chamber to heat the flow of air.

Another embodiment relates to a method of generating at least one of steam or heated air in a shower steam system. The method includes receiving, by a steam generator, a signal to produce at least one of steam or heated air. The steam generator includes a first chamber, a second chamber, and an intermediate heat transfer member fluidly separating the first chamber from the second chamber. The intermediate heat transfer member includes a heating element. The method further includes providing at least one of water to the first chamber or a flow of air to the second chamber in response to the received signal. The method further includes generating, by the heating element, heat energy in response to the received signal. The method further includes transferring, by the intermediate heat transfer member, the generated heat energy to the first chamber and the second chamber.

DETAILED DESCRIPTION

Referring generally to the FIGURES, disclosed herein is a steam system and method that includes a steam generator for providing steam and heated air to, for example, a sauna or a shower environment. The disclosed steam generator includes a first chamber (e.g., a steam chamber, etc.) for receiving water from a water source. The first chamber is in fluid communication with an area to receive steam, such as a sauna, a shower environment, or other area for receiving steam. The steam generator further includes an intermediate heat transfer member including a heating element coupled to, or integrally formed with, the intermediate heat transfer member. The intermediate heat transfer member fluidly separates the first chamber from a second chamber (e.g., an air chamber, etc.) of the steam generator. The second chamber can receive a flow of air from an air supply source. The intermediate heat transfer member can transfer heat energy generated by the heating element to the flow of air to produce heated air. The intermediate heat transfer member can also transfer heat energy from the heating element to indirectly heat the water received in the first chamber to produce steam. The heated air and steam generated by the steam generator are separately provided to the shower environment or sauna to control the humidity and temperature therein.

The intermediate heat transfer member of the steam generator can, advantageously, help to distribute heat energy produced by the heating element to water within the first chamber, while avoiding direct contact between the water and the heating element. In this manner, the disclosed steam generator can heat water more efficiently and quickly to produce steam, as compared to conventional steam generators. In addition, since the heating element is not submerged or otherwise in direct contact with the water in the first chamber, the heating element is less likely to develop calcium deposits, thereby prolonging the useful life of the heating element. Additionally, by separately providing heated air and steam to an environment, the disclosed system allows for greater and more precise control of temperature and humidity in the environment, as compared to conventional steam systems, which typically just cycle on and off to maintain an average temperature in an environment.

Referring toFIGS. 1-2, a steam system10is shown according to an exemplary embodiment. The steam system10includes a steam generator20in fluid communication with an environment, shown schematically as an enclosure30that defines an interior space30a, for receiving steam and heated air from the steam generator20. According to various exemplary embodiments, the enclosure30may be a sauna, a shower environment, or any other area for receiving steam and heated air. The enclosure30may be a partial or full enclosure, according to various exemplary embodiments. The steam system10further includes a blower14(e.g., air blower, air pump, etc.) fluidly coupled to the enclosure30by a first conduit12. The blower14is also fluidly coupled to the steam generator20by a second conduit13a. The blower14is configured to receive a flow of air (represented by arrow “A” inFIG. 1) from an air supply source, which is shown as the interior space30ain the embodiment ofFIG. 1, although the flow of air may be received from a different air supply source, such as ambient, according to other exemplary embodiments. The blower14is further configured to direct the flow of air A to the steam generator20via the second conduit13a. The steam generator20includes an intermediate heat transfer member28that is configured to heat the flow of air A and provide a heated flow of air (represented by arrow “B” inFIG. 1) via a third conduit13bto the interior space30a, so as to adjust the temperature of the interior space30a.

Referring toFIGS. 1-2, the steam generator20is also fluidly coupled to a water supply source16, such as a household water supply, although other water supply sources may be used, according to other exemplary embodiments. The steam generator20is configured to receive a flow of water from the water supply source16, and to heat the received water via the intermediate heat transfer member28to generate steam. The steam generator20is configured to direct the generated steam (represented by arrow “C” inFIG. 1) via a fourth conduit18to the interior space30aof the enclosure30, where the steam can be combined with the heated air generated by the steam generator20. The steam may be provided to selectively increase the humidity of the interior space30a. In this manner, the steam system10can separately provide heated air and steam to a sauna or shower environment to provide for greater and more precise control of temperature and humidity, as compared to conventional systems that typically provide a combined flow of air and steam to an environment.

Referring toFIGS. 2-3, the steam generator20includes a first housing21that defines a first chamber21a. The first housing21has a generally cuboidal shape with an open bottom portion to provide access to the first chamber21a. According to other exemplary embodiments, the first housing21may have other shapes, such as spherical, hemi-spherical, trapezoidal, or other shapes that define a chamber. An upper portion of the first housing21includes a plurality of openings for receiving various components in the first chamber21a. For example, the first housing21includes a pair of first openings21bfor receiving spray nozzles23, respectively, at least partially therein. According to other exemplary embodiments, the first housing21may include more or fewer than two openings21bto receive a different number of spray nozzles23. The first housing21further includes a second opening21clocated at a middle portion of the housing21. The second opening21cis configured to be coupled to the fourth conduit18to fluidly couple the first chamber21ato the enclosure30, so as to distribute steam generated by the steam generator20to the enclosure30. The first housing21further includes a third opening21dfor receiving a pressure relief valve25at least partially therein for controlling pressure in the first chamber21a.

According to the exemplary embodiment ofFIGS. 2-3, each of the spray nozzles23includes a solenoid24that is electrically coupled to a control system40. Each of the spray nozzles23is also fluidly coupled to the water supply source16. The spray nozzles23are configured to receive a flow of water from the water supply source16and to provide an atomized spray of water16a(e.g., fine water spray droplets, etc.) into the first chamber21ain response to a signal received by the solenoids24from the control system40. The received signal may be indicative of a request to produce steam in a sauna or shower environment to raise the humidity in the environment. The signal may be from a sensor (e.g., in response to a humidity level dropping below a threshold value, etc.), a mobile device, a thermostat, or other source. According to an exemplary embodiment, the water flow rate to the spray nozzles23can be selectively controlled to adjust the temperature/humidity of the enclosure30. For example, the solenoids24may be modulated between on and off to provide greater control of temperature, as compared to conventional systems which can have large temperature swings. According to an exemplary embodiment, when the steam room or shower environment reaches a desire ambient temperature, the solenoids24can be pulsed on and off for a period of time to reduce the flow of water, thereby making less steam. This allows the temperature in the steam room or shower environment to be controlled more precisely.

Still referring toFIGS. 2-3, the steam generator20further includes a second housing22(e.g., manifold, air distributor, etc.) coupled to the first housing21below the open bottom portion of the first housing21. The second housing22has a second chamber22athat is defined by a lower wall and two substantially parallel sidewalls. The second housing22defines a first end22band an opposite second end22c. The steam generator20further includes an inlet adapter27acoupled to, or integrally formed with, the first end22b. The steam generator20further includes an outlet adapter27bcoupled to, or integrally formed with, the second end22c. The inlet adapter27ais configured to be coupled to the second conduit13ato fluidly couple the second chamber22ato the blower14. The inlet adapter27aincludes a partition27a′ disposed therein for distributing or redirecting the flow of air from the blower14toward the heat transfer elements of the intermediate heat transfer member28to heat the flow of air, the details of which are discussed in the paragraphs that follow. The outlet adapter27bis configured to be coupled to the third conduit13bto fluidly couple the second chamber22ato the enclosure30, so as to direct heated air to the enclosure30. For example, the blower14can be selectively operated in response to a signal received from the control system40to provide a flow of air to the second chamber22a. The received signal may be indicative of a request to produce heated air in a sauna or shower environment to raise the temperature in the environment. The signal may be from a sensor (e.g., in response to a temperature level dropping below a threshold value, etc.), a mobile device, a thermostat, or other source. According to an exemplary embodiment, the air volume from the blower14can be selectively controlled to adjust the temperature/humidity of the enclosure30.

Still referring toFIGS. 2-3, the steam generator20further includes an intermediate heat transfer member28disposed between the first housing21and the second housing22. The intermediate heat transfer member28fluidly separates the first chamber21afrom the second chamber22a. A sealing member26(e.g., gasket, etc.) may be disposed between the first housing21and the intermediate heat transfer member28, so as to provide a substantially watertight seal of the first chamber21afrom the second chamber22a. The intermediate heat transfer member28includes an upper portion28athat is configured to be at least partially exposed in the first chamber21a. The upper portion28acan extend the entire surface area of the open bottom portion of the first housing21, so as to cooperatively define a full enclosure of the first chamber21a. In other words, the top surface of the upper portion28adefines a bottom wall of the first chamber21. The upper portion28ais configured to distribute heat energy to the atomized spray of water16ain the first chamber21a, so as to generate steam in the first chamber21a, the details of which are discussed below. In the embodiment shown, the upper portion28ais substantially planar, however, it should be appreciated that the upper portion28amay be substantially non-planar or include substantially non-planar portions, according to other exemplary embodiments.

The intermediate heat transfer member28further includes a middle portion28bextending from the upper portion28a. The middle portion28bincludes one or more heating elements29disposed therein. According to an exemplary embodiment, the heating elements29are integrally formed with the intermediate heat transfer member28to define a unitary member. According to other exemplary embodiments, the heating elements29are coupled to the middle portion28bin corresponding openings defined therein. The heating elements29may be resistive heating rods that are electrically coupled to the control system40of the steam system10, so as to allow for the selective control of the heating elements29, although it should be appreciated that other types of heat generating elements may be used instead, according to other exemplary embodiments. The heating elements29are configured to produce heat energy in response to a signal received from the control system40, so as to selectively produce steam and/or heated air to control the humidity and/or temperature of an environment. According to an exemplary embodiment, the heating elements29can be selectively turned on and off to adjust the humidity/temperature in the enclosure30.

The intermediate heat transfer member28further includes a plurality of heat transfer elements, shown as fins28c, extending away from the middle portion28btoward the second housing22. The fins28care arranged laterally spaced apart from each other, and each extending lengthwise between the first end22band the second end22c. The fins28cextend longitudinally into the second chamber22afrom the middle portion28b, so as to distribute heat energy from the heating elements29via conduction to a flow of air received in the second chamber22a(e.g., from blower14, etc.). The intermediate heat transfer member28is also configured to distribute heat energy from the heating elements29to the upper portion28avia conduction, so as to generate steam within the first chamber21a. The intermediate heat transfer member28may be made from a rigid or a substantially rigid material having good heat transfer properties, such as aluminum. In this way, the steam generator20can heat water more efficiently and quickly to produce steam, as compared to conventional steam generators. In addition, since the heating elements29are not submerged or otherwise in direct contact with the water in the first chamber21a, the heating elements29are less likely to develop calcium deposits, thereby prolonging the useful life of the heating elements29.

Referring toFIG. 4, a method100of generating steam and heated air for a sauna or a shower environment is shown according to an exemplary embodiment. In a first step110, the control system40receives a signal (e.g., from a sensor, a mobile device, a thermostat, etc.) to produce at least one of steam or heated air to adjust the humidity and/or temperature of a sauna or a shower environment. In response to the received signal, the heating elements29of the steam generator20are operated to generate heat energy in a second step120. If the received signal is indicative of a request for heated air, such as to raise the temperature, the blower14can be selectively operated to provide a flow of air to the second chamber22aof the steam generator20in a third step130. The heat energy generated by the heating elements29can be transferred to the flow of air via the intermediate heat transfer member28(e.g., the fins28c, etc.), so as to generate heated air in the second chamber22ain a fourth step140. The heated air can be provided from the second chamber22ato the sauna or the shower environment to adjust the temperature. If the received signal from the control system40is indicative of a request for steam, such as to raise the humidity, the spray nozzles23can be selectively operated to provide an atomized spray of water16afrom the water supply source16to the first chamber21aof the steam generator20in the third step130. The heat energy generated by the heating elements29can be indirectly transferred to the atomized spray of water16avia the intermediate heat transfer member28(e.g., the upper portion28a, etc.), so as to generate steam in the first chamber21ain the fourth step140. The steam can be provided from the first chamber21ato the sauna or the shower environment to adjust the humidity.

In this manner, the disclosed steam generator20can heat water more efficiently and quickly to produce steam, as compared to conventional steam generators. In addition, since the heating elements29are not submerged or otherwise in direct contact with the water in the first chamber21a, the heating elements29are less likely to develop calcium deposits, thereby prolonging the useful life of the heating elements29. Additionally, by separately providing heated air and steam to an environment, the disclosed system allows for greater control of temperature and humidity in the environment, as compared to conventional steam systems. Furthermore, the disclosed system allows for more precise control of humidity/temperature of an environment by allowing for control of water flow rate to the spray nozzles23, air volume from the blower14, or operation of heating elements29.

It is important to note that the construction and arrangement of the system as shown in the various exemplary embodiments is illustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein.