Electric steam iron

Abstract: An electric steam iron (10) includes a housing (12), a water reservoir (16), a boiler (30) in fluid flow communication with the water reservoir (6), a soleplate (24), a first heater for the boiler (40), and a second heater (28) for the soleplate. A fluid control device (23) regulates the flow of fluid from the reservoir (16) to the boiler (30). First and second thermostats (82,91) respectively independently regulate the operation of the boiler heater (40) and the soleplate heater (28). The boiler (30) comprises a first member (32) in direct contact with the first heater (40) for receiving water from the reservoir and transforming the water into steam. A second member (44) overlies the first member (32) and defines therebetween a first flow path for the steam. A third member (46) overlies the second member (44) and defines therebetween a second flow path (72) for the steam. The first and second flow paths are in fluid flow communication such that the steam flowing in the second flow path flows in a direction opposite to the steam flowing in the first flow path. The steam flowing through the second flow path is supplied to the soleplate for distribution onto a garment.

Description: This invention relates to an electric steam iron and in particular, to a boiler thereof used for generating steam. Generally, most electric steam irons in use today employ a "flash" steam system wherein water contained in a water reservoir is dropped directly onto a hot soleplate to generate steam. The steam generated is usually superheated and its temperature is directly proportional to the temperature of the soleplate. It has been found that relatively high temperature superheated steam is not as effective for ironing garments as steam at or near saturated conditions (100°C). It has been also determined that saturated steam with some moisture content can relax the fabric of the garment being ironed and result in a more satisfactorily ironed garment. To generate lower steam temperature in conventional irons, the soleplate temperature must be reduced which sometimes results in water spotting and inadequate heat for the fabric being ironed. To overcome the disadvantages of a "flash" steam system, irons having separate boilers for generating steam, and which are heated and controlled independently of the soleplate, have been designed. Examples of irons with separate soleplate and boiler heaters are described in U.S. Patents 2,387,757, 2,499,835, and 3,263,350. The addition of a second heater dedicated to the generation of steam has typically increased the elevational profile of the iron, making the iron more expensive to manufacture, and less aesthetically attractive. Further, it has been found that when operating an electric iron at or near saturation conditions, the generated steam must be directed through a relatively tortuous path to separate relatively large droplets of condensation from the steam. If relatively large droplets or slugs of water are not separated from the steam and are discharged from the iron, these droplets tend to cause water spotting of the fabric being ironed. It is therefore an object of this invention to manufacture an electric steam iron that has a first heater for generating steam and a second heater for heating the soleplate of the iron. It is a further object to produce steam at or near its saturation temperature. It is still a further object of the invention to generate steam at or near its saturation temperature and effectively to remove relatively large droplets of water entrained in the steam before the steam is discharged onto fabric. The present invention provides an electric steam iron having a housing; a water reservoir mounted in the housing; the housing further defining a boiler in fluid flow communication with said water reservoir; a soleplate; a heater for said boiler; a heater for said soleplate; fluid control means for regulating the flow of fluid from said water reservoir to said boiler; first and second thermostatic means for respectively independently regulating the operating temperature of said boiler and said soleplate heaters; said boiler comprising a first member in direct contact with said boiler heater for receiving water from said reservoir and transforming said water into a steam, a second member overlying said first member and defining therebetween a first flow path for said steam, and a third member overlying said second member and defining therebetween a second flow path for said steam, said first and second flow paths being in fluid flow communication such that the steam flowing through said second flow path flows in a direction opposite to the steam flowing in said first flow path; and means for distributing the steam flowing from said second flow path through said soleplate. An embodiment of a steam iron according to the invention will now be described with reference to the drawings in which; FIGURE 1 is an elevational view, partially in section, of an electric iron; FIGURE 2 is an exploded perspective view; FIGURE 3 is a plan view of one of the members; FIGURE 4 is a sectional view taken along line 4-4 of FIGURE 5 and FIGURE 5 is an enlarged longitudinal sectional view of a portion of the iron illustrated in FIGURE 1. Referring now to the various figures of the drawings, a preferred embodiment of the invention shall now be described in detail. In referring to the various figures, like numerals shall refer to like parts. Referring specifically to Figure 1, electric iron 10 includes a housing 12 formed from a suitable material such as polypropylene. An electric cord 14 extends from the rear of the housing 12 and connects the iron 10 to a source of electrical power. A water reservoir 16 is mounted or contained in the housing 12. The housing 12 includes a handle 15 and a saddle portion 17. A control knob 18 is mounted on the saddle portion 17 for regulating the operation of a thermostat 19. The thermostat 19 controls the operating temperature of a first heater 28. The heater 28 is operatively connected to soleplate 24. The temperature of the soleplate may be varied by the user of the iron 10 through appropriate movement of the control knob 18. A first control knob 22 is mounted at the top forward portion of the housing 12 and operates to regulate the operation of a fluid control means 23. The fluid flow control means 23 meters the flow of fluid from water reservoir 16 into a boiler 30 for a reason that shall be more fully described hereinafter. A second control knob 20 is also mounted at the top of the housing 12. The control knob 20 operates a pump 25 which is used to inject a relatively large quantity of water into the boiler 30. The water is injected when a surge of steam is desired by the user. The pump 25 is also connected to a spray nozzle located at the nose 27 of housing 12. As noted previously, the thermostat 19 can be regulated by the user of the iron to vary the temperature of the heater 28 and thus the operating temperature of the soleplate 24. Some fabrics, such as cotton, must be ironed at a relatively high temperature to obtain an acceptably ironed garment. Other fabrics such as rayon or silk, are delicate and can only be ironed at relatively low temperatures. In fact, these rather delicate fabrics may be ironed at temperatures at or even below the vaporization temperature of water and thus steam cannot be generated when these fabrics are being conventionally ironed. Similarly, when the relatively high temperature fabrics are being ironed, the temperature of the soleplate is significantly above the vaporization temperature of water and thus when the user requires steam from the iron, the generated steam has a significant amount of superheat and does not provide an ironed garment that is as acceptable to the user as is a garment ironed with steam at or near saturated conditions. Iron 10 includes the separate boiler 30, details of which are specifically shown in Figures 2 to 5. Unlike a conventional iron, the boiler 30 has a separate heater 40 which is designed to generate steam at or near saturation temperature. The boiler 30 is mounted in the housing 12 and includes a first member 32 having a generally centrally located axially extending portion or passage 34 defined by a vertically upwardly extending generally U-shaped rib 33. Water under control of the fluid control means 23 is metered from the reservoir 16 into the forward section of portion 34 of the first member 32. The bottom wall or floor 35 of member 32 is canted or sloped in a forward direction approximately 5 degrees relative to a horizontal line. A generally U-shaped heater 40 provides sufficient heat to transform the water into steam. The member 32 includes a generally flat ledge-like surface 83 for mounting a single set-point thermostat 82. The thermostat 82 regulates the operation of heater 40, and is electrically separate from the thermostat 19. Thus the operation of the thermostats are independent of each other and the heaters 28 and 40 are independently controlled. The boiler 30 includes a second member 44 which overlies first member 32. Member 44 in combination with first member 32 defines a first flow path for the steam generated in the passage 34. The member 44 includes an opening 38 which is aligned with the rear portion of the passage 34. An inclined baffle 36 extends upwardly from the opening 38 and is axially aligned therewith. The member 44 also includes a fluid flow opening 54 and a pair of fluid flow slots 56. The purposes of the flow opening 54 and slots 56 shall be more fully explained hereinafter. The boiler 30 includes a third member 46 which is provided in overlying relationship with the member 44. As illustrated particularly in Figure 5, the member 46 includes an inverted cuplike element 48 in general vertical alignment with the inclined baffle 36 and defining therebetween a second steam flow passage 72. As illustrated by the arrows drawn in Figure 1, the steam flow through the first passage 34 is in a direction opposite to the steam flow through the second passage 72. It should also be noted that the inclined baffle 36 directs the steam upwardly as the steam leaves the first flow passage 34 and enters the second flow passage 72. The element 48 includes a pair of laterally extending wings 50 which define lateral extensions for the flow of steam in the second flow passage 72. The lateral extensions 50 are in vertical alignment with the slots 56 provided in the second member 44. The slots 56 in turn are in alignment with the generally U-shaped channel 58 in the member 32. The member 46 also includes the flow opening 52 vertically aligned with the opening 54 of the member 44. The fluid flow control means 23 regulates the flow of fluid from the reservoir 16 through the flow openings 52 and 54 into the passage 34 of the boiler 30. The member 46 includes a further flow opening 76 in vertical alignment with the flow opening 78 in the member 44. The opening 76 communicates with the reservoir 16 under control of the pump 23. When a surge of steam is desired the pump 25 is activated and water is injected from the reservoir 16, through the aligned openings 76 and 78 into a channel 80 formed about the top surface of the heater 40. The water is directly heated by the heater 40 and is transformed into steam to satisfy the user's requirements for a surge of steam. The steam flowing in the channel 80 exits therefrom to mix with the steam formed in the passage 34. The member 32 includes a generally U-shaped rib 88 defining a chamber. The members 44 and 46 include the openings 84 and 86 respectively. A tube 87 (shown in phantom in Figure 3) runs from the chamber in the member 32 to the air space formed in the top of the reservoir 16. A rib 88 prevents water from entering into the bottom of the tube. The tube equalizes the pressure between the boiler 30 and the reservoir 16. Steam flowing through the second passage 72 flows outwardly in each direction via the laterally extending wings 50 and thence passes downwardly through the openings 56 into the channel 58. The steam exits from the channel 58 via a slot 60 which communicates with the soleplate 24. The steam is distributed from the soleplate via a plurality of orifices 26 which are formed in the lower surface of the soleplate. The orificies 26 communicate with a steam exit chamber 68 formed between the lower surface of the member 32 and the top surface of the soleplate 24. Suitable steam seals 42 between adjoining surfaces of the members 32, 44 and 46 may be obtained via liquid injection molding or sheet stampings. The members forming the boiler 30 are joined together via fastening means 64 such as screws, rivets or staking, to upstanding posts which extend through the vertically aligned openings 74, 70 and 66 formed respectively in the members 46, 44 and 32. As illustrated particularly in Figures 5, the bottom surface of the member 32 and the top surface of the soleplate 24 define the chamber 68. Suitable sealing material such as a liquid injection moldable gasket is placed at interfaces 96 and 98 to prevent loss of steam from the chamber 68 and to prevent significant heat transfer from the soleplate 24 to the member 32. To further minimize heat conduction from the soleplate 24 to the boiler 30, the boiler is only connected to and supported by the soleplate at two points, namely via screws, 94 and 92. In normal operation, the user of the iron 10 regulates the supply of wattage to the heater 28 to obtain a desired soleplate temperature in accordance with the specific temperature requirements of the fabric being ironed. When the user desires steam, the control knob 22 is actuated to cause the fluid control means 23 to supply water from the reservoir 16 to the first flow passage 34 formed in the member 32 of the boiler 30. The water from the water reservoir 16 flows through the opening 52 formed in the plate 46 and the opening 54 formed in the member 44, into the passage 34. As noted, the floor 35 is sloped forwardly approximately 5 degrees. This slope functions to prevent water from migrating towards the opening 38 and percolating therethrough into the second flow passage 72. The wattage supplied to the dedicated heater 40 of the boiler 30 is designed to convert the water to steam at or near saturation conditions. The steam thus formed therefore has some water vapour entrained in the gaseous molecules. It has been determined that this water vapour relaxes the fabric of the garment being ironed to improve the quality of the finished ironed garment. The steam flowing through the passage 34 exits through the opening 38 and is directed by the inclined baffle member 36 upwardly into the second flow passage 72. Although it is desirable that the steam contain a certain quantity of water vapour, it is not desirable that the steam contains, large droplets or slugs of water. It has been found that large droplets of water can cause undesirable water spotting of the fabric being ironed. The inclined baffle member 36 serves two purposes. The first is to cause the steam to change direction as it passes from the first flow passage into the second flow passage. The change in direction of the steam flow results in separation of large droplets of water, from the steam vapour. Further, the inclination of the baffle 36 results in the steam flow being directed vertically upwards. Large droplets of water will separate from the steam as a consequence of gravity and fall onto the top surface of the baffle member 36. Due to the inclination of the baffle member, the water will flow downwardly along the top surface of the member and return via the opening 38 to the first flow passage 34 where the droplets will again be exposed to the heat generated from the heater 40. The second steam flow passage 72 channels the steam flow in a counter-flow direction relative to the steam flowing through the passage 34. The steam in the second passage is in heat transfer relation with the steam flowing in the first passage. The somewhat warmer temperature steam in the first flow passage transfers heat to the somewhat colder steam flowing through the second flow passage to maintain the temperature of the steam in the second passage at or near its original temperature level and thereby prevent the formation of excessive water condensation. The steam flowing through the second flow path 72 defined by the top surface of the baffle member 36 and the lower surface of the element 48 passes outwardly into the wings 50, and then downwardly through the openings 56 formed in the member 44. The steam then enters, the channel 58 in the first member 32 and passes outwardly from the member via the slot 60 for distribution through the orifices 26 formed in the bottom surface of the soleplate. The slots 56 are generally aligned with the heater 40. Any water droplets remaining in the steam transmitted through the slots 56 should be vaporized as a result of direct contact with the heater 40. The boiler 30 is effective in producing steam at or near saturation temperature. Due to the compact size of the boiler, the boiler does not significantly increase the elevational profile of the iron. The tortuous path established for the flow of steam through boiler 30 effectively separates any large droplets or slugs of water.

Claims: An electric steam iron (10) comprising: a housing (12); a water reservoir (16) mounted in the housing (12); means comprising a boiler (30) mounted within the housing in fluid flow communication with the water reservoir; a sole plate (24) connected to the housing (12); a first electrically operated heater (40) and a second electrically operated heater (28) mounted in the sole plate; characterised in that the first electrically operated heater (40) is mounted in the boiler (30) and the second electrically operated heater (28) is mounted in the sole plate, which iron further comprises fluid control means (23) for regulating flow of fluid from the water reservoir (16) to the boiler (30); first thermostatic means (82) for independently regulating the operating temperature of the boiler heater and second thermostatic means (19) for independently regulating the operating temperature of the soleplate heater; the boiler comprising a first member (32) for receiving water from the reservoir and having the first heater mounted therewithin for transforming the water into steam, a second member (44) overlying the first member and encompassing therebetween a first flow path for the steam generated in the first member, and a third member (46) overlying the second member and encompassing therebetween a second flow path (72) for the steam, the first and second flow paths being in fluid flow communication such that the steam flowing in the second flow path (72) flows in a direction opposite to the steam flowing in the first flow path; and means (26) for distributing the steam flowing from the second flow path (72) through the soleplate. A steam iron according to claim 1 characterised in that the third member (46) includes a pair of laterally extending wings (50) in fluid flow communication with the second flow path (72) and the second member (44) includes at least one opening (56) aligned with each wing. A steam iron according to claim 1 or claim 2 characterised in that the first member (32) includes a channel (58) aligned with the openings (56) formed in the second member (44) so that steam flowing through the second flow path (72) is directed into the channel (58) through the openings (56); and means (60) for communicating the channel with the steam distributing means. A steam iron according to any of the preceding characterised claims in that the second member (44) includes an inclined baffle member (36) for directing the steam exiting the first flow path upwardly along the second flow path (72). A steam iron according to any of the preceding claims characterised in that the first member (32) has a bottom wall (35) sloped at substantially a 5 degree angle relative to the horizontal. An electric steam iron according to any of the preceding claims characterised in that the first electrically operated heater (40) is operatively connected to the boiler (30); the second electrically operated heater (28)is operatively connected to the soleplate (24) ;and the boiler (30) comprises a first member (32) in direct contact with the boiler heater (40) and including a first portion (34) for receiving water from the water reservoir and forming a boiler section for converting the water into steam, a second member (44) spaced vertically above the first member (32) for encompassing therebetween a longitudinally extending first flow path for the steam formed in the boiler section (34), a third member (46) spaced vertically above the second member (44) for encompassing therebetween a longitudinally extending second flow path (72), the end of the first flow path communicating with the beginning of the second flow path (72) so that steam flowing through the second flow (72) path is moving in an opposite direction to the steam flow through the first flow path, the third member (46) including a pair of laterally extending wings (50) in fluid flow communication with the end of the second flow path (72) for defining lateral flow path extensions for the steam exiting the second flow path (72); and means (56, 58, 26) in fluid flow communication with the wings (50) and the soleplate (24) for distributing steam from the wings (50) through the soleplate (24). A steam iron according to claim 6 characterized in that the first member (32) includes a channel (58) in fluid flow communication with the wings, and means (60) for communicating the channel with the steam distributing means. A steam iron according to claim 6 or claim 7 characterised in that the second member (44) includes an inclined baffle member (36) for directing the steam exiting the first flow path upwardly along the second flow path (72). A boiler (30) for generating steam in an electric steam iron (10) having a water reservoir (16) and a soleplate (24), which boiler (30) comprises: a first member (32) for receiving water from the water reservoir (16) and having an electrically operated heater (40) for converting the water into steam; characterised in that the boiler (30)further comprises passage means (34) in the first member for directing the steam in a first axial direction; a second member (44) overlying the first member and including a first opening (38) aligned with an end of the passage means (34) and an axially extending inclined baffle member (36) having a lower end aligned with the opening; a third member (46) overlying the second member (44) for defining therebetween a second flow path (72) for the steam, the second flow path (72) being in communication with the first opening (38) and being vertically above the passage means (34) for directing steam flowing therethrough in an axial direction opposite to the direction of flow of steam through the passage means (34); and fluid distribution means (50,56,58,60) communicating with the second flow (72) path for distributing steam flowing through the flow path to the soleplate (24). A boiler according to claim 9 characterized in that third member (46) includes a pair of laterally extending wings (50) in fluid flow communication with the second flow path (72) and the second member includes at least one opening (56) aligned with each wing. A boiler according to claim 9 or claim 10 characterised in that the first member (32) includes a channel (58) aligned with the openings(56) formed in the second member (44) through which steam flowing from the second flow path (72) is directed into the channel. A boiler according to any of claims 9 to 11 characterised in that the first member (32) has a bottom wall (34) sloped at substantially a 5 degree angle relative to the horizontal.

Inventors: CHASEN JAMES E, CHASEN, JAMES E.
Applicants: BLACK & DECKER INC, BLACK & DECKER INC.
Application year: 1992
Main classification: D06F75
IPC codes: D06F75