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, a soleplate (24), a steam cover (34) overlying the soleplate (24) in spaced relation thereto for defining a steam boiler chamber (30). An electrically operated heater (28) is associated with the soleplate (24). A fluid control device (23) regulates the flow of fluid from the reservoir (16) to the steam boiler chamber (30). The chamber has a first portion for receiving water from the reservoir and a second portion (33). An extraction channel (40) is formed overlying the second portion of the steam chamber. The steam cover has a first opening (44) communicating the steam chamber (30) with the extraction channel (40). The soleplate (24) has a steam distribution chamber (54) spaced from the steam boiler chamber (30). The steam cover (34) has a second opening (46) for communicating the extraction channel (40) with the steam distribution chamber (54).

Description: This invention relates to an electric steam iron and in particular, to a steam generating and extracting system for high rates of steam generation. 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 generated steam is usually super-heated and its temperature is proportional to the soleplate temperature. It has been found that relatively high temperature super heated steam is not as effective for ironing garments as steam at or near saturated conditions (100°C). It has also been 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. It has also been determined that the use of relatively high steam rates can significantly improve the ironing characteristics of many common fabrics. Typically, in irons using the "flash" steam system, the steam is directed through a tortuous path to separate any entrained water from the steam. The typical tortuous path is reasonably effective for moderate steam rates, e.g. 10 grams of steam per minute. The effectiveness of a typical tortuous path however does not generally permit steam to be generated at all ironing temperatures or at relatively high steam rates. Generally, electric steam irons start to water spot at about 130-135°C at a steam rate of only 10 grams per minute. This shortcoming of conventional irons is particularly important since it has been found that superior ironing results for moisture sensitive fabrics such as cotton and cotton blends can be obtained by utilizing wet steam at lower than conventional temperatures, e.g. 110°-150°C and at relatively high steam rates. These ironing conditions reduce the risk of the scorching damage to the garment that can occur at the higher conventional ironing temperatures commonly used for cottons, e.g. 175-195°C. Additionally when using a higher steam rate such as 20 grams per minute at the higher temperatures conventionally used for cotton and cotton blends, e.g. 145-175°C, water spotting can occur due to the limited effectiveness of typical tortuous paths and soleplate designs. These designs can typically only support high steam rates at the highest temperature settings of the iron, e.g. 175-205°C, without water spotting the garment. There have been some attempts to overcome this problem by the use of very high steam chambers with tall vertical walls cast into the iron's soleplate. The very height of these walls under most circumstances prevents relatively large droplets of water from escaping the steam generating chamber. While being generally effective in reducing water spotting at high steam rates and low temperatures, this solution adds significantly to the cost of the iron, consumes much space, and adds a significant amount of weight which makes the iron less user friendly. French Patent Application No 2 444 108 describes and claims an electric steam iron in which communication between the vaporisation chamber and the distribution chamber is effected by channels formed in the division separating these chambers, characterised in that the device for the injection of water is located at the front of the iron, adjacent to the base of the U formed by the heating element and in which the channels are located in the rear part of the said chambers, relative top the normal direction of use of the iron. It is accordingly an object of this invention to generate relatively low temperature steam at relatively high steam rates without significantly increasing the height and/or weight of the iron. The present invention provides an electric steam iron comprising a housing; a water reservoir mounted in the housing; a steam cover overlying a soleplate in spaced relation thereto for encompassing a steam boiler chamber therebetween, the chamber having a first portion for receiving water from the reservoir and a second portion positioned rearwardly of the first portion, said soleplate being connected to the housing and having a steam distribution chamber separated from the steam boiler chamber; an electrically operated heater associated with the soleplate; fluid control means for regulating the flow of fluid from the water reservoir to the steam boiler chamber; means comprising at least one extraction channel overlying the rear portion of the steam cover; the steam cover having at least one opening for communicating the steam chamber with the extraction channel and means for directing the steam from the distribution chamber across the electrically operated heater to a plurality of steam distribution ports formed in the soleplate; characterised in that the soleplate has a steam distribution chamber positioned rearwardly of the steam boiler chamber and the steam cover has at least a second opening positioned rearwardly of the first opening for communicating the extraction channel with the steam distribution chamber; which iron further comprises ramp means for deflecting any water droplets entrained in the steam. Three preferred embodiments of a steam iron according to the invention will now be described with reference to the accompanying drawings in which FIGURE 1 is a longitudinal sectional view of a first embodiment of steam iron; FIGURE 2 is an exploded perspective view of the steam iron of Figure 1; FIGURE 3 is a partial longitudinal sectional view of a second embodiment of an iron and; FIGURE 4 is a similar view to that of Figure 3 showing a third embodiment. 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 Figures 1 and 2 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 thermostat 18 controls the operating temperature of a heater 28. A control knob 19 located on the saddle portion 17 is used to adjust the thermostat 18. The heater 18 is operatively connected to a soleplate 24. The temperature of the soleplate may be varied by the user of the iron 10 through appropriate adjustment of the thermostat. A second control knob 22 is mounted at the top forward portion of the housing 12 and operates to regulate the operation of the fluid control means 23. The fluid flow control means 23 meters the flow of fluid from the water reservoir 16 into a steam boiler chamber 30. A control button 20 is also mounted at the top of the housing 12. The control button 20 operates a pump 25 which is used to inject a relatively large quantity of water into the boiler chamber 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 21 located at the nose 27 of the housing 12 for wetting fabric. As noted previously, it is advantageous that the iron 10 be capable of producing steam at lower than conventional temperatures and at relatively high rates as well as producing steam at relatively high temperatures. To achieve the foregoing desiderata, relatively large droplets or slugs of water must be separated from the steam, otherwise water spotting of the garment being ironed will take place. To achieve the separation of water from the steam generated in the steam boiler chamber 30, the iron 10 of the present invention includes a steam cover plate 34. The cover plate 34 defines the upper surface of the steam boiler chamber 30. The cover plate 34 includes a pair of openings 56, 58 which selectively communicate the chamber 30 with the reservoir 16 under control respectively of the fluid control means 23 and the surge control means 25. The cover plate 34 has a generally U-shaped housing 36 mounted on its top surface towards the rear portion thereof. The housing 36 defines an extraction channel 40. A pair of rectangular gaskets 41 provide a seal between each leg of the housing 36 and cover plate 34. The cover plate 34 includes a pair of laterally aligned openings 44. Each opening 44 is vertically aligned with one of the legs of the housing 36. Each opening 44 includes a deflector formed as an inclined ramp 38. The ramps 38 extend downwardly from the cover plate 34 into the steam boiler chamber 30 for a reason to be more fully described hereinafter. The cover plate 34 further includes a second pair of openings 46, positioned rearwardly of the openings 44. Each opening 46 is vertically aligned with one of the legs of the housing 36. Each opening 46 includes an inwardly extending diverter or rib 42. The purpose of the rib 42 shall be fully explained hereinafter. The steam flowing through the channel 40 passes through the openings 46 into the steam collection chambers 54. From the collection chambers 54, the steam is distributed to ports 57 formed in the bottom wall of the soleplate 24. The ends of each leg of U-shaped heater 28 are adjacent the chambers 54. When the user of the iron 10 desires steam, the user operates either the button 20 or knob 22 to obtain either a surge of steam, or steam generated by the metering of water into the chamber 30 via the operation of the fluid control means 23. The water delivered into the chamber 30 is heated by the heater 28 and is vaporized into steam when the temperature of the water reaches 100°C or higher. The steam in the chamber 30 flows towards the rear of the iron 10 and thus contacts the front surface of the ramp 38. The ramp 38 deflects any large water droplets entrained in the steam downwardly to separate the water droplets from the steam. The steam enters the extraction channel 40 via the openings 44 and passes rearwardly in the channel towards the openings 46. Steam flows through the openings 46 into the outlet chambers 54. The outlet chambers 54 communicate across the top of the heater element via passages 59 with the steam distribution ports 57 formed in the soleplate. Some slight cooling of the steam may occur inside the channel 40. Thus, water droplets may form in the steam flowing through the channel 40. The rib 42 prevents any droplets of water flowing through the openings 46 from wicking along the bottom side of the steam cover 34 and being distributed to the soleplate steam ports without touching the rear portion of the legs of the heating element 28. The flange 42 directs the steam into the chambers 54 to insure that any large slugs of water are transformed into steam before reaching the soleplate ports. Any excessive moisture or condensation remaining in the steam flowing into the chambers 54 is vaporized as the steam passes over the rear portion of the legs of the heating element 28. The openings 44 are spaced forwardly of the rear wall 33 forming the chamber 30. When the operating iron is placed on heel rest 52, the space between the wall 33 and the openings 44 functions as a reservoir or trap for the water/steam remaining in the chamber 30. The remaining water/steam slowly exits from the chamber 30 through the openings 44, extraction channel 40, openings 46, chambers 54 and soleplate 24. When the steam rate becomes very high, a large pool of water is formed on the floor of the chamber 30. The ramp 38 prevents the pool of water from easily exiting from the chamber due to wave action and in addition deflects most water particles entrained in the steam. The boiler chamber 30 may become entirely flooded provided that the heater 28 has enough wattage to produce steam across the entire wetted surface of the chamber and maintain the soleplate temperature while heat is being input to the fabric being ironed. It has been shown experimentally that 1300 watts produces acceptable results with a steam rate of 20 grams per minute while ironing cotton broadcloth at a variety of operating temperatures. Less wattage was needed at lower steam rates. While the embodiment illustrated in Figures 1 and 2 requires, a separate housing 36 to form the extraction channel 40, Figure 3 illustrates an alternative embodiment in which the bottom surface of the plastic skirt 56 typically employed on an iron forms the roof of the channel. A retangular gasket 48 which is held between the lower surface of the skirt 56 and the top surface of the steam cover plate 30 defines the ends of the channel and provides a suitable seal. The embodiment illustrated in Figure 3 provides an extremely low cost means for implementing the invention. Figure 4 illustrates a third embodiment. A metal cover 60 is spaced below the skirt 56 and is retained in a recessed groove formed in a gasket 62. The cover 60 forms the top surface of the boiler chamber 30.

Claims: An electric steam iron (10) comprising: a housing (12); a water reservoir (16) mounted in the housing; a steam cover (34) overlying a soleplate (24) in spaced relation thereto for encompassing a steam boiler chamber (30) therebetween, the chamber (30) having a first portion for receiving water from the reservoir and a second portion (33) positioned rearwardly of the first portion, said soleplate (24) being connected to the housing and having a steam distribution chamber (54) separated from the steam boiler chamber (30); an electrically operated heater (28) associated with the soleplate (24); fluid control means (23) for regulating the flow of fluid from the water reservoir (16) to the steam boiler chamber; means comprising at least one extraction channel (40) overlying the rear portion of the steam cover (34); the steam cover (34) having at least one opening (44) for communicating the steam chamber (30) with the extraction channel (40) and means (59) for directing the steam from the distribution chamber (54) across the electrically operated heater (28) to a plurality of steam distribution ports (57) formed in the soleplate; characterised in that the soleplate (24) has a steam distribution chamber (54) positioned rearwardly of the steam boiler chamber (30) and the steam cover (34) has at least a second opening (46) positioned rearwardly of the first opening (44) for communicating the extraction channel (40) with the steam distribution chamber (54); which iron further comprises ramp means (38) for deflecting any water droplets entrained in the steam. A steam iron according to Claim 1 characterized in that the steam cover (34) includes first diverter means (38) adjacent to the first opening (44) and extending from the cover (34) into the steam boiler chamber (30). A steam iron according to Claim 1 or Claim 2 characterized in that the second opening (46) includes a downwardly extending second diverter (42) for preventingfluid flow from the second opening (46) along the surface of the cover facing the steam boiler chamber. A steam iron according to any of claims 1 to 3 characterised in that the steam boiler chamber (30) includes means (33) forming a reservoir for collecting water when the iron is oriented such that the soleplate is held in a vertically upward direction relative to a horizontal plane.

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