Abstract:
Gravity and flow operated diverter valves are disclosed for diverting liquid flow from one source to either of two output destinations, the valves including a housing defining an inlet opening through a base wall, a first outlet opening through a first upper wall and a second outlet opening through a second upper wall. The housing is operable in a configuration with the base wall arranged vertically beneath the first and second upper walls. A valve member has a first end, a second end, and a central portion, the valve member being movably suspended within the housing by the first end when no liquid is flowing into the inlet opening. The valve member is pivotable in a first direction to seal the first outlet opening and pivotable in a second direction to seal the second outlet opening. The housing interior and the valve member are cooperatively configured so that on successive liquid flows into the inlet opening the valve member automatically and alternatingly seals the first outlet opening and the second outlet opening. Related dishwasher designs are also disclosed.

Description:
FIELD OF THE INVENTION 
       [0001]    The present disclosure relates generally to water diverter valves which can be used in a dishwasher. 
       BACKGROUND OF THE INVENTION 
       [0002]    Dishwashers of various types have been proposed wherein items are placed in a wash chamber which is filled and emptied according to desired wash sequences. Recently, dishwasher manufacturers have focused even more on efficiency in implementing new designs. Thus, an amount of electricity, an amount of detergent, and an amount of water used are all monitored in an attempt to provide efficient and environmentally sensitive machines. 
         [0003]    Many dishwashers have more than one outlet within them for spraying water within the wash chamber. For example, dishwashers typically have an upper rack and a lower dish rack. Such dishwashers may have a multiple rotating spray arms located at a lower level, a midlevel (between dish racks), and an upper level that spray during a wash or rinse cycle. Some dishwashers have two such sprayers and some have more. 
         [0004]    To reduce the amount of water used in such multiple sprayer dishwashers, it is desirable to alternate spraying between the multiple spray arm assemblies. Doing so requires a smaller amount of water in the wash chamber because only half of the spray system need be actively filled with water at a time. Conventional devices accomplish such alternation with solenoid valves to divert water from one spray assembly or the other. This adds to cost and complexity of the device. Other devices accomplish such switching with a pump driven column of water moving a floating ball or other diverter element. However, such solution requires extra water and has higher pumping requirements. 
         [0005]    Accordingly, other designs for alternating water flow between multiple outlets within a wash chamber and related dishwashers including those addressing one or more drawbacks of conventional devices and dishwashers would be welcome. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0006]    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. 
         [0007]    According to certain aspects of the present disclosure, gravity and flow operated diverter valves are disclosed for diverting liquid flow from one source to either of two output destinations, the valves including a housing defining outer walls including a base wall, a first upper wall and a second upper wall at an angle to the first upper wall. There is an inlet opening through the base wall, a first outlet opening through the first upper wall and a second outlet opening through the second upper wall. The housing is operable in a configuration with the base wall arranged vertically beneath the first and second upper walls. A valve member has a first end, a second end, and a central portion, the valve member being movably suspended within the housing by the first end when no liquid is flowing into the inlet opening. The valve member is pivotable in a first direction to seal the first outlet opening and pivotable in a second direction to seal the second outlet opening. The housing interior and the valve member are cooperatively configured so that on successive liquid flows into the inlet opening the valve member automatically and alternatingly seals the first outlet opening and the second outlet opening. Various options and modifications are possible. 
         [0008]    According to certain other aspects of the disclosure, a dishwasher is disclosed includes a cabinet, a wash chamber within the cabinet, a first spray device for spraying liquid into the wash chamber and a second spray device for spraying liquid into the wash chamber. A circulation pump assembly pumps water from a sump area of wash chamber to either the first spray device or the second spray device. A valve includes a housing defining outer walls including a base wall, a first upper wall and a second upper wall at an angle to the first upper wall. There is an inlet opening through the base wall in communication with an outlet of the pump assembly, a first outlet opening through the first upper wall in communication with an inlet of the first spray device, and a second outlet opening through the second upper wall in communication with an inlet of the second spray device. The housing is mounted in the cabinet with the base wall arranged vertically beneath the first and second upper walls. A valve member has a first end, a second end, and a central portion, the valve member being movably suspended within the housing by the first end when the circulation pump assembly is not pumping. The valve member is pivotable in a first direction to seal the first outlet opening and pivotable in a second direction to seal the second outlet opening. The housing interior and the valve member are cooperatively configured so that as the circulation pump assembly is cycled on and off the valve member automatically and alternatingly seals the first outlet opening and the second outlet opening. Again, various options and modifications are possible. 
         [0009]    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 embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    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: 
           [0011]      FIG. 1  provides a side partial cut-away view of an exemplary dishwasher that may be configured in accordance with aspects of the invention; 
           [0012]      FIG. 2  is a schematic view of one possible fluid system the dishwasher of  FIG. 1 ; 
           [0013]      FIG. 3  provides a schematic front view of one valve housing interior suitable for use with the dishwasher of  FIG. 1  in a first, no flow condition; 
           [0014]      FIG. 4  provides a schematic front view of the valve housing interior in a first flow condition; 
           [0015]      FIG. 5  provides a schematic front view of the valve housing interior in a second, no flow condition; 
           [0016]      FIG. 6  provides a schematic front view of the valve housing interior in a second flow condition; 
           [0017]      FIG. 7  provides a schematic cross-sectional view of the valve housing taken along line  7 - 7  in  FIG. 3 ; 
           [0018]      FIG. 8  provides a schematic front view of another valve housing interior suitable for use with the dishwasher of  FIG. 1  in a first, no flow condition; 
           [0019]      FIG. 9  provides a schematic front view of the valve housing interior of  FIG. 8  in a first flow condition; 
           [0020]      FIG. 10  provides a schematic front view of the valve housing interior of  FIG. 8  in a second, no flow condition; 
           [0021]      FIG. 11  provides a schematic front view of the valve housing interior of  FIG. 8  in a second flow condition; and 
           [0022]      FIG. 12  provides a schematic cross-sectional view of the valve housing taken along line  12 - 12  in  FIG. 8 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]    Reference now will be made in detail to 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. 
         [0024]    As discussed in greater detail below, embodiments of the present disclosure relate to a flow sensing float device that can be used with a dishwasher.  FIG. 1  depicts an exemplary domestic dishwasher  100  that may be configured in accordance with aspects of the disclosure. For the particular embodiment of  FIG. 1 , the dishwasher  100  includes a cabinet  102  having a tub  104  therein that defines a wash chamber  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 chamber  106  is sealed shut for washing operation, and a horizontal open position for loading and unloading of articles from the dishwasher. 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 the upper and lower racks  130 ,  132  is fabricated 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 chamber  106 , and a retracted position (shown in  FIG. 1 ) in which the rack is located inside the wash chamber  106 . A silverware basket (not shown) may be removably attached to the lower rack  132  for placement of silverware, utensils, and the like, that are too small to be accommodated by the upper and lower racks  130 ,  132 . 
         [0025]    The dishwasher  100  further includes a lower spray-arm-assembly  144  that is rotatably mounted within a lower region  146  of the wash chamber  106  and above a tub sump portion  142  so as to rotate in relatively close proximity to the lower rack  132 . A mid-level spray-arm assembly  148  is located in an upper region of the wash chamber  106  and may be located in close proximity to upper rack  130 . Additionally, an upper spray arm assembly (not shown) may be located above the upper rack  130 . 
         [0026]    The lower and mid-level spray-arm assemblies  144 ,  148  and the upper spray arm assembly are fed by a fluid circulation assembly for circulating water and dishwasher fluid in the tub  104 . The fluid circulation assembly may be located in a machinery compartment  140  located below the bottom sump portion  142  of the tub  104 , as generally recognized in the art. Each spray-arm assembly includes an arrangement of discharge ports or orifices for directing washing liquid onto dishes or other articles located in the upper and lower racks  130 ,  132 , respectively. The arrangement of the discharge ports in at least the lower spray-arm assembly  144  provides a rotational force by virtue of washing fluid flowing through the discharge ports. The resultant rotation of the lower spray-arm assembly  144  provides coverage of dishes and other dishwasher contents with a washing spray. 
         [0027]    The dishwasher  100  is further equipped with a controller  137  to regulate operation of the dishwasher  100 . The controller may include a memory and microprocessor, such as a general or special purpose microprocessor operable to execute programming instructions or micro-control code associated with a cleaning cycle. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. 
         [0028]    The controller  137  may be positioned in a variety of locations throughout dishwasher  100 . In the illustrated embodiment, the controller  137  may be located within a control panel area of door  120  as shown. In such an embodiment, input/output (“I/O”) signals may be routed between the control system and various operational components of dishwasher  100  along wiring harnesses that may be routed through the bottom  122  of door  120 . Typically, the controller  137  includes a user interface panel  136  through which a user may select various operational features and modes and monitor progress of the dishwasher  100 . In one embodiment, the user interface  136  may represent a general purpose I/O (“GPIO”) device or functional block. In one embodiment, the user interface  136  may include input components, such as one or more of a variety of electrical, mechanical or electro-mechanical input devices including rotary dials, push buttons, and touch pads. The user interface  136  may include a display component, such as a digital or analog display device designed to provide operational feedback to a user. The user interface  136  may be in communication with the controller  137  via one or more signal lines or shared communication busses. 
         [0029]    It should be appreciated that the invention is not limited to any particular style, model, or other configuration of dishwasher, and that the embodiment depicted in  FIG. 1  is for illustrative purposes only. For example, instead of the racks  130 ,  132  depicted in  FIG. 1 , the dishwasher  100  may be of a known configuration that utilizes drawers that pull out from the cabinet and are accessible from the top for loading and unloading of articles. 
         [0030]      FIG. 2  schematically illustrates an embodiment of a fluid circulation assembly  170  configured below the wash chamber  106 . Although one embodiment of a fluid circulation assembly that is operable to perform in accordance with aspects of the disclosure is shown, it is contemplated that other fluid circulation assembly configurations may similarly be utilized without departing from the spirit and scope of the invention. The fluid circulation assembly  170  includes a circulation pump assembly  172  and a drain pump assembly  174 , both in fluid communication with the sump  150 . Additionally, the drain pump assembly  174  is in fluid communication with an external drain  173  to discharge used wash liquid. Further, the circulation pump assembly  172  is in fluid communication with lower spray arm assembly  144  and conduit  154  which extends to a back wall  156  of wash chamber  106 , and upward along the back wall  156  for feeding wash liquid to the mid-level spray arm assembly  148  ( FIG. 1 ) and the upper spray arm assembly. A diverter valve  250 ,  350  is located between circulation pump assembly output and the conduits to the different spray arm assemblies  144  and  148  and diverts flow one way or the other, as described below. This configuration also applies to a drawer-type of dishwasher, as mentioned above. 
         [0031]    As wash liquid is pumped through either the lower spray arm assembly  144  or the mid-level spray arm assembly  148  and the upper spray arm assembly (not shown), washing sprays are generated in the wash chamber  106 , and wash liquid collects in the sump  150 . The sump  150  may include a cover to prevent larger objects from entering the sump  150 , such as a piece of silverware or another dishwasher item that is dropped beneath lower rack  132 . A coarse filter and a fine filter (not shown) may be located adjacent the sump  150  to filter wash liquid for sediment and particles of predetermined sizes before flowing into the sump  150 . Furthermore, a turbidity sensor may be coupled to the sump  150  and used to sense a level of sediment in the sump  150  and to initiate a sump purge cycle where the contents or a fractional volume of the contents of the sump  150  are discharged when a turbidity level in the sump  150  approaches a predetermined threshold. The sump  150  is filled with water through an inlet port  175  which outlets into wash chamber  106 . 
         [0032]    As shown, a drain valve  186  is established in flow communication with the sump  150  and opens or closes flow communication between the sump  150  and a drain pump inlet  188 . The drain pump assembly  174  is in flow communication with the drain pump inlet  188  and may include an electric motor for pumping fluid at the inlet  188  to an external drain system via drain  173 . In one embodiment, when the drain pump is energized, a negative pressure is created in the drain pump inlet  188  and the drain valve  186  is opened, allowing fluid in the sump  150  to flow into the fluid pump inlet  188  and be discharged from fluid circulation assembly  170  via the external drain  173 . Alternatively, pump assemblies  172  and  174  may be connected directly to the side or the bottom of sump  150 , and the pump assemblies may each include their own valving replacing drain valve  186 . Other fluid circulation systems are possible as well, drawings fluid from sump  150  and providing as desired within wash chamber  106  or draining out of washing machine  100 . 
         [0033]    Referring to  FIG. 2 , a water supply  200  may be configured with the inlet port  175  for supplying wash liquid to the wash chamber  106 . The water supply  200  may provide hot water only, cold water only, or either selectively as desired. As depicted, water supply  200  has a hot water inlet  204  that receives hot water from an external source, such as a hot water heater and a cold water input  206  that receives cold water from an external source. It should be understood that the term “water supply” is used herein to encompass any manner or combination of valves, lines or tubing, housing, and the like, and may simply comprise a conventional hot or cold water connection. 
         [0034]      FIG. 3  shows one example of a diverter valve according to certain aspects of the disclosure in a first no-flow condition. As shown, valve  250  has a housing  252  with outer walls that include a base wall  254 , a first upper wall  256  and a second upper wall  258  at an angle (about a right angle, as shown) to the first upper wall. An inlet opening  260  extends through base wall  254 , a first outlet opening  262  extends through first upper wall  256 , and a second outlet opening  264  extends through second upper wall  258 . Valve  250  is operable in a configuration with base wall  254  arranged vertically beneath first and second upper walls  256  and  258 , as will be described below. 
         [0035]    A track  266  is defined within housing  252  adjacent the intersection of the first and second upper walls  256 , 258 . Track  266  has a first arm  268  and a second arm  270  both extending downward at about a right angle from a central peak  272  where first and second upper walls  256 , 258  meet. The first arm  268  terminates at a first arm end  274  and the second arm  270  terminates at a second arm end  276 . Track  266  has two symmetrical parts, one part  278  attached to a rear wall  280  of housing  252  and a second identical part  282  attached to a front wall  284  of housing  252  (see  FIG. 7 ). The track parts  278 , 282  are spaced apart by a distance  286  along their lengths. Flanges  287  can be used to connect housing parts  280  and  284 . 
         [0036]    A valve member  288  is movably mounted within housing  252 . Valve member  288  includes a first ball  290  sized to seal either of the first or second outlet openings  262 , 264 , a follower in the shape of a second ball  292  sized to move along track  266  between first and second arm ends  274 , 276 , and a central portion  294  connecting the first and second balls. Essentially, valve member  288  is barbell-shaped. As shown, balls  290 , 292  have different diameters, but they may have the same diameters or have their relative sizes switched if desired. Further, follower need not be in the shape of ball  292 , and could have other curved shapes, could be cylindrical, etc., as long as the follower can travel readily along track  266  from end  274  to end  276 . 
         [0037]      FIGS. 3 to 6  show the cycling of valve member  288  to alternatingly connect outlets  262  and  264  with inlet  260  as the circulation pump assembly is turned on and off.  FIG. 3  shows an initial, no flow position. Follower  292  is at end  276  of track arm  270  and ball  290  hangs down. Once flow starts through opening  260 , rising liquid pushes valve member  288  upward. As liquid rises and any air evacuates, valve member  288  moves upward with follower  292  rising along track  266  and first ball member  290  being moved toward second opening  264  by liquid passing through the opening. Since ball member  290  is to one side of housing  252 , the ball member is moved toward the outlet opening on that side, namely opening  264 . Eventually, valve member  288  reaches the position of  FIG. 4 , with ball  290  sealing a corresponding seat of opening  264 . Accordingly, at this point all flow from inlet  260  goes out opening  262  and not opening  264 . Note that follower  292  is now to the right side of track  266  in arm  268  (due in part to the length of central portion  294 ). 
         [0038]    When flow is shut off, valve member  288  falls, with follower  292  falling to end  274  of arm  268  and ball  290  hanging below as shown in  FIG. 5 . Basically, valve member  288  has simply changed sides within housing  252  as compared to  FIG. 3 . When flow enters again as in  FIG. 6 , valve member  288  again rises and this time ball  290  seals opening  262 . Turning off the flow again results in valve member  288  returning to the position of  FIG. 3 , and the cycle can start again. 
         [0039]      FIG. 8  shows an alternate diverter valve according to certain aspects of the disclosure. As shown, valve  350  has a housing  352  with outer walls that include a base wall  354 , a first upper wall  356  and a second upper wall  358  at an angle to the first upper wall. An inlet opening  360  extends through base wall  354 , a first outlet opening  362  extends through first upper wall  356 , and a second outlet opening  364  extends through second upper wall  358 . As above, valve  350  is operable with base wall  354  arranged vertically beneath first and second upper walls  356  and  358 . Flanges  387  can be used to connect housing parts together. 
         [0040]    A valve member  388  is movably mounted within housing  352 . Valve member  388  includes a first end  390  having an axle  392  pivotably attached to a hole in (but not through) housing  352 . Valve member  388  has a central portion with a flat sealing surface  394  on a first side for sealing first outlet opening  362  and a flat sealing surface  396  on a second side for sealing a second outlet opening  364 . 
         [0041]    Valve member  388  has a second end  398  with a pivotable end arm  400  attached to an axle  401  at the second end. End arm  400  is movable between a first position (see  FIG. 10 ) directed toward first outlet opening  362  and a second position (see  FIG. 8 ) directed to second outlet opening  364 . When liquid flow is introduced into inlet opening  360  by activating the circulation pump assembly, end arm  400  directs valve member  388  to move toward the one of the first or second outlet openings  362 , 364  toward which the pivotable end arm is pointed. In other words, as flow comes through inlet opening  360 , it initially impinges on arm  400  moving the whole valve member  388  to the side—at which point the flow starts impinging on the sealing surface  394  or  396  now facing opening  360 , thereby allowing the flow to rapidly push the valve member to seal outlet opening  362  or  364 . 
         [0042]    A camming surface  402  is located adjacent each outlet opening  362 , 364 . Camming surfaces  402  contact and move pivotable end arm  400  from the first or second position of the arm  400  to the other when valve member  388  moves fully to seal the respective first or second outlet openings  362 , 364 . As shown, camming surfaces  402  are placed so that arm  400  will contact the camming surfaces and pivot about axle  401  when valve member  388  is sealing. Retainers  404  may be provided on either side of arm  400  at second end  398  of valve member  388  to define a range of motion for arm  400 . Recesses  406  may be provided between openings  362 , 364  and camming surfaces  402  so that retainers  404  and the thicker part of arm  400  around axle  401  do not prevent valve member  388  from moving fully against openings  362 , 364  to seal them. 
         [0043]      FIGS. 8-11  show the cycling of valve member  388  to alternatingly connect outlets  362  and  364  with inlet  360  as above.  FIG. 8  shows an initial, no flow position. Arm  400  points toward second outlet opening  364 . Once flow starts through opening  360 , rising liquid hits arm  400  and pivots valve member  388  to the left until it closes second opening  364  with sealing surface  396 . Near the end of travel, arm  400  hits camming surface  402  and pivots to the position shown in  FIG. 9 . The leftward (as shown) retainer  404  is in recess  406 . Accordingly, at this point all flow from inlet  360  goes out opening  362  and not opening  364 . 
         [0044]    When flow is shut off, valve member  388  pivots down, with arm  400  pointing toward opening  362 , on the right as shown in  FIG. 10 . Valve member  388  is now in the same position as in  FIG. 8 , except that arm  400  is pointed in the opposite direction. When flow enters again as in  FIG. 11 , valve member  388  again pivots upward to the right and seals opening  362  with surface  394 . Arm  400  hits the other camming surface  402  and pivots back to the left. Turning off the flow again results in valve member  388  pivoting back down, with arm  400  pointing to the left, returning to the position of  FIG. 8 , and the cycle can start again. 
         [0045]    Parts of valve members  288 ,  388  may be plastic, metal, rubber, etc. if desired, but should have a density and weight chosen in view of the desired flow needed for the spray devices used so that that the valve member reliably moves upward and seals when flow occurs. Accordingly, valves  250 ,  350  provide inexpensive and reliable diverters. No electronics are required, and all moving parts are essentially self-actuated by the circulation pump assembly. Mounting valves  250 ,  350  at or near the circulation pump, beneath the sump, etc., allows a lesser amount of water to have to be cycled through the system and the different spray elements within the wash chamber to achieve a given desired cycle. No ball-driven water column is needed, saving water and complexity. Such valve device can be used not only within a dishwasher but also within other devices. 
         [0046]    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.