Abstract:
A dish-cleaning appliance comprising a sink having a bowl defining a wash chamber with an open top for providing access to the wash chamber. A liquid recirculation system is provided for spraying liquid onto the dish rack to effect the cleaning of any dishes along the rack. The lid is mounted to the sink and is movable to selectively cover the open top of the bowl. The lid includes a sound absorber and a sound dampener for reducing the transfer of sound from the wash chamber through the lid.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The invention relates to an in-sink dishwasher for automatically washing household dishes without requiring the physical space of a built-in automatic dishwasher.  
           [0003]    The invention further relates to an in-sink dishwasher having an sound absorbing lid for reducing the noise emitted by the in-sink dishwasher into the surrounding environment.  
           [0004]    2. Description of the Related Art  
           [0005]    In-sink dishwashers use the bowl of a sink to form part of the dishwasher housing that defines a wash chamber, with the open top of the bowl providing access thereto. A liquid recirculation system sprays wash liquid throughout the wash chamber to clean any dishes placed within. A lid covers the open top of the bowl when the in-sink dishwasher is being used to prevent the splashing or spraying of the recirculating wash liquid out of the open top of the bowl.  
           [0006]    The impact of the sprayed liquid on the surface of the lid facing the wash chamber is transmitted through the lid and into the surrounding environment. The resulting environmental noise is undesirable by most consumers. Therefore, it is important to minimize the environmental noise generated by the in-sink washer.  
         SUMMARY OF THE INVENTION  
         [0007]    The invention relates to a dish-cleaning appliance comprising a sink having a bowl defining a wash chamber with an open top for providing access to the wash chamber. A liquid recirculation system is provided for spraying liquid into the wash chamber for cleaning any dishes therein. The lid is mounted to the sink and is movable to selectively cover the open top of the bowl and thereby close the wash chamber. The lid comprises an upper surface and a lower surface. The upper surface faces away from the wash chamber when the lid covers the open top and the lower surface faces toward the wash chamber when the lid covers the open top. A sound absorption layer and a vibration-dampening layer are disposed between the upper and lower surfaces. The vibration-dampening layer can be disposed between the sound absorbing layer and one of the upper and lower surfaces.  
           [0008]    The sound absorbing layer can be made from a fibrous layer forming interstitial spaces between the fibers. Non-woven fibers can be used. The vibration-dampening layer is made from a relatively dense material. A suitable material is mastic.  
           [0009]    The sound absorbing layer is disposed between the vibration dampening layer and the upper surface. The vibration-dampening layer is located adjacent the lower surface.  
           [0010]    The lid can further comprise a frame to which the upper and lower surfaces are mounted. A frame preferably circumscribes the sound absorption layer and the vibration-dampening layer. The frame can be made from a material that also has vibration-dampening characteristics to prevent the transfer of vibrations from the lower surface to the upper surface.  
           [0011]    The lid further can comprise a gasket that is mounted to the frame and seals the lid relative to the sink. The frame can include a peripheral groove in which is received a portion of the gasket to thereby mount the gasket to the frame.  
           [0012]    The lid can be hingedly mounted to the basket to effect selective movement of the lid to and from the closed position. The dish-cleaning appliance can also include a basket for receipt in the wash chamber and adapted to hold dishes and the like for cleaning.  
           [0013]    The recirculation system preferably comprises a spray arm for spraying liquid throughout the wash chamber to clean the dishes therein. The spray arm is preferably mounted to a lower surface of the basket.  
           [0014]    In another aspect, the invention relates to a dish-cleaning appliance comprising a sink having a bowl defining a wash chamber with an open top for providing access to the wash chamber. A liquid recirculation system is provided for spraying liquid into the wash chamber for cleaning any dishes therein. The lid is mounted to the sink and is movable to selectively cover the open top of the bowl and thereby close the wash chamber. The lid comprises an upper surface and a lower surface. The upper surface faces away from the wash chamber when the lid covers the open top and the lower  60  surface faces toward the wash chamber when the lid covers the open top. A vibration dampening layer and a fibrous layer are disposed between the upper and lower surfaces. The fibrous layer is disposed between the vibration dampening layer and one of the upper and lower surfaces.  
           [0015]    In another embodiment, the invention comprises a dish cleaning appliance comprising a sink having a bowl defining a wash chamber for receiving dishes to be washed. The sink having an open top for providing access to the wash chamber. A liquid recirculation system sprays liquid into the wash chamber for cleaning any dishes within the wash chamber. A lid is mounted to the sink and is movable to selectively cover the open top of the bowl and thereby close the wash chamber.  
           [0016]    The lid comprises an upper surface facing away from the wash chamber when the lid covers the open top and a lower surface facing toward the wash chamber when the lid covers the open top. An acoustic frame is included and to which the upper surface and the lower surface are mounted such that the upper and lower surfaces are sonically isolated by the acoustic frame.  
           [0017]    The frame preferably has an upper side and a lower side and the upper and lower surfaces are assembled to the frame from the same one of the upper and lower side. The upper and lower surfaces are preferably assembled to the frame from the upper side.  
           [0018]    The appliance further comprise a gasket mounted to the lower side. Preferably, the fasteners extend through the frame lower side and into the lower surface to mount the lower surface to the frame. The gasket can overlie the fasteners and hide them from view.  
           [0019]    The frame can have an exterior edge connecting the upper side to the lower side. Fasteners extend through the upper surface and into the exterior edge to mount the upper surface to the frame.  
           [0020]    The lid can further comprising a vibration dampening layer disposed between the upper and lower surfaces. Additionally, the lid can include a fibrous layer disposed between the vibration dampening layer and one of the upper and lower surfaces. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]    In the drawings:  
         [0022]    [0022]FIG. 1 is a perspective view of an in-sink dishwasher according to the invention, with the in-sink dishwasher shown mounted in a cabinet, the sink being of a double-bowl configuration and the one bowl forming part of the in-sink dishwasher having a lid, shown in an opened position, for covering the one bowl.  
         [0023]    [0023]FIG. 2 is a perspective view substantially identical to FIG. 1 except that the lid is shown in the closed position.  
         [0024]    [0024]FIG. 3 is a schematic illustration of the major components of the in-sink dishwasher.  
         [0025]    [0025]FIG. 4 is an assembly view of the lid of FIG. 1 and illustrating the major components of the lid comprising an upper lid and lower lid mounted to a frame carrying a gasket, with a sound absorber and sound dampener disposed between the upper and lower lid.  
         [0026]    [0026]FIG. 5 is a top view of the lid of FIG. 1 and illustrating the upper surface of the lid.  
         [0027]    [0027]FIG. 6 is a right-side view of the upper surface of the lid.  
         [0028]    [0028]FIG. 7 is a bottom perspective view of the lower surface showing the lower surface as seen from within the sink.  
         [0029]    [0029]FIG. 8 is a side view of the lower surface.  
         [0030]    [0030]FIG. 9 is a top perspective view of the frame.  
         [0031]    [0031]FIG. 10 is a side view of the frame.  
         [0032]    [0032]FIG. 11 is a sectional view taken along line  11 - 11  of FIG. 2 and illustrating the mounting of the gasket to the frame.  
         [0033]    [0033]FIG. 12 is a sectional view of the gasket.  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0034]    [0034]FIG. 1 illustrates an in-sink dishwasher  10  mounted in a traditional cabinet fixture  12  having doors  14  providing access to the cabinet interior where the lower portion of the in-sink dishwasher  10  is located.  
         [0035]    The in sink dishwasher  10  is illustrated in the environment of a double-bowl sink  16  comprising a first bowl  18  and a second bowl  20 . The first bowl  18  performs the function of a traditional sink bowl and includes a drain opening  21 . The second bowl  20  performs the dual function of a traditional sink bowl while also forming a portion of the housing for the in-sink dishwasher.  
         [0036]    The first and second bowls  18 ,  20  are spaced from each other to define an intervening flange portion  22  that intersects a peripheral flange  24  surrounding both of the bowls  18 ,  20 . Preferably, the double-bowl sink is made from stainless steel.  
         [0037]    A traditional water faucet  28  is located in the peripheral flange  24  of the double-bowl sink and provides water to either of the first and second bowls  18 ,  20 .  
         [0038]    Referring to FIGS. 1 and 2, the in-sink dishwasher  10  comprises a wash chamber  30  that is defined by the second bowl  18 , which has an open top. A lid  32  is hingedly mounted to the peripheral flange  24  of the double-bowl sink  16  and is movable between an opened position as shown in FIG. 1 and a closed position as shown in FIG. 2.  
         [0039]    A drain  34  along with a water inlet  36  are provided in the bottom of the second bowl  20  and provide for the draining and introduction of water from and into the wash chamber  30 . The drain  34  is coupled to a drain line  35  that serves as a drain during the use of the bowl  20  as a traditional sink and when used as a wash chamber  30  for the in-sink dishwasher  10 .  
         [0040]    [0040]FIG. 3 schematically illustrates the major components of the in-sink dishwasher  10 , which include a rack  40  comprised of multiple wire segments for holding various dishes and utensils. The exact shape and configuration of the rack  40  is not germane to the invention and is preferably made similar to those found in automatic dishwashers.  
         [0041]    A spray arm  42  is preferably mounted to the bottom of the rack  40  such that the spray arm is free to rotate relative to the rack  40  and is removed from the wash chamber when the rack is removed. The spray arm  42  couples with the water inlet  36  when the rack  40  is positioned within the second bowl  20 .  
         [0042]    The drain  34  has one outlet that is fluidly coupled to an in-line water heater  44 . The output of the water heater  44  is received as input to a recirculation pump  46 , whose output is sent to a valve  48  forming part of the water inlet  36 .  
         [0043]    The drain  34 , water inlet  36 , in-line water heater  44 , recirculation pump  46 , valve  48 , and spray arm  42  collectively form a recirculation system for recirculating wash liquid throughout the wash chamber  30 .  
         [0044]    The drain  34  has another outlet that is fluidly connected to a drain pump  52 . The output of the drain pump  52  is fluidly connected to the traditional drain line for the second bowl  20 . The drain pump  52  provides for a positive draining of liquid from the wash chamber  30 , such as, for example, when it is no longer desire to recirculate the wash liquid with the recirculation system.  
         [0045]    A controller  54 , preferably a microprocessor-based controller, is electronically coupled to the in-line heater  44 , recirculation pump  46 , and drain pump  52  to control their respective operation. If the valve  48  is an actuated valve, such as a solenoid-actuated valve, instead of a check valve, then the controller  54  can also be connected to the valve  48  and control its operation.  
         [0046]    The controller  54  operates the in-line heater  44 , recirculation pump  46 , and drain pump  52  to implement a wash cycle. Preferably, the wash cycle is one of many well-known wash cycles stored in the memory of the microprocessor.  
         [0047]    A user interface  58  is located adjacent the second bowl  20  and is electronically coupled to the controller  54 . The user interface  58  permits the user to select the desired wash cycle from the multiple wash cycles stored in the memory of the microprocessor and enter any necessary or optional operating data or parameters for the wash cycles.  
         [0048]    Referring to FIG. 4, the various components of the lid  32  are shown. The lid  32  comprises an upper surface  70  and a lower surface  72 , which are both mounted to a frame  74  to form the structural skeleton for the lid  32 . A sound absorption layer  78  and a vibration-dampening layer  76  are disposed between the upper surface  70  and lower surface  72  and circumscribed by the frame  74 . A gasket  80  is mounted to the frame and seals the lid with respect to the sink.  
         [0049]    Referring to FIGS.  4 - 6 , the lid upper surface  70  has a generally planar top surface  71 , which is bound by a depending lip  82 . A recess  84  defined by a beveled periphery  86  is formed in the top surface  71  of the upper surface  70 . The recess  84  is substantially rectangular and extends laterally across the upper surface  70 . Preferably, the recess does not extend all the way to the peripheral edge of the lid.  
         [0050]    A series of longitudinally extending ribs  88  are located in the recess  84  and effectively divide the recess  84  into multiple or sub-recesses  90 . The ribs  88  are preferably of a height such that they do not extend beyond the plane defined by the upper surface  70 .  
         [0051]    A hinge arm opening  92  is formed in depending lip  82  in a rear edge of the upper surface  70  and is sized to receive the arm of a hinge (not shown) for hingedly mounting the lid  32  to the sink.  
         [0052]    Fastener openings  94  are formed in the depending lip  82  and receive fasteners  96  for securing the upper surface  70  to the frame  74 .  
         [0053]    Referring to FIGS. 4 and 7- 8 , the lower surface  72  of the lid  32  is shown in greater detail. The lower surface  72  comprises a generally planar central portion  100  that is circumscribed by a downwardly extending channel  102  (when viewed from FIG. 4), with an interior edge  104  formed by the junction of the channel  102  and the central portion  100  (see FIG. 11) and an outer edge formed by the outwardly extending lip  106 . The lip  106  is positioned above the central portion  100 . The peripheral mounting flange  108  extends from the peripheral lip  106 . A series of openings  110  are formed in the peripheral lip  106  and are used in securing the lower surface  72  to the frame  74 .  
         [0054]    The upper and lower surfaces  70 ,  72 , like the sink, are preferably made from stainless steel.  
         [0055]    [0055]FIGS. 4 and 9- 11  disclose the details of the frame  74 , which comprises inner, middle, and outer walls  120 ,  122 , and  124 , which partially define an inner or gasket channel  126  and a middle channel  128 . The inner wall  120  terminates below the middle wall  122  and is connected thereto by a first transverse wall  130 , closing the bottom of the gasket channel  126 . Similarly, middle wall  122  terminates below the outer wall  124 . A second transverse wall  132  extends between the middle and outer walls to close the bottom of the middle channel  122 .  
         [0056]    A peripheral rib  134  extends from the first transverse wall  130  and into the gasket channel  126  and is interrupted by fastener openings  136 . When assembled (FIG. 11), the lip  106  rests on the first flange  130  and fasteners extend through the lip and into the fastener openings to secure the lower surface  72  to the frame  74 .  
         [0057]    A plurality of dogs  138  extend from the inner wall  120  and middle wall  122  and into the gasket channel  126  and are used to secure the gasket  80  within the gasket channel  126 . The dogs are spaced about the interior of the gasket channel  126 .  
         [0058]    Embossments  144  are formed in the middle channel  128  and function to strengthen the outer wall  124 . The embossments  144  also provide a structure into which fasteners  96  can be received through the outer wall  124  and the openings  94  in the depending lip  82  of the upper surface to secure the upper surface  70  to the frame  74 .  
         [0059]    The outer wall  124  terminates in an upwardly turned lip  150  to define an outer channel  152 , which is sized to receive the edge of the depending lip  82  of the upper surface  70  when the upper surface  70  is mounted to the frame  74 . Multiple fastener openings  154  extend through the outer wall  124  and are used to receive fasteners  96  extending through the fastener openings  94  to thereby mount the upper surface  72  to the frame  74 .  
         [0060]    Preferably, the frame  74  is molded from a suitable plastic such as polypropylene. The plastic preferably has some flexibility to permit the inner, middle, and outer walls  120 ,  122 , and  124  to at least slightly flex relative to each other, which aids in decoupling the movement of the inner surface from the outer surface. The plastic also has acoustic properties that prevent the transfer of sound and thereby sonically isolates the upper surface from the lower surface.  
         [0061]    The structure of the frame  74  and the upper and lower surfaces  70 ,  72  are unique in that they permit one-side assembly. That is the upper and lower surfaces  70 ,  72  can be assembled to the frame  74  without flipping over the frame  74 . The frame  74  can be thought of a having a upper side and a lower side. Referring to FIG. 11, the upper side is the side seen down or at the first and second transverse flanges  130 ,  132 . The lower side is the side when looking up or at the open tops of the inner and outer channels  126 ,  144 .  
         [0062]    To assemble the upper and lower surfaces  70 ,  72  to the frame  74 , the lower surface  72  is placed against the frame such that the channel lies within open interior of the frame  74  and the lip  106  and mounting flange  108  abuts the first and second transverse flanges  130 ,  132 . A screw  96  passing though the opening  110  in the first transverse flange  130  to secure the lower surface  72  to the frame  74 .  
         [0063]    The upper surface is assembled to the frame by positioning the upper surface  70  such that the depending lip  82  is received within the outer channel  152 . Screws  96  also pass through the openings  94  in the upper surface and into the outer wall  124  to secure the upper surface  70  to the frame  74 . The gasket is received within the inner channel  126  and hides the screws  94  providing an aesthetically pleasant assembly.  
         [0064]    Referring to FIGS. 4 and 11- 12 , the gasket  80  comprises a hollow sealing body  160  connected to a base  162  by a tapered or neck portion  164 . The sealing body  160  has a curved upper surface  166  terminating in an inner flange  168 , which overlies the inner wall  120 , and an outer flange  170 , which overlies the middle wall  122 . The curved upper surface  166  is compressible into the hollow interior  172  of the sealing body  160  to aid in sealing the lid  32  against the sink when the lid is in the closed position.  
         [0065]    The junction of the base  162  and neck  164  forms annular grooves  172  having a cross section that is complementary to the profile of the dogs  138 . To mount the gasket  80  within the gasket channel  126 , the base  162  is inserted into the gasket channel  126  until the dogs  138  are received within the annular grooves  172 . The receipt of the dogs  138  within the annular grooves  172  provides for the removable mounting of the gasket  80  to the frame  74 , which permits the easy replacement of the gasket if needed.  
         [0066]    When the lid  32  is assembled, the sound dampening layer  76  is preferably adjacent to or permanently affixed to the central portion  100  of the lower surface  72 . The sound absorbing layer  78  is disposed between the vibration dampening layer  76  and the upper surface  70 .  
         [0067]    The vibration dampening layer  76  is preferably made from a very dense and nonporous material that substantially prevents the transfer of sound from the wash chamber to the upper surface  70  by dissipating vibration energy through conversion into heat. A preferred material is known as mastic and is affixed directly to the central portion  100  of the lower surface  72 .  
         [0068]    The sound absorbing layer  78  functions to absorb any sound waves and thereby further prevents the transfer of the sound to the upper surface  70  generated by the movement of the lower surface  72 . A suitable material for accomplishing these functions is one that is compressible and porous, with a serpentine air path. The compressible nature of the material aids in absorbing any sound waves propagating from the vibration of the lower surface in the lid, whereas the porous nature of the material functions to create a longer path through which the sound waves must pass to reach the upper surface. The increased path length causes more reflections for the sound wave to make it through the material. The increased reflections absorb the sound waves by converting more of the wave pressure into mechanical energy by vibrating the material forming the sound absorption layer.  
         [0069]    A preferred material is a fibrous batting. The fibrous batting is compressible and the interstitial spaces formed between the fibers increases the effective length that the sound must travel to pass through the sound absorption layer  78 . The effective length of the sound path will be greater than the physical thickness of the fibrous batting. In the most preferred form, the fibrous batting comprises non-woven fibers, which are preferably sandwiched between woven support layers. The preferred fiber is polyester.  
         [0070]    The lid construction according to the invention is especially advantageous in reducing or eliminating the sound generated by the in-sink washer and passing through the lid and into the surrounding environment. Most of the sound emanating from the wash chamber is created by the impact of the sprayed wash liquid as the liquid contacts the sink and the lower surface  72 . The impact of the wash liquid on the lower surface  72  can transmit noise from the wash chamber through the lid by direct radiation and by inducing a vibration in the lower surface  72 , which can be transferred to the upper surface  70  and into the surrounding environment.  
         [0071]    The vibration associated with the impact of the wash liquid on the lower surface  72  is substantially eliminated solely by the mass of the vibration dampening layer  76 . In other words, the mass of the vibration dampening layer  76  is sufficiently great enough that the force of the water acting on the lower surface  72  is not sufficient to induce a substantial vibration of the lower surface  72 . To the extent that a vibration of the lower surface  72  is induced, the sound absorbing layer  78  will compress and expand in response to the vibrations to dampen the remaining vibrations.  
         [0072]    The lid construction also stops the propagation of the sound from the wash chamber. Any sound that passes through the vibration-dampening layer is absorbed by the sound absorption layer as previously described.  
         [0073]    The mounting of the upper surface and the lower surface to the frame also enhances the sound-reducing features of the lid. Since the upper surface and the lower surface are mounted to the frame and not to each other, the frame effectively decouples the upper surface and the lower surface for purposes of noise isolation. Therefore, there can be no direct transfer of sound between the upper and lower surfaces.  
         [0074]    While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.