Patent Publication Number: US-10321797-B2

Title: Pump plate for conditioning fluid flow in a dishwasher

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a national stage application, filed under 35 U.S.C. § 371, of International Application No. PCT/US2013/053382, filed Aug. 2, 2013, the contents of which are hereby incorporated by reference in its entirety. 
     FIELD 
     Embodiments of the present invention relate to dishwashing appliances and, more particularly, to systems, methods, and apparatuses for conditioning fluid flow in a dishwasher. 
     BACKGROUND 
     Dishwashers have become an integral part of everyday household use. Consumers place dishware and other utensils onto dishwasher racks inside dishwashers for cleaning. Dishwashers typically clean the dishware with wash systems that utilize spray arms and spray jets to propel water and/or wash fluid onto the dishware to remove food particles and otherwise clean the dishware. 
     Dishwashers typically comprise a sump in the base of the dishwasher tub. The wash fluid in the dishwasher runs down inside of the dishwasher tub and collects in the sump. A circulation pump then recirculates the collected wash fluid through one or more spray arms inside the dishwasher. For the circulation pump to efficiently recirculate the wash fluid, it is important to prevent air and/or vapor from entering the pump (i.e., starving or cavitating the pump). Therefore, during operation, the inlet of the circulation pump is fully submerged (e.g., covered) by a minimum level of wash fluid to ensure that air and/or vapor doesn&#39;t enter the circulation pump inlet. 
     Energy and water conservation is important and, thus, there is a desire to reduce the amount of water used in dishwashers. However, simply reducing the amount of water used by a dishwasher reduces the amount of wash fluid available for sufficiently submerging the inlet to the circulation pump. As noted above, if the fluid level at the circulation pump inlet is not sufficient, the circulation pump will starve to some degree, causing the circulation pump to work inefficiently and/or fail. Indeed, in some cases, a large volume of wash fluid is needed to ensure that the fluid level at the circulation pump inlet remains sufficient at all times during operation. This is due to the fact that, during operation, wash fluid may be spread throughout the dishwasher tub (e.g., in the circulation system, in the spray arms, in upside down dishware, running down the dishwasher tub, etc.). In some embodiments, the fluid height at the pump inlet can provide the pressure necessary at the circulation pump inlet to prevent cavitation by keeping the pressure along the blades of the impeller above the vapor pressure. Increased fluid height at the circulation pump inlet also helps to avoid the formation of vortices in the fluid that can draw vapor down into the pump inlet, a process called carry under. These vortices can be formed where fluid acceleration into and near the circulation pump inlet is relatively high and the available pressure, due to fluid height, is not sufficient to prevent the vapor from being drawn down into the fluid. As the fluid height increases the buoyant force available for lifting vapor up through the fluid to escape or to prevent it from being drawn down into the wash fluid to the circulation pump inlet is increased. The actual volume of wash fluid necessary to achieve the required fluid height is dependent upon the geometry below the fluid level, especially that of the sump and tub. 
     In a dishwasher, the wash fluid is sprayed onto the dishware by one or more spray arms. The wash fluid then drips off the dishware and/or runs down the sides of the tub to the bottom of the tub and into the sump. Due to the nearly infinite number of possible dishware configurations within the dishwasher, the flow of the wash fluid into the sump of the dishwasher is difficult to predict. In this regard, air may enter the fluid returning to the pump in a variety of ways. This includes at least the aeration that may occur as fluid passes through a filter mesh and the entrainment of air in the fluid due to the capture of air during unbounded flow, as in the case of flow over an obstruction like a rib or ledge or the crashing of waves droplets or streams into the fluid surface. Wash fluid flowing from different parts of the tub tends to carry various angular and linear momentums in various directions, resulting in a turbulent flow. The turbulence of the fluid flow can pull air downwards and thus works against the natural buoyant forces that would otherwise cause the air to rise up and out of the fluid. Turbulence may also result in fluid momentum in directions that are opposed to what the circulation pump is designed to create and that are, by definition, not the preferred, laminar flow. Turbulent flow may also contribute to the creation of vortices that pull air and/or vapor down into the pool at the circulation pump inlet, increasing the air and/or vapor passing through the circulation pump. Unsteady and turbulent flow can also result in an uneven fluid surface height with the low points being more susceptible to the creation of vortices that can cause carry under. 
     BRIEF SUMMARY 
     Embodiments of the present invention dissipate the random angular and linear momentum components in the fluid flow in order to settle the wash fluid prior to entrance into the circulation pump inlet by way of a pump plate as described herein. The pump plate for conditioning fluid flow in a dishwasher described herein reduces the turbulence in the flow of wash fluid in the sump of a dishwasher thereby increasing fluid flow efficiency and also allowing a dishwasher to function with less water while maintaining efficient operation of the circulation pump. 
     In various embodiments, the pump plate comprises a plate portion defining a first surface and a second surface. A plurality of holes may be defined in the plate portion and may extend between the first surface and the second surface. The plurality of holes may be dispersed across the plate portion and configured to allow fluid to pass through the plate portion. The pump plate may further include at least one first upper guide vane extending outwardly from the first surface and at least one second upper guide vane extending outwardly from the first surface. The at least one second upper guide vane may intersect with the at least one first upper guide vane. 
     In some embodiments, the pump plate further includes a first lower guide vane extending outwardly from the second surface. The first lower guide vane defines a first side and a second side. The pump plate may further include a second lower guide vane extending outwardly from the first side and the second side of the first lower guide vane. The second lower guide vane may extend in a plane that is perpendicular to the first lower guide vane and parallel to the plate portion. 
     In some embodiments, the at least one first upper guide vane comprises a plurality of upper guide vanes. In some such embodiments, at least two of the plurality of first upper guide vanes extend outwardly from the plate portion at different heights and/or at least two of the plurality of first upper guide vanes extend along the plate portion to define different lengths. 
     In some embodiments, the at least one first upper guide vane and the at least one second upper guide vane are perpendicular to the first surface. 
     In some embodiments, the at least one first upper guide vane comprises a plurality of first upper guide vanes, and the at least one second upper guide vane comprises a plurality of second upper guide vanes 
     In some embodiments, two of the plurality of first upper guide vanes are spaced apart and each intersect with one of the second upper guide vanes to form a channel. The channel may be configured to align with at least one of the plurality of holes defined in the plate portion such that fluid is conditioned to flow through the channel and the at least one of the plurality of holes aligned with the channel. In some embodiments, the plurality of first upper guide vanes and the plurality of second upper guide vanes may intersect to form a plurality of channels. Each channel may be configured to align with at least one of the plurality of holes defined in the plate portion such that fluid is conditioned to flow through the channel and the at least one of the plurality of holes aligned with the channel. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIG. 1  is a perspective view of a dishwasher, in accordance with some embodiments discussed herein; 
         FIG. 2  is a perspective view of an example sump, in accordance with some embodiments discussed herein; 
         FIG. 3  is a perspective view of an example pump plate for conditioning fluid flow preceding a circulation pump inlet, in accordance with some embodiments discussed herein; 
         FIG. 4  is perspective view of another example pump plate for conditioning fluid flow preceding a circulation pump inlet, in accordance with some embodiments discussed herein; 
         FIG. 5  is a perspective view of the pump plate shown in  FIG. 3  installed in the sump shown in  FIG. 2 , in accordance with some embodiments discussed herein; 
         FIG. 6  is a cross-sectional view of the pump plate and sump shown in  FIG. 5  taken along line AA of  FIG. 5 , in accordance with some embodiments discussed herein 
         FIG. 6A  is a cross-sectional view of another example pump plate installed in the sump shown in  FIG. 5  taken along line AA of  FIG. 5 , in accordance with some embodiments discussed herein; and 
         FIG. 7  is a cross-sectional view of the pump plate shown in  FIG. 4  installed in the sump shown in  FIG. 2 , in accordance with some embodiments discussed herein. 
     
    
    
     DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS 
     The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. 
       FIG. 1  illustrates an example of a dishwasher  10  capable of implementing various embodiments of the present invention. Such a dishwasher  10  typically includes a tub  12  (partly broken away in  FIG. 1  to show internal details), having a plurality of walls (e.g., side wall  13 ) for forming an enclosure in which dishes, utensils, and other dishware may be placed for washing. As known in the art, the dishwasher  10  may also include slidable lower and upper racks (not shown) for holding the dishes, utensils, and dishware. A door  18  may be pivotably engaged with the tub  12  to selectively permit access to the interior of the tub  12 . The door  18  may be configured to close in order to cover and seal the tub  12  when the dishwasher is in operation. 
     The tub  12  may include a sump  14  in which wash fluid or rinse fluid (herein collectively referred to as wash fluid) is collected, typically under the influence of gravity. The wash fluid may be pumped by a circulation pump  50  (such as through circulation conduit  26 ) to one or more spray arms (e.g., lower spray arm  20  and/or middle spray arm  25 ) mounted in the interior of the tub  12  for spraying the wash fluid, under pressure, onto the dishes, utensils, and other dishware contained therein. 
     The dishwasher  10  may also comprise a controller  40  that may be in communication with one or more of the operational components of the dishwasher  10 . For example, the controller  40  may be in communication with the circulation pump  50  and may be configured to selectively operate the circulation pump  50  to pump wash fluid to at least one spray arm and/or spray jet. In some embodiments, the controller  40  may comprise a processor or other computing means such that operations can be performed in the dishwasher. Additionally or alternatively, the controller  40  may comprise a memory for storage of data such as routines for operation of the dishwasher  10 . In some embodiments, the controller  40  may be housed in the lower end  22  of the dishwasher  10 . 
       FIG. 2  illustrates an example sump  14  that may be used in the dishwasher  10  capable of implementing various embodiments of the present invention. The inlet  51  to the circulation pump  50  may be disposed in the sump  14 . In the example sump  14  shown in  FIG. 2 , a flow inlet channel  52  for collecting wash fluid may precede the pump inlet  51 . As further explanation, the illustrated circulation pump  50  includes the circulation pump body and the volute cover. 
     During normal operation of the dishwasher  10 , the circulation pump  50  directs (e.g., pumps) wash fluid to one more spray arms  20 ,  25 . For example, the circulation pump  50  may define an impeller (e.g., the closed vane impeller shown in  FIG. 6 ) that draws in wash fluid by the creation of low pressure (e.g., suction). The circulation pump  50  creates an increase in pressure by transferring the mechanical energy from the motor of the circulation pump to the wash fluid through the rotating impeller. In such a manner, a high pressure gradient is created at the circulation pump outlet, which leads to fluid flow within the circulation system (e.g., spray arms  20 ,  25 ). The high pressure gradient drives the wash fluid from the circulation pump inlet to the circulation pump outlet. In particular, fluid is accelerated as it travels along the spinning impeller blades. The flow then enters a volute which has a larger cross sectional area and the velocity is converted to pressure. This pressure drives the fluid through the circulation system. Though the above description details a circulation pump with a closed vane impeller, some embodiments of the present invention contemplate use with a circulation pump with an open vane impeller. 
     The wash fluid then drips off of the dishes, utensils, other dishware, or racks or runs down the side walls  13  into the sump  14 . In some embodiments, as the wash fluid collects in the sump  14 , the wash fluid may pool in the flow inlet channel  52  and the remainder of the sump  14  for submerging the pump inlet  51  below a sufficient height of fluid so as to prevent air and/or vapor from being drawn into the circulation pump  50  during operation. The wash fluid in the flow inlet channel  52  then enters the circulation pump inlet  51  and is pumped through the one or more spray arms  20 ,  25  via the circulation pump  50 . In some embodiments, the designed level of wash fluid for submerging the pump inlet  51  may be determined to be in excess of the minimum requirement to maintain a primed circulation pump and so include an added factor for safety. Additionally, in some embodiments, other factors may be considered for designing the level of wash fluid for submerging the pump inlet  51  (e.g., maintaining pressure conditions, rotation speed of the impeller of the circulation pump, general performance desires, etc.). 
     Though the depicted embodiment shows a circulation pump  50  that is directly mounted to the sump  14 , some embodiments of the present invention contemplate use of a pump plate with a circulation pump that is indirectly mounted to a sump (e.g., the circulation pump body may be mounted external to the sump). For example, the indirectly mounted circulation pump may define an inlet hose and an outlet hose. The inlet hose may lead to the sump  14  and may be configured to receive the wash water from the sump  14  prior to entrance into the circulation pump. In this regard, in some embodiments, reference to the term circulation pump inlet may, in some embodiments, include the inlet hose. Likewise, reference to the area preceding the circulation pump inlet may, in some embodiments, refer to an area within the sump preceding the inlet hose of an indirectly mounted circulation pump. 
     The variety of surfaces the wash fluid may encounter after being sprayed out of the one or more spray arms  20 ,  25  tends to result in a fluid flow comprising a spectrum of angular momentum and linear momentum components. This spectrum of angular and linear momentum components carried by the wash fluid flowing from different parts of the tub  12  contributes to the overall flow of wash fluid within the dishwasher  10  being turbulent. Additionally, there are nearly an infinite number of ways to place dishware within the dishwasher  10 . This results in the flow of the wash fluid into the sump  14  of the dishwasher  10  being turbulent and difficult to predict. The turbulence of the fluid flow causes the wash fluid to take longer to settle into a pool in the sump  14  and contributes to the creation of vortices that can pull air and/or vapor down into the pool, increasing the air and/or vapor being run through the circulation pump  50 . 
     In the past, a large volume of wash fluid has been used to mitigate the effects of the turbulent flow of the wash fluid collecting in the sump  14 . Using a large volume of wash fluid helps nullify the effects of the turbulent flow since a pool of wash fluid is created in the sump  14 . In as much as this pool of wash fluid is large in comparison to the circulation pump  50  flow rate an increased residence time for the wash fluid will result. This increased amount of residence time allows for the turbulence in the flow to dissipate and also provides a still pool of fluid that acts as a damper to the incoming flow streams. The resultant, still pool does not resist the buoyant forces that naturally cause vapor to rise up through the surface of the pool. In this regard, the greater the fluid height above the pump inlet the greater the buoyant force available for driving out the vapor. The circulation pump  50  can then draw in the settled wash fluid available in the pool within the sump  14 . In this way both entrained vapor and conflicting momentum within the pool in the sump  14  are removed from the inlet flow to the circulation pump  50 . Further, the surface of the still pool is relatively smooth and of consistent height and so does not contribute to further vapor entrainment or to the creation of carry under causing vortices. However, if the volume of wash fluid is simply decreased then the portion of the fluid flow that has time to settle before being drawn into the circulation pump is decreased along with the height of fluid available for preventing carry under, for driving vapor up and out of the fluid and for preventing cavitation. The decreased wash fluid level at the pump  50  inlet  51  may not enable efficient or even effective pump operation. Thus, turbulent fluid flow, which may include a significant amount of air and/or vapor that has been entrained by any of a number of means or has been carried under by vortices that pull air from the volume over the wash fluid in the area preceding the inlet  51  may enter the inlet  51  of the circulation pump  50 . Some embodiments of the present invention enable a reduced total amount of water to be used and still provides for mitigating the effects of the turbulent flow of the wash fluid collecting in the sump  14  to allow for efficient operation of the circulation pump  50 . 
     In such a regard, some embodiments of the present invention provide a pump plate for conditioning a fluid flow preceding an inlet of a circulation pump of a dishwasher. As described in greater detail herein, the pump plate may be positioned within the sump of the dishwasher and configured to condition fluid flow so as to settle the wash fluid prior to entrance into the inlet of the circulation pump. Indeed, in some embodiments, the pump plate may define features (e.g., holes, upper guide vanes, lower guide vanes, etc.) that reduce turbulence generation in the wash fluid heading toward the inlet of the circulation pump. For example, in some embodiments, the pump plate may transition the wash fluid to become steadier and more stable such as to create a more laminar flow prior to entrance into the inlet of the circulation pump. Additionally, in some embodiments, the pump plate (such as through its various features) may be configured to reduce noise emanating from the dishwasher due to the conditioning and settling of the fluid flow. 
     With reference to  FIGS. 5 and 6 , an example pump plate  60  may be positioned within the sump  14  of a dishwasher. The position of the pump plate  60  (e.g., the height of the pump plate  60  with respect to the inlet  51  of the circulation pump  50 ) may be designed based on a number of factors, such as the height of the top of the inlet  51  of the circulation pump  50  and the anticipated fluid flow path within the sump and dishwasher. Though the pump plate  60  is shown such that the plate portion  61  of the pump plate  60  lies in a horizontal plane, some embodiments of the present invention contemplate positioning the pump plate such that the plate portion lies at any angle within the sump (e.g., the plate portion  61  may be tilted with respect to the inlet  51  of the circulation pump  50 ). 
       FIG. 3  shows an example pump plate  60  for conditioning a fluid flow preceding an inlet of a circulation pump of a dishwasher, according to various embodiments of the present invention. The pump plate  60  comprises a plate portion  61 . In the embodiment illustrated in  FIG. 3 , the plate portion  61  is substantially planar. In various other embodiments, the plate portion  61  may define any shape (e.g., the plate portion may be convex, concave, stepped, curved, etc.). The plate portion  61  defines a first surface  611  and a second surface  612 . In various embodiments, the first surface  611  may be an upper surface of the plate portion  61  and the second surface  612  may be a lower surface of the plate portion. 
     In some embodiments, the pump plate  60  may further comprise a plurality of holes  62  defined in the plate portion  61 . The plurality of holes  62  may extend between the first and second surfaces  611 ,  612  of the plate portion  61 . In various embodiments, each hole may define different characteristics, such as size (e.g., diameter size), shape (e.g., circular, square, hexagonal, etc.), and surface details. Along these lines, in some embodiments, at least one hole may define different edge characteristics. For example, in some embodiments, at least one of the plurality of holes may have a sharp edge in common with the first surface  611 . In other embodiments, at least one of the plurality of holes may have a chamfered or radiused edge in common with the first surface  611 . Further, in some embodiments, at least one of the plurality of holes may have a sharp edge in common with the second surface  612 . In other embodiments, at least one of the plurality of holes may have a chamfered or radiused edge in common with the second surface  612 . In some embodiments, the edge characteristics may be configured to influence the pressure drop of the fluid flowing through the hole and/or the direction of the fluid flow through the hole (and, thus, pump plate). Additionally, in some embodiments, the edge characteristics may be configured to breakdown vapor bubbles (e.g., the sharp edge may be configured to breakdown a vapor bubble that comes into contact with it). 
     In some embodiments, a hole defined in a pump plate may be positioned around the perimeter of the pump plate such that the profile of the hole is not completely enclosed. In this regard, in some embodiments, the pump plate may define one or more partial holes around its perimeter. Further, in some embodiments, the pump plate may be designed with a gap between the plate portion  61  and the surrounding sump  14 , such as to effectively create a gap for the wash fluid to flow around the pump plate to the circulation pump inlet. 
     The plurality of holes  62  through the plate portion  61  may be configured to allow wash fluid to pass through the pump plate  60 . In this regard, in some embodiments, the plurality of holes may be configured to condition the fluid flowing toward the circulation pump through the pump plate. Along these lines, in some embodiments, the plurality of holes may be configured to help break up air bubbles that form in the wash fluid heading toward the circulation pump inlet  51 . In this regard, an air bubble larger than the hole could be forced to break down in order to pass through the hole, thereby making the smaller air bubbles that are easier to handle by the circulation pump. Along these lines, in some embodiments, the plurality of holes may be configured to condition the fluid flow through the pump plate, thereby reducing noise that is created as the wash fluid heads toward the circulation pump. 
     In various embodiments, the plurality of holes  62  may be uniform in size. Alternatively, the plurality of holes  62  may define a variety of different size holes. In various embodiments, the plurality of holes may be uniformly distributed over plate portion  61  or, in some cases, at least uniformly distributed over at least a portion of the plate portion  61 . In other embodiments, at least a portion of the plurality of holes  62  may be clustered in a region of the plate portion  61  and more sparsely distributed over other regions of the plate portion  61 . In various embodiments, the plurality of holes  62  may pass straight through the plate portion  61 . In such embodiments, the axis of the hole may be perpendicular to the plate portion  61 . In other embodiments, one or more of the plurality of holes  62  may pass through the plate portion  61  at an angle such that the axis of the hole is not perpendicular to the plate portion. This may be advantageous, for example, in directing the fluid flow more towards the pump inlet. 
     In some embodiments, variables concerning the holes (e.g., the number of holes, the size of the holes, the location of the holes on the pump plate, and/or the axis of the holes) may be determined based on the desired effect on the fluid flow within the dishwasher tub preceding the inlet of the circulation pump. For example, such variables may be determined to allow a maximum fluid volume to transfer through the pump plate with the least amount of pressure loss. In such a regard, the maximum fluid volume may be available immediately to the inlet of the circulation pump with a path of least resistance. In another example embodiment, the variables concerning the holes may be determined based on the desire to achieve a uniform velocity profile across the surface (e.g., the plate portion  61 ) defined by the pump plate  60  so as not to encourage the formation of a vortex. In still another example embodiment, the variables concerning the holes may be determined based on the resultant shear force that can be created to break down larger vapor bubbles. 
     Remaining with  FIG. 3 , the pump plate  60  may further comprise at least one upper guide vane  63  extending outwardly from the first surface  611  of the plate portion  61 . In some embodiments, the pump plate  60  may comprise at least one first upper guide vane  631  extending outwardly from the first surface  611  of the plate portion  61  and at least one second upper guide vane  632  extending outwardly from the first surface  611  of the plate portion  61  and intersecting with the at least one first upper guide vane  631 . In some embodiments, the at least one first upper guide may intersect with at least one second upper guide vane at an approximately 90 degree angle (e.g., the first upper guide vane may be perpendicular to the second upper guide vane). With reference to  FIG. 3 , in some embodiments, the first upper guide vane extends up to (and not past) a second upper guide vane (see e.g., the intersection of first upper guide vane  631  and second upper guide vane  632 ). In some embodiments, such a configuration is considered to be “intersecting,” as the term “intersecting” is not meant to be limited to upper guide vanes extending past each other (see e.g., the intersection of first upper guide vane  633  and second upper guide vane  634 ). In various embodiments, the at least one upper guide vane  63  may be configured to destroy and/or prevent the formation of vortices within the fluid flow. In various embodiments, the at least one upper guide vane may also be configured to impart a desired direction to the fluid flow. 
     In various embodiments, the pump plate  60  may comprise a plurality of first and/or second upper guide vanes  63 . In various embodiments, at least some of the upper guide vanes  63  may extend outwardly from the plate portion  61  at different heights. For example, in the embodiment shown in  FIG. 3 , upper guide vanes  631  and  632  are taller than upper guide vanes  633 ,  634 ,  635 , and  636 . Further, in some embodiments, at least some of the upper guide vanes may each define varying heights by themselves. For example, with reference to  FIG. 6A , the upper guide vane  63 ′ defines a height that tapers (e.g., from generally the center of the pump plate  60  to the perimeter). In various embodiments, at least some of the upper guide vanes  63  may extend along the plate portion to define different lengths. For example, in the embodiment shown in  FIG. 3 , upper guide vanes  631  and  633  are longer than upper guide vanes  632 ,  634 ,  635 , and  636 . In various embodiments, the use of different heights, varying heights, and/or different lengths of the upper guide vanes  63  may enable efficient destruction and/or prevention of the formation of vortices within the fluid flow. Indeed, in some embodiments, the different heights, varying heights, and/or different lengths of the upper guide vanes may enable a tiered approach to destruction and/or prevention of the formation of vortices such that the turbulent fluid flow more rapidly settles. 
     In some embodiments, the height of each upper guide vane may be designed based on the anticipated fluid flow inside the dishwasher tub and sump. In this regard, the tallest upper guide vane may, in some embodiments, be located on the pump plate in a position that corresponds to the anticipated location of a primary vortex within the fluid flow. In this regard, the tallest upper guide vane may be designed and specifically located so as to destroy and/or prevent formation of the primary vortex within the fluid flow. Additionally, in some embodiments, additional (e.g., secondary) upper guide vanes of lesser height may be located on the pump plate extending outwardly from the tallest upper guide vane. Such secondary upper guide vanes may be designed and specifically located so as to destroy and/or prevent formation of secondary vortices that are anticipated to form upon destruction of the primary vortex by the tallest upper guide vane. In such a manner, in some embodiments, the pump plate can be designed to counteract anticipated turbulence within the fluid flow for the specific dishwasher in which it is being used. Likewise, the varying height and/or length of each upper guide vane may be designed based on the anticipated fluid flow inside the dishwasher tub and sump so as to counteract anticipated turbulence within the fluid flow for the specific dishwasher in which it is being used. Likewise, the varying height and/or length of each upper guide vane may be based on a desire to limit flow restriction and pressure drop. 
     For example, with reference to  FIG. 3 , the pump plate  60  includes a tallest first upper guide vane  631  that is specifically located (e.g., in the center of the area preceding the circulation pump inlet  51 , which is shown in  FIG. 6 ). Additionally, the pump plate  60  includes secondary first upper guide vanes  633  and  635  that each extend upward at a shorter height than the tallest first upper guide vane  631  and are each located on the pump plate  60  outwardly from the location of the tallest first upper guide vane  631 . Similarly, the pump plate  60  includes a similar configuration for the second upper guide vanes (e.g., a tallest second upper guide vane  632  and secondary second upper guide vanes  634  and  636 ). Further, as shown in  FIG. 3 , in some embodiments, the configuration in height, length, or location of the first and/or second upper guide vanes may be symmetrical on the pump plate. 
     The example pump plate  60  shown in  FIG. 3  includes just one example of a configuration of height, length, and location for the first and second upper guide vanes. In such a regard, some embodiments of the present invention contemplate any type of configuration such that the pump plate may be designed with first and/or second upper guide vanes that define varying or different heights, lengths, or locations. For example, the upper guide vanes may define different heights from each other. Additionally or alternatively, the location of each upper guide vane may vary. Further, the number of first and/or second upper guide vanes may also vary. Along these lines, in some embodiments, the configuration in height, length, or location of the first and/or second upper guide vanes may be asymmetrical on the pump plate. In such a regard, the illustrated example pump plate  60  is not meant to be limiting and is provided as an example of how a pump plate contemplated by the present invention may be designed to counteract and settle the fluid flow of a specific dishwasher (e.g., with specific components and a specific anticipated fluid flow within the tub and sump). 
     In various embodiments, the at least one upper guide vane  63  extends outwardly from the plate portion  61 , such that the angle between the plate portion  61  and each upper guide vane  63  is greater than about 0 degrees and less than or equal to about 90 degrees. In various embodiments, the at least one upper guide vane  63  may be perpendicular to the first surface  611  of the plate portion  61 . In various embodiments in which the upper guide vane  63  is perpendicular to the plate portion  61 , the upper guide vane  63  may provide a larger surface area for momentum dissipating collisions with various portions of the turbulent fluid flow, allowing the upper guide vane  63  to more efficiently dissipate various components of angular or linear momentum within the fluid flow. In some embodiments, the at least one upper guide vane  63  may extend from the first surface of the plate portion  61  at an angle other than 90 degrees (e.g., 35 degrees, 45 degrees, etc.). For example, in some embodiments, the at least one upper guide vane may be tilted relative to the plate portion  61 . In such embodiments, the at least one upper guide vane may be tilted so as to direct the fluid flow into the plate portion  61  (e.g., toward at least one of the plurality of holes positioned on the plate portion  61 ) such that the fluid flows more rapidly through the plate portion  61  toward the inlet  51  of the circulation pump  50 . 
     In various embodiments, wherein the pump plate  60  comprises a plurality of first guide vanes  631  and/or a plurality of second guide vanes  632 , two first upper guide vanes  631 ,  635  may be spaced apart from each other and each intersect with one second upper guide vane  632  (or one first upper guide vane  631  and two second upper guide vanes  632 ,  634 ) to define a channel  64 . For example, in the embodiment shown in  FIG. 3 , first upper guide vanes  631  and  635  and second upper guide vane  632  define a channel  64 . In various embodiments, the channel  64  may be configured to align with at least one of the plurality of holes  62 . Thus, a portion of the fluid flow may enter the channel  64  and interact with upper guide vanes  631 ,  632 , and/or  635 . By interacting with upper guide vanes  631 ,  632 , and/or  635 , the portion of the fluid flow flowing into the channel  64  may dissipate angular and/or linear momentum in one or more directions, allowing that portion of the fluid flow to pass through the at least one of the plurality of holes  62  aligned with the channel  64 . As described in greater detail herein, in some embodiments, the upper guide vanes may be configured to interact with the fluid flowing toward the circulation pump to destroy and/or prevent formation of vortices therein. In this regard, an upper guide vane may break down a large vortex into smaller vortices. Further, in some embodiments, additional upper guide vanes may then further break down the now smaller vortices, thereby conditioning the fluid flow prior to passing through the pump plate and ultimately into the circulation pump. 
     Additionally, in various embodiments, the channel  64  is configured such that the channel is not closed. For example, the channel  64  may be defined by only three upper guide vanes (e.g., upper guide vanes  631 ,  635 , and  632 ), allowing wash fluid flowing along the first surface  611  of the plate portion  61  to flow into the channel  64 . Indeed, in some embodiments, if a channel is configured such that the channel is closed, the closed channel may encourage the formation of a vortex and thereby increase the amount of air and/or vapor that is passed into the circulation pump  50 . 
     In various embodiments, a plurality of first and/or second upper guide vanes  63  may intersect to form a plurality of channels  64 , wherein each channel is configured to align with at least one of the plurality of holes  62 . Each channel  64  may be configured to dissipate angular and/or linear momentum of a portion of the fluid flow that flows into the channel  64 , allowing that portion of the fluid flow to pass through the at least one of the plurality of holes  62  aligned with that channel  64 . By including multiple channels  64 , the pump plate  60  may condition the flow of fluid in the dishwasher  10  more efficiently. 
     In some embodiments, the pump plate  60  may further comprise at least one attachment feature  65 . The attachment feature  65  may be a projection with an opening for securement within the dishwasher. In various embodiments, the attachment feature  65  may be used to secure the pump plate  60  within the dishwasher  10 . For example, the at least one attachment feature  65  may be configured to secure the pump plate  60  into the sump  14  of the dishwasher  10 . In various embodiments, such as the embodiment shown in  FIG. 5 , the at least one attachment feature  65  may be configured to attach to a portion of the dishwasher  10  to secure the pump plate  60  within the dishwasher  10  such that the pump plate  60  fluidly-encloses an area preceding the inlet  51  of the circulation pump  50  such that the fluid within the dishwasher  10  flows through the pump plate  60  prior to entering the inlet  51  of the circulation pump  50 . In various embodiments in which the area preceding the inlet  51  of the circulation pump  50 , including, for example, the flow inlet channel  52 , is fluidly-enclosed by the pump plate  60 , all or most of the fluid flow entering flow inlet channel  52  may be conditioned by the pump plate  60 . Therefore, after interacting with the pump plate  60 , the turbulence in the fluid flow may be significantly dissipated prior to entrance into the area preceding the circulation pump inlet  51 . 
     In various embodiments, a pump plate may further comprise at least one lower guide vane. As shown in  FIG. 4 , in some embodiments, the pump plate  60  may comprise a plurality of lower guide vanes  66 . For example, the lower guide vanes  66  may comprise a first lower guide vane  661  extending outwardly from the second surface of the plate portion  61 . The first lower guide vane  661  may define a first side and a second side. In various embodiments, the lower guide vanes  66  may further comprise a second lower guide vane  662  extending outwardly from the first side and the second side of the first lower guide vane  661  such that the second lower guide vane  662  extends in a plane that is perpendicular to the first lower guide vane  661  and parallel to the plate portion  61 . Thus, in various embodiments, the lower guide vanes  66  may appear as a “+”-shaped appendage extending outwardly from the second surface of the plate portion  61 . In some embodiments, with reference to  FIG. 7 , the lower guide vanes  66  may be configured to align with the circulation pump inlet  51 . The lower guide vanes  66  may be configured to further condition the fluid flow before the fluid flow enters the inlet  51  to the circulation pump  50 . For example, the lower guide vanes  66  may be configured to further dissipate any linear or angular momentum components remaining in the fluid flow that are not parallel to the axis of the inlet  51 . Though the example embodiment of the lower guide vanes  66  described above intersect perpendicularly to define a “+”-shaped appendage, some embodiments of the present invention contemplate any configuration and/or shape of lower guide vanes that extend from the plate portion of the pump plate (e.g., the lower guide vanes may each extend outwardly from the plate portion, the lower guide vanes may intersect at a different angle, more than two lower guide vanes may be used, etc.). 
     In various embodiments, a pump plate  60  may be molded as a single component. For example, a pump plate  60  comprising a plate portion  61 , a plurality of holes  62 , at least one upper guide vane  63 , and at least one attachment feature  65  may be integrally molded. In another example, a pump plate  60  comprising a plate portion  61 , a plurality of holes  62 , a plurality of upper guide vanes  63 , at least one channel  64 , and at least one attachment feature  65  may be integrally molded. In yet another example, a pump plate  60  comprising a plate portion  61 , a plurality of holes  62 , at least one upper guide vane  63 , lower guide vanes  66 , and at least one attachment feature  65  may be integrally molded. Thus, in such embodiments, a pump plate  60  may be manufactured easily and inexpensively. Moreover, in such embodiments, a pump plate  60  may be easily installed in a dishwasher  10  and, as the pump plate  60  comprises only one piece, may require minimal maintenance. In various embodiments, a pump plate  60  may be molded out of plastic or constructed of some other appropriate material. 
     Reference will now be made to  FIGS. 5, 6, and 7 .  FIGS. 5-7  illustrate various embodiments of an example pump plate  60  positioned within an example sump  14  of a dishwasher  10 . In various embodiments, the pump plate  60  may be secured in a dishwasher  10 , possibly via the at least one attachment device  65 , such that the pump plate  60  fluidly encloses an area preceding the inlet  51  of the circulation pump  50  such that fluid within the dishwasher flows through the pump plate  60  prior to entering the inlet  51  of the circulation pump  50 . 
     As previously described herein, the unconditioned flow of wash fluid into the sump  14  of a dishwasher may comprise a spectrum of angular momentum and linear momentum components. In some embodiments, the various momentums should be dissipated for the wash fluid to settle into the flow inlet channel  52  to efficiently feed the circulation pump  50  through inlet  51 . Indeed, as the wash fluid runs down the dishwasher tub into the sump  14 , vortices may be created that can cause air and/or vapor to be pulled into the flow of wash fluid. This occurrence can be referred to as carry under and it reduces the efficiency of the circulation pump  50 . The pump plate  60  may act to reduce the turbulence in the flow of wash fluid before the wash fluid reaches the inlet  51 , therefore providing a consistent supply of wash fluid to the circulation pump  50  while minimizing and/or reducing carry under. 
     In some embodiments, the pump plate  60  comprises a plurality of holes  62 . In various embodiments wherein the pump plate  60  fluidly-encloses an area preceding the inlet  51 , the wash fluid may pass through the plurality of holes  62  to reach the flow inlet channel  52  and/or the inlet  51 . As the wash fluid reaches the pump plate  60 , portions of the fluid flow with a linear momentum having a significant downward component may pass through at least one of the plurality of holes  62 . However, a majority of portions of the fluid flow with significant momentum components in a direction other than downward, may travel across the first surface  611  of the pump plate  60 , colliding with other portions of the fluid flow or components of the dishwasher (e.g., the walls of the sump  14  or the like). These collisions may act to dissipate various momentums within the fluid flow. As the non-downward momentum components in various portions of the fluid flow are reduced, those portions of the fluid flow may pass through at least one of the plurality of holes  62 . 
     In some embodiments, the size of the plurality of holes  62  may offer some control over the maximum and/or average non-downward momentum that a portion of the fluid flow may have and still pass through at least one of the plurality of holes  62 . For example, the maximum and/or average non-downward momentum component of a portion of the fluid flow passing through a plurality of holes with a smaller diameter may be less than the maximum and/or average non-downward momentum component of a portion of the fluid flow passing through a plurality of holes with a larger diameter. However, in some embodiments, it may be beneficial to define the diameter of each of the plurality of holes  62  to be large enough in size to allow a sufficient flow rate of wash fluid through the pump plate  60  to feed the circulation pump  50 . Additionally or alternatively, in some embodiments, it may be beneficial to define a certain number of holes with the plate portion to allow a sufficient flow rate of wash fluid through the pump plate  60  to feed the circulation pump  50 . 
     In various embodiments, the ratio of the combined surface area of the plurality of holes  62  to the surface area of the inlet  51  may be configured to minimize the maximum and/or average non-downward momentum components of the portions of the fluid flow passing through the plurality of holes  62  while still allowing a sufficient flow rate of wash fluid through the pump plate  60 . In some embodiments, the ratio of the combined surface area of the plurality of holes  62  to the surface area of the inlet  51  is about 1.7. 
     The pump plate  60  may further comprise at least one upper guide vane  63 . In various embodiments, the at least one upper guide vane  63  may be configured to dissipate momentum components of the fluid flow and destroy and/or prevent formation of vortices in the flow of wash fluid. In various embodiments, portions of the fluid flow carrying angular and/or linear momentum may collide with the at least one upper guide vane  63 . The collision between the fluid flow and the at least one upper guide vane  63  may cause dissipation of angular and/or linear momentum within the fluid flow. By reducing the angular momentum carried by the wash fluid, the upper guide vanes  63  may destroy and/or prevent formation of vortices within the fluid flow and reduce carry under within the fluid flow, thereby reducing the amount of air and/or vapor entering the pump inlet  51 . Thus, the at least one upper guide vane  63  may increase the efficiency of the circulation pump  50 . 
     In various embodiments, the pump plate  60  may comprise at least one first upper guide vane  631  and at least one second upper guide vane  632 . As described above, one or more first upper guide vanes  631  and one or more second upper guide vanes  632  (e.g., first upper guide vanes  631  and  635  and second upper guide vane  632 ), may define a channel  64 . At least one of the plurality of holes  62  may be aligned with the channel  64 . In various embodiments, as the fluid flow travels across the pump plate  60 , a portion of the fluid flow may flow into the channel  64 . Eventually, a portion of the fluid flow flowing into the channel  64  may collide with at least one of the upper guide vanes  63  (e.g.,  631 ,  632 , and/or  635 ) that define the channel  64 , causing the portion of the fluid flow to dissipate at least some of the angular and/or linear momentum carried by that portion of the fluid flow. When the angular and/or linear momentum of the portion of the fluid flow is sufficiently depleted, the portion of the fluid flow may pass through the at least one of the plurality of holes  62  aligned with the channel  64 . Thus, in various embodiments, a channel  64  may cause at least a portion of the fluid flow to dissipate angular and/or linear momentum and may direct that portion of the fluid flow to pass through the at least one of the plurality of holes  62 . 
     As noted herein, in some embodiments, the pump plate  60  may be configured to reduce the linear and/or angular momentum carried by wash fluid collecting in the area preceding the inlet  51  of the circulation pump  50  (e.g., the flow inlet channel  52 ). By calming the flow of wash fluid before the wash fluid reaches the flow inlet channel  52 , an overall reduction in water may be achieved while still maintaining efficient use of the circulation pump  50 . Indeed, in some embodiments, the volume of water used by dishwasher  10  to complete a wash or rinse cycle may be reduced by the use of pump plate  60  to condition the flow of wash fluid because the wash fluid collects in the flow inlet channel  52  preceding the inlet  51  of the circulation pump  50  in an improved state. By providing the circulation pump  50  with a consistent, conditioned flow of wash fluid, a pump plate  60  may allow the circulation pump  50  to function efficiently while reducing the volume of water needed by dishwasher  10  to complete a wash or rinse cycle. 
     In various embodiments, with reference to  FIG. 7 , the flow of wash fluid into the inlet  51  of the circulation pump  50  may be further conditioned through the use of a pump plate  60  comprising lower guide vanes  66 . The lower guide vanes  66  may be suspended below the pump plate  60  and precede the inlet  51  of the circulation pump  50 . Thus, in such embodiments, at least a portion of wash fluid may pass through the lower guide vanes  66  before entering the inlet  51  of the circulation pump  50 . In various such embodiments, the lower guide vanes  66  may act to further straighten the flow of wash fluid entering the circulation pump inlet  51 . For example, if at least a portion of the flow of wash fluid comprises an angular momentum component, the portion of wash fluid may collide with at least one of the lower guide vanes  66  before entering the pump inlet. The collision of the portion of the fluid flow with at least one of the lower guide vanes  66  may reduce the amount of angular momentum carried by the portion of the fluid flow. Thus, in various embodiments of a pump plate  60  comprising lower guide vanes  66 , the lower guide vanes  66  may be configured to further reduce the angular momentum carried by the flow of wash fluid as the flow of wash fluid approaches the circulation pump inlet  51 . As such, the lower guide vanes  66  may allow the pump plate  60  to further condition the flow of wash fluid entering the circulation pump  50  via inlet  51 . Therefore, in some embodiments, a dishwasher  10  comprising a pump plate  60  comprising lower guide vanes  66  may require a smaller volume of water to complete a wash or rinse cycle than a dishwasher not comprising a pump plate while maintaining efficient functioning of the circulation pump  50  due to the consistent, conditioned flow of wash fluid with a minimized volume of air and/or vapor entrained within the fluid flow provided to the circulation pump  50  via inlet  51 . 
     Remaining with  FIGS. 5, 6, and 7 , a method for manufacturing a dishwasher comprising a pump plate  60  shall now be described. In various embodiments, the method of manufacturing may comprise providing a pump plate  60 . In various such embodiments, pump plate  60  may comprise a plate portion  61  defining a first surface  611  and a second surface  612 . A plurality of holes  62  may be defined in the plate portion and may extend between the first surface  611  and the second surface  612 . The plurality of holes may be dispersed across the plate portion and configured to allow fluid to pass through the plate portion  61 . The pump plate  60  may further comprise at least one upper guide vane  63  extending outwardly from the first surface  611 . In various embodiments, the at least one upper guide vane  63  may comprise at least one first upper guide vane  631  extending outwardly from the first surface  611  and at least one second upper guide vane  632  extending outwardly from the first surface  611  and perpendicular to the at least one first upper guide vane  631 . 
     In various embodiments, the pump plate  60  may be secured within the dishwasher  10 . In such a regard, in some embodiments, the method of manufacturing may comprise securing the pump plate within a dishwasher. For example, in some embodiments, the pump plate  60  may comprise at least one attachment feature  65  that may be used to secure the pump plate within the dishwasher  10 . In some embodiments, the pump plate  60  may be secured within the sump  14  of dishwasher  10 . In various embodiments, the pump plate  60  may be secured within the dishwasher  10  to fluidly-enclose an area preceding the inlet  51  of the circulation pump  50  such that fluid within the dishwasher flows through the pump plate prior to entering the inlet of the circulation pump. As noted above, in some embodiments, the pump plate  60  may be specifically designed to include a gap between the perimeter of the pump plate  60  and the surrounding surfaces of the sump to enable fluid to flow around the pump plate (and, in some cases, act in similar fashion to a hole in the pump plate). In various embodiments, the pump plate  60  may be secured within dishwasher  10  in a factory setting. In other embodiments, the pump plate  60  may be secured within dishwasher  10  in a warehouse or retail store setting. In still other embodiments, the pump plate  60  may be secured within the dishwasher  10  in a residential or commercial setting where the dishwasher may be used. 
     Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included herein. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.