Patent Publication Number: US-6666218-B2

Title: Universal shelving system and method of use

Description:
This application claims the benefit of Provisional Application No. 60/181,440 filed Feb. 10, 2000. 
     This application is a divisional of application Ser. No. 09/777,447, filed Feb. 6, 2001, now U.S. Pat. No. 6,571,812. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to the cleaning and decontamination art. It finds particular application in the washing, sterilizing and disinfecting apparatus typically employed to clean, sterilize and disinfect laboratory glassware, such as volumetric flasks, beakers, test tubes, and the like, and will be described with particular reference thereto. It will be appreciated, however, that the invention may be applicable to a wide variety of apparatus used in sanitizing. 
     Flasks, beakers, test tubes and other glassware which are commonly used in laboratories are thoroughly cleaned after use in order to remove deposits which could contaminate materials subsequently contained in the glassware. Glassware is often cleaned manually with a brush. However, this manual procedure is generally undesirable because it requires considerable time and effort which could be spent on more productive tasks. 
     To minimize manual cleaning time, several laboratory glassware washing machines have been introduced. Known laboratory glassware washing machines operate analogous to household dishwashers wherein glassware is inverted and the mouth and neck are received by a spindle extending vertically from a rack. The rack is selectively moveable in and out of a washing chamber of the machine. Optionally, a second slidable rack is provided above the first rack for accommodating additional glassware. At least one spray arm is typically located beneath the rack which applies upwardly directed wash and rinse sprays for washing and rinsing the glassware. Heated air for drying the glassware is circulated within the washer chamber during the drying cycle. 
     Although this type of machine effectively cleans and dries a variety of different types of glassware articles, it has some drawbacks. Beakers, flasks, test tubes and other types of glassware come in many different sizes and shapes. For example, test tubes are generally smaller in width and height than beakers. In addition, graduated cylinders are manufactured having a wide range of heights and diameters. Flasks and beakers are typically enlarged at bottom portions and require more room when being washed. Known glassware washing machines are typically configured to accommodate only a limited range of sizes and configurations of beakers, flasks and test tubes. 
     As already noted, known glassware washing machines typically have racks which are slidable in and out of the washing chamber. Spindles extend vertically upward from the racks and receive the mouth and neck of the glassware. The height of the spindle directly relates to the height of the particular glassware to be washed. For example, a tall piece of glassware is typically received by a relatively tall spindle for adequate support during glassware washing operations. In contrast, a shorter piece of glassware is placed on a shorter spindle. Moreover, glassware with larger diameters, such as bulb shaped flasks, need additional spacing between adjacent spindles. Known glassware washing machines generally include a series of evenly spaced spindles having a uniform height. As such, these devices do not efficiently accommodate the needs of glassware articles having differing sizes and shapes. 
     To overcome the foregoing shortcomings, one known device is manufactured having a removable and replaceable rack system. Such a system allows an operator to choose from multiple complete racks each having spindles designed to receive a particular size of glassware. Therefore, the washer is adapted to sanitize multiple sizes of glassware. Although this device is capable of washing several sizes and shapes of glassware, it does so in separate washing cycles and therefore is not capable of washing differing articles at the same time. This has obvious efficiency problems due to the increased time which elapses during the several washing intervals. 
     In addition, washers of the foregoing nature are relatively large and constructed of heavy material. Because the racks are bulky and awkward, they are difficult to handle during changing periods and often require the work of at least two people. Additional workers add to the cost operation and slow the changeover process. 
     Additional problems are created when glassware washing machines are constructed with two or more levels of racks. If the height of a glassware article is greater than the spacing between the top and bottom rack or the spacing between the top rack and the top of the washing chamber, the washer will be unable to clean the article. The work may be done manually or the top rack can be removed to provide additional height for larger articles. However, removing the top rack cuts the capacity in half. When there are only one or a few tall articles, significant washing potential is lost. Such a device may again need additional workers to remove the heavy and awkward top shelf. 
     The present invention provides a new and improved construction which overcomes the above-referenced problems and others. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention, a decontamination unit comprises a washing chamber defined by a series of walls. A first shelf is mounted within the washing chamber. The first shelf has at least one washing section for receiving and supporting articles to be cleaned during operation of the decontamination unit. A second shelf is slidably mounted within the washing chamber vertically above the first shelf. The second shelf has at least two shelf sections that are operatively associated. At least one of the shelf sections is selectively detachable from the second shelf and removable from the washing chamber so that additional space may be provided for larger articles that need to be decontaminated. 
     In accordance with another aspect of the present invention, a shelving assembly for a decontamination unit comprises a shelf having at least two shelf sections that are operatively associated. Each of the two shelf sections has a surface for carrying a set of articles to be cleaned. At least one of the shelf sections is detachable and removable from the shelf. A channel is operatively connected to each of the shelf sections for providing decontamination solutions to the articles to be cleaned. At least one support member is mounted to an outer edge of the shelf for allowing the shelving assembly to be slidably mounted within a decontamination device. 
     A first advantage of the present invention is that it provides greater flexibility and efficiency in decontaminating diverse sizes of glassware articles simultaneously. 
     Another advantage of the present invention is that the device can be changed over between different configurations quickly with minimal labor. 
     Still further advantages of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating a preferred embodiment and are not to be construed as limiting the invention. 
     FIG. 1 is a front perspective view of a washing device with its front closure raised to expose the interior and with its spindle sections removed in accordance with the present invention; 
     FIG. 2 is a front perspective view of a washing device of FIG. 1 having a series of spindle headers disposed therein; 
     FIG. 3 is a partial perspective view of a channel having a valve in accordance with the present invention; 
     FIG. 4 is a lower perspective view of a portion of a hollow beam of a shelf section in accordance with the present invention; 
     FIG. 5 is a perspective view of the washing device with the upper shelf pulled half way out and its second and third shelf sections removed; 
     FIG. 6 is a front perspective view of the washing device with two sections of the upper shelf removed accommodating relatively large glassware articles; 
     FIG. 7 is a perspective view of a third (right) upper shelf section viewed from below; 
     FIG. 8 is a front perspective view of the washing device showing the second (middle) upper shelf section removed and the other sections loaded with spindle headers; 
     FIG. 9 is a front perspective view of the washing device with the second (middle) upper shelf section removed and with spindle headers; 
     FIG. 10 is an expanded perspective view of the upper shelf with the center section pulled out; 
     FIG. 11 is a perspective partial view of the third shelf section from below with the rotary sprayer removed; 
     FIG. 12 is a perspective view of the second (middle) upper shelf section in accordance with the present invention; 
     FIG. 13 is a perspective partial view of the second shelf section viewed from below; and 
     FIG. 14 is an enlarged view of a locking assembly for locking/releasing the upper shelf as a whole from the washer. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED INVENTION 
     With reference to FIGS. 1 and 2, a washing device  10  includes a washing chamber  12  defined by a back wall  14 , opposing sidewalls  16 ,  18  and opposing top and bottom walls  20 ,  22 . A vertically sliding door  24 , having a window  26  formed integrally therewith, slides vertically downward to close the washing chamber during operation. Upper shelf  30  and a lower shelf  32  are horizontally disposed within the washing chamber and are preferably made of stainless steel. However, it will be appreciated that the washing device can be manufactured having any desired number of shelves including only one, three, etc. 
     A pump P, located in a cabinet beneath the washing device  10 , pushes water through a heater H and into an injector I that communicates with the upper and lower shelves  30 ,  32 . A detergent dispenser D communicates with the injector and provides detergent to be mixed with the heated water. The pump P is a two speed pump. When the upper shelf is not being used or is removed, the amount of pressure needed to provide cleaning solution to the washing chamber is decreased. As such, the pump operates at a first lower speed. When the upper shelf is being used, the system needs more pressure. Thus, the pump operates at a second higher speed. 
     The lower shelf  32  is preferably a rigid, non-removable structure comprising a pair of transverse horizontal beams  34 ,  36  disposed in parallel relation which span the two opposing sidewalls  16 ,  18 . A series of C-channels or tracks  40  each extend perpendicularly from a top surface of one beam to a top surface of the other beam, effectively dividing the lower shelf into equally sized first, second, and third washing sections  42 ,  44 ,  46 . However, a lower shelf with any desired number of washing sections, such as two or four is within the scope of the present invention. The series of tracks are arranged in such a manner that each washing section has a pair tracks  40  spaced from one another in parallel relation so that their open channels are facing each other. 
     Each washing section carries a spindle header or rack  50  having an effective width equal to the distance between the pair of tracks of each washing section. The racks are supported by wheels  52  which enables them to be easily rolled in and out of the C-channels of the washing sections. It will be appreciated, however, that the rack may be supported by any other means such as low coefficient of friction slide blocks. The racks  50  each include an essentially rectangular frame  54  and a grid of supports  56  running the width and length of the rectangular frame. Extending vertically upward from the grid of supports  56  are a plurality of spindles  58  over which glassware, such as beakers, flasks, and test tubes can be placed for washing. Nozzles  59  on each spindle direct fluid to the interior of each piece of glassware. The spindle size and spacing varies with each rack in order to accommodate different sizes of glassware. In the illustrated embodiment, up to three different types of racks can be inserted into the three washing sections of the lower shelf at any given time. 
     Horizontally extending upper and lower flanges  60 ,  62  of the C-channels prevent substantial vertical movement of the racks during washing operations. The lower flange  62  of the C-channel is wider than the upper flange  60 . To prevent backward and forward movement of the racks during operation, the rack wheels fall into apertures (not shown) located at predetermined positions along the lower flange of the C-channels. Alternatively, recesses, protrusions, or bumps may be provided to hinder forward and backward movement of the racks. 
     In order to provide water, soap, etc. to the lower shelf  32 , a member  66  extends perpendicularly from sidewall  16  and travels beneath the lower shelf until it terminates at the approximate center of the third washing section  46 . A substantially rectangular channel  68  distributes washing liquids to each section. First, second, and third fluid sealing connectors, such as diaphragms or membranes  70 ,  72 ,  74 , are operatively associated with a top surface of the rectangular channel and are positioned at the approximate center of the first, second, and third washing sections  42 ,  44 ,  46 , respectively. When the racks  50  are inserted into each washing section, each has an inlet aperture which registers with the membrane beneath that particular washing section. Under fluid pressure, the membranes expand and seal around the inlet aperture directing washing liquid into manifolds  75  which direct water to each spindle  58  of the racks. Spray from the nozzles  59  on each spindle assure that the interior of each piece of glassware is thoroughly washed. 
     The upper shelf  30  is disposed vertically above the lower shelf and has first and second side support members  76   a ,  76   b  which slidably connect the upper shelf to the opposing sidewalls  16 ,  18  at a predetermined or adjustable height. Since the upper shelf is slidably connected to the opposed sidewalls  16 ,  18 , the entire upper shelf is capable of sliding in and out of the washing chamber as shown in FIG. 5. A channel  78  extends across the back edge of the upper shelf and bends forward 90° upon reaching members  76   a ,  76   b . After bending 90°, the channel terminates below the side support members at a predetermined location. An inlet valve  80  (see FIG. 3) is located on a side surface of the channel which allows water, soap, etc. to enter the channel. The channel then distributes the washing liquids around the upper shelf. 
     The upper shelf  30  comprises a first shelf section  82   a , a second shelf section  82   b , and a third shelf section  82   c . Although the upper device will be described having three shelf sections, it will be understood that any number of shelf sections, such as two or four, is contemplated by the present invention. First and second oppositely faced tracks or C-channels  86 ,  88 , identical to the tracks  40  used for the lower shelf  32 , are mounted back to back and effectively partition the first and second shelf sections  82   a ,  82   b . Similarly, third and fourth oppositely faced tracks  90 ,  92  effectively partition the second and third shelf sections  82   b ,  82   c . Spindle headers or racks  50 , identical to those used for the lower shelf  32 , are carried by each shelf section. 
     Each shelf section includes a front member  94   a ,  94   b ,  94   c  having an effective width equal to the width of a rack  50 . The front member comprises a vertical face  96   a ,  96   b ,  96   c  and upper and lower backwardly extending flanges. Each front member defines two substantially rectangular openings. On the first and the third shelf sections  82   a ,  82   c , the face of the front member has a canted outer edge  98   a ,  98   c.    
     Each shelf section further includes a hollow rectangular beam  110   a ,  110   b ,  110   c  extending longitudinally between their front member  94   a ,  94   b ,  94   c  and channel  78  in order to provide water, soap, etc. to the shelf sections. First, second, and third fluid sealing connectors  112   a ,  112   b ,  112   c , such as membranes or diaphragms, each having a fluid outlet are operatively associated with an approximate center of the rectangular beams  110   a ,  110   b ,  110   c  respectively. As the fluid pressure in the sealing connectors increases, the connectors expand and seal around the inlet aperture of an associated rack, thereby directing washing liquid from the fluid outlets into the rack manifolds  75  which direct water to each spindle  58  of the racks. 
     First spray arms  114  and second spray arms  116  are rotatably mounted beneath each rectangular beam for providing water, soap, etc. to the exterior of the glassware articles. Holes are provided in the spray arms at a variety of locations for directing water, soap, etc. in all directions. The first and second spray arms are mounted on first and second hubs  118   a ,  118   b  (see FIG. 4) respectively, which rotate the first and second spray arms in different horizontal planes in order to prevent them from colliding. 
     In order to accommodate glassware articles having a height greater than the distance between the upper and lower shelves  30 ,  32  or the upper shelf and the top wall  20 , the second and third shelf sections  82   b ,  82   c  are individually removable. With reference to FIGS. 5 and 6, the washing device is shown with the second and third shelf sections removed. With both the second and third shelf sections removed, the washing chamber  12  can accommodate small, medium, and large articles simultaneously. 
     To allow insertion and removal of the second and third shelf sections, first and second openings  120 ,  122  are provided in channel  78  for receiving the hollow rectangular beams  110   b ,  110   c  of the second and third shelf sections  82   b ,  82   c  respectively. First and second flap valves  124 ,  126  are mounted to channel  78  to close the first and second openings  120 ,  122  when a self section is removed. When it is desired to use the second and third shelf sections, they are inserted into the valves  124 ,  126 , respectfully, and suspended in the washing chamber in a cantilevered manner. 
     Removing the second and third shelf sections merely requires an operator to manually urge the rectangular beams  110   b ,  110   c  from the first and second openings  120 ,  122  respectfully. Because the sections comprise only one third of the entire upper shelf, they are relatively easy to handle and remove when compared to an entire upper shelf. As illustrated, racks for larger articles having fewer spindles which are spaced further apart from one another can be used when the second and/or third shelf section(s) is/are removed. 
     With continued reference to FIGS. 5 and 6, the first shelf section  82   a  is preferably a rigid non-removable structure. However, the washing device can be designed having a removable first section if desired. The first support member  76   a  has a flat bottom surface  136  which forms the outer edge of the first shelf section  82   a . The flat bottom surface of the first support member and a lower flanged portion of the first track  86  support a rack  50  carried by the first shelf section. A series of tabs  138  extend horizontally inward from the first support member which with bottom surface  136  prevents substantial vertical movement of the rack  50  at the outer edge of first shelf section. Upper and lower flanges of the first C-channel prevent vertical movement of the rack at the inner edge of the first shelf section. To prevent forward and backward movement of a rack during washing operations, the wheels  52  of the rack fall into apertures  144  located at predetermined positions along surface  136  and the lower flange of the first C-channel. Alternatively, recesses, protrusions, or bumps may be provided to hinder forward and backward movement of the racks. 
     If only a few large glassware articles need to be cleaned, it may be desirable to remove only one shelf section in order to maximize the device&#39;s washing potential. When two upper shelf sections are being used, the third section  82   c  is preferably placed in the washing chamber  12  along with the first section  82   a  (see FIGS.  8  and  9 ). However, any two sections may be used without going outside the scope and meaning of the present invention. 
     Turning now to FIG. 7, the third shelf section  82   c  comprises the opposed third and fourth tracks  90 ,  92  which extend backwardly from a top surface of front member  94   c . In addition hollow rectangular beam  110   c  extends backwardly from a central portion of front member  94   c . Just before terminating, the rectangular beam bends downward, preferably 450, and then back to horizontal. Such a design facilitates insertion of the rectangular beam into the opening of the second valve  126 . The third diaphragm  112   c  is operatively associated with a top surface of rectangular beam  110   c . First and second spray arms  114 ,  116  are rotatably mounted beneath rectangular beam  110   c  on horizontal planes different from one another. A guiding bar  146  extends between the rectangular beam and the opposed tracks to maintain the appropriate spacing therebetween and to facilitate proper alignment when the third shelf member is placed into the washing chamber. 
     With reference to FIGS. 9 and 10, when use of the third shelf section is desired, rectangular beam  110   c  of the third shelf section is inserted into the opening of the second valve  126  so that it is suspended in a cantilevered manner. Preferably, pinch fingers  150  are mounted to channel  78  to engage the ends of the opposed tracks and hold them in proper position. 
     The second support member  76   b  has a flat bottom surface  156  which forms the outer edge of the third shelf section  82   c . A fastener  158  (see FIG.  11 ), extending from beneath the horizontal flange of front face  94   c , connects the bottom surface  156  of the second support member to the first shelf section. The flat bottom surface  156  of the second support member and a lower flanged portion of the fourth track  92  are adapted to support a rack  50 . A series of tabs  160  extend horizontally inward from the second support member which with bottom surface  156  prevents substantial vertical movement of the rack  50  at the outer edge of third shelf section. Upper and lower flanges of the fourth C-channel  92  prevents vertical movement of the rack at the inner edge of the first shelf section. To prevent forward and backward movement of the rack during washing operations, the wheels  52  of the rack fall into apertures  166  located at predetermined positions along surface  156  and the lower flange of the fourth C-channel. Alternatively, recesses, protrusions, or bumps may be provided to hinder forward and backward movement of the racks. 
     If only relatively small glassware articles need be cleaned, the second shelf section  82   b  may be placed in the washing chamber with the first and third shelf sections  82   a ,  82   c  (see FIGS.  1  and  2 ). Referring to FIG. 12, the second shelf section comprises rectangular hollow beam  110   b  extending from front member  94   b . Just before terminating, the rectangular beam bends downward, preferably 45°, and then back to horizontal. The second diaphragm  112   b  is operatively associated with a top surface of rectangular beam  110   b . The first and second spray arms  114 ,  116  are rotatably mounted beneath rectangular beam  110   b  on horizontal planes different from one another. 
     Turning back to FIG. 10, rectangular beam  110   b  is inserted into the opening of the valve  124  when use of the second shelf section is desired. The second and third tracks  88  and  90  form the outer edges of the second shelf section once the second shelf section has been fully inserted. Fasteners  170 ,  172  (see FIG.  13 ), extending from beneath the flange of front member  94   b , attach the second shelf section to the second and third tracks  88 ,  90 . In order to prevent forward and backward movement of the rack  50 , the wheels  52  of the rack fall into apertures  174  provided in the lower flanges of the second and third tracks. Additionally, the upper and lower flanges of tracks  88 ,  90  prevent substantial vertical movement of the rack during washing operations. 
     When it is desirable to use only the lower shelf  32 , the upper shelf may be completely removed. First and second locking assemblies  180 ,  182  are mounted to the two support members  76   a ,  76   b  respectively for allowing removal of the upper shelf. Preferably, each locking assembly includes a lever  184  (see FIG. 14) which is manually activated to unlock the top shelf and allow it to be removed. However, any known locking assembly is within the scope of the present invention. 
     The present invention provides a washing device capable of sanitizing small, medium, and large glassware articles simultaneously in a multi-level system, thereby maximizing the efficiency and washing potential of the machine. In addition, because the shelf assembly is divided into relatively small and easy to handle sections, the required number of workers to operate the machine is minimized. Importantly, the invention can be incorporated into already existing machines. 
     The present invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. For example, the upper shelf could be manufactured with more or less than three shelf sections. In addition, the washing device could be manufactured with more or less than two shelves. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.