Patent Description:
Steam irons are well known as providing a clothes smoothing device comprising a water reservoir within the iron body and comprising a heated sole plate having a surface for contacting clothing. Water may be heated by the sole plate or a separate heater to create steam that can be continuously delivered through holes of the sole plate or may be controlled to be delivered as a response to activation by a trigger or the like or as a result of certain sensed conditions.

More recently, steam stations have been developed that utilize an iron as such is provided with a heated sole plate but without a water reservoir, wherein the iron is connected with a steam generation base unit that includes a water reservoir and a heating device for creating steam. The steam and usually electrical power are delivered to the iron by way of a steam conduit and electrical wires, respectively, that are provided within a flexible hose that allows the iron the be manipulated independently of the base unit of the steam station.

Typically, the steam generation base unit and iron device are also physically connectable to one another, such as by a latching mechanism of a mechanical type. The iron is also then releasable from the base unit by unlatching of the mechanism for use. The iron itself of such a steam station is typically designed like a conventional iron having a handle portion to allow manipulation of the iron, in particular its soleplate, for steaming and pressing clothing or the like. As compared with a conventional iron, a stream station including a steam generator can produce a much greater quantity of steam over longer time since the steam is generated within the base unit, which is typically larger than an iron and includes a bigger water reservoir and more powerful steam generator.

A water reservoir of a steam station is typically provided so as to be refillable with water either by providing an access to the reservoir as positioned within the steam station or by providing a removable reservoir. Either way, the reservoir is sized and shaped to hold a sufficient quantity of water based upon the needs for typical usage.

Prior art steam stations and steam generators have a common shortcoming related to the build-up of minerals within the steam generator components during use in the form of calcification, especially when using so-called "hard" water. Calcium carbonate and other calcium compounds are forms of calcification commonly found in household or business water supplies. As such, when the phase of the water changes to steam (gas) during boiling, the calcium compound can build up as calcification (also referred to as scale, limescale, calcium carbonate, calcium compound, etc.) where the liquid water was vaporized into steam gas by a boiler. Calcification is especially prone to formation on hot surfaces, e.g., surfaces contacting the water as it is boiled. Steam garment care appliances can build up calcification on the boiler surfaces, which over time causes reduced boiler performance and efficiency. Also, calcification solids or precipitate can travel down the steam path and out of the iron, onto the garment.

As boilers tend to be hottest closest to the various heating elements or heat sources, these areas also tend to suffer from the most calcification. Calcification, when built-up over time, can negatively affect the utility of the steam station's steam generator, and in some cases clog the steam generator rendering it ineffective. The boiler units, where the majority of calcification tends to occur, also tend to be very difficult to clean (i.e., remove the calcification deposits built-up over time). In fact, many boiler units are hermetically sealed for proper operation, and therefore need to be substantially disassembled to access the internal parts of the boiler, making cleaning difficult and often not able to be accomplished by a user. In order to prevent calcification a heating tube in a metallic heat transfer member, disclosed in the document <CIT>, is made of Teflon. Furthermore, to prevent calcification of a filter of a steam distribution circuit, the document <CIT> discloses the provision of a fluoropolymer material to the filter. There is, however, a need to further prevent calcification of steam generators.

Typical steam generators of steam stations include a water heater, such as a boiler or pre-heater for heating a received fluid, such as water, where most of the calcification build-up occurs during the heating of liquid. This build-up then leads to less direct heating and reduced passage size as the calcification builds-up over time and continued use. The present invention includes a system that reduces calcium carbonate from building up within a heater or boiler of a steam generator. As used herein, a boiler is an example of a water heater. Water heaters can also include pre-heaters and/or any apparatus or element that causes a fluid to become heated. Although the term boiler is used throughout, any instance where boiler is used is understood to also include embodiments of the broader, water heater terminology. Embodiments also facilitate cleaning of the steam generator components.

The provision of a non-stick substance, surface, and/or coating to various surfaces of various components reduces build-up of calcification on the non-stick surfaces but increases solids within the steam, water, or any mixture of the two (or other fluid) stream passing through the steam station or steam generator. This can improve functionality and improve longevity of steam stations and steam generator units.

The present invention includes improvements to a steam station as defined by the appended claims. A first aspect of an improved station includes a steam generator that includes a non-stick substance on inner heater and/or boiler surfaces to reduce formation and adhesion of solids to the inner heater surface and components. A second aspect of an improved steam station includes an in-line filter configuration wherein a filter is located downstream of a heater to collect solids precipitated from the water or other liquid as such solids are present in the fluid flow from the heater. The amount of solids in the fluid flow is therefore increased by the provision of the non-stick substance. Additionally, instead of simply ejecting the calcium carbonate calcification particulate solids (which can be referred to also as "particulates," "solids," etc.) onto a garment being ironed, a filter assembly with a replaceable and/or cleanable filter element can be added to the steam generator fluid flow path to filter out the calcification solids flowing out of the heater before exiting the iron. The following describes embodiments of the invention in greater detail. It is noted that like components are labelled with like numerals throughout the several figures.

A heater (e.g., a boiler) within the steam generator of the steam station can first receive water (or other fluid) from a source where the water is heated, followed by a filtering of the heated, liquid water using a filter that works with the heated water to catch calcium compound solids. The heater raises the water temperature to potentially create steam. Prior to the water reaching boiling temperatures, the water within the heater can be heated enough to cause the calcium compound in the water to precipitate and form the solids, such as solids that form within the heater, including on heater surfaces. As another aspect, adhesion to heater surfaces can be reduced by providing a non-stick substance/coating to the inner surfaces of the heater, reducing the likelihood of solids depositing on the heater surfaces. The solids flow out of the heater and into the filter to be caught therein. The filter catches the solids before they would travel to a material or garment being treated with the steam generator. In some embodiments, a filter can be provided post any heating element, heater, boiler, etc., and in particular, a heating element that is controlled to heat liquid above a temperature causing solids within a fluid to precipitate.

By including such a filter downstream of the heater where a majority of calcification solids can be caught in operation, solids travel from the steam generator can be minimized. Preferably, a user can clean the steam generator by flushing filtered solids from the filter during filter cleaning instead of descaling the steam generator heater itself. The filter is preferably reusable, so the consumer can remove it, wash out the solids from it, and replace the filter in the steam station appliance for continued use.

According to a first aspect of the present invention, a water heating apparatus is disclosed. According to the first aspect, the water heating apparatus includes a first water heater including an interior surface and a heating element, where the first water heater is configured to heat water such that steam is produced. The water heating apparatus also includes a first non-stick substance providing at least a portion of the first water heater interior surface, the first non-stick substance configured to reduce adhesion to the first water heater interior surface with respect to a calcium compound within the water, where the calcium compound in the water is caused to flow out of the first water heater as calcium compound solids within a fluid flow. The water heating apparatus also includes a filter assembly in fluid communication with the first water heater to receive the fluid flow and compound solids, the filter assembly including a particulate filter element configured to filter out at least some of the calcium compound solids received within the fluid flow.

According to a second aspect of the present invention, a method of making a water heating apparatus is disclosed. According to the second aspect, the method includes providing a water heater having an interior surface, where the water heater is configured to heat water such that steam is produced. The method also includes providing a non-stick substance as at least a portion of the interior surface, the non-stick substance configured to reduce adhesion to the interior surface with respect to a calcium compound within the water, where the calcium compound in the water is caused to flow out of the water heater as calcium compound solids. The method also includes providing a filter assembly in fluid communication with the water heater, the filter assembly including a removable particulate filter element configured to filter out at least some of the calcium compound solids received from the water heater.

According to a third aspect of the present invention, a method of using a water heating apparatus is disclosed. According to the third aspect, the method includes heating water including a calcium compound at a first water heater that comprises a non-stick substance provided as at least a portion of an interior surface of the first water heater, where the non-stick substance is configured to reduce adhesion to the interior surface with respect to the calcium compound in the water. The method also includes causing the heated water to flow out of the first water heater along with at least a portion of the calcium compound. The method also includes filtering the water flowing out of the first water heater using a filter assembly such that at least some of the portion of the calcium compound is filtered from the water.

The present invention is directed to a steam station that includes a steam generator within a base unit that includes one or more improved anti-calcification features. Existing steam stations suffer from accumulation of calcification on components, leading to reduced steaming performance. An improved, decalcifying steam station, which can include a steam generator base and an iron are disclosed, through which steam can be applied to a garment. As used herein, water is an example use of a fluid to be softened, filtered, and/or distributed during steam station use. Many other fluids, liquids, and other substances are also contemplated herein.

Water commonly used in steam stations often includes elements of hard water. One common element in hard water is calcium carbonate, the build-up of which is a common limiting factor to the efficiency, performance, and usable life of present steam stations. The terms "steam generator" and "steam station" can be used interchangeably, but the term steam station herein is intended to refer to an entire assembly that include a steam generator base unit and a an iron that is used to apply steam produced within the steam generator.

A steam station <NUM>, as illustrated in <FIG>, is useful for steaming garments and the like, wherein the steam generator base <NUM> can provide significantly more steam in quantity and flow rate to the iron <NUM>, as compared with a conventional steam iron. A steam station <NUM> of the present invention provides desirable steam production by way of a unit with improved anti-calcification (i.e., descaling, or anti-scale) performance.

The steam generator base <NUM> is shaped to support the iron <NUM> on a top surface <NUM> thereof. Preferably, the top surface <NUM> is inclined to position the iron <NUM> in an ergonomic position for a user. The steam generator base <NUM> also preferably houses a number of operative components to provide a supply of steam from the steam generator base <NUM>. Specifically, a water reservoir <NUM> provides a refillable supply of water that can be turned into steam. It is preferable that the size of the water reservoir <NUM> be sufficient to supply a desired quantity of steam at a desired rate from the iron <NUM>, as discussed more in detail below.

The water reservoir <NUM> is also preferably removable from the steam generator base <NUM> for filling and refilling with water. However, in other embodiments, the water reservoir <NUM> is non-removably fixed to the steam generator base <NUM>. In the shown embodiment, the water reservoir <NUM> comprises a slidable component, like a drawer, that is slidably supported to move within the steam generator base <NUM> and to be removable for filling. Slide components (not shown) can include commercially available slide devices that can be mounted within the interior of the steam generator base <NUM>, or the steam generator base <NUM> can be formed with integral components that provide slide bearing surfaces to guide the water reservoir <NUM> within the steam generator base <NUM>. Otherwise, the water reservoir <NUM> can simply be removed from the steam generator base <NUM>, which action may require manipulation of a latching mechanism, or the removal of a component for access or not. As shown, the water reservoir <NUM> can be formed with a handle portion <NUM> that allows for easy manipulation of the water reservoir <NUM> to and from the steam generator base <NUM>. The water reservoir <NUM> can also be transparent, as illustrated, so that a water level therein can be easily ascertained.

Also within the steam generator base <NUM>, the water reservoir <NUM> is operatively fluidly connected with a steam generation and/or boiler components (for example boiler <NUM>, an example of a water heater, is described in more detail below with respect to <FIG>), the function of which is to heat and boil water from the water reservoir <NUM> and supply steam from the steam generator base <NUM>. A fluid transport hose can fluidly connect the water reservoir <NUM> to the boiler in order to supply water to the boiler <NUM>. Fluid connection to and from the boiler can be accomplished with conventional hoses, connectors, clamps, and the like for handling the fluid transport of water and steam, respectively. The boiler components can be fixed within the interior space of the steam generator base <NUM> in any known or developed manner.

The boiler <NUM> can also be conventionally controlled. A controller or control unit <NUM> may be included in the steam generator base <NUM> at any suitable location, which control unit can be used to control the quantity and/or rate of steam production. As shown with respect to <FIG>, the controller <NUM> can be in operative communication with a water pump <NUM>, the boiler <NUM>, and/or a filter assembly <NUM>. The controller <NUM> can set a temperature ffilterof a heating element (e.g., <NUM> shown in <FIG> and <FIG>), a duration of temperature exchange, a quantity of water supply and/or flow rate, among other things. In some embodiments, a user control <NUM> can be configured to change various parameters of the controller <NUM> including by reference to those parts above here showing connected control components. The steam generator base <NUM> is also preferably connectable to a power source, such as conventional line power or electricity, by a cord or the like to provide electrical power to operate the control unit, the boiler <NUM>, any pumps (such as water pump <NUM>) or the like, and preferably also to the iron <NUM>, as discussed below. A power cord can be accommodated within a portion of the steam generator base <NUM> as shown at <NUM>. Cord reels and the like can be incorporated as desired.

Connected between the steam generator base <NUM> and the iron <NUM> can be a flexible hose <NUM> that preferably provides a conduit within which both a steam transport line and an electrical cord can be contained. The flexible hose <NUM> can utilize conventional connectors, clamps, and the like to make the appropriate connections with the steam generator base <NUM> and the iron <NUM>. A steam transport line (not shown) can be operatively fluidly connected, as discussed above, with the boiler <NUM> within the steam generator base <NUM> and can also be operatively fluidly connected with an interior space of the iron <NUM> in any conventional manner. From the interior of the iron <NUM>, steam can be delivered through the iron's soleplate <NUM> by way of steam holes, as such are also conventionally known. Electrical power is preferably delivered from the steam generator base <NUM> (as such can be operatively connected to power) to the iron <NUM> by the electrical cord. Electrical power can be used to heat the soleplate <NUM> and to provide control power to an iron control unit having a user control <NUM>, for example, for setting the desired temperature of the soleplate <NUM>. A trigger <NUM> is also preferably provided for selectively delivering steam from the soleplate <NUM>, which triggers and delivery control elements are also well-known.

A length of the flexible hose <NUM> provides a range of movement of the iron <NUM> relative to the steam generator base <NUM>. This allows a user to move about a garment or the like from a single position of the steam generator base <NUM>. A handle portion <NUM> of the iron <NUM> provides a gripping feature for a user to manipulate the iron <NUM>. A hose bracket <NUM> can be provided from the steam generator base <NUM>, for example, to facilitate stowing of the hose <NUM>, especially during any movement of the steam station <NUM>.

With reference to <FIG>, an improved fluid transfer and delivery system is shown for handling a conversion of liquid, such as water, to gas, such as steam, and for delivery of the steam for usage. According to various embodiments, a component configuration for a fluid transfer and delivery system (shown schematically in <FIG>) can include the water pump <NUM>, the boiler <NUM>, and the filter assembly <NUM>. The water reservoir <NUM> can supply water to various components of the system located downstream of the water reservoir <NUM>. A fluid or gas, such as various physical states of water, can leave the system at exit <NUM> (see <FIG>). Water can flow downstream through the steam generator through various fluid conduits <NUM>, <NUM>, <NUM>, and <NUM> that each can fluidly connect the various components as shown in particular with respect to <FIG>. <FIG> show the water pump <NUM>, the boiler <NUM>, the filter assembly <NUM>, and various components thereof in fluid communication and in several views.

Water begins in reservoir <NUM> and can be caused to be operatively pumped or caused to be moved downstream along operative or fluid connections or conduits (<NUM>, <NUM>, <NUM>, and <NUM>) provided between the various components, and the water pump <NUM> may preferably be located between the water reservoir <NUM> and the boiler <NUM>. Water pump <NUM> (and/or other pump[s]), operatively supported within steam station <NUM>, can be located elsewhere along the flow path so long as water/steam flow is provided from water reservoir <NUM> through to exit <NUM>, as needed or applicable for suitable fluid flow. During operation of steam station <NUM>, the water pump <NUM> can operatively cause water to flow downstream from the water reservoir <NUM> to the boiler <NUM>, whereby the water can be caused to boil and to controllably change phase or condition, becoming steam and/or water vapor are (referred to generally as steam, herein). The water pump <NUM> can run continuously, as needed for a batch, or otherwise as suitable and can be controlled and operated by controller <NUM>.

A water reservoir <NUM>, as used in <FIG>, can include a suitable fillable water source, as applicable and discussed above. As shown in <FIG>, a water reservoir <NUM> is fluidly connected and in fluid communication with water pump <NUM> via pump inlet <NUM> and fluid conduit <NUM> (or operative connection). The water reservoir <NUM> and/or fluid conduit <NUM> can also include various components, such as additional pumps, filters, junctions, heaters, etc. Water received at the water pump <NUM> can be motivated or propelled downstream by various motors and pump components, causing water to continue downstream to the boiler <NUM> through a pump outlet <NUM> and fluid conduit <NUM>. The water pump <NUM> can also include a pump housing <NUM> having electrical pump contacts <NUM>, as shown.

The water pump <NUM> can include a pump housing <NUM> and a pump motor (not shown), which can be an electric motor, preferably. The water pump <NUM> can be controlled by a user or other control system such as controller <NUM>, according to various embodiments. For example, the water pump <NUM> can be activated by controller <NUM> in order to pump water into the boiler <NUM> when the boiler <NUM> is empty, low, or when a user has begun using the steam station <NUM>, among other circumstances.

With reference to <FIG> and <FIG>, the water pump <NUM> is fluidly connected to receive a flow of water from the water reservoir <NUM> via fluid conduit <NUM>, e.g., by gravity, draw, or pump. In some embodiments (not shown), the water pump <NUM> can be omitted from steam generator or steam station, and other non-pump functionality, such as gravity-based fluid propagation and the like, can be used to move fluid between the various components. As described herein, a water pump <NUM> is described, but various embodiments described herein are understood to use the water pump <NUM> as one example of a component that includes fluid movement or propagation functionality.

The water pump <NUM> causes the received water to flow to the boiler <NUM> through fluid conduit <NUM>. The boiler <NUM> then operatively raises the water temperature to preferably a boiling temperature (e.g., about <NUM> degrees Celsius [°C] or above). The received water can include water having various degrees of "hardness," including various levels of minerals or other compounds. Water hardness can be defined in terms of the quantity of calcification based on volume or weight of solids, minerals, etc. as a ratio of an amount of water being received. In some embodiments, the boiler <NUM> is configured to maintain at least some steam when the steam station <NUM> is not in active use. In other embodiments, the boiler <NUM> is configured and controlled to produce steam only when in active use by controller <NUM>.

Still referring to <FIG>, the water pump <NUM> is shown in fluid communication with the boiler <NUM> located downstream, via fluid conduit <NUM> (or other operative connection). The fluid conduit <NUM> is connected to the pump outlet <NUM> and the boiler inlet <NUM> of the boiler inlet fitting <NUM>. As shown in an exploded view in <FIG>, boiler <NUM> includes a boiler housing <NUM>, a boiler cover <NUM>, boiler cover fasteners <NUM>, a boiler cavity (or chamber) <NUM> (see <FIG>), and a boiler heating element <NUM>. Boiler inlet fitting <NUM> can be configured to be threaded into a threaded boiler inlet fitting hole <NUM> of boiler cover <NUM>, according to various embodiments (see <FIG>). The illustrated boiler heating element <NUM> can be as shown, or can be configured differently. In some embodiments, the boiler heating element <NUM> is located outside the boiler cavity <NUM>, but in contact with the boiler housing <NUM>. The heating element <NUM> can include Calrod, resistive-type electrical heating device(s), gas-based heating device(s), a thin-film heating element(s), a tube heating element(s), combinations thereof, among other types of heating elements, as known in the art or developed. Preferably, the heating element(s) <NUM> will be controllable so that water contained in the boiler <NUM> will reach the boiling point of water to generate steam.

Depending on configuration, steam station <NUM> can operate on one of at least two steam delivery principles. Steam may be generated by the boiler <NUM> so as to be directed to an iron <NUM> for direct use. Alternatively, steam can be accumulated and stored for later use, as may be desired. For example, steam can accumulate in the boiler <NUM> or elsewhere until the user activates a steam-releasing function causing the steam to exit the iron <NUM>.

The water pump <NUM> can take any form of a suitable fluid pump, including but not limited to various forms of a positive displacement pump, an impulse pump, a velocity pump, a gravity pump, a steam pump, a valve-less pump, an electromagnetic vibration (EMV) or other linear pump, any combination thereof, or any other suitable pump that can deliver a desired volume and flow rate of liquid to the boiler <NUM> for use in a steam generator such as steam station <NUM>. More specifically, during operation of the boiler <NUM>, at least some water received may remain in the liquid phase (i.e., not be boiled into gaseous steam), according to various embodiments. In other embodiment, substantially all water received at the boiler <NUM> can be boiled into steam. In various embodiments, additional water pumps similar to water pump <NUM> can be utilized for assisting in the fluid flow of either the water or steam as may be desirable or necessary during steam station <NUM> operation.

In more detail, as water is pumped downstream from the water pump <NUM> reaches the boiler <NUM>, the water can completely or partially fill the boiler cavity <NUM> defined by an interior of a boiler upper portion <NUM> and lower portion <NUM>. As shown in <FIG> and <FIG>, the example of a boiler heating element <NUM> is approximately shaped as a coil or spiral, and is attached to a lower side of boiler <NUM> lower portion <NUM>. In this case, heat from heating element <NUM> is conducted through the lower portion <NUM> to heat the water within boiler <NUM>. In some embodiments, the location of the heating element <NUM> (whether inside or outside the boiler <NUM> itself) can affect the heating distribution of the water contained in the boiler <NUM> at a particular point in time. Heating element <NUM> can include a Calrod, resistive-type electrical heating device(s), gas-based heating device(s), a thin-film heating element(s), a tube heating element(s), combinations thereof, among other types of heating elements, as known in the art or developed. Heating element <NUM> can include a heating element connection <NUM>, as shown in <FIG>. Preferably, the heating element <NUM> (or elements) is controllable so that water contained in the boiler <NUM> will reach a boiling point, but may also be heated to various other temperatures. Boiler <NUM> can receive electrical power for use in heating from boiler contact(s) <NUM>, as shown in <FIG>.

The boiler <NUM> can be configured to maintain an amount of steam when activated, awaiting only a user's activation of steam through the steam generator controls or switches, and having a nearly instant supply of steam when desired. In alternative embodiments, the boiler <NUM> can remain idle when the user is not steaming garments, or may merely pre-heat the water while awaiting further control prior to heating water contained in the boiler cavity <NUM> to the boiling point of water (e.g., <NUM> at standard atmospheric pressure). In some embodiments, the boiler <NUM> can receive about <NUM>-<NUM> grams (or milliliters) of water from water pump <NUM> at a time, as a cycle. In other embodiments, the boiler <NUM> can operatively receive a constant or steady supply of incoming water and can continuously heat the water to create steam.

The boiler <NUM> can also include a steam exit housing <NUM>. Steam can be caused to exit the boiler <NUM> via boiler outlet fitting <NUM> and boiler outlet <NUM> of a steam exit housing <NUM> having a steam exit cover <NUM>. The boiler outlet <NUM> can be in fluid communication with a steam exit <NUM> via fluid conduit <NUM>. Steam exit <NUM> can be connected, for example, to an iron <NUM>, whereby the steam can be applied to a garment. As described herein, a filter assembly <NUM> can be provided in fluid connection to the boiler <NUM> in order to trap and gather solids from water/steam before or after boiling. The steam preferably has little to no calcium compound solids that reach the garment from the steam station <NUM> after passing through filter assembly <NUM>, as described below. If the iron <NUM> of steam station <NUM> is present, the iron <NUM> may have a control function whereby a user can choose a free flow or steam or a set steam cycle. In other embodiments, the steam flow may be determined automatically, for example, based on preset parameters or circumstances.

The steam exit housing <NUM> of the boiler <NUM> can also include a steam bypass exit <NUM>. Steam bypass exit <NUM> can be set to relive pressure of boiler <NUM> in a case of boiler <NUM> pressure that exceeds a pressure threshold. The pressure threshold can be set based on suitable pressure based on a configuration of boiler <NUM> by way of a pressure valve where steam pressure exceeds a set pressure, e.g., set either mechanically or electronically using controller <NUM>. Preferably, steam from boiler <NUM> will exit through boiler outlet <NUM>, but in some cases, steam can also exit boiler <NUM> through the steam bypass exit <NUM>. The steam exit cover <NUM> attached to the steam exit housing can be fastened using fasteners <NUM>, which can include screws and/or bolts according to various embodiments. Fasteners <NUM> can preferably tightly secure the steam exit cover <NUM> to the steam exit housing <NUM>.

Steam, temperature, and other forms of control systems (including controller <NUM>), can be included to manage and maintain a desired water temperature and/or pressure within the boiler <NUM>. For example, using various control systems, water temperature can be determined (and the water heated) as a function of heat applied to a present, past, or future flow rate of water. In preferable embodiments, the water can be operatively heated in a continuous heating process at the boiler <NUM> meaning the water can enter the water pump <NUM> and boiler <NUM> at a supplied temperature (e.g., ambient) from the water reservoir <NUM> and at a flow rate, the water can be heated as it flows through or along the boiler <NUM> at the flow rate, and the water can exit the boiler <NUM> at a desired or preset temperature to cause precipitation of the calcium carbonate particulates/solids from the water at the same flow rate. Alternatively, the water can be heated in stages or all at once as the water is supplied at a desired volume on a cycle-by-cycle basis.

Once water received from water reservoir <NUM> is caused to be heated at boiler <NUM>, the boiler outlet <NUM> may fluidly communicate the water and proceed to flow to filter assembly <NUM> by fluid conduit <NUM>, as shown in <FIG>. The water can enter the filter assembly <NUM> by filter inlet <NUM>, and the water may then pass through filter housing <NUM>, and filter element(s) <NUM>, which may preferably be supported by filter structure <NUM> having filter structure support members <NUM> with water-passable gaps defined thereby and located therebetween. Filter element(s) <NUM> can preferably filter water, steam, or mixtures thereof of calcification as the fluid passes through the passable gaps of filter structure <NUM> and filter structure support member <NUM>. The filter element(s) <NUM> themselves can include pores or openings sized between <NUM> and <NUM> microns, as described herein, such that the pores or openings are configured to filter solids from the fluid passing therethrough. Any number of filter structure support members <NUM> can be included in filter structure <NUM>. The fluid can then pass out of filter assembly <NUM> through filter exit <NUM> through fluid conduit <NUM>.

As shown in more detail with respect to <FIG> and <FIG>, an example filter assembly <NUM> can include one or more filter elements <NUM> and filter structure <NUM> that together can be removed from the filter housing <NUM> as a cartridge unit. The filter element(s) <NUM> (and optionally the filter structure <NUM>) can then be emptied of water and/or filtered calcification, rinsed, cleaned, and/or washed, and replaced into filter housing <NUM> for continued use. In one embodiment, simply removing the filter element(s) <NUM> and filter structure <NUM> cartridge unit from the filter housing <NUM>, turning them over, and running tap water over the unit can substantially empty and clean the filter components.

The filter element(s) <NUM> can include a stainless steel (or similar) metal mesh component, and may have a mesh pore size of about <NUM>-<NUM> microns, such as <NUM>, <NUM>, or <NUM> microns, in various embodiments. A preferable pore size of a metal mesh filter element <NUM> can be sized at <NUM> microns in various embodiments. The size of the mesh openings can be smaller or larger, but is preferably sized based upon the effective size of the precipitate that results from the boiling of water in boiler <NUM>.

In accordance with an aspect of the present invention, one or more surfaces of the boiler <NUM> is provided to be non-stick. In some embodiments, boiler <NUM> is constructed of materials that lack non-stick properties, such as cast aluminum or stainless steel. A non-stick substance (such as a coating) can therefore be caused to be applied to some of or all of the boiler's <NUM> interior surfaces of the boiler cavity <NUM> that contact fluid being heated during use. In some cases, a boiler cavity <NUM> includes a non-stick substance on all interior surface except a top, where gravity can make a build-up of calcification or other solids less likely. In a case where the non-stick substance is a coating, the coating can be applied to the boiler cavity <NUM> through various known forms of coating deposition.

By applying a non-stick substance to various water/fluid heating components, such as the boiler <NUM>, the useful lifespan of the steam station <NUM> and components thereof can improve. As described herein, one or more filters can operate to collect solids that do not stick to the boiler <NUM> and exit the boiler <NUM> accordingly. In particular, the boiler <NUM> can see increased useful life as calcification solids will be less likely to accumulate on the interior walls of the boiler cavity <NUM>. Accumulated calcification solids presently reduces a boiler's performance and lifespan. A boiler, such as boiler <NUM>, if otherwise strained by excessive calcification build-up, can become overworked, overheated, or otherwise malfunction or wear. By reducing calcification build-up in the boiler <NUM>, and instead catching the calcification solids in the filter assembly <NUM>, the filter assembly <NUM> can collect the calcification solids, in a unit specifically configured to do so.

In accordance with the present invention, a non-stick surface is one that is less conducive to deposition of calcium compounds to a heater surface than the material of a typical heater, such as various metals. The terminology "non-stick" is used herein with reference to various surfaces, walls, interiors, components, materials, substances, etc. within this disclosure. Non-stick can refer to one or more characteristics of such substances, etc. In general, it is understood that non-stick can refer to a substance, which can include a coating of a substance applied to another ordinary substance that is not non-stick. Generally speaking, a non-stick substance is defined as having a low or very low coefficient of friction, but can include substances having a coefficient of friction that approaches zero. In other words "non-stick," although implying no adhesion whatsoever on its face, may not completely eliminate friction or stick altogether, as is known in the art. One well-known non-stick substance is a polytetrafluoroethylene (PTFE) polymer, also known by the trade name of "Teflon. " Many other examples of non-stick substances exist and can be employed in various described embodiments.

As used herein, a means for making a component, surface, or substance into a non-stick surface includes producing a component (and/or coating an existing component) with a non-stick substance. Such non-stick substances include PTFE, ceramics, anodized aluminum, silicone, enameled cast iron, superhydrophobic substances, and/or any substance that has a low coefficient of friction. Non-stick substances also include substances that are less prone to adhesion of particulate matter such as calcification and/or that have a low propensity for nucleation at the surface of the substance. Various non-stick substances can be employed as "food-safe" in food processing service apparatuses like coffee makers and the like, while other embodiments may not.

Heaters are made of materials designed for efficient heat transfer properties during a heating process. Such materials commonly include various metals, which are not typically non-stick materials. Examples of such typical substances that lack non-stick properties can include metals, such as some forms of aluminum (die-cast aluminum), iron, steel (e.g., stainless steel), and silica, among many others. A common characteristic of non-stick substances is that these substances have properties making them relatively not conducive to surface nucleation, whereas substances that lack non-stick properties generally include a surface that is relatively conducive to nucleation, and therefore build-ups of substances such as calcification.

A coefficient of friction (COF) is a dimensionless scalar value (typically shown in terms of µ) which describes the ratio of the force of friction between two bodies and the force pressing them together. The coefficient of friction depends on the materials used. Some substances have a low coefficient of friction with respect to other substances. For example, ice on steel has a low coefficient of friction, while rubber on pavement has a high coefficient of friction. Coefficients of friction range from near zero to greater than one. At a micro level, friction (kinetic or static) between two substances (or two of the same substance) is affected by surface asperities (unevenness or roughness of a surface) on each respective substance. Asperities that can lead to increased friction can also lead to increased propensity of a surface for nucleation, for example, of various calcium compounds. Therefore, a surface with a lower COF can also have a lower propensity for nucleation in some cases.

COFs for various substances are known, although variation in practice is common and care should be taken when approximating a COF between two substances. For the purposes of the example below, it will be assume that the friction is dry friction, without a lubricant between the two substances. For example, aluminum-aluminum friction is typically between µ=<NUM> and µ=<NUM> (static or kinetic). And steel-steel friction is typically between µ=<NUM> and µ=<NUM>. Steel-aluminum friction can be about µ=<NUM> to µ=<NUM>. In contrast, PTFE (Teflon)-PTFE is typically about µ=<NUM>, or roughly one-tenth the COF of two metals. As PTFE is an example non-stick substance as used herein, it is also noted that steel-PTFE is also, likewise about µ=<NUM> to µ=<NUM>. Therefore, using a non-stick substance can reduce a COF with respect to various substances, even substances that would otherwise have higher COFs.

Therefore, as used herein, a non-stick substance can be defined in some embodiments, as a substance that has a COF such that a µ with respect to various metals such as aluminum or steel is about less than µ=<NUM>, and more preferably µ=<NUM> or less. In even more preferable embodiments, a non-stick substance can have a COF of µ=. <NUM> or less with respect to various metals, such as aluminum or steel. In more preferable embodiments, a non-stick substance can have a COF of µ=. <NUM> or less with respect to various metals, such as aluminum or steel.

With reference to <FIG>, boiler <NUM> includes the boiler cavity <NUM>, which can contain a boiler dome <NUM>. Boiler dome <NUM> can be configured to assist in the formation of steam within boiler cavity <NUM>, and can be a separate component from boiler housing <NUM> and boiler cover <NUM>. Boiler dome <NUM> can be formed and shaped to be conducive to boiling of water into steam within the boiler <NUM>, and a dome shape can reduce calcification build-up on walls, e.g., by having fewer crevasses or corners in which particulates can become lodged, and can include internal surface area to assist boiling performance in some embodiments.

In some embodiments, the various steam generator components (e.g., filter assembly <NUM>, water pump <NUM>, or boiler <NUM>) can contain and hold varying amount of air or non-steam gas. For example, following heating or boiling of water at least partially into steam at boiler <NUM>, the heated steam/water can proceed to filter assembly <NUM>. The filter assembly <NUM> can be operated even when not fully filled with the heated steam/water if necessary. In various embodiments, the system can be completely or substantially filled with H<NUM>O, including water, water vapor, and/or steam in various locations. However, some air can be present in the steam generation system where steam is not present and therefore, although a fluidly-full system may be optimal for pumping or steam generation performance.

In a case where water is in the process of heating within the boiler <NUM>, dissolved calcium carbonate or other calcium compounds already existing in the received water can precipitate and form particulate solids within the heated, and eventually boiling, water. Solids tend to deposit and build-up on various interior surfaces or walls of boiler <NUM>. Some solids also can stay within the steam flow from the boiler <NUM>. Traditional boilers are formed of metal (such as steel, etc.), lack a non-stick substance, and are prone to calcification solids build-up at least partially caused by the separation of the pure water (H<NUM>O) from other substances (e.g., CaCO<NUM> or CCaO<NUM>) during a fluid heating and boiling process.

Referring back to <FIG>, once the water has been filtered by filter assembly <NUM> and the calcification solids are removed from the water, the water can exit filter outlet <NUM> and exit the system at exit <NUM>. The filter outlet <NUM> can be configured to be in fluid communication with the exit <NUM> by fluid conduit <NUM>, which can include a hose or other suitable fluid conduit.

With reference to <FIG> in particular, the boiler <NUM> can be assembled in part using one or more boiler cover fasteners <NUM> that can be threaded bolts or screws and can be configured to be threaded into boiler housing <NUM> and/or boiler cover <NUM>. The boiler cover fasteners <NUM> can also take other fastening forms, including adhesives, epoxies, and other forms of fasteners known in the art, such as clips, pins, detents, etc. In preferred embodiments, the boiler cover fasteners <NUM> can be tightened such that the boiler housing <NUM> and the boiler cover <NUM> form a substantially or entirely hermetically sealed assembly, with the exception of various boiler inlets and/or outlets, as described herein.

With respect to <FIG>, a non-stick substance <NUM> on an interior surface of boiler <NUM> can reduce sticking of calcification flakes or solids to the boiler <NUM> during or after formation. In other words, the calcium compounds found in the water being heated is preferably kept from sticking to coated surfaces so as to remain in the water, but converted from a dissolved form to a particulate solid form, suspended in the heated water.

In embodiments, the non-stick substance <NUM> may be a coating applied to the walls of the interior cavity <NUM> of the boiler <NUM> to resist precipitated calcification from adhering to the walls of the boiler <NUM>. The filter assembly <NUM> is operatively located after the boiler <NUM> so it can trap and collect the solids from the heated water, preventing them from entering the steam generator or of the steam station <NUM> or reaching the iron <NUM> (and any material being ironed thereby). A similar non-stick substance can also be applied to various pre-heaters as described below in various embodiments, and can be accompanied by a filter assembly following the pre-heater, which is some cases means there would be two filter assemblies within a single steam station <NUM>.

Also, additional or substitute filters, filter housings, and other water treatment components can be included within steam station <NUM>, such as a filter assembly <NUM>. Examples of filters for use win the filter assembly <NUM> can include cylindrical, planar, and various other suitable shapes, sizes, and types of filters, especially filters configured to separate calcium compound solids, limescale, or other calcification from water being filtered. Filters, as used herein, can preferably include three-dimensionally usable filters, where a total amount of filtration can be a function of the volume of the filter elements of the filters in use. Examples of filters, as used herein, as described in more detail below.

The combination of the non-stick coated/composed boiler <NUM> and filter assembly <NUM> that follows may also reduce the likelihood of calcification solids travelling to the iron <NUM> (e.g., exit <NUM>) and clogging up fluid flow within, related thereto, or other aspects of the iron <NUM>, its sole plate holes, or discoloring the garments. Advantageously, the filter assembly <NUM> (specifically the filter element <NUM> and filter structure <NUM> within the filter housing <NUM>) can be cleanable and reusable, so the so the consumer does not need to purchase or procure consumable resin packets or devices. Alternatively, the filter element <NUM> can be consumable and/or replaceable. Filter structure <NUM> preferably supports a number of filter elements <NUM>, which can comprise mesh panels in an arrangement around the filter structure <NUM> for particulate solid filtration from the water.

As above, the mesh size of the filter elements <NUM> can be based on solids size. In preferred embodiments, water including solids can operatively flow from an inside of filter element <NUM> to outside, where the water reaching the outside of the filter element <NUM> will have its solids already filtered out of the water. In this way, solids will be captured within and potentially fill the inside volume of the filter element(s) <NUM> and filter structure <NUM> cartridge unit. In other embodiments, the filter assembly <NUM> is not intended to be cleaned by a user, and can be replaced once a useful filter life has been reached. In some embodiments, the controller <NUM> can indicate to a user that a new, replacement filter should be inserted into the steam station <NUM> for optimal performance.

Various components of stream generator <NUM> are described in greater detail, below. Although not shown, other components, including known components and configurations, can also be included in the various component configurations (e.g., <NUM>) of steam station <NUM>. In other embodiments, the components shown in <FIG> can be employed in diverse other steam generation and/or boiler units (e.g., boiler <NUM>) and systems.

<FIG> is a perspective assembled view of a boiler <NUM> of the steam station <NUM> of <FIG>, according to various embodiments. Boiler <NUM> is shown in greater detail, including steam exit housing <NUM>, steam exit cover <NUM>, fasteners <NUM>, boiler inlet <NUM>, boiler inlet fitting <NUM>, steam bypass exit <NUM>, boiler cover <NUM>, boiler cover fasteners <NUM>, boiler lower portion <NUM>, and boiler outlet <NUM>.

<FIG> is a high-angle perspective exploded view of a boiler (e.g., boiler <NUM>) of the steam generator of <FIG>, according to various embodiments. <FIG> includes a view similar to the perspective view of <FIG> of boiler <NUM> and various components thereof, but shows an exploded view of the various components. In particular boiler dome <NUM>, boiler cavity <NUM> (having a boiler interior wall), non-stick substance <NUM> are shown in <FIG> that are not shown in <FIG>. <FIG> is a low-angle perspective exploded view of a boiler <NUM> of the steam station <NUM> of <FIG>, according to various embodiments. The view of <FIG> is a low-angle view similar to the view of <FIG>. Also shown in <FIG> are heating element <NUM> and boiler contact(s) <NUM>.

<FIG> is an exploded view of a filter assembly <NUM> of the steam station <NUM> of <FIG>, according to various embodiments. Shown are filter housing <NUM>, filter inlet <NUM>, filter assembly mounting tabs <NUM>, filter outlet <NUM>, filter bypass exit <NUM>, filter structure <NUM>, filter structure support members <NUM>, filter removal spline <NUM>, and filter cover <NUM>.

Still with reference to <FIG>, the various filter assembly <NUM> components can form a cylindrical, inside-out water flow configuration (described above), as shown. Alternatively and not shown, outside-in water flow configurations are also contemplated in various embodiments. Filter assembly <NUM> can also include a filter bypass exit <NUM>, as shown. Filter bypass exit <NUM> can be configured to relieve water and/or steam pressure from within filter assembly <NUM>. Filter assembly <NUM> can include filter assembly mounting tabs <NUM> for mounting of filter assembly <NUM> within various steam generator base <NUM> configurations and arrangements, and mounting tabs <NUM> can include any number or arrangement of suitable mounting tab <NUM> configurations, including no tabs in some embodiments. As shown in <FIG>, filter structure <NUM> can also include a filter removal spline <NUM> configured to receive filter cover <NUM>. Filter removal spline <NUM> can be shaped and configured to permit threaded filter element <NUM> removal from filter housing <NUM>, according to various embodiments.

In other embodiments, filter assembly <NUM> may take any other suitable shape, such as a flat, planar filter configuration, among others. Filter element(s) <NUM> can be sized and configured to have a maximum water flow rate that exceeds typical need when the filter element <NUM> is relatively free of calcification solids in to allow for cases where filter element <NUM> is partially clogged with calcium carbonate (or other calcification) solids caught in pores of the filter element <NUM> (e.g., pore size of <NUM>-<NUM> microns or other suitable pore size). In some embodiments, the filter assembly <NUM> has a filter volume that fills with solids as the solids are filtered from the water flowing through filter assembly <NUM>.

Preferably, filter structure <NUM> and filter element <NUM> are removable as a unit from filter housing <NUM>, whereby the filter components can be emptied, cleaned, rinsed, and/or washed by a user or consumer. After removing and cleaning the filter components, the filter element <NUM> and filter structure <NUM> can be replaced back into the filter housing <NUM> of filter assembly <NUM>. In alternative embodiments, various replacement components (e.g., filter element <NUM> and filter structure <NUM>) can be purchased and/or replaced in place of cleaning, especially, e.g., if the particular parts have been in heavy use or been in use for substantial amounts of time.

<FIG> show an alternative embodiment with a pre-heater <NUM> and filter assembly <NUM> as a single, combined assembly <NUM>, according to various embodiments. Various benefits can stem from combining various components into combined assemblies, such as simpler manufacturing, lower costs, more efficient use of space, and the like.

<FIG> is a perspective view of a pre-heater and filter combined assembly <NUM>, and <FIG> is a cross-sectional schematic view of the pre-heater and filter combined assembly <NUM>, according to various embodiments.

The shown combined assembly <NUM> includes both a pre-heater <NUM> and a filter assembly <NUM>. As used herein, a pre-heater is another example of a water heater, as a boiler is also an example of a water heater. Any instances of the use of boiler or pre-heater can be understood to also refer to water heater, and/or boiler/pre-heater as appropriate. Pre-heaters, especially pre-heaters coated with or composed of non-stick substances, such as pre-heater <NUM>, can be and operate similar to a boiler, such as boiler <NUM> above. Combined assembly <NUM> as shown is composed of various sub-components, which can be related to or similar to other similar components described with respect to <FIG> or <FIG>, herein. Although the combined assembly <NUM> as shown include the pre-heater <NUM> and the filter assembly <NUM>, various other components can be similarly combined into single assemblies, such as various boilers, pumps, conduits, etc. in various combinations. In some embodiments combined assemblies can include more than two components (e.g., pumps, filters, heaters, etc.), such as three or more components in a single assembly.

As shown, the filter assembly <NUM> includes a filter structure <NUM> that can include a filter element as described in other embodiments herein. As described with respect to various embodiments herein, the filter assembly <NUM> (and/or any constituent parts thereof, such as filter structure <NUM>, filter member <NUM>, a filter element, etc.) can be cleanable and reusable or can be disposable, depending on preferences. The filter structure <NUM> can be connected to an intermediate filter member <NUM>, which can be operatively connected to an upper filter member <NUM> and a filter handle <NUM>. As shown in particular with respect to <FIG>, the upper filter member <NUM> can be operatively connected, such as by threading, to a filter housing collar <NUM>. A filter exit <NUM> can be used to operatively connect the combined assembly <NUM> to other components within a steam system.

Preferably, prior to being filtered, a fluid such as water and/or steam can be pre-heated at pre-heater <NUM> that includes a non-stick substance (e.g., as a tube or other unit of a material having non-stick properties, a non-stick substance, and/or a non-stick coating, etc.) on a pre-heater chamber <NUM> interior surfaces, walls, or any part of the pre-heater chamber that could come in contact with fluid to be heated prior to filtering at the filter assembly <NUM>. Pre-heater <NUM> can include a heating element <NUM>, which can be similar to heating element <NUM>. Heating element <NUM> can include a Calrod, resistive-type electrical heating device(s), gas-based heating device(s), a thin-film heating element(s), a tube heating element(s), combinations thereof, among other types of heating elements, as known in the art or developed. The heating element <NUM> can be heated to approximately <NUM>-<NUM> in preferred embodiments, which can represent a temperature higher than a fluid being heated within the pre-heater chamber <NUM>.

The pre-heater <NUM> can also include a fluid intake <NUM> which can be mounted to the pre-heater <NUM> by a lower plate <NUM>. Preferably, after fluid is heated at pre-heater <NUM>, fluid exits the pre-heater <NUM> and passes to the filter assembly <NUM> via passage <NUM>, which can form an integral part of the connecting bridge <NUM> of the combined assembly <NUM>. Passage <NUM> can represent an operative and/or fluid connection as described herein. As fluid passes through the pre-heater <NUM>, solids can precipitate as described herein, pass out of the pre-heater <NUM> and be filtered and caught in the filter assembly <NUM>.

<FIG> is a side exploded cross-section view of various decalcification components <NUM> of a steam generator for use with a steam station that includes a pre-heater and an operative fluid flow and schematic control diagram, according to various embodiments.

Applicant hereby incorporates by reference <CIT>, in its entirety for all purposes.

According to another set of embodiments, various decalcification and/or fluid heating components <NUM> of a steam generator system can include a boiler <NUM>, where the system further comprises a (e.g., sub-boiling) a pre-heater (e.g., a pre-heat chamber) <NUM> and a filter assembly <NUM> between the water reservoir <NUM> and the boiler <NUM> for purposes described below. According to various embodiments, a component configuration <NUM> for a steam generator can include the pre-heater <NUM>, the filter assembly <NUM>, a water (or any other fluid) pump <NUM>, and the boiler <NUM>. All disclosed arrangements and embodiments display a particular arrangement of components, but it is also contemplated that each embodiment can alternatively include some or all shown components arranged in any other order. Each of the components, above, is described in greater detail, herein.

During the appliance operation, the water pump <NUM> will cause water to flow along the system from the water reservoir <NUM> to the boiler <NUM>, where it can boil and turn to steam. Depending on the appliance operation, the steam can immediately leave the boiler <NUM> and travel out the iron <NUM>, or it can accumulate in the boiler <NUM> or elsewhere until the user activates a steam function. Is it noted that iron <NUM> is merely an example of a steam delivery device, which can alternatively include a garment steamer head, or any other known or developed steam delivery device.

According to various embodiments, the pre-heater <NUM> receives a flow of water from the water tank and raises the temperature to preferably about <NUM>-<NUM> (i.e., below the boiling point of water), more preferably to <NUM>-<NUM>, but in some cases <NUM> or greater. In some embodiments the pre-heater <NUM> can heat to water to <NUM> or above. At above <NUM>, dissolved calcium carbonate in the water can precipitate and form solid particulates within the pre-heated, but preferably not, but optionally boiling, water. In other words, the calcium carbonate found in the water being heated is kept in the water, but converted from a dissolved form to a particulate form, suspended in the heated water. In some embodiments, a non-stick (e.g., PTFE, etc.) coating may be applied to the walls of the interior cavity <NUM> (or otherwise made to be composed of a non-stick substance as used herein) of the pre-heater <NUM> to resist precipitated calcification from adhering to the walls of the pre-heater <NUM>. The filter <NUM> is operatively located after the pre-heater <NUM> so it can trap and collect the solid particulates from the water, preventing them from reaching the boiler <NUM>. Water can be moved along fluid connections provided between the various components, and the pump <NUM> may preferably be located between filter <NUM> and boiler <NUM>. Pump <NUM> (or other pump(s)) can be located elsewhere so long as water flow is provided from water reservoir <NUM> through to boiler <NUM>, as needed.

As shown, the filter assembly <NUM> is operatively located after the pre-heater <NUM> so it can trap and collect the solid particulates from the water, preventing them from reaching the boiler <NUM>. Water can be moved along fluid connections provided between the various components, and the water pump <NUM> may preferably be located between filter assembly <NUM> and boiler <NUM>. Water pump <NUM> (or other pump(s)) can be located elsewhere so long as water flow is provided from water reservoir <NUM> through to boiler <NUM>, as needed. A gravity feed may also be used, for example, to supply water from reservoir <NUM> to pre-heater <NUM>.

Filter assembly <NUM> can include a filter cartridge <NUM> that can include one or more filter elements <NUM> and filter structure <NUM>, which can include structural rib(s) <NUM>. The filter elements <NUM> and the filter structure <NUM> together can be removed from the filter housing <NUM> as the filter cartridge <NUM>. The filter element(s) <NUM> (and optionally the filter structure <NUM>) can then be preferably emptied, rinsed, cleaned, and/or washed, and replaced for continued use. In one embodiment, simply removing the filter element(s) <NUM> and filter structure <NUM> as the filter cartridge <NUM>, turning them over, and running tap water over the unit can substantially empty and clean the filter components of the filter cartridge <NUM>. The filter element(s) <NUM> can comprise a stainless steel (or similar) mesh material, and may have a mesh pore size of about <NUM>-<NUM> microns, in various embodiments. The size of the mesh openings can be smaller or larger, but is preferably sized based upon the effective size of the precipitate that results from the pre-heating. A disposable filter element <NUM> can instead be used.

Various steam generation components can be fixed within the interior space of the steam generator base <NUM> in any known or developed manner. In various embodiments, one or more water pumps <NUM> can be utilized for assisting in the fluid flow of either the water or steam as may be desirable or necessary. Also, additional filter assemblies <NUM>, filter cartridges <NUM>, filter housings <NUM>, and other water treatment components can be included. Examples of filter elements <NUM> can include cylindrical, planar, and various other suitable shapes, sizes, and types of filter elements <NUM>, especially filters configured to separate particulate calcium carbonate or other calcification from water being filtered. Filter elements <NUM>, as used herein, can preferably include three-dimensionally usable filter elements <NUM>, where a total amount of filtration can be a function of the volume of the filter element(s) <NUM> of the filter cartridge <NUM> in use.

One advantage of described pre-heating systems is that they can increase the useful lifespan of the various steam generator components (in particular boiler <NUM>), as solids will be less likely to accumulate on the interior walls of the boiler cavity <NUM>, which presently reduce boiler <NUM> performance and life. The advantages of the pre-heat/filter based systems can be further improved by implementing a non-stick substance <NUM> on interior walls of the pre-heater <NUM>. Optionally, a similar non-stick substance <NUM> can be applied to inner walls of the boiler <NUM>. Boiler <NUM>, if otherwise strained by excessive calcium carbonate solid build-up, can become overworked, overheated, or otherwise malfunction or wear. By reducing solids build-up in the boiler <NUM>, and instead catching the solids in the filter assembly <NUM>, the filter assembly <NUM> can collect the solids, in a unit designed to do so. The combination of pre-heater <NUM> and filter assembly <NUM> may also prevent solids or particulates from travelling to the iron <NUM> and clogging up the iron <NUM>, its soleplate holes, or discoloring the garments. In various embodiments, and as described herein, various other steam delivery devices can be substituted for iron <NUM>.

Advantageously, the components of filter cartridge <NUM>, including the filter element <NUM> and filter structure <NUM> that together fit within the filter housing <NUM>, is preferably cleanable and reusable. Filter structure <NUM> preferably supports a number of filter elements <NUM> using structural rib(s) <NUM>. The filter element(s) <NUM> can comprise mesh panels in an arrangement around the filter structure <NUM> for particulate filtration from the water. The mesh size of the filter elements <NUM> can be based on particulate size. In preferred embodiments, water including particulates can be controlled to flow from filter inlet <NUM> to filter outlet <NUM> of filter housing <NUM> from an inside of filter element <NUM> to an outside, where the water once reaching the outside of the filter element <NUM> will have its particulates already filtered out of the water. As described herein, the filter assembly <NUM> components can take a cylindrical, inside-out water flow configuration (described above), as shown, or the filter assembly <NUM> may take any other suitable shape, such as a flat, planar filter configuration, among others. In this way, solids will be captured within and potentially fill the inside volume of the filter element(s) <NUM> and filter structure <NUM> of the filter cartridge <NUM>.

A schematically-shown water source <NUM> can include water reservoir <NUM> or any other water source <NUM>, as applicable. Water source <NUM> is fluidly connected and in fluid communication with pre-heater <NUM> via pre-heater inlet <NUM> and fluid conduit <NUM>. Water source <NUM> and/or fluid conduit <NUM> can also include various components, such as additional pumps, filters, junctions, heaters, etc. Once water from water source <NUM> reaches the pre-heater <NUM>, the water can completely or partially fill a pre-heater cavity <NUM> defined by walls <NUM>. An example of a pre-heater heating element <NUM> can be approximately shaped as a partial toroid, and can be attached to a lower side of pre-heater <NUM>. In this case, heat is conducted through the wall <NUM> to within the pre-heater <NUM> to heat the water.

In some embodiments, the location of the heating element <NUM> (whether inside or outside the pre-heater wall <NUM>) can affect the heating distribution of the water contained in the pre-heater <NUM> at a particular point in time. According to various embodiments, the heating element <NUM> can be located on a surface of the pre-heater <NUM>. Heating element <NUM> can include a Calrod, resistive-type electrical heating device(s), gas-based heating device(s), a thin-film heating element(s), a tube heating element(s), combinations thereof, among other types of heating elements, as known in the art or developed. Preferably, the heating elements are controllable so that water contained in the pre-heater will not reach a boiling point (but in some cases may reach a boiling point), but may be controlled to be heated to various temperatures. Any number and/or location of temperature, fluid flow rate, or volume sensors can be incorporated for controller <NUM> use.

Control systems (including controller <NUM>, which can be similar to controller <NUM>), as known, can be included to manage and maintain a desired water temperature within pre-heater <NUM>. For example, using various control systems, water temperature can be determined (and the water heated) as a function of heat applied to a present, past, or future flow rate of water. In preferable embodiments, the water can be heated in a continuous heating process at the pre-heater <NUM> and/or the boiler <NUM> meaning the water can enter the pre-heater <NUM> at a supplied temperature (likely ambient) from the water source <NUM> and at a flow rate, the water can be heated as it flows through or along the pre-heater <NUM> at the flow rate, and the water can exit the pre-heater <NUM> at a desired temperature to cause precipitation of the calcium compound from the water at the same flow rate. Alternatively, the water can be heated in stages or all at once as the water is supplied at a desired volume on a cycle by cycle basis.

Once water from water source <NUM> is pre-heated at the pre-heater <NUM>, the pre-heater outlet <NUM> may fluidly communicate the water and precipitate to filter assembly <NUM> by fluid conduit <NUM>. The water can enter the filter assembly <NUM> by filter inlet <NUM>, and the water may then pass through filter housing <NUM>, and filter element(s) <NUM>, which may preferably be supported by filter structure <NUM>. Filter element(s) <NUM> can be size, configured, and/or controlled to have a maximum water flow rate that exceeds typical need when the filter element <NUM> is relatively free of particulates and to allow for cases where filter element <NUM> is partially clogged with calcium carbonate (or other) particulates caught in pores of the filter element <NUM> (e.g., pore size of <NUM>-<NUM> microns or any other suitable pore size). In some embodiments, the filter element <NUM> of the filter cartridge <NUM> has a filter volume that fills with particulates as the particulates are filtered from the water flowing through filter assembly <NUM>.

Preferably, filter structure <NUM> and filter element <NUM> are removable as a unit from filter housing <NUM>, whereby the filter components can be emptied, cleaned, rinsed, and/or washed by a user or consumer. After removing and cleaning the filter components, the filter element <NUM> and filter structure <NUM> can be replaced back into the filter housing <NUM> of filter assembly <NUM>. In alternative embodiments, various replacement components (e.g., filter element <NUM> and filter structure <NUM> individually, or together as filter cartridge <NUM>) can be purchased in place of cleaning, especially, e.g., if the particular parts have been in heavy use for substantial amounts of time.

As shown in <FIG>, once the water has been filtered by filter assembly <NUM> and the particulates removed from the water, the filtered water can exit filter outlet <NUM> and enter the water pump <NUM> at pump inlet <NUM>. The filter outlet <NUM> can be configured to be in fluid communication with the pump inlet <NUM> by an operative connection such as fluid conduit <NUM>. Fluid conduits, as used herein, can include any suitable hose, conduit, conveyance means, connection, etc. capable of carrying and/or transferring a liquid and/or fluid, and that can be fixed in place by conventional means including clamps and the like. Fluid conduits can include various fluid, operative, and other connections.

Water pump <NUM> can include a pump housing <NUM> and a pump motor (not shown), which can be an electric motor, preferably. Water pump <NUM> can be controlled by a user or a controller (e.g., controller <NUM>) according to various embodiments. For example, water pump <NUM> can be activated to pump water into boiler <NUM> when boiler <NUM> is empty, low, or when a user has begun using the steam generator and/or steam station, among other circumstances.

The water pump <NUM> is shown in fluid communication with the boiler <NUM> via fluid conduit <NUM>. Fluid conduit <NUM> is connected to the water pump outlet <NUM> and the boiler inlet <NUM>. Boiler <NUM> includes a boiler housing <NUM>, a boiler cavity <NUM>, and a boiler heating element <NUM>. Boiler <NUM> can also optionally include a non-stick substance <NUM> on walls of the boiler cavity <NUM> to reduce occurrence of build-up on the boiler cavity <NUM> walls. The boiler heating element <NUM> can be similar to the pre-heater heating element <NUM>, or can be configured and/or controlled differently. In some embodiments, the boiler heating element <NUM> is located outside the boiler chamber <NUM>, but in contact with boiler housing <NUM>. Heating element <NUM> can include a Calrod, resistive-type electrical heating device(s), gas-based heating device(s), a thin-film heating element(s), a tube heating element(s), combinations thereof, among other types of heating elements, as known in the art or developed. Preferably, the heating elements are controllable so that water contained in the boiler <NUM> will reach the boiling point of water to generate steam. As described above, any number and/or position of temperature, fluid flow rate, or volume sensors can be located within the system.

The boiler <NUM> can be controlled to maintain an amount of steam when activated, awaiting only a user's input, such as an activation of steam through steam generator controls or switches, and having a nearly instant supply of steam when desired. In alternative embodiments, the boiler <NUM> can remain idle when the user is not steaming garments, or may merely pre-heat the water while awaiting further instructions prior to heating water contained in the boiler chamber <NUM> to the boiling point of water (e.g., <NUM>). In some embodiments, the boiler <NUM> can received about <NUM>-<NUM> grams or ml of water from water pump <NUM> at a time, as a cycle. Likewise, the pre-heater <NUM> can receive a similar amount (<NUM>-<NUM>) of water per user steam cycle or operation. In other embodiments, the pre-heater <NUM> and/or the boiler <NUM> can receive a constant or steady supply of incoming water and can continuously heat the water to create steam and/or water vapor.

Steam can be caused to exit the boiler <NUM> via boiler outlet <NUM>, which itself can be in fluid communication with a steam exit <NUM> via fluid conduit <NUM>. Steam exit <NUM> can be connected, for example, to a steam delivery device such as iron <NUM>, whereby the steam can be applied to a garment. The steam will preferably have little to no calcium carbonate that reaches the garment, as described. If iron <NUM> is used, the iron may have a control function whereby a user can choose a free flow or steam or a set steam cycle. In other embodiment, the steam flow may be determined automatically, for example, based on preset parameters or circumstances at controller <NUM>.

In some embodiments, the various steam generator components (e.g., pre-heater <NUM>, filter assembly <NUM>, water pump <NUM>, or boiler <NUM>) can contain varying amounts of fluids such as air or non-steam gas. For example, following pre-heating of water at the pre-heater <NUM>, the heated water can proceed to filter assembly <NUM>, but the filter assembly <NUM> may not be completely full with the pre-heated water. Therefore, filter assembly <NUM> can operate even when not fully filled with the pre-heated water. Some degree of air in the system, including at the filter assembly <NUM>, can be accommodated and may not substantially reduce the performance of the various components described, herein. In other embodiment, the system can be controlled to be completely filled with H<NUM>O, including water, water vapor, and/or steam in various locations. Some air can be present in the steam generation system without substantially affective performance, although a full system may be optimal for pumping or steam generation performance.

<FIG> is a flowchart of a process <NUM>, according to various embodiments. The process <NUM> can be in accordance with the description and structures of <FIG>, described herein. According to various embodiments, process <NUM> is a method of making a steam generator or steam station.

Process <NUM> can begin by providing a water heater having an interior surface and configured to heater water such that steam is produced at operation <NUM>. Process <NUM> can continue by providing a non-stick substance as at least a portion of the interior surface, the non-stick substance configured to reduce adhesion to the interior surface with respect to a calcium compound within the water, where the calcium compound in the water is caused to flow out of the water heater as calcium compound solids at operation <NUM>.

Process <NUM> can continue by providing a filter assembly in fluid communication with the water heater, the filter assembly including a removable particulate filter element configured to filter out at least some of the calcium compound solids received from the water heater at operation <NUM>.

In one particular experiment of the present invention by Applicant, when water with <NUM> parts-per-million (PPM) calcium concentration was heated and filtered according to embodiments of this disclosure, water exiting the water heater was found to have only <NUM> PPM calcium concentration in the stream, a reduction of about <NUM>% of the calcium previously in the water entering a steam station.

It is noted that while it may be preferable for various pre-heater devices as described herein to heat received fluid (e.g., water) to approximately <NUM>, even if water were to boil in a pre-heater, precipitated particulates/solids would still be beneficially separated from the fluid in question.

As noted in several embodiments, following a pre-heater apparatus (or optionally a boiler unit) a filter system can be implemented to collect precipitated particulates. The filter system can include a removable filter, a permanent filter, a pre-heater system configuration that stores the precipitated particulates and is user-cleanable, etc. Multiple possible configurations for capturing and removing the particulates from the system are contemplated.

Also as noted herein in various embodiments, a non-stick (or stick-resistant) layer can be applied on inside surface(s) of various pre-heater and/or boiler units to prevent particulates from sticking to the pre-heater walls, and thereby allowing the particulates to travel to a downstream filter, which can collect the particulates.

Various mechanical configurations are contemplated. In particular, one embodiment includes all separate components, such as separate and individual pre-heater, filter, and boiler components. Therefore, a steam generator base unit can include a water reservoir, a pump, a pre-heater, a filter, and a boiler, and a steam generator iron unit can be separate. In another embodiment, a pre-heater and filter system can be combined into a single unit with a separate boiler. In another embodiment, a filter system and boiler can be combined into a single unit, and the pre-heater system can remain separate and individual. In yet another embodiment, a pre-heater, a filter, and a boiler system can all be integrated into a single assembly.

In addition, various embodiments that employ a pre-heater can include configurations where the pre-heater is either horizontally or vertically mounted. In preferable embodiments, physical components can be placed between a pump and a boiler unit of an existing steam generator system.

Non-stick substances, coatings, etc. as used herein can alternatively be formed as one or more non-stick components that contact with liquid or water during heating. For example, in a case involving an example pre-heater, a tube can be a non-stick component implemented for non-stick purposes within the pre-heater. Non-stick components can take the form of cylinders, or other shapes that can be applied to, inserted into, or used with various water heaters, boilers, pre-heaters, and other fluid-exposed tubes and connections as used herein. A non-stick component can be formed such that an internal contour of a water heater is contoured by the non-stick component once formed, inserted, etc. Therefore, non-stick substances can be performed prior to implementation, and can be combined with, used with, and/or attached to various components described herein.

Claim 1:
A steam station apparatus for garments, comprising:
a first water heater (<NUM>, <NUM>) comprising a chamber (<NUM>, <NUM>) including a chamber interior surface and a heating element (<NUM>, <NUM>), and wherein the first water heater is configured to heat water such that steam is produced;
a first non-stick substance applied to at least a portion of the chamber (<NUM>, <NUM>) interior surface, the first non-stick substance configured to reduce adhesion to the chamber (<NUM>, <NUM>) interior surface of the first water heater (<NUM>, <NUM>) with respect to a calcium compound within the water;
a filter assembly (<NUM>) downstream of and in fluid communication with the first water heater (<NUM>, <NUM>), the filter assembly (<NUM>) including a particulate filter element configured to filter out at least some calcium compound solids received within a fluid flow from the chamber of the first water heater (<NUM>, <NUM>).