Dishwashing apparatus and method

Abstract

A dishwashing apparatus comprises a housing containing a series of zones, each zone adapted for performing a step of a dishwashing cycle. A drive means transports a shuttle loaded with a soiled item in a loop from a loading/unloading area atop the housing, into the housing, through each of the wash-step zones and out of the housing back to the loading/unloading area. Different shuttle types are provided, each type adapted to carry one of: an individual item of plateware, an individual item of cupware or an individual place setting of cutlery. A method of washing dishes utilising the apparatus is described. The apparatus is compact for installation flush with countertop adjacent to a kitchen sink. The apparatus and method permit rapid and efficient washing of small numbers of items such as a single place setting.

Claims

1. A dishwashing apparatus comprising: a housing containing a series of zones, each zone adapted for performing a step of a dishwashing cycle; a loading/unloading area atop the housing; a plurality of shuttles for receiving and conveying soiled items, the shuttles arranged in rows, each row containing shuttles of a different type to each other row, the rows comprising: a row of plateware shuttles, each plateware shuttle configured to receive and carry an individual item of plateware, a row of cutlery shuttles, each cutlery shuttle configured to receive and carry an individual place-setting of cutlery and/or utensils, a row of cupware shuttles, each cupware shuttle configured to receive and carry an individual item of cupware; and a drive means comprising a plurality of independently operable drive mechanisms, each of said drive mechanisms configured for transporting a shuttle from one of said rows of shuttles in a loop from the loading/unloading area, through an ingress flap into the housing, through each zone, and through an egress flap out of the housing back to the loading/unloading area, wherein the drive means is operable to transport a shuttle from one row of shuttles independently of other shuttles from the same row and independently of shuttles from each other row of shuttles, and wherein each drive mechanism is configured to permit a shuttle that is transported out of the housing to free roll and stack up in a row with shuttles of like type in the loading/unloading area.

2. The apparatus of claim 1, in which the series of zones comprises a wash zone, a rinse zone and a drying zone.

3. The apparatus of claim 2, in which the series of zones further comprises a sanitation zone.

4. The apparatus of claim 1, in which each zone is separated from adjacent zones by a physical barrier, said physical barrier being displaceable to permit passage of one or more shuttles selected from a plateware shuttle, a cutlery shuttle and a cupware shuttle therethrough.

5. The apparatus of claim 1, in which each drive mechanism comprises a pair of track assemblies, each track assembly comprising a rack and pinion drive mechanism in which a pinion is sandwiched between a movable rack in the form of a loop and a fixed rack which is not a complete loop, permitting shuttles to rack together and remain in place at the loading/unloading area even when the movable rack is moving.

6. A method for washing tableware, which comprises: loading a soiled item of tableware into a shuttle located in the loading/unloading area atop the housing of a dishwashing apparatus according to claim 1; transporting the loaded shuttle through the series of zones contained in the housing, such that the soiled item is subjected to a full washing cycle; transporting the loaded shuttle out of the housing and returning it to the loading/unloading area, wherein each type of shuttle is transported through the housing independently of each other type of shuttle.

Description

DESCRIPTION OF THE DRAWINGS

(1) An embodiment of the invention shall now be described, by way of example, with reference to the drawings, of which:

(2) FIG. 1 is a diagram showing a top view of a dishwashing apparatus according to an embodiment of the invention.

(3) FIG. 2 is a diagram showing a side view of the dishwashing apparatus of FIG. 1 with front panel removed to show internal components.

(4) FIG. 3 is a diagram showing a top view of the dishwashing apparatus of FIG. 1 with the rack shuttles removed to expose the upper drain arrangement.

(5) FIG. 4 is a diagram showing in side view the drive mechanism and components for transporting shuttles through the apparatus of FIG. 1.

(6) FIG. 5 is a diagram showing a top view of the interior drain pan and additional components of the apparatus of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

(7) An embodiment of the invention shall now be described, by way of example, with reference to the accompanying figures.

(8) With reference to FIG. 1, the apparatus 100 is installed next to a kitchen sink 10 with the top of the housing, which comprises the loading/unloading area, level with the countertop 11. Apparatus 100 includes three separate rows of shuttles: a row of plateware shuttles 1, each made in a shape capable of accepting and holding typical plateware; a row of cutlery shuttles 2, each adapted to receive one or a few typical items of cutlery; and a row of cupware shuttle 3, each adapted to receive a typical glass/cup. Each shuttle is supported by a transversal axle having a sprocket type gear at each end, which sit in their own respective tracks, allowing the shuttles 1, 2, 3 to travel through the apparatus independently.

(9) Each of the shuttles 1, 2, 3, when loaded with a soiled item, travels down into the housing through respective ingress flaps 4, 5, 6, travels through successive wash-step zones and exits the housing through the egress flaps 7, 8, 9.

(10) As shown in FIG. 2, as each respective shuttle 1, 2, 3 enters the housing through the ingress flaps 4, 5, 6, they travel through four distinct zones, and processes.

(11) The first zone is the wash zone 17 which applies a wash cycle as the shuttles travel through the zone. The items are sprayed with dish soap, stored on board in dish soap tank 39, from several movable or stationary jet spray nozzles 13 located at different points and aimed at the soiled item/items.

(12) The second zone is the rinse zone 18, which sprays rinse water over the items from several movable or stationary jet spray nozzles 14, located at different points, aimed at the soiled item/items.

(13) The third zone is the sanitation zone 19, which sprays heated water or steam, to sanitize the items, from several, either movable or stationary jet spray nozzles 15, located at different points, aimed at the item/items to be sanitized.

(14) The final zone is a drying zone 20, which directs either heated or cool air onto the items from several either movable or stationary air nozzles 16, located at different points, aimed at the item/items to be dried.

(15) The drain tub 21, located at the bottom of the apparatus serves as a receptacle for water and debris, as well as housing the motors, dish soap tank, water heaters, steamers, and valves, power supply, controllers, etc., and is equipped with a drain trap 22 for debris collection.

(16) As shown in FIG. 3, the upper floor 23 of the apparatus which is located below the shuttles performs an additional role as a drain, as it allows discards and liquids to drain through this area and down into the housing and into the drain tub 21 below. This arrangement allows easy cleaning where the kitchen faucet can be used to rinse the entire shuttle rack area.

(17) In order to keep this surface clean several spray nozzles 24 are located throughout this area.

(18) The drive mechanism and components are shows in FIG. 4. The simple drive mechanism is made up of a pair of track assemblies, each consisting of a rack and pinion type drive mechanism, whereby the pinion 26 is sandwiched between two racks, one stationary or fixed rack 30 and one moveable drive rack or chain 25. The direction of travel of the moveable or drive chain 25, indicated by arrow 41, determines the direction of travel of the shuttles 1, 2, 3, indicated by arrow 42.

(19) The drive chain is in turn driven by a reversable AC or DC electric motor 29 equipped with a worm gear 28, for braking purposes. A sprocket or a tension device 27 is used to grasp the drive chain and move it along its designated track 25.

(20) The stationary track 30 does not create a complete loop but is terminated for a portion of the shuttle travel 31. This permits the shuttles to rack together 32, i.e., accumulate in a row, at the top of the apparatus and to remain in place even though the drive chain is moving. This results in each of the shuttles moving independently of the others.

(21) FIG. 5 shows the drain pan with additional internal components. The drain pan 21 receives all liquids and discards for disposal through the apparatus and into the municipal waste disposal system. A trap 33 for solids is provided so only liquids proceed into the drain 34.

(22) Other components include drive motors 35, 36, 37, water heater/steamer 38, dish soap tank 39, power supply 41, and controller 40.

(23) Operation of the disclosed apparatus will now be described.

(24) Each of the shuttles 1, 2, 3 is provided with a pair of tracks which enables the shuttles 1, 2, 3 to be carried, in any combination, through each of the four process cycles, namely, washing, rinsing, sanitizing and drying. All without user intervention.

(25) Each row of shuttles 1, 2, 3 operates independently of the other rows and shuttles, thus permitting each work item to proceed through the apparatus independently of the other items, allowing an as needed operation.

(26) A grill in the upper floor 23 below the all of the shuttles 1, 2, 3 permits debris to flow through the apparatus and into the lower drain pan 21 inside of the apparatus.

(27) As a soiled item is placed in its specific shuttle receptacle 1, 2 or 3, the shuttle descends into the housing and begins its progress through the wash-step zones.

(28) An ingress flap 4, 5, 6 for each row allows the shuttle 1, 2, 3 to enter into the apparatus. Wash step 1: as the shuttle 1, 2, 3 travels through the wash zone 17 the work (soiled item) in the shuttle 1, 2, 3 is sprayed with dishwashing soap from the spray nozzles 13 located underneath the grill, as well as the floor of the zone. Wash step 2: as the shuttle 1, 2, 3 continues to travel through the apparatus it enters the rinse zone 18 and the second cycle begins, where fresh clean water is sprayed onto the work in the shuttle, from other spray nozzles 14 located underneath the grill, as well as the floor of the zone. Wash step 3: as the shuttle 1, 2, 3 continues to travel through the apparatus it enters the sanitation zone 19 where the third stage cycle begins, where heated water or steam is sprayed onto the surface of the work in the shuttle as a sanitizing stage. Wash step 4: as the shuttle 1, 2, 3 continues to travel through the apparatus it enters the drying zone 20 and the fourth and final stage, the drying cycle, begins, where hot air or ambient air is blown over the surface of the work in the shuttle, as a drying and cooling process.

(29) At this point the shuttle 1, 2, 3 continues to travel back to the top surface of the apparatus through an egress flap 7, 8, 9, where the shuttle 1, 2, 3 is left to free roll and stack up behind the other respective shuttles on the exposed top portion of the housing (loading/unloading area) ready for unloading and reuse.