Steam Booster for Warewasher

Abstract

A steam booster for a warewasher or other industrial equipment comprises a tank having an inlet for connection to a water supply and an outlet for connection to a sprayer, a steam manifold including an inlet for connection to a supply of steam and an outlet for return of wet steam, a plurality of elongated steam circuits extending from the steam manifold and configured to be inserted into the tank through respective openings in the front face of the tank, an adapter assembly configured to be mounted to the front face of the tank, and a plurality of flexible hoses disposed around respective steam circuits, each flexible hose being connected at one end to the adapter assembly and at the opposite end to the manifold..

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to dishwashers and warewashers and more particularly to a steam booster for dishwashers and warewashers.BACKGROUND

[0002] Booster tanks are used in warewashers to heat water for rinsing wares. Hot water supplied to the booster tank at a temperature of about 110-120 degrees Fahrenheit is heated to about 180° Fahrenheit (F) and supplied to spray nozzles in the cabinet of the warewashers.

[0003] Conventional casted steam heat exchangers currently used in warewashers are heavy, expensive, and overpowered for low water consumption that the industry is moving toward. The steam to water ratio is very high, making it difficult to maintain the final rinse temp within the 15° F range (180° to 195°) that National Sanitation Foundation (NSF) allows. Surges of + / - 30° can occur depending on conditions. There is a need in the industry for a more efficient booster tank with low water consumption and more stable operating temperature.SUMMARY

[0004] The present disclosure relates to a steam booster for use in a warewasher. The steam booster comprises tank having an inlet for connection to a water supply and an outlet for connection to a sprayer, a steam manifold including an inlet for connection to a supply of steam and an outlet for return of wet steam, a plurality of elongate steam circuits extending from the steam manifold and configured to be inserted into the tank through respective openings in the front face of the tank, an adapter assembly configured to be mounted to the front face of the tank, and a plurality of flexible hoses disposed around respective steam circuits, each flexible hose being connected at one and to the adapter assembly and at the opposite end to the manifold.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 is a schematic diagram of a commercial warewasher.

[0006] FIG. 2 is an exploded perspective view of an exemplary steam booster for a warewasher.

[0007] FIG. 3 is a perspective view of an exemplary steam booster for a warewasher.

[0008] FIG. 4 is an elevation view of the steam booster.

[0009] FIG. 5 is an end view of the adapter assembly for the steam booster.

[0010] FIG. 6 is a section view of the steam manifold.

[0011] FIG. 7 is a section view of an end cap in a steam circuit.

[0012] FIG. 8 is a section view showing the connection between the steam manifold and steam circuit.

[0013] FIG. 9 is a front perspective of a warewasher with panels removed to show the steam booster.

[0014] FIG. 10 is a rear perspective view showing the water supply from the steam booster to the rinse arms.DETAILED DESCRIPTION

[0015] The present disclosure relates to a steam booster for rapidly heating water to a desired temperature. The steam booster is described herein in the context of a commercial warewasher. Commercial warewashing machines come in various styles, including undercounter, door-type, conveyor-type, and flight-type models, each designed to suit specific operational needs and volumes. The description of the warewasher herein is not intended to limit the application or use of the steam booster. Those skilled in the art will appreciate that the steam booster may be used in any type of commercial or industrial equipment that requires rapid heating of water.

[0016] FIG. 1 is a schematic diagram of a high capacity warewasher 10 designed for efficiently cleaning and sanitizing dishes, glassware, cookware, and utensils in food service and industrial settings. The main components of the warewasher 10 comprise a cabinet 12 defining a washing chamber 20, a conveyor 26 for conveying racks containing wares to be cleaned through the wash chamber 20, a wash tank 30 for storing a mixture of heated water and detergent, wash arms 40 connected to the wash tank for spraying the water / detergent mixture on wares conveyed through the washing chamber 20, a water heater 46 for heating water supplied to the wash tank 30; a steam booster 100 for heating rinse water to a desired temperature (e.g., 180° - 195° F); and rinse arms 50 connected to the steam booster 100 for spraying rinse water on the wares conveyed through the washing chamber 20.

[0017] The cabinet 12 is typically made of stainless steel for durability and hygiene. The cabinet 12 includes an entry opening 14 and an exit opening 16. Curtains 18 hang down from the top of entrance opening 14 and exit opening 16 respectively to contain the spray from the wash arms 40 and rinse arms 50. The curtains 18 typically comprises overlapping strips of plastic or rubber that also help contain heat in the washing chamber 20 thereby enhancing energy efficiency.

[0018] The cabinet 12 defines a washing chamber 20 that may be divided into two or more zones. In the illustrated embodiment, the washing chamber 20 comprises two zones: a wash zone 22 and a rinse zone 24. The wash zone 22 and rinse zone 24 may be separated by a curtain 18. Those skilled in the art will appreciate that the warewasher may have more than one wash zone and / or more than one rinse zone. Also, the washing chamber may comprise a single zone where both washing and rinsing take place.

[0019] A conveyor 26 transports racks containing wares to be cleaned through the wash chamber 20. The conveyor 26 may comprises a moving belt or series of individual rollers that mover racks through the wash chamber 20. One end of the conveyor 26 extends from the entrance opening 14 to provide a loading zone for loading racks of wares. The other end of the conveyor 26 extends from the exit opening 16 to an unloading zone where clean wares can be removed from racks. Those skilled the art will appreciate that the conveyor 26 is an optional component. For example, in a warewasher having a washing chamber 20 with a single zone, racks containing wares to be cleaned could be manually loaded into and unload from the washing chamber 20.

[0020] A wash tank 30 is typically disposed in the lower portion of the cabinet 12. The wash tank 30 is typically made of durable stainless steel to ensure resistance to corrosion, easy cleaning, and compliance with hygiene standards. The wash tank 30 includes a water inlet 32 connected to a water supply and an outlet 34 connected to the wash arms 40. A dispenser (not shown) automatically dispenses precise amounts of cleaning agents into the wash tank to ensure optimal cleaning performance. Some embodiments include insulation around the wash tank 30 to retain heat, improving energy efficiency and reducing operational costs. A manual or automatic drain valve (not shown) is located at the bottom of the tank for easy emptying during cleaning or water replacement.

[0021] A wash pump 36 draws water through the outlet and directs it to the wash arms 40. The wash arms 40 may comprise either rotating or stationary arms equipped with spray nozzles 42 that spray high-pressure water mixed with detergent onto the wares for cleaning as the wares are conveyed through the wash zone 22. Used water is filtered and recirculated through the wash tank 30 to conserve water and detergent.

[0022] The water heater 46 heats water supplied to the wash tank 30 to a desired temperature required for cleaning and sanitizing. In some embodiments, the water heater 46 comprises a heat pump located in the supply line between the water supply and wash tank 30, i.e., external to the wash tank 30. In other embodiments, the water heater 46 may comprise internal heating elements to heat the water / detergent mixture in the wash tank. The internal heating elements 46 may comprise electrical heating elements.

[0023] The steam booster 100 is designed to rapidly heat water to the high temperatures required for effective rinsing and sanitization and maintain the final rinse temp within a 15° F range (180° to 195°) that National Sanitation Foundation (NSF) allows. The steam booster 100 is disposed between the water supply and rinse arms. The steam booster 100 will be described in more detail below.

[0024] Water pressure pushes heated water from the steam booster 100 and directs it through the rinse arms 50. In some embodiments, a rinse pump (not shown) may be used to supply water to the rinse arms. The rinse arms 50 may comprise either rotating or stationary arms equipped with spray nozzles 52 that spray the heated rinse water onto the wares for rinsing the wares as they are conveyed through the rinse zone 24. Used rinse water can be filtered and recirculated through the wash tank 30 to conserve water.

[0025] A typical warewasher 10 includes many other components that are not material to the present disclosure and are therefore omitted for the sake of brevity. For example, the warewasher 10 may include a drying system 60 using heated air or condensation drying to quickly dry cleaned items. Additionally, a commercial warewasher 10 will typically have a control panel including a controller or other processing circuitry to control the operation of the warewasher 10. The control panel may include a user interface with a display and input controls that allows a user to manage and monitor the washing cycle.

[0026] FIG. 2 illustrates an exemplary steam booster 100 adapted for use with the warewasher 10 in FIG. 1. The main components of the steam booster 100 comprise a booster tank 102, a steam manifold 120 with three steam circuits 130, and an adapter assembly 150 for connecting the steam manifold 120 to the booster tank 102. A mounting system 180 is provided for mounting the steam booster to the cabinet.

[0027] The booster tank 102 comprises a generally cylindrical tank 104 having a water inlet 106 for connection to a supply of water and a water outlet 108 for connection with a sprayer in the rinse section of the warewasher. The booster tank 102 includes three openings 112 in a front face 110 of the booster tank 102. Threaded studs 114 extend from the front face 110 of the booster tank 102, which are used to connect the adapter assembly 140 to the booster tank 102. There are a total of nine threaded studs 114– three for each opening 112.

[0028] The steam manifold 120, shown in FIG. 6, comprises a housing 122, an inlet 126 for fresh steam, an outlet 128 for wet steam, and a dividing wall 123 that internally divides the manifold 120 into an inlet chamber 124 and an outlet chamber 125. Three steam circuits 130 extend from one side of the manifold 120. Each steam circuit 130 comprises a set of pipes forming a loop with an inlet side and an outlet side. The inlet side of each steam circuit 130 comprises one or more supply pipes 132 in fluid communication with the inlet chamber 124 of the manifold 120. The outlet side of each steam circuit 130 comprises one or more return pipes 134 in fluid communication with the outlet side 125 of the manifold 120. End caps 136 (FIG. 7) connect the distal end of the inlet pipes 132 and the distal ends of the return pipes 134 to form a loop.

[0029] Fresh steam enters the manifold through the inlet 126. The inlet chamber 124 distributes the steam flow to the inlet side 132 of the steam circuits 130. The end cap 136 redirects the flow of steam from the inlet pipes 132 to the return pipes 134. The steam flow through the steam circuits 130 heats water in the booster tank 102 to a desired temperature, e.g. 180° - 195° degrees Fahrenheit. The return pipes 134 return wet steam to the outlet chamber 125 of the manifold 120. Wet steam collected in the outlet chamber 125 is directed to the outlet 128 of the manifold 120.

[0030] The outer surface of the manifold 120 facing the booster tank 102 includes three hose connectors 138 that surround respective steam circuits 130 (FIG. 8). The hose connectors 138 provide means for connecting the flexible hoses 150 to the manifold 120. The flexible hoses 150 fit over the hose connectors 138 and are secured by hose clamps 152.

[0031] The adapter assembly 140 (FIG. 5) comprises three individual adapters 142, each including a hose connector 144 and flange 146. The flange 146 of each adapter 142 includes three openings that align with the threaded studs 114 protruding from the front face 110 of the booster tank 102. The adapter 142 is secured to the front face 110 of the booster tank 102 by nuts that screw onto the threaded studs 114. O-ring seals 148 are disposed between the flange 146 of each adapter 142 and the front face 110 of the booster tank 102 to prevent leakage of water contained in the booster tank 102.

[0032] Flexible hoses 150 connect the adapters 142 to the steam manifold 130. One end of each hose 150 fits around the hose connector 144 of a respective adapter 142 and the other end fits around a respective hose connector 138 on the manifold 120. Each end is secured by a hose clamp 152. Once assembled, the steam circuits 130 extend through respective hoses 150 and into the booster tank 102. The hoses 150 disposed around each steam circuit 130 allow for some movement and flexibility when assembling the steam booster 100 to account for manufacturing tolerances of the booster tank 102.

[0033] The steam booster 100 as herein described provides a more stable temperature than a conventional steam booster. The flexible coupling between the steam manifold and booster tank allows for manufacturing tolerances in the booster tank and reduces manufacturing costs.

Claims

1. A steam booster for a warewasher, the steam booster comprisinga tank having an inlet for connection to a water supply and an outlet for connection to a sprayer;a plurality of openings in a front face of the tank;a steam manifold including an inlet for connection to a supply of steam and an outlet for return of wet steam;a plurality of elongate steam circuits extending from the steam manifold and configured to be inserted into the tank through respective openings in the front face of the tank;an adapter assembly configured to be mounted to the front face of the tank; anda plurality of flexible hoses disposed around respective steam circuits, each flexible hose being connected at one and to the adapter assembly and at the opposite end to the manifold.

2. The steam booster of claim 1, wherein the adapter assembly comprises a plurality of individual adapters, each including a hose connector configured to connect to a respective hose and a flange for securing the adapter to the front face of the booster tank.

3. The steam booster of claim 2, further comprising seals disposed between the individual adapters and the front face of the tank.

4. The steam booster of claim 1, wherein steam manifold comprises a housing that is internally divided into an inlet chamber in fluid communication with the inlet and an outlet chamber in fluid communication with the outlet.

5. The steam booster of claim 4, wherein an outer surface of the housing facing the booster tank includes a plurality of hose connectors configured to connect to a respective hose.

6. The steam booster of claim 5, wherein each hose connector encircles a respective steam circuit.

7. The steam booster of the claim 4, wherein each steam circuit comprises an inlet side in fluid communication with the inlet chamber of the steam manifold and an outlet side that is in fluid communication with the outlet chamber of the steam manifold.

8. The steam booster of claim 7, wherein the inlet side of each steam circuit comprises at least one inlet pipe and wherein the outlet side of the steam circuit comprises at least one return pipe.

9. The steam booster of claim 8, wherein the inlet pipe and outlet pipe are connected by an end cap.

10. The steam booster of claim 8, wherein the inlet side of each steam circuit comprises two inlet pipes and wherein the outlet side of the steam circuit comprises two return pipes.

11. A warewasher comprising:a housing including a washing chamber;a spray arm in the washing chamber for directing water onto wares to be cleaned;a steam booster connected to the spray arm in the washing chamber, the steam booster comprising:a tank having an inlet for connection to a water supply and an outlet for connection to a sprayer;a plurality of openings in a front face of the tank;a steam manifold including an inlet for connection to a supply of steam and an outlet for return of wet steam;a plurality of elongate steam circuits extending from the steam manifold and configured to be inserted into the tank through respective openings in the front face of the tank;an adapter assembly configured to be mounted to the front face of the tank and having a plurality of hose connectors; anda plurality of flexible hoses disposed around respective steam circuits, each flexible hose being connected at one and to a respective hose connector and at the opposite end to the manifold.

12. The warewasher of claim 11 wherein the adapter assembly comprises a plurality of individual adapters, each including a hose connector configured to connect to a respective hose and a flange for securing the adapter to the front face of the booster tank.

13. The warewasher of claim 12, further comprising seals disposed between the individual adapters and the front face of the tank.

14. The warewasher of claim 11, wherein steam manifold comprises a housing that is internally divided into an inlet chamber in fluid communication with the inlet and an outlet chamber in fluid communication with the outlet.

15. The warewasher of claim 14, wherein an outer surface of the housing facing the booster tank includes a plurality of hose connectors configured to connect to a respective hose.

16. The warewasher of claim 15, wherein each hose connector encircles a respective steam circuit.

17. The warewasher of the claim 14, wherein each steam circuit comprises an inlet side in fluid communication with the inlet chamber of the steam manifold and an outlet side that is in fluid communication with the outlet chamber of the steam manifold.

18. The warewasher of claim 17, wherein the inlet side of each steam circuit comprises at least one inlet pipe and wherein the outlet side of the steam circuit comprises at least one return pipe.

19. The warewasher of claim 18, wherein the inlet pipe and outlet pipe are connected by an end cap.

20. The warewasher of claim 18, wherein the inlet side of each steam circuit comprises two inlet pipes and wherein the outlet side of the steam circuit comprises two return pipes.

21. The warewasher of claim 11, whereinthe washing chamber includes a wash zone and a rinse zone; andthe spray arm comprises a rinse arm in the rinse zone.

22. The warewasher of claim 11, further comprising a conveyor for transporting wares to be cleaned through the washing chamber.

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