AU2006202065B2

AU2006202065B2 - An iron

Info

Publication number: AU2006202065B2
Application number: AU2006202065A
Authority: AU
Inventors: Mark Thomas
Original assignee: Newell Australia Pty Ltd
Current assignee: Newell Australia Pty Ltd
Priority date: 2005-06-28
Filing date: 2006-05-16
Publication date: 2010-09-02
Anticipated expiration: 2026-05-16
Also published as: AU2006202065A1

Description

S&F Ref: 764855 AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name and Address Sunbeam Corporation Limited, of Applicant: an Australian company, ACN 000 006 771, of Units 5 & 6, 13 Lord Street, Botany, New South Wales, 2019, Australia Actual Inventor(s): Mark Thomas Address for Service: Spruson & Ferguson St Martins Tower Level 35 31 Market Street Sydney NSW 2000 (CCN 3710000177) Invention Title: An iron Associated Provisional Application Details: [33] Country: [31] Appl'n No(s): [32] Application Date: AU 2005903412 28 Jun 2005 The following statement is a full description of this invention, including the best method of performing it known to me/us:

CQAC-

I AN IRON Technical Field The present invention relates to irons and more particularly but not exclusively to domestic irons that provide for the rapid delivery of a burst of steam (typically known as a "shot" of steam). 5 Background of the Invention Irons are provided with a heated soleplate. Embedded in the soleplate is a heating element that heats the ironing surface as well as water delivered to a steam chamber at least partly enclosed by the soleplate. Frequently water is pumped to adjacent to the heating element to provide a shot of steam. 10 The above discussed iron has a number of problems that arise when ironing at relatively low temperatures, that is temperatures applicable to delicate fabrics. When operating at low temperatures steam generation is frequently unreliable with the result that water droplets are delivered to the ironing surface and therefore the garment being ironed. This frequently leads to staining of the garment. The problem is exacerbated when a burst of steam is to 15 be generated. The above discussed problems are at least partly addressed by separating the steam chamber from the soleplate. By separating the steam chamber, and providing the steam chamber with its own heating element, the steam chamber can be operated at a raised temperature irrespective of the soleplate temperature. Such an arrangement is disclosed in British Patent 2383587and USA Patent 20 Application 2003/0094445. However the arrangement described in these two patent specifications does not address the issue of problems associated with producing bursts of steam. Accordingly typical domestic irons with built in water reservoirs cannot generate adequate steam when ironing at low temperatures because there is insufficient power in the heating element to evaporate the water. At low temperature, the steaming chamber of the iron soleplate fills with 25 water and eventually overflows, escaping through the steam holes of the soleplate. This results in damage to delicate fabrics and often presents staining as the water droplets may carry mineral deposits built up within the steam chamber over time.

2 The above problem is generally addressed by the inclusion of anti-drip mechanisms that prevents water entering the steaming chamber when the temperature of the iron is too low. These devices operate through a bimetallic plate that controls water flow through a regulating valve, or steam valve. While such mechanisms prevent water leaking at low temperatures, they also prevent 5 the production of steam. Any reference in this specification to the prior art does not constitute, nor should it be considered, an admission that such prior art was widely known or forms part of the common general knowledge in Australia, or in any other jurisdiction, before the priority date of any of the appended claims. 10 Object of the Invention It is the object of the present invention to overcome or substantially ameliorate at least one of the above discussed disadvantages, or at least to provide the public with a useful alternative. Summary of the Invention There is disclosed herein an iron including: 15 a soleplate assembly including a first heating element, a surface heated by said element and that is to contact an article to be ironed, the surface including a plurality of apertures, a first steam chamber, and ducting connecting said steam chamber to said apertures to provide for the delivery of steam to said surface; a steam chamber assembly attached to said soleplate assembly and including a second steam 20 chamber; a duct extending from said second steam chamber to said first steam chamber to provide for the flow of steam from said second steam chamber to said first steam chamber; a second heating element operatively associated with said chamber assembly to cause water delivered thereto to evaporate to produce steam; 25 a water reservoir to contain water; a user-controlled water burst delivery device connected to said reservoir to deliver bursts of water therefrom to said second steam chamber to produce, on demand from a user of the iron, bursts of steam.

3 In one embodiment, said water delivery device includes a regulated water delivery device to deliver a flow of water to said second steam chamber, wherein the iron includes a user control that enables the user to also control the follow of water delivered by the regulated water delivery device. In one embodiment, said iron includes a control mechanism to control the temperature of 5 said first heating element independently of said second heating element. In one embodiment, said second steam chamber is at least substantially coterminate with respect to said first steam chamber. In one embodiment, the duct extending from said second steam chamber to said first steam chamber passes through said chamber assembly. 10 In one embodiment, the user-controlled water delivery device delivers said bursts of water to a location substantially immediately adjacent to the second heating element. In one embodiment, said second steam chamber assembly includes a base encasing said second heating element, with said base having a recess extending longitudinally adjacent said second heating element and to which water is delivered to produce said bursts of steam. 15 In one embodiment, the second heating element includes two arms joined to form an approximate 'U' shape and wherein said recess extends substantially entirely along said arms. In one embodiment, each exit of the recess is located proximate the duct. In one embodiment, the second steam chamber includes a baffle between each exit of the recess and the duct, around which steam exiting each said exit must travel before entering the duct. 20 In one embodiment, when said surface is generally horizontally oriented said recess is located in a generally horizontal plane. In one embodiment, said recess follows a tortuous path. In one embodiment, said duct extending from said second steam chamber to said first stem chamber has an inlet opening and an outlet opening, with said outlet opening facing said soleplate 4 assembly, and said iron includes an insulating member adjacent said outlet opening so that steam leaving said outlet opening contacts said insulating member. In one embodiment, said insulating member is a plate attached to said soleplate assembly but having a substantial portion spaced therefrom. The insulating member may have a generally 5 convex shape. In one embodiment, said soleplate assembly includes a soleplate base within which the first heating element is embedded, and a plate attached to the soleplate base and providing the ironing surface. Further aspects of the present invention and further embodiments of the aspect described in 10 the preceding paragraphs will become apparent from the following description and the accompanying drawings. Brief Description of the Drawings A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings wherein: 15 Figure 1 is a schematic sectioned side elevation of an iron; Figure 2 is a schematic parts exploded isometric view of portions of the iron of Figure 1, Figure 3 is a schematic isometric view of a soleplate assembly of the iron of Figure 1; Figure 4 is an isometric view of the soleplate assembly of Figure 3 together with a steam chamber assembly; 20 Figure 5 is a schematic top plan view of the steam chamber assembly of Figure 4; Figure 6 is a schematic section side elevation of the assembly as shown in Figure 5 sectioned along the line "A-A"; Figure 7 is a schematic bottom plan view of the assembly of Figure 5; Figure 8 is a schematic top plan view of the assembly as seen in Figure 4; 25 Figure 9 is a schematic sectioned side elevation of the assembly of Figure 8 sectioned along the line "B-B", Figure 10 is a schematic sectioned and elevation of the assembly of Figure 8 sectioned along the line "C-C"; 5 Figure 11 is a schematic sectioned end evaluation of the assembly of Figure 8 sectioned along the line "D-D"; and Figure 12 is a schematic sectioned end elevation of the assembly of Figure 8 sectioned along the line "E-E". 5 Detailed Description of the Preferred Embodiments In the accompanying drawings there is schematically depicted an iron 10. The iron 10 has a body 11 providing a handle 12 and generally enclosing a reservoir 13 to receive water. Attached to the body 11 is a soleplate assembly 14 that includes a base 15 to which there is secured a plate 16. The plate 16 provides an ironing surface 17 that has a plurality of apertures 18 10 through which steam is delivered to fabric being ironed. Typically the base 15 is cast metal (typically an aluminum alloy) while the plate 16 is preferably stainless steel. The apertures 18 receive steam from a duct 19 that extends from adjacent the "nose" 20 to adjacent the rear 21. The base 16 includes a wall 22 that surrounds a first steam chamber 23. Embedded in the wall 22 is a heating element 24 that heats the base 15 and therefore the plate 16 15 and chamber 23. Closing the chamber 23 is a steam chamber assembly 25. The assembly 25 includes a base 26 and a plate 27. The plate 27 includes a lip 28 that is received within a recess 29 of the wall 22 to close the chamber 23. Typically a seal would be located in the recess 29 to sealingly connect the lip 28 and wall 22. As best seen in Figures 10 to 12 the plate 27 is spaced from the base 26 to aid in 20 insulating the chamber 23 from the base 26. The base 26 has a wall 30 that surrounds a further steam chamber 31, with a further heating element 32 being embedded in the wall 30. Typically the base 26 would be cast metal (typically aluminum alloy) while the plate 27 would be formed from sheet metal. The steam chamber 31 is closed by a plate 33. The plate 33 has a lip 34 that is received 25 within a recess 35 in the wall 30. Typically a seal would be located in the recess 35 to sealingly connect the plate 33 with the wall 30. The base 26 and plate 27 provide a duct 36 that provides for the flow of steam from the chamber 31 to the chamber 23. In particular the duct 36 has an outlet opening 6 37 that is located adjacent an insulating plate 38, with an inlet opening 39 communicating with the chamber 31. The plate 38 acts as an insulator so that steam and water exiting the outlet opening 37 does not directly engage the base 15 to thereby inhibit steam and/or water 5 being propelled backward into the chamber 31. Typically the plate 38 is a metal disc that is dome shaped. That is the plate 38 is at a lower temperature than the base 15. Water is delivered to the chamber 31 by a first water delivery device 40. The device 40 includes a shaft 41 having a longitudinal slot 42 that cooperates with a resilient seal 43. Movement of the slot 42 longitudinally varies the aperture size for a passage 10 extending from the reservoir 13 to the chamber 31 to thereby regulate the flow of water to the chamber 31. This passage includes a passage portion 44 that communicates with the reservoir 13 as well as the slot 42. The slot 42 communicates with a duct 45 extending to the steam chamber 31. An extremity of the shaft 41 is provided with a knob 46 that is gripped by a user is and caused to move angularly about the longitudinal axis 47 of the shaft 41 to cause longitudinal movement of the shaft 41 along the axis 47. The knob 46 has a series of slots 48 that locate the shaft 41 at the desired longitudinal position, exposing a desired portion of the slot 42 to thereby regulate the flow of water to the chamber 31. Accordingly a user by angularly moving the knob 46 can determine the "steady state" flow of steam from the 20 chamber 31, to the chamber 23 and therefore the duct 19. When a burst of steam is required an operator of the iron 10 manipulates a second water delivery device 47. The device 47 is essentially a pump including a pump chamber 48 that receives a piston 49. Extending from the piston 49 is a shaft 50 that terminates with a button 51. When the button 51 is depressed the piston 49 moves down 25 the chamber 48 to cause water to flow through the tube 52 for delivery to a recess 53. The recess 53 is located adjacent the heating element 32 so that a burst of steam is produced. The chamber 48 communicates with the reservoir 13 by means of a tube 54. A spring 55 is located in the chamber 48 to return the button 51 to the rest position.

7 Extending from the chamber 48 is a "one-way valve" 56 that provides for the flow of water from the reservoir 13 to the chamber 48 but prevents reverse flow so that water is forced to exit the chamber 48 through the tube 52. A further button 57 is provided that operates a pump 58. The pump 58 also 5 communicates with the reservoir 13 and delivers water under pressure to a nozzle 59 to deliver a spray of water to the fabric being ironed. The pump 58 is connected to the nozzle 59 by means of a tube knob illustrated. The recess 53 has a forward portion 60 to which water is delivered by the water delivery device 47. The recess 53 then diverges from the forward portion 60 along a 10 "tortuous" path as best seen in Figures 2 and 7. The recess 53 has rear portions 61 that communicate with the chamber 31 from where the steam exits via duct 36 to the chamber 23. Passages 62 provide for the flow of steam from the chamber 23 to the duct 19. Operatively associated with the water delivery device 40 is a valve 63. The is valve 63 is operated by a bimetal strip 64. The bimetal strip 64 when heated opens the valve 63 and permits water to flow to the water delivery device 40. However when the iron 10 is "cold" the strip 64 permits the valve 63 to close thereby blocking the flow of water. The heating element 24 has terminals 65 that receive current from a control 20 mechanism "processor" 66, while the heating element 32 has terminals 67 that also receive electric current governed by the processor 66. The processor 66 receives information from a control system operated by the user as well as temperature sensors 68. To prevent overheating of the iron 10 electrical safety thermostatic devices 69 are provided including temperature sensitive fuse elements 70. The devices 69 are controlled 25 via thermal conductivity with the respective base 15/26, preventing overheating of the plate 16 for a processor 66 in failure mode. In the operation of the above described iron 10, when the iron 10 is cold the water delivery device 40 is essentially inoperative since the valve 63 is closed. However 8 as the elements 24 and 32 heat their respective bases 15 and 26, the bimetal strip 64 opens the valve 63 so that water is delivered to the water delivery device 40. Thereafter when the iron 10 is generally positioned with the surface 17 horizontal, water flows through the device 41 at a regulated rate to the chamber 31. Water in the chamber 31 is heated by the 5 base 26 so that steam via the duct 36 is delivered to the chamber 23 from where it flows via passage 62 to duct 19 to be delivered to the fabric via openings 18. When a burst of steam is required the water delivery device 47 is operated to take water from the reservoir 13 and deliver it to the recess 53 where the water evaporates and is delivered to the duct 36 and therefore the chamber 23 and ultimately apertures 18. 10 By operation of the processor 66 a user of the iron can regulate the temperature of the base 15 independently of the base 26, that is independently regulated the flow of current to the heating elements 24 and 32. Accordingly steam can be generated even when the base 15 is operating at a generally low temperature, that is when the iron 10 is being used to iron delicate fabrics. Accordingly steam can be generated reliably 15 irrespective of the temperature of the base 15.

Claims

1. An iron including: a soleplate assembly including a first heating element, a surface heated by said element and that is to contact an article to be ironed, the surface including a plurality of apertures, a first steam 5 chamber, and ducting connecting said steam chamber to said apertures to provide for the delivery of steam to said surface; a steam chamber assembly attached to said soleplate assembly and including a second steam chamber; a duct extending from said second steam chamber to said first steam chamber to provide for 10 the flow of steam from said second steam chamber to said first steam chamber; a second heating element operatively associated with said chamber assembly to cause water delivered thereto to evaporate to produce steam; a water reservoir to contain water; water delivery means including a user-controlled water burst delivery device connected to 15 said reservoir to deliver bursts of water therefrom to said second steam chamber to produce, on demand from a user of the iron, bursts of steam.

2. The iron of claim 1, wherein said water delivery means includes a regulated water delivery device to deliver a flow of water to said second steam chamber, wherein the iron includes a flow control mechanism that enables the user to also control the flow of water delivered by the 20 regulated water delivery device.

3. The iron of claim 1 or 2, wherein said iron includes a control mechanism to control the temperature of said first heating element independently of said second heating element.

4. The iron of claim 1, 2 or 3, wherein said second steam chamber is at least substantially coterminate with respect to said first steam chamber. 25

5. The iron of any one of claims I to 4, wherein the duct extending from said second steam chamber to said first steam chamber passes through said chamber assembly.

6. The iron of any one of claims 1 to 5, wherein the user-controlled water burst delivery device delivers said bursts of water to a location substantially immediately adjacent to the second heating element. 10

7. The iron of claims 6, wherein said second steam chamber assembly includes a base encasing said second heating element, with said base having a recess extending longitudinally adjacent said second heating element and to which water is delivered to produce said bursts of steam. 5

8. The iron of claim 7, wherein said second heating element includes two arms joined to form an approximate 'U' shape and wherein said recess extends substantially entirely along said arms.

9. The iron of claim 7 or claim 8, wherein each exit of said recess is located proximate said duct.

10 10. The iron of claim 9, wherein the second steam chamber includes a baffle between each exit of the recess and the duct, around which steam exiting each said exit must travel before entering the duct.

11. The iron of any one of claim 7 to 10, wherein when said surface is generally horizontally oriented, said recess is located in a generally horizontal plane. 15

12. The iron of any one of claims 7 to 11, wherein said recess follows a tortuous path.

13. The iron of any one of claims I to 12, wherein said duct extending from said second steam chamber to said first stem chamber has an inlet opening and an outlet opening, with said outlet opening facing said soleplate assembly, and said iron includes an insulating member adjacent said outlet opening so that steam leaving said outlet opening contacts said insulating member. 20

14. The iron of claim 13, wherein said insulating member is a plate attached to said soleplate assembly but having a substantial portion spaced therefrom.

15. The iron of claim 14, wherein the insulating member has a generally convex shape.

16. The iron of any one of claims 1 to 15, wherein said soleplate assembly includes a soleplate base within which the first heating element is embedded, and a plate attached to the 25 soleplate base and providing the ironing surface. 11

17. The iron of any one of claims 1 to 16, wherein every entrance to said ducting connecting the first steam chamber to the apertures in the surface is located generally at a first end of the first steam chamber and wherein the duct extending from said second steam chamber to said first steam chamber is located to deliver steam generally at a second end of the first steam chamber. 5

18. The iron of any one of claims I to 17, wherein the second steam chamber includes a baffle, around which steam entering the first steam chamber from the second steam chamber must travel before entering the ducting connecting the first steam chamber to the apertures in the surface.

19. An iron including a first steam chamber and a second steam chamber substantially as herein described with reference to the accompanying drawings. 10

20. An iron substantially as herein described with reference to the accompanying drawings.