CN111981452B

CN111981452B - Steam system and method

Info

Publication number: CN111981452B
Application number: CN202010440589.2A
Authority: CN
Inventors: D·P·弗雷尔
Original assignee: Kohler Co
Current assignee: Kohler Co
Priority date: 2019-05-22
Filing date: 2020-05-22
Publication date: 2023-02-28
Anticipated expiration: 2040-05-22
Also published as: CN111981452A

Abstract

A steam generator for a shower steam system includes a first chamber, a second chamber, and an intermediate heat transfer member. The first chamber is configured to receive water. The second chamber is configured to receive an air flow. An intermediate heat transfer member fluidly separates the first chamber from the second chamber. The intermediate heat transfer member includes a heating element configured to generate thermal energy. The intermediate heat transfer member is configured to transfer thermal energy generated by the heating element to the first chamber to generate steam in the first chamber and to transfer thermal energy generated by the heating element to the air flow in the second chamber.

Description

Steam system and method

Cross Reference to Related Applications

This application claims the benefit and priority of U.S. provisional application No.62/851,191, filed on 22/5/2019, the entire disclosure of which is incorporated herein by reference.

Background

The present disclosure relates generally to steaming systems and, more particularly, to a steam generator for controlling temperature and humidity in a sauna or shower environment.

In conventional steam generators, the heating element is typically immersed in a tank of water. The heating element may be operated to heat water until the water boils to produce steam, for example for use in a sauna or shower environment. This arrangement typically requires a significant amount of heat to raise the temperature of the water in the tank before any steam is generated, which can result in a relatively long start-up time. Furthermore, direct contact between the heating element and the water may cause calcium to gradually deposit on the heating element, thereby shortening the service life of the heating element.

Furthermore, the heating elements in conventional steam generators are typically cycled on and off to maintain an average temperature in the environment, which can cause temperature fluctuations in the water and make it difficult to accurately control the humidity level downstream of the steam generator.

It would be advantageous to provide a steam generator that addresses one or more of the above-identified deficiencies associated with conventional steam generators. These and other advantageous features will become apparent to those reading the present disclosure.

Disclosure of Invention

At least one embodiment relates to a steam generator for a shower steam system. The steam generator includes a first chamber, a second chamber, and an intermediate heat transfer member. The first chamber is configured to receive water. The second chamber is configured to receive an air flow. The intermediate heat transfer member fluidly separates the first chamber from the second chamber. The intermediate heat transfer member includes a heating element configured to generate thermal energy. The intermediate heat transfer member is configured to transfer thermal energy generated by the heating element to the first chamber to generate steam in the first chamber and to transfer thermal energy generated by the heating element to the air flow in the second chamber.

Another embodiment relates to a shower steam system. The shower steam system includes a steam generator, a nozzle, and a blower. A steam generator includes a first chamber, a second chamber, and an intermediate heat transfer member that fluidly separates the first chamber from the second chamber. The intermediate heat transfer member includes a heating element configured to generate thermal energy. The nozzle is in fluid communication with the first chamber and is configured to provide an atomized spray of water to the first chamber. A blower is in fluid communication with the second chamber and is configured to provide a flow of air to the second chamber. The intermediate heat transfer member is configured to transfer thermal energy generated by the heating element to the atomized water spray in the first chamber to generate steam and to transfer thermal energy generated by the heating element to the air flow in the second chamber to heat the air flow.

Another embodiment relates to a method of generating at least one of steam or hot air in a shower steam system. The method comprises the following steps: a signal is received by the steam generator to generate at least one of steam or hot air. The steam generator includes: a first chamber, a second chamber, and an intermediate heat transfer member fluidly separating the first chamber from the second chamber. The intermediate heat transfer member includes a heating element. The method also includes at least one of providing water to the first chamber or providing air flow to the second chamber in response to the received signal. The method also includes generating, by the heating element, thermal energy in response to the received signal. The method also includes transferring the generated thermal energy to the first chamber and the second chamber through the intermediate heat transfer member.

Drawings

FIG. 1 is a schematic illustration of a steam system including a steam generator, according to an exemplary embodiment.

Fig. 2 is a partial sectional view of the steam generator of fig. 1.

Fig. 3 is an exploded view of the steam generator of fig. 1.

Fig. 4 is a flowchart illustrating a method of generating steam and hot air according to another exemplary embodiment.

Detailed Description

Referring to the drawings in general, herein is disclosed a steaming system and method comprising a steam generator for providing steam and hot air to, for example, a sauna or shower environment. The disclosed steam generator includes a first chamber (e.g., a steam chamber, etc.) for receiving water from a water source. The first chamber is in fluid communication with an area that receives steam (e.g., a sauna, shower environment, or other area that receives steam). The steam generator also includes an intermediate heat transfer member that includes a heating element coupled to or integrally formed with the intermediate heat transfer member. The intermediate heat transfer member fluidly separates a first chamber from a second chamber (e.g., air chamber, etc.) of the steam generator. The second chamber may receive a flow of air from an air supply. The intermediate heat transfer member may transfer thermal energy generated by the heating element to the air flow to generate hot air. The intermediate heat transfer member may also transfer thermal energy from the heating element to indirectly heat the water received in the first chamber to produce steam. The hot air and steam generated by the steam generator are separately supplied to the shower environment or the sauna room to control the humidity and temperature therein.

The intermediate heat transfer member of the steam generator may advantageously help to distribute the thermal energy generated by the heating element to the water in the first chamber while avoiding direct contact between the water and the heating element. In this manner, the disclosed steam generator may more efficiently and quickly heat water to generate steam as compared to conventional steam generators. In addition, since the heating element is not submerged nor otherwise in direct contact with the water in the first chamber, the heating element is less likely to form calcium deposits, thereby extending the useful life of the heating element. In addition, by providing hot air and steam separately to the environment, the disclosed system allows for better and more accurate control of the temperature and humidity in the environment, as compared to conventional steam systems (which are typically cycled on and off only to maintain an average temperature in the environment).

Referring to fig. 1-2, a steam system 10 is shown according to an exemplary embodiment. The steam system 10 includes a steam generator 20 in fluid communication with an environment, schematically illustrated as an enclosure 30 defining an interior space 30a, for receiving steam and heated air from the steam generator 20. According to various exemplary embodiments, the enclosure 30 may be a sauna, a shower environment, or any other area for receiving steam and hot air. According to various exemplary embodiments, the enclosure 30 may be a partial or complete enclosure. The steam system 10 also includes a blower 14 (e.g., an air blower, an air pump, etc.), the blower 14 being fluidly coupled to the enclosure 30 by the first conduit 12. The blower 14 is also fluidly coupled to the steam generator 20 by a second conduit 13 a. The blower 14 is configured to receive an air flow (represented by arrow "a" in fig. 1) from an air supply, which is shown as the interior space 30a in the embodiment of fig. 1, although according to other exemplary embodiments, the air flow may be received from a different air supply (e.g., ambient environment). The blower 14 is further configured to direct the air flow a to the steam generator 20 via a second duct 13 a. The steam generator 20 includes an intermediate heat transfer member 28 configured to heat the air flow a and provide the heated air flow (represented by arrow "B" in fig. 1) to the interior space 30a via the third conduit 13B, thereby regulating the temperature of the interior space 30 a.

Referring to fig. 1-2, the steam generator 20 is also fluidly coupled to a water supply source 16, such as a domestic water supply, although other water supply sources may be used according to other exemplary embodiments. The steam generator 20 is configured to receive a flow of water from the water supply source 16 and heat the received water via an intermediate heat transfer member 28 to generate steam. The steam generator 20 is configured to guide the generated steam (indicated by arrow "C" in fig. 1) via the fourth conduit 18 to the inner space 30a of the enclosure 30, where the steam may be combined with the hot air generated by the steam generator 20. Steam may be provided to selectively increase the humidity of the interior space 30 a. In this manner, the steaming system 10 can separately provide heated air and steam to a sauna or shower environment to provide more precise temperature and humidity control than conventional systems that typically provide a combined flow of air and steam to the environment.

Referring to fig. 2-3, the steam generator 20 includes a first housing 21 defining a first chamber 21a. The first housing 21 has a generally rectangular parallelepiped shape with an open bottom to provide access to the first chamber 21a. According to other exemplary embodiments, the first housing 21 may have other shapes, such as spherical, hemispherical, trapezoidal, or other shapes that define a chamber. The upper portion of the first housing 21 includes a plurality of openings for accommodating various components in the first chamber 21a. For example, the first housing 21 includes a pair of first openings 21b for respectively at least partially accommodating the nozzles 23 therein. According to other exemplary embodiments, the first housing 21 may contain more or less than two openings 21b to accommodate a different number of nozzles 23. The first housing 21 further includes a second opening 21c at a middle portion of the housing 21. The second opening 21c is configured to be coupled to the fourth conduit 18 to fluidly couple the first chamber 21a to the enclosure 30 to distribute steam generated by the steam generator 20 to the enclosure 30. The first housing 21 further comprises a third opening 21d, the third opening 21d being adapted to at least partially accommodate a pressure relief valve 25 therein for controlling the pressure in the first chamber 21a.

According to the exemplary embodiment of fig. 2-3, each nozzle 23 includes a solenoid 24 electrically connected to a control system 40. Each nozzle 23 is also fluidly coupled to the water supply 16. The nozzle 23 is configured to receive a flow of water from the water supply source 16 and provide an atomized water spray 16a (e.g., fine water spray droplets, etc.) into the first chamber 21a in response to a signal received by the solenoid 24 from the control system 40. The received signal may represent a request to generate steam in a sauna or shower environment to increase the ambient humidity. The signal may come from a sensor (e.g., in response to a humidity level falling below a threshold, etc.), a mobile device, a thermostat, or other source. According to an exemplary embodiment, the flow rate of water to the nozzles 23 may be selectively controlled to adjust the temperature/humidity of the enclosure 30. For example, the solenoid 24 may be modulated between on and off to provide better temperature control than conventional systems that may have large temperature fluctuations. According to an exemplary embodiment, when the steam chamber or shower environment reaches a desired ambient temperature, the solenoid 24 may be pulsed on and off for a period of time to reduce the flow of water, thereby producing less steam. This allows for more precise control of the temperature in the steam chamber or shower environment.

Still referring to fig. 2-3, the steam generator 20 further includes a second housing 22 (e.g., manifold, air distributor, etc.) connected to the first housing 21 below the open bottom of the first housing 21. The second housing 22 has a second chamber 22a defined by a lower wall and two substantially parallel side walls. The second housing 22 defines a first end 22b and an opposite second end 22c. The steam generator 20 also includes an inlet adapter 27a coupled to the first end 22b or integrally formed with the first end 22 b. The steam generator 20 further includes an outlet adaptor 27b coupled to or integrally formed with the second end 22c. Inlet adapter 27a is configured to be coupled to second conduit 13a to fluidly couple second chamber 22a to blower 14. The inlet adapter 27a includes a partition 27a' disposed therein for distributing or redirecting the air flow from the blower 14 to the heat transfer elements of the intermediate heat transfer member 28 to heat the air flow, the details of which will be discussed in subsequent paragraphs. Outlet adapter 27b is configured to be coupled to third conduit 13b to fluidly couple second chamber 22a to enclosure 30 to direct heated air to enclosure 30. For example, the blower 14 may be selectively operated in response to signals received from the control system 40 to provide a flow of air to the second chamber 22 a. The received signal may indicate a request to generate hot air in a sauna or shower environment to increase the ambient temperature. The signal may come from a sensor (e.g., in response to a temperature level falling below a threshold, etc.), a mobile device, a thermostat, or other source. According to an exemplary embodiment, the amount of air from the blower 14 may be selectively controlled to adjust the temperature/humidity of the enclosure 30.

Still referring to fig. 2-3, the steam generator 20 further includes an intermediate heat transfer member 28 disposed between the first and

second housings

21 and 22. The intermediate heat transfer member 28 fluidly separates the first chamber 21a from the second chamber 22 a. A sealing member 26 (e.g., gasket, etc.) may be disposed between the first housing 21 and the intermediate heat transfer member 28 to provide a substantially water-tight seal of the first chamber 21a with the second chamber 22 a. The intermediate heat transfer member 28 includes an upper portion 28a, the upper portion 28a being configured to be at least partially exposed in the first chamber 21a. The upper portion 28a may extend the entire surface area of the open bottom of the first housing 21, thereby collectively defining a complete enclosure for the first chamber 21a. In other words, the top surface of the upper portion 28a defines the bottom wall of the first chamber 21. The upper portion 28a is configured to distribute thermal energy to the atomized water spray 16a in the first chamber 21a to generate steam in the first chamber 21a, the details of which are discussed below. In the illustrated embodiment, the upper portion 28a is substantially planar, however, it should be understood that the upper portion 28a may be substantially non-planar, or contain substantially non-planar portions, according to other exemplary embodiments.

The intermediate heat transfer member 28 also includes an intermediate portion 28b extending from the upper portion 28 a. The intermediate portion 28b contains one or more heating elements 29 disposed therein. According to an exemplary embodiment, the heating element 29 is integrally formed with the intermediate heat transfer member 28 to define a unitary member. According to other exemplary embodiments, the heating elements 29 are coupled to the intermediate portion 28b in respective openings defined in the intermediate portion 28b. The heating element 29 may be a resistive heating rod that is electrically coupled to the control system 40 of the steam system 10, thereby allowing selective control of the heating element 29, although it should be understood that other types of heat generating elements may be used instead according to other exemplary embodiments. The heating element 29 is configured to generate thermal energy in response to signals received from the control system 40 to selectively generate steam and/or hot air to control the humidity and/or temperature of the environment. According to an exemplary embodiment, the heating element 29 may be selectively switched on and off to adjust the humidity/temperature in the enclosure 30.

The intermediate heat transfer member 28 also contains a plurality of heat transfer elements (shown as fins 28 c) that extend from the intermediate portion 28b toward the second casing 22. The fins 28c are arranged laterally spaced from one another and each extend longitudinally between the first and second ends 22b, 22c. Fins 28c extend longitudinally into the second chamber 22a from the intermediate portion 28b to distribute thermal energy from the heating element 29 by conduction to the air flow received in the second chamber 22a (e.g., from the blower 14, etc.). The intermediate heat transfer member 28 is also configured to distribute thermal energy from the heating element 29 to the upper portion 28a by conduction, thereby generating steam within the first chamber 21a. The intermediate heat transfer member 28 may be made of a rigid or substantially rigid material (e.g., aluminum) having good heat transfer characteristics. In this manner, the steam generator 20 may heat water to generate steam more efficiently and more quickly than conventional steam generators. In addition, since the heating element 29 is not submerged nor otherwise in direct contact with the water in the first chamber 21a, the heating element 29 is less likely to form calcium deposits, thereby extending the useful life of the heating element 29.

Referring to FIG. 4, a method 100 of generating steam and hot air for a sauna or shower environment is shown, according to an exemplary embodiment. In a first step 110, control system 40 receives a signal (e.g., from a sensor, a mobile device, a thermostat, etc.) to produce at least one of steam or hot air to adjust the humidity and/or temperature of the sauna or shower environment. In a second step 120, in response to the received signal, the heating element 29 of the steam generator 20 is operated to generate heat energy. In a third step 130, if the received signal indicates a request for hot air (e.g., elevated temperature), the blower 14 may be selectively operated to provide a flow of air to the second chamber 22a of the steam generator 20. In a fourth step 140, the thermal energy generated by the heating element 29 may be transferred to the air flow via the intermediate heat transfer member 28 (e.g., fins 28c, etc.), thereby generating heated air in the second chamber 22 a. Heated air may be provided from the second compartment 22a to a sauna or shower environment to regulate the temperature. In a third step 130, if the signal received from the control system 40 indicates a request for steam (e.g., increased humidity), the nozzle 23 may be selectively operated to provide atomized water 16a from the water supply 16 to the first chamber 21a of the steam generator 20. In a fourth step 140, the thermal energy generated by the heating element 29 may be indirectly transferred to the atomized water 16a via the intermediate heat transfer member 28 (e.g., upper portion 28a, etc.), thereby generating steam in the first chamber 21a. Steam may be supplied from the first chamber 21a to the sauna room or shower environment to adjust the humidity.

In this manner, the disclosed steam generator 20 may more efficiently and quickly heat water to generate steam as compared to conventional steam generators. In addition, since the heating element 29 is not submerged and is not otherwise in direct contact with the water in the first chamber 21a, the heating element 29 is less likely to form calcium deposits, thereby extending the useful life of the heating element 29. In addition, by providing the heated air and steam separately to the environment, the disclosed system allows for better control of the temperature and humidity in the environment as compared to existing steam systems. Furthermore, the disclosed system may more accurately control the humidity/temperature of the environment by allowing control of the water flow rate to the nozzles 23, the amount of air from the blower 14, or the operation of the heating element 29.

As used herein, the terms "about," "approximately," "substantially," and similar terms are intended to have a broad meaning consistent with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure relates. Those of ordinary skill in the art who review this disclosure will appreciate that these terms are intended to allow a description of certain features described and claimed without limiting the scope of these features to the precise numerical ranges provided. Thus, these terms should be interpreted as: insubstantial or inconsequential modifications or alterations indicative of the described and claimed subject matter are considered to be within the scope disclosed in the appended claims.

It should be noted that the term "exemplary" and variations thereof as used herein to describe various embodiments are intended to indicate that such embodiments are possible examples, representations or illustrations of possible embodiments (and these terms are not intended to represent that such embodiments are necessarily extraordinary or superlative examples).

As used herein, the term "couple" and variants thereof refer to two members being directly or indirectly connected to each other. Such a connection may be fixed (e.g., permanent or fixed) or movable (e.g., removable or releasable). Such a connection may be made by the two members being directly coupled to each other, the two members being coupled to each other using a separate intermediate member and any other intermediate member, or the two members being coupled to each other using an intermediate member that is integrally formed as a single unitary body with one of the two members. If "coupled" or variations thereof are modified by additional terms (e.g., directly coupled), then the general definition of "coupled" provided above will be modified by the plain language meaning of the additional terms (e.g., "directly coupled" means that two members are connected without any separate intervening members), resulting in a narrower definition than that provided above. Such coupling may be mechanical, electrical or fluidic.

References herein to the position of elements (e.g., "top," "bottom," "above," "below") are merely used to describe the orientation of the various elements in the drawings. It should be noted that the orientation of the various components may differ according to other exemplary embodiments, and such variations are intended to be covered by the present disclosure.

The hardware and data processing components described in connection with the embodiments disclosed herein to implement the various processes, operations, illustrative logic, logic blocks, modules, and circuits may be implemented or performed with a general purpose single-or multi-chip processor, a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, certain processes and methods may be performed by circuitry that is dedicated to a given function. The memory (e.g., memory unit, storage device) may include one or more devices (e.g., RAM, ROM, flash memory, hard disk memory) for storing data and/or computer code to complete or facilitate the various processes, layers, and modules described in this disclosure. The memory may be or include volatile memory or non-volatile memory, and may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in this disclosure. According to an exemplary embodiment, the memory is communicatively connected to the processor via the processing circuitry and contains computer code for performing (e.g., by the processing circuitry or the processor) one or more processes described herein.

Although the figures and description may show a particular order of method steps, the order of the steps may differ from that depicted and described unless specifically noted above. Likewise, two or more steps may be performed concurrently or with partial concurrence, unless otherwise indicated above. Such variations may depend, for example, on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the present disclosure. Likewise, software implementations of the described methods could be accomplished with standard programming techniques with rule based logic and other logic to accomplish the various connection steps, processing steps, comparison steps and decision steps.

It is important to note that the construction and arrangement of the system as shown in the various exemplary embodiments is illustrative only. Additionally, any component disclosed in one embodiment may be combined with or used with any other embodiment disclosed herein.

Claims

1. A steam generator for a shower steam system, the steam generator comprising:

a first chamber configured to receive water;

a second chamber configured to receive a flow of air; and

an intermediate heat transfer member fluidly separating the first chamber from the second chamber, the intermediate heat transfer member comprising an upper portion configured to be at least partially exposed in the first chamber, an intermediate portion containing a heating element configured to generate thermal energy, and a plurality of heat transfer elements extending from the intermediate portion into the second chamber;

wherein the intermediate heat transfer member is configured to:

transferring thermal energy generated by the heating element through the upper portion to the first chamber to generate steam in the first chamber, an

Transferring thermal energy generated by the heating element to the air flow in the second chamber through the plurality of heat transfer elements.

2. The steam generator of claim 1, wherein the first chamber is defined by a first housing, and wherein the second chamber is defined by a second housing coupled to the first housing.

3. A steam generator according to claim 1, wherein the first chamber is configured to be in fluid communication with an enclosure via a first flow path, and wherein the second chamber is configured to be in fluid communication with the enclosure via a second flow path separate from the first flow path.

4. A steam generator according to claim 1, wherein the heating element is physically separated from the first and second chambers by the intermediate heat transfer member.

5. A steam generator according to claim 1, further comprising a nozzle in fluid communication with the first chamber, wherein the nozzle is configured to provide an atomized water spray to the first chamber.

6. A steam generator according to claim 1, wherein the second chamber is configured to receive the flow of air from a blower.

7. A steam generator according to claim 1, wherein the plurality of heat transfer elements are fins.

8. A shower vapor system comprising:

a steam generator, the steam generator comprising:

a first chamber;

a second chamber; and

a nozzle in fluid communication with the first chamber, wherein the nozzle is configured to provide an atomized water spray to the first chamber; and

a blower in fluid communication with the second chamber, the blower configured to provide a flow of air to the second chamber;

wherein the intermediate heat transfer member is configured to:

transferring thermal energy generated by the heating element through the upper portion to the atomized water spray within the first chamber to generate steam, an

Transferring thermal energy generated by the heating element to the airflow within the second chamber through the plurality of heat transfer elements to heat the airflow.

9. The shower steam system of claim 8, wherein the first chamber is defined by a first housing, and wherein the second chamber is defined by a second housing coupled to the first housing.

10. The shower steam system of claim 8, wherein the first chamber is configured to be in fluid communication with an enclosure through a first flow path, and wherein the second chamber is configured to be in fluid communication with the enclosure through a second flow path separate from the first flow path.

11. The shower steam system of claim 8, wherein the heating element is physically separated from the first and second chambers by the intermediate heat transfer member.

12. The shower steam system of claim 8, wherein the plurality of heat transfer elements are fins.

13. A method of generating at least one of steam or hot air in a shower steam system, the method comprising:

receiving, by a steam generator, a signal to generate at least one of steam or hot air, the steam generator comprising:

a first chamber;

a second chamber; and

an intermediate heat transfer member fluidly separating the first chamber from the second chamber, the intermediate heat transfer member comprising an upper portion configured to be at least partially exposed in the first chamber, an intermediate portion, and a plurality of heat transfer elements extending from the intermediate portion into the second chamber, the intermediate portion containing a heating element;

at least one of providing water to the first chamber or providing air flow to the second chamber in response to the received signal;

generating thermal energy by the heating element in response to the received signal; and

transferring the generated thermal energy to the first and second chambers through the upper portion of the intermediate heat transfer member and the plurality of heat transfer elements, respectively.

14. The method of claim 13, wherein providing water to the first chamber comprises injecting an atomized spray of water into the first chamber through a nozzle of the shower steam system.

15. The method of claim 13, wherein providing the air flow to the second chamber comprises generating the air flow by a blower of the shower steam system.

16. The method of claim 13, wherein receiving the signal to generate at least one of steam or hot air comprises receiving the signal by a controller of the shower steam system.