US3386582A - Water softener for use with an automatic washing machine - Google Patents

Description

June 4, 1968 B. J. BREZOSKY WATER SOFTENER FOR USE WITH AN AUTOMATIC WASHING MACHINE Filed March 50, 1966 2 Sheets-Sheet 1 FlG.l

v-us TToRUEV 4 5 3%. l A j 1 A h l 2 4'4- fl 33 June 4, 1968 B. J. BREZOSKY 3,386,582

WATER SOFTENER FOR USE WITH AN AUTOMATIC WASHING MACHINE Filed March 50, 1966 2 Sheets-Sheet 2 FIG].

INVENTOR. BERNARD I BREZOSKY BY F g {1 ms ATTQRMEQ United States Patent 3,386,582 WATER SOFTENER FOR USE WITH AN AUTOMATIC WASHING MACHINE Bernard J. Brezosky, Louisville, Ky., assignor to General Electric Company, a corporation of New York Filed Mar. 30, 1966, Ser. No. 533,706 7 Claims. (Cl. 210-436) ABSTRACT OF THE DISCLOSURE An improved water softener for an automatic washing machine, The softener is of the regenerative ion-exchange resin type including a resin containing chamber and an adjacent liquid inlet chamber. The inlet chamber is made substantially rectangular and either or both of its respective inlet spouts for raw Water and for regenerating solution are angularly oriented relative to the inlet chamber wall to provide uniform distribution of these liquids throughout the cross-sectional area of the adjacent resin chamber. The regenerating solution spout is restricted to give jet action and also includes a check valve to prevent back flow from the softener to the source of regenerating solution.

This invention relates generally to an improved water softener and, more specifically, to a watersoftener particularly adapted for use with an automatic washing machine.

When a water softener is adapted for integral use with an automatic washing machine such as, for example, an automatic dishwasher, the design requirements involve space limitations. This is particularly true when it is desired to incorporate a water softener into an automatic washing machine without increasing the overall dimensions of the washing machine. Moreover, in the present era of sophisticated homemakers, any improvement in automatic washing machines must not compromise the automatic feature of the machine. Therefore, a water softener integrated with an automatic washing machine must be automatically operative and automatically regenerated if it is to be commercially acceptable. The foregoing factors place strict design limitation on any water softener proposed for incorporation into an automatic washing machine. Because the size is limited, the efficiency of the water softener must be maximized so that the limited amount of ion-exchange media will adequately reduce the calcium content of the volume of water necessary within the time available. Since this operation must be automatic, and integrated with the normal operational cycle of the washing machine, regeneration of the ion-exchange media must take place automatically and must not unreasonably elongate the overall operational cycle of the automatic washing machine. Therefore, regeneration must take place within the shortest time possible.

In view of these criteria, flow through the ion-exchange media during both the softening process and the regeneration process becomes critical. If the flow of water through the ion-exchange media is substantially evenly distributed throughout the cross-sectional area of the chamber containing the media, the media is more efficiently uti lized during softening process and therefore the amount of media can be kept to a minimum. Similarly, if the flow of regenerating solution into the chamber containing the ion-exchange media is substantially uniformly distributed throughout the cross-sectional area of the chamber, regeneration is more eflicient, resulting in less solution and shorter time being required for regeneration.

Accordingly, it would be desirable to provide in a water softener for use with an automatic washing machine 3,386,582 Patented June 4, 1968 means to cause substantially even distribution, throughout the cross-sectional area of the chamber containing the ion-exchange media, of both water flowing through the media during softening and regenerating solution flowing into the chamber during regeneration.

It is an object of the present invention to provide an improved water softener particularly adapted for use with an automatic washing machine.

It is another object of this invention to provide means in a water softener to assure reasonably even distribution of flow throughout the cross-sectional area of the chamber containing the ion-exchange media during the softening process.

It is another object of this invention to provide means in a water softener to assure reasonably even distribution of flow into the cross-sectional area of the chamber containing the ion-exchange media during regeneration of the ion-exchange media.

Briefly stated, in accordance with one aspect of the present invention, there is provided a water softener, for use with an automatic washing machine, comprising a resin chamber adapted to receive and contain an ion-exchange mcdia. A substantially rectangular inlet chamber is provided adjacent to, and in liquid communication with, the resin chamber. A spout is provided in one wall of the inlet chamber to admit water to the inlet chamber and the spout has an angled relationship with that wall to direct the incoming water in a substantially diagonal direction across the inlet chamber.

In accordance with another aspect of the invention, a spout to admit regenerating solution to the inlet chamber is provided and has a reduced internal diameter to provide increased velocity of the regenerating solution as it leaves the spout and enters the inlet chamber. This spout may also be angled with respect to the wall of the chamber to direct the incoming regenerating solution in a substantially diagonal direction across the inlet chamber.

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention, it is believed the invention will be better understood from the following description taken in connection with the accompanying drawings, in which:

FIGURE 1 is a side view, partly cut away to show details, of an automatic dishwasher employing the present invention;

FIGURE 2 is an elevational view, partly cut away to show details, of the water softener of the present invention;

FIGURE 3 is a sectional view taken along line 3-3 of FIGURE 2; and

FIGURE 4 is a fragmentary sectional view taken along line 4-4 of FIGURE 3.

Referring now to the drawings, and particularly to FIGURE 1 thereof, an automatic dishwasher 10 is provided with an outer cabinet 11 defining therein a wash chamber 12. Access to wash chamber 12 is provided by means of a closure member or door 13 which pivots about a substantially horizontal axis defined by a pair of hinges 14, only one of which is visible in FIGURE 1. Dish- sup porting racks 15 and 16 are provided within wash chamber 12 to support dishes or other articles to be washed therein.

The bottom wall 17 of wash chamber 12 has a centrally depressed portion forming a sump 18 wherein wash fluid or other liquids will collect. Disposed within sump 18, and supported by bottom wall 17, is a motor-pump assembly 19 including an electrically-reversible motor 20 and a pump 21. Pump 21 is provided with an inlet 22 through which fluid is withdrawn by pump 21 from sump 18 and, in one direction of rotation of motor 20, is propelled through an effluent discharge outlet 23 and, in the opposite direction of rotation of motor 20, is propelled upwardly into a spray means or spray arm 24. Spray arm 24 is mounted on the top of pump 21 for rotation about a substantially vertical axis and is provided with a plurality of orifices which eject the fluid pumped by pump 21 upwardly into wash chamber 12 to effectuate a wash action upon articles supported by racks 15 and 16. Certain of the orifices in arm 24 are directed in a manner whereby the reaction force created by the ejection of the fluid causes arm 24 to rotate,

A generally annular electrical-resistance heating ele ment 25 is supported by bottom wall 17 at one point by means of a bracket 26 and at another point by means of a flange 27 on element 25 and a threaded nut 28. Heating element 25 has an electrical terminal 29 to which an electrical conductor (not shown) may be connected to provide electrical energy to heating element 25. Heating element 25 may be employed to heat wash fluid present within the wash chamber 12 during the washing and/or rinsing operation of the dishwasher however, the more important function of heating element 25 is to effectuate drying of articles supported by racks and 15 upon completion of the washing and rinsing operations.

With the foregoing arrangement, a conventional complete dishwasher cycle of operation includes initially the admission of water into the wash chamber 12.. After a sufficient quantity of water has been admitted to wash chamber 12, motor is energized to rotate in a direction wherein the water is pumped by pump 21 up through spray arm 24 to effectuate a pre-rinse of the articles supported by racks 15 and 16. Motor 20 is then de-energized and then re-energized in the opposite direction of rotation so that Water is withdrawn from sump 13 and pumped out through discharge outlet 23. This sequence of events is repeated several times with at least one of the times including the addition of a detergent to the water. Following the final rinse, heating element is energized to heat the air within wash chamber 12 to facilitate drying of articles supported by racks 15 and 16. After completion of this drying cycle, all components of the dishwasher are de-energized and the complete cycle of operaation is terminated.

A water softener 30 is supported on the inner surface of outer cabinet 11, below bottom wall 17, :by means of a bracket 31. Referring briefly to FIGURE 2, it can be seen that water softener 34 is shaped substantially like a rectangular box and includes a resin chamber 32. Resin chamber 32 is defined at its upper extremity by an upper perforated partition or screen 33 and at its lower extremity by a lower perforated partition or screen 34-. Screens 33 and 34 have openings therethrough which allow water or other liquid to pass through but which prevent passage of the particulate ion-exchange resin, or other ion-exchange media, disposed within resin chamber 32. An opening 35 is provided in one wall of resin chamber 32 so that the ion-exchange media may be replenished or replaced if necessary. Opening 35 is provided with threads 36 which receive a threaded cap (not shown) to prevent the escape of liquid or ion-exchange media through opening 35. A rectangular inlet chamber 37 is defined at the lower portion of water softener 3G by lower screen 34 and the bottom wall of water softener 30. Similarly, an outlet chamber 38 is defined at the upper portion of water softener 30 by upper screen 33 and the upper wall of water softener 30. Outlet chamber 33 has a port 39 which opens into a passageway 40 extending downwardly adjacent resin chamber 32. A port 41 provides communication between the lower end of passageway 4t) and the lower portion of a reservoir 42. Reservoir 42 has a series of bafiies 43 projecting thereinto from the side walls defining reservoir 42. An outlet 44 is provided at the upper portion of reservoir 42.

With the foregoing arrangement, liquid entering inlet chamber 37 will pass upwardly through lower screen 34,

through resin chamber 32, through upper screen 33 and into outlet chamber 38. From outlet chamber 38, the liquid will pass through port 39, downwardly through passageway 40 and through port 41 into reservoir 42. The liquid will then flow upwardly through reservoir 42, following a tortuous path defined by baffles 43, and out through outlet 44.

Referring again to FIGURE 1, a water inlet conduit 45 is adapted for connection to a source of hard water (not shown). In the case of a portable dishwasher such as that illustrated in FIGURE 1, conduit 45 would be provided with means to removably connect it to a faucet associated with a kitchen sink. Customarily, the conduit 45 would be connected to the faucet at the beginning of the operational cycle of the dishwasher ltl and removed shortly after termination of the dishwasher cycle. Such connection and disconnection frequently results in air being trapped within conduit 45 and, as will become obvious hereinafter, this air can enter inlet chamber 37 creating an air lock therein. Water entering dishwasher 1% through conduit 45 encounters two electricallyoperated valves 46 and 47. Valve 46 is operated by solenoid 48 while valve 47 is operated by solenoid 49. When solenoid 48 opens valve 46, water passes from conduit 45 through valve 46 into conduit 50. Water passing through conduit 50 enters inlet chamber 37 by means of a spout 51 (FIG- URE 3). Water thus entering inlet chamber 37 will pass through water softener 30 in the manner described above and, as it passes through outlet 44, it will enter conduit 52. Conduit 52 extends across dishwasher 10 below bot tom wall 17 and then upwardly outside of wash chamber 12 in a compartment 53 defined by a housing 54 secured to, but having a wall spaced from, outer cabinet 11. Conduit 52 terminates in an inverted U-shaped nozzle 55 which directs water into a fill funnel 56 formed in the front wall of outer cabinet 11. Fill funnel 56 directs the water issuing from nozzle 55 into wash chamber 12.

Thus, it can be seen that all water entering wash chamber 12 for the purpose of washing or rinsing articles supported by racks 15 and 16 passes through the resin chamber 32 of water softener 30. In order to integrally associate the water softener with the dishwasher without increasing the overall size of the dishwasher, it is necessary to limit the size of the water softener. Accordingly, because the :size of the water softener is limited, and in turn the size of the resin chamber 32 is limited, it is necessary to periodically regenerate the ion-exchange media within resin chamber 32. To achieve regeneration, the valve 47 is opened by solenoid 49 and water is allowed to pass through valve 47 into conduit 57. Conduit 57 extends up into compartment 53 and terminates at a regenerating agent container 58 which is provided with a funnel-like inlet 59 so that regenerating agent may be inserted into container 58 conveniently. Inlet 59 is provided with a removable cap 60 which prevents water or wash fluid from entering container 58 during rinse or wash operation of the dishwasher 10. Water entering container 58 from conduit 57 places the regenerating agent in solution and forces the solution from container 58 into conduit 61. Conduit 61 extends down through compartment 53 and across dishwasher 10 below bottom wall 17 and communicates with inlet chamber 37 through a spout 62 (FIGURE 3). Thus, the regenerating solution entering inlet chamber 37 will, from that point on, follow the course described above with respect to water entering inlet chamber 37 through spout 51.

The most suitable regenerating agent for ion-exchange media is ordinary table salt (sodium chloride). The water passing through container 58 creates a saline solution which passes through conduit 61 and up through the ion-exchange media in chamber 32. As the saline solution is in contact with the ion-exchange granules, the granules release calcium ions in exchange for sodium ions released by the saline solution in a manner well known in the water softening art. However, the regenerating solution maintains a relatively high degree of salinity after regenerating the ion-exchange media. This high degree of salinity would prove corrosive to the components of the dishwater if it were immediately admitted to the dishwasher and allowed to remain therein for any substantial length of time.

Dishwasher is provided with a sequence control means (not shown) which energizes solenoid 49 to open valve 47 briefly at the one point during the operational cycle of dishwasher 10. This brief period during which valve 47 is opened results in the admission of saline solution in a quantity suflicient to immerse the ion-exchange media in chamber 32. The sequence control means maintains valve 47 closed for several minutes during which time regeneration of the ion-exchange media takes place. Following this, the sequence control means re-energizes solenoid 49 to open valve 47 a second time. The second opening of valve 47 allows a second charge of saline solution to enter resin chamber 32, displacing the first charge into reservoir 42. The system remains in this condition until solenoid 48 opens valve 46 to admit fresh water into resin chamber 32 displacing the saline solution in reservoir 42 and in chamber 32. During this time, motor is energized to rotate pump 21 in a direction so that any fluid entering pump 21 through inlet 22 will be discharged through outlet 23. Thus, the saline solution is displaced through conduit 52 into wash chamber 12 and immediately pumped into the sewer system by pump 21. Ballies 43 in reservoir 42 provide a tortuous path to assure that the saline solution does not short circuit from port 41 to outlet 44 during the time that the second charge of saline solution is being admitted to resin chamber 32. This minimizes the possibility of saline solution entering wash chamber 12 prior to the time when pump 21 would with draw it therefrom and pump it out through outlet 23.

The foregoing arrangement is described and claimed in pending application Ser. No. 538,707 of Norman L. Kendt, filed Mar. 30, 1966, for Dishwasher With Integral Water Softener, and assigned to the General Electric Company, assignee of the present invention.

The present invention is directed toward means to cause substantially even distribution, throughout the cross-sectional area of chamber 32, of both water flowing through the ion-exchange media within chamber 32 during softening and regenerating solution flowing into chamber 32 during regeneration. Because of height limitations, spouts 51 and 62 are located in side'by-side relationship rather than over and under. if the fresh water spout 51 were oriented squarely with the wall of inlet chamber 37 through which it passes, the water would flow along the adjacent wall of inlet chamber 37 creating a swirling action around the walls of inlet chamber 37 with extreme cavitation in the central area of chamber 37. Two problems are created with such an arrangement, the first problem is that little or no water flows up through the central portion of the ion-exchange media within chamber 32, creating poor efliciency due to the incomplete exposure of the media to the'water. Secondly, normal operation of a portable dishwasher, such as that illustrated in FIGURE 1, results in air being trapped in conduit 45, as described above. This air will form bubbles beneath lower screen 34 which, in effect, provide an air lock which blocks flow up through the central portion of the chamber 32. By orienting spout 51 in angular relationship with the wall of chamber 37, the incoming water is directed substantially diagonally across chamber 37 and into the opposite corner where it is broken up by random agitation. This action breaks up the air bubbles and disperses the air lock by forcing the bubbles through screen 34 and on through softener It also minimizes the swirling action which would otherwise be created.

The flow rate through spout 62, because it is handling regenerating solution, is significantly less than that through spout 51, and is approximately .1 gallon per minute. This is because flow rate through regenerating agent container 58 must be slow enough to allow the regenerating agent (sodium chloride) to dissolve in the solution with the water entering container 58. Accordingly, flow out of container 58 through conduit 61 is relatively low. With this low flow rate, if spout 62 were oriented squarely with respect to the wall through which it passes, the regenerating agent would only flow slowly along one side of inlet chamber 37 and up along one side of chamber 32 thereby resulting in a very inefficient regeneration of the ion-exchange media within chamber 32. Accordingly, spout 62 is oriented with respect to the wall through which it passes in a manner similar to the orientation of spout 51 to provide more uniform distribution across the cross-sectional area of chamber 37.

Moreover, the aforementioned low flow rate would result in the regenerating solution travelling only a short distance into chamber 37 which again would result in inefficient regeneration of the ion-exchange media. To overcome this latter problem, the internal diameter of spout 62 is tapered, as illustrated most clearly in FIGURE 4, or otherwise configurated to increase the velocity of the regenerating solution as it leaves spout 62 and enters chamber 37. This increased velocity carries it across chamber 37 for more even distribution throughout the cross-sectional area of chamber 37. Additionally, with the increased velocity, if spout 62 were squarely oriented with respect to the wall through which .it passes, it is pos sible that the aforementioned cavitation problem with respect to spout 51 would be created. The angular relationship between spout 62 and the wall through which it passes minimizes the likelihood of the cavitation problem during regeneration.

Referring briefly to FIGURE 4, spout 62 is shown in detail and reveals a check valve disposed therein. The check valve includes a movable member 63 having an elongated stem 64 with a sealing member 65 in one end thereof. The purpose of the check valve is to prevent the flow of liquid from chamber 37 int o conduit 61. Such flow, if it were allowed to occur, would result in fresh water finding its Way into container 5%. This fresh water would dissolve regenerating agent into solution and, as the pressure within water softener 30 decreased, the saline regenerating solution would find its way into chamber 37 thereby contaminating the fresh water then contained within softener 30. FIGURE 4 illustrates the check valve in the closed position. In the open position, sealing member 65' moves to the left until it engages surface 66. When in this position, liquid may flow around the outer periphery of the sealing member 65 and through passages 67. Stem 64 simply maintains sealing member 65 properly oriented with respect to the surface upon which it seats to prevent counterflow through spout 62.

Thus, it can be seen that the present invention provides, in a water softener for use in an automatic washing ma chine, means to cause substantially even distribution, throughout the cross-sectional area of the chamber containing the ion-exchange media, of both water flowing through the media during softening and regenerating solution flowing into the chamber during regeneration.

As will be evident from the foregoing descripton, certain aspects of the invention are not limited to the particular details of construction of the example illustrated, and it is contemplated that various other modifications or applications will occur to those skilled in the art. It is therefore intended that the appended claims shall cover such modifications and applications as do not depart from the true spirit and scope of the invention.

What I claim as new and desire to secure by Letters Patent of the United States is:

1. A water softener for use in connection with an automatic washing machine comprising:

(a) a resin chamber adapted to receive and contain an ion-exchange media,

(b) a substantially rectangular inlet chamber adjacent said resin chamber and in liquid communication therewith through a perforated partition, and

(c) a spout in one wall of said inlet chamber to admit unsoftencd water into said inlet chamber,

(d) said spout having an angled relationship with said wall to direct the incoming water in a substantially diagonal direction across said inlet chamber.

2. A water softener for use in connection with an automatic washing machine comprising:

(a) a resin chamber adapted to receive and contain an ion-exchange media,

(1)) a substantially rectangular inlet chamber adjacent said resin chamber and in liquid communication therewith through a perforated partition, and

(c) a spout in one wall of said inlet chamber to admit a regenerating solution into said inlet chamber for regeneration of said ion-exchange media,

(d) said spout having a reduced internal diameter to provide increased velocity of the regenerating solution as it leaves said spout and enters said inlet chamber.

3. The invention of claim 2 wherein said spout has associated therewith a check valve to prevent liquid flow in a direction from said inlet chamber.

4. The invention of claim 2 wherein said spout has an angled relationship with said wall to direct the incoming regenerating solution in a substantially diagonal direction across said inlet chamber.

5. The invention of claim 2 further comprising a second spout in said wall to admit unsoftened water into said 'inlet chamber, said second spout having an angled relationship with said wall to direct the incoming Water in a substantially diagonal direction across said inlet chamber.

6. The invention of claim 5 wherein said spout to admit 21 regenerating solution has an angled relationship with said wall to direct the incoming regenerating solution in a substantially diagonal direction across said inlet chamber.

7. A Water softener comprising:

(a) a resin chamber adapted to receive and contain an ion-exchange media,

(b) a substantially rectangular inlet chamber adjacent said resin chamber and in liquid communication therewith through a perforated partition,

(c) a spout in one wall of said inlet chamber to admit unsoftened Water into said inlet chamber, and

(d) means including a conduit to removably interconnect said spout with a source of unsoftened Water,

(c) said means, at least some times, trapping air within said conduit upon connection with the source of unsoftened Water with the trapped air travelling to said inlet chamber and forming an air lock therein,

(i) said spout having an angled relationship with said wall to direct the incoming water in a substantially diagonal direction across said inlet chamber to break up and disperse any air lock therein.

References ited UNITED STATES PATENTS 418,335 12/1889 Jewell 2l0l36 2,265,741 12/1941 Morse 210275 2,292,814 8/1942 Bariffi 68l3 X 2,776,755 1/1957 Craig 21G-4S6 X 3,148,687 9/1964 Dosch 68-43 X REUBEN FRIEDMAN, Primary Examiner.

F. SPEAR, Assistant Examiner.

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