Steam iron and method of manufacture of the steam chamber

Details Steam iron and method of manufacture of the steam chamber Steam iron and method of manufacture of the steam chamber

1999-09-01

2001-04-03

Izaguirre, Ismael (Department: 3741)

Textiles: ironing or smoothing

Smoothing implements

Flatirons

Reexamination Certificate

active

06209239

ABSTRACT:

FIELD OF THE INVENTION
This invention relates generally to a steam iron and a method of manufacturing the same. This invention is primarily concerned with household steam irons but aspects of the invention may be useful in other applications.
BACKGROUND OF THE INVENTION
Steam irons commonly have a soleplate comprising a metal casting having insert-molded heating elements extending through the casting, typically along a generally U-shaped path parallel to the bottom of the soleplate. A portion of the top the soleplate is covered by a sheet metal lid to form a steam chamber. The steam chamber is typically divided into a vaporization section, a blast path, and a steam vent section. The steam vent section may be divided into two or more subsections which may or may not be in open communication with one another. The vaporization section is located within the area between the legs of the U-shaped path of the heating element. Steam is produced during the normal course of operation by water dripped into the vaporization section onto a heated, upwardly-facing surface of the soleplate. The water is heated as it flows along the upper surface of the soleplate and converted into steam. The steam thus produced exits from the vaporization section into the steam vent sections through tortuous steam channels formed by surfaces included in the design of the soleplate. Plural steam outlet vents in the steam vent section permit steam to exit from the bottom of the soleplate onto the fabric or other material being pressed by the steam iron.
The steam blast path is located directly above, or almost directly above, an elongate portion of the heating element. Steam created along the blast path usually enters the steam vent sections through the same tortuous channels, or a portion of such channels, along which steam formed in the vaporization section passes.
A pair of ribs, namely an outer rib and an inner rib define the sides of a blast path. The ribs are ordinarily covered and sealed by the steam chamber lid. If the seal between the outer rib of the blast path and the chamber lid fail, water or water vapor from the blast path could escape the blast path and enter directly into the steam vent section. As result, water could exit the steam vent and cause undesirable “trailing” of streaks of water on the material being pressed. Trailing can also occur if water which has not been entirely vaporized into steam, either in the vaporization section or along the blast path, is permitted to enter the steam vent sections through the steam channels which are intended to direct only steam into the steam vent sections.
SUMMARY OF THE INVENTION
This invention provides an improved steam chamber for a steam iron and a method of manufacturing the improved steam chamber.
A primary object of this invention is to provide manufacturing methods and steam iron constructions for reducing trailing caused by the passage of water from the steam vents of a steam iron.
A more specific object of this invention is to prevent water particles or mist carried by steam exiting from the outlet of either the vaporization section or the blast path from entering into the steam vent section. In addition to providing a tortuous path through which the steam must flow in order to enter the steam vent section, in accordance with this invention a baffle is located at the rear of the steam chamber. The baffle has a concave front face spanning across substantially the entire rearward end of the vaporization section. The baffle functions in a manner analogous to a concave mirror, with regard to the blast path, tending to direct vapor toward the center and the front of the vaporization section. The baffle also functions, with respect to the vaporization section and the blast path, to keep water particles not completely vaporized from entering into the steam vent sections. Water particles striking the baffle will tend to accumulate and puddle in front of the baffle. Advantageously, the blast path has rearwardly facing openings that tend to direct vapor exiting from the blast path toward the baffle. Accordingly, whether the source of any water particles that have not been completely vaporized in the vaporization section or the blast path, the water will be confined in front of the baffle and be restrained from entering into the steam vent sections.
Another more specific object of this invention is to provide an improved seal between the steam chamber lid and the ribs that define the sides of the blast path. In accordance with this aspect of the invention, the inner and outer ribs forming the sides of the blast path are at different heights, the inner rib being slightly lower than the outer rib, and, during manufacture, the steam chamber lid is pressed onto the inner and outer ribs with sufficient force that the lid is sealed to the tops of both the inner and the outer ribs. Rivets are provided to help maintain the seals between the lids and the inner and outer ribs. If a failure in the sealing of the lid to the ribs should occur, the failure is most likely to occur between the lid and the inner rib because the inner rib has a height lower than the outer rib. Upon the occurrence of such a failure, water may extend over the inner wall into the vaporization section but will not extend over the outer wall into the steam vent section. Water entering the vaporization section will most probably be completely vaporized into steam or else be confined to an area in front of the rear baffle, as described above, so that the failure of the seal between the inner rib and the lid will not lead to a trailing problem.
In another aspect of this invention, an object is to improve the response of a canister type thermal cut off device (TCO) to prevent an excessive thermal runaway of an iron. It is conventional to locate a TCO between the soleplate and the base cover of a steam iron. This invention follows such conventional practice and, in addition, provides a base cover having a dome in which the TCO is located. Accordingly, the TCO has a substantial volume of air surrounding it within which heat can be retained so that a thermal build-up is sensed more rapidly than if the TCO were closely confined between the soleplate and the base cover.
Other objects and advantages will become apparent from the following description and the drawings.


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