Patent 10512385

Derivative works

Defensive disclosure: derivative variations of each claim designed to render future incremental improvements obvious or non-novel.

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Derivative works

Defensive disclosure: derivative variations of each claim designed to render future incremental improvements obvious or non-novel.

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Defensive Disclosure Document for Innovations in Dishwasher Rack Technology

Publication Date: May 1, 2026
Field: Domestic and Industrial Cleaning Appliances
Technology Area: Dishwasher Racks, Fluid Dynamics in Cleaning, Smart Appliances, Automated Washing Systems.

This document discloses a series of derivative inventions and improvements based on the core concepts described in U.S. Patent 10,512,385. The purpose of this disclosure is to place these concepts into the public domain, thereby establishing them as prior art for patent examination purposes.

Part 1: Derivatives of Coordinated, Parallel-Inclined Rack Systems

This section expands upon the concept of a dishwasher system comprising a first (e.g., upper) rack with a tiered bottom defining an effective inclination angle, and a second (e.g., lower) rack with a non-tiered, flat bottom wall inclined at a matching and parallel angle, as generally described in Claim 1 of US 10,512,385.

1.1 Material & Component Substitution

Derivative 1.1.1: Shape-Memory Alloy Rack with Thermal Actuation

  • Enabling Description: The wire structure of the first, tiered dish rack is fabricated from a nickel-titanium alloy (Nitinol) trained to have a shape memory effect. At room temperature (the "martensite" phase), the tiered sections of the rack are collapsed into a flat, horizontal plane, allowing for easier loading of bulky items. Upon the introduction of hot water (above ~50°C) during the initial rinse cycle, the alloy transitions to its "austenite" phase, causing the pre-programmed "memory" of the tiered structure to emerge. The rack automatically forms into its designed tiered configuration with a specific effective inclination angle. The lower rack, mechanically linked to the upper rack's support slides, is simultaneously tilted to a parallel angle by a simple cam mechanism activated by the upper rack's transformation. This provides the functional benefits of the parallel inclination only when thermally activated during a wash cycle.

  • Mermaid.js Diagram:

    stateDiagram-v2
    [*] --> Loading
    Loading: Upper Rack is Flat (Martensite)
    Lower Rack is Horizontal
    Loading --> Washing: Heat > 50°C
    Washing: Upper Rack transforms to Tiered/Inclined (Austenite)
    Washing: Cam mechanism tilts Lower Rack to parallel angle
    Washing --> Cooling: Cycle Ends
    Cooling: Upper Rack returns to Flat
    Cooling: Lower Rack returns to Horizontal
    Cooling --> [*]

Derivative 1.1.2: Rack with Superhydrophobic and Oleophobic Surfaces

  • Enabling Description: The wire frame of both the upper tiered rack and the lower inclined rack is coated with a nano-textured silica-based superhydrophobic and oleophobic coating. This coating creates a high contact angle (>150°) for both water and oils. The geometric inclination of the racks, as described in the base patent, is combined with this material science enhancement. The inclination provides the macro-level drainage path, while the superhydrophobic surface prevents the formation of residual droplets ("pinning"), ensuring near-perfect water sheeting and residue-free drying. This synergy reduces the energy required for heated drying cycles and minimizes spotting on glassware.

  • Mermaid.js Diagram:

    graph TD
    A[Water Spray] --> B{Dishware on Racks};
    B --> C[Macro-Drainage via Inclination];
    C --> D[Micro-Drainage via Superhydrophobic Surface];
    D --> E{Water Sheeting Effect};
    E --> F[Reduced Droplet Pinning];
    F --> G[Spot-Free Drying];

1.2 Operational Parameter Expansion

Derivative 1.2.1: Industrial Scale Conveyor-Belt Washing System

  • Enabling Description: This variation applies the core concept to a continuous-feed, industrial washing machine for applications like bottling plants or pharmaceutical vial cleaning. The "first rack" is a continuous conveyor belt with a surface molded into a series of transverse, tiered levels. The entire conveyor path is inclined, creating an "effective inclination angle." Below this primary conveyor, a "second rack" (a fixed, non-tiered, and perforated catch-pan) is positioned at a precisely parallel angle. This lower pan catches falling debris and drains cleaning fluid, while a series of high-pressure sprayers are located between the conveyor and the pan, ensuring consistent spray distance and angle to the items on the tiered belt.

  • Mermaid.js Diagram:

    graph LR
    subgraph Washing Tunnel
        direction LR
        A(Load Zone) --> B[Tiered Conveyor Belt];
        subgraph Cleaning_Chamber
            B -- Inclined at Angle X --> C[Washing Zone];
            D[Spray Nozzles] --> C;
            E[Inclined Catch Pan] -- Parallel at Angle X --> F(Drainage);
        end
        C --> G(Unload Zone);
    end

Derivative 1.2.2: Cryogenic Decontamination Chamber

  • Enabling Description: A sealed chamber for cryogenic cleaning uses a tiered rack system to support sensitive electronic components or medical implants. The upper rack is tiered to expose maximum surface area. The "treating liquid" is a spray of liquid nitrogen (LN2) or crushed CO2 pellets. The entire rack assembly, including the parallel-inclined lower rack (which is a solid, non-tiered surface in this case), is made from 316L stainless steel to withstand cryogenic temperatures. The parallel inclination ensures that the super-cooled contaminants, which become brittle upon contact with the cryo-agent, are shed from the parts and slide down the surfaces of both racks to a collection hopper, preventing re-contamination.

  • Mermaid.js Diagram:

    sequenceDiagram
    participant Controller;
    participant LN2_Spray;
    participant Tiered_Rack;
    participant Parallel_Pan;

    Controller->>LN2_Spray: Activate Spray;
    LN2_Spray->>Tiered_Rack: Apply Cryogenic Agent;
    Note over Tiered_Rack: Contaminants Freeze & Fracture;
    Tiered_Rack->>Parallel_Pan: Fractured Contaminants Fall via Gravity;
    Parallel_Pan->>Controller: Evacuate Contaminants from Hopper;

1.3 Cross-Domain Application

Derivative 1.3.1: Aerospace Turbine Blade Chemical Finishing

  • Enabling Description: A system for chemical etching or coating of complex-shaped turbine blades. A first, upper rack is custom-tiered, with each tier having fixtures to hold blades of a specific size and geometry. The tiered structure creates an effective inclination for optimal drainage of corrosive etchants. Below it, a second, non-tiered rack is inclined at a parallel angle and serves as a drip tray and secondary electrode (for electro-chemical processes). The parallel configuration is critical for maintaining a uniform electric field and ensuring consistent chemical exposure across all blades.

  • Mermaid.js Diagram:

    graph TD
    subgraph Etching_Tank
        A[Chemical Inlet] --> B{Spray Manifold};
        B --> C[Tiered Rack with Turbine Blades];
        C --> D[Parallel Inclined Drip Tray/Electrode];
        D --> E[Chemical Outlet];
    end
    style C fill:#f9f,stroke:#333,stroke-width:2px
    style D fill:#ccf,stroke:#333,stroke-width:2px

Derivative 1.3.2: Vertical Farming Nutrient Delivery System

  • Enabling Description: A hydroponics system for vertical farming. The "first rack" is a series of tiered grow beds, creating an overall slope. This allows for gravity-fed nutrient-film technique (NFT) irrigation. The "second rack" is a parallel-inclined, non-tiered root channel and collection gutter located directly beneath the grow beds. This parallel geometry ensures a consistent vertical distance between the plant roots and the nutrient channel, promoting uniform root development and preventing waterlogging or dry spots, while efficiently recycling the nutrient solution.

  • Mermaid.js Diagram:

    graph LR
    A[Nutrient Reservoir] --> B(Pump);
    B --> C{Top of Tiered Grow Bed};
    subgraph Grow_Tower
        C -- Gravity Flow --> D[Tier 2];
        D --> E[Tier 3];
    end
    E -- Runoff --> F[Parallel Collection Gutter];
    F --> A;
    style C fill:#9f9,stroke:#333
    style D fill:#9f9,stroke:#333
    style E fill:#9f9,stroke:#333

1.4 Integration with Emerging Tech

Derivative 1.4.1: AI-Optimized Adaptive Rack Geometry

  • Enabling Description: The upper rack consists of multiple, independently-actuated tiers. Each tier is mounted on a pivot and driven by a small stepper motor. The lower rack is mounted on a separate motorized tilting mechanism. An internal camera and a series of piezoelectric load sensors in the rack's base provide data to an AI model. The model identifies the types and positions of the dishes loaded. It then calculates the optimal "effective inclination angle" for the upper rack to maximize water exposure and drainage for that specific load. The AI directs the stepper motors to adjust the tiers accordingly and simultaneously adjusts the lower rack to maintain the parallel orientation, thus dynamically optimizing the dishwasher's internal geometry for every cycle.

  • Mermaid.js Diagram:

    sequenceDiagram
    participant User;
    participant Vision_System;
    participant AI_Controller;
    participant Rack_Actuators;

    User->>Vision_System: Loads Dishes;
    Vision_System->>AI_Controller: Send Image & Weight Data;
    AI_Controller->>AI_Controller: Calculate Optimal Inclination Angles;
    AI_Controller->>Rack_Actuators: Adjust Upper Tiers & Lower Rack Angle;
    Rack_Actuators-->>AI_Controller: Acknowledge Position;
    AI_Controller->>User: Signal "Ready to Wash";

Part 2: Derivatives of Glassware Rack with Integrated Sprayer

This section expands upon the concept of a dish rack with a specifically contoured bottom wall for holding glasses at an incline, which also integrates a mounting feature for a dedicated spray tube that moves with the rack, as generally described in Claims 13 and 17 of US 10,512,385.

2.1 Material & Component Substitution

Derivative 2.1.1: Flexible Elastomeric Spray Manifold

  • Enabling Description: The rigid spray tube is replaced with a high-durometer, food-grade silicone extrusion that functions as a flexible manifold. This manifold is press-fit into the "curved mounting portion" of the wire rack. Instead of discrete nozzles, the manifold has a series of laser-drilled micro-perforations angled towards the interior of the supported glassware. This design creates a fine, conical mist rather than a hard jet, providing more gentle but comprehensive coverage for delicate stemware. The flexibility of the material makes it more resilient to clogs from mineral deposits and less prone to damage.

  • Mermaid.js Diagram:

    graph TD
    A[Water Inlet Dock] --> B[Flexible Silicone Manifold];
    B -- Seated in Curved Rack Portion --> C{Micro-perforations};
    C -- Conical Mist --> D((Interior of Glass));
    style B fill:#bde,stroke:#333,stroke-width:2px

Derivative 2.1.2: Translucent Rack with Integrated Turbidity Sensing

  • Enabling Description: The dish rack is injection-molded from a high-temperature, translucent polymer such as polysulfone (PSU). An infrared (IR) LED and a phototransistor are embedded at opposite ends of the "curved mounting portion." This creates an active optical beam that passes through the wash water being agitated near the base of the glassware. The spray tube, also mounted along this path, has nozzles that create a vortex inside the glasses, drawing out soil. As soil is released, it attenuates the IR beam. The controller measures this attenuation to determine the real-time soil level and modulates the flow to the spray tube, continuing the spray until the water runs clear.

  • Mermaid.js Diagram:

    sequenceDiagram
    participant Rack_Controller;
    participant IR_LED;
    participant Phototransistor;
    participant Spray_Tube;
    participant Glass;

    Rack_Controller->>IR_LED: Activate;
    IR_LED->>Phototransistor: Emit IR Beam;
    Spray_Tube->>Glass: Spray & Release Soil;
    Note over Phototransistor: Soil Attenuates Beam;
    Phototransistor->>Rack_Controller: Report Light Level;
    Rack_Controller->>Spray_Tube: Adjust Pressure Based on Soil Level;

2.2 Operational Parameter Expansion

Derivative 2.2.1: Rack with Integrated Ultrasonic Transducers

  • Enabling Description: The "spray tube" is replaced by a solid-state cleaning system. A series of piezoelectric ultrasonic transducers are hermetically sealed and bonded along the "curved mounting portion" of the rack's bottom. When the rack is docked in the dishwasher, it connects to a high-frequency power supply. The transducers operate at 40 kHz, inducing acoustic cavitation in the surrounding wash water. The angled portion of the rack holds the glassware in the optimal focal zone of the ultrasonic field, directing the energy inside the glass. The implosion of cavitation bubbles provides microscopic scrubbing action, removing tough residues like lipstick or dried wine sediment without high-pressure water.

  • Mermaid.js Diagram:

    graph TD
    A[Power Dock] --> B[Ultrasonic Generator];
    B --> C{Piezoelectric Transducers};
    C -- Mounted on Curved Portion --> D[40kHz Sound Waves];
    D -- Propagate through Water --> E{Acoustic Cavitation};
    subgraph Glass_Interior
        E --> F[Micro-bubble Implosions];
        F --> G[Scrubbing Action];
    end

2.3 Cross-Domain Application

Derivative 2.3.1: Autoclave Cassette for Surgical Instruments

  • Enabling Description: An autoclave cassette for sterilizing hollow instruments (e.g., trocars, cannulas). The cassette's internal frame mimics the "contoured bottom" of the dish rack, holding instruments at a precise angle to ensure no air is trapped. The "spray tube" is a high-pressure steam lance integrated into the cassette. When docked in the autoclave, the lance receives steam from the main chamber and injects it directly into the lumens of the instruments, ensuring complete sterilization of internal surfaces, which is a common point of failure in standard autoclaving.

  • Mermaid.js Diagram:

    classDiagram
    class AutoclaveChamber {
        +SteamInlet
        +DockingPort
    }
    class InstrumentCassette {
        +ContouredInstrumentHolder
        +IntegratedSteamLance
        +ExternalConnector
    }
    class SurgicalInstrument {
        +Lumen (hollow channel)
    }
    AutoclaveChamber "1" -- "1..*" InstrumentCassette : contains
    InstrumentCassette "1" -- "1..*" SurgicalInstrument : holds
    InstrumentCassette ..> AutoclaveChamber : DocksWith

Derivative 2.3.2: 3D Printing Resin Removal System

  • Enabling Description: A post-processing rack for parts made via vat polymerization (SLA/DLP) 3D printing. The rack's wireframe has inclined portions to hold complex, resin-filled parts and allow uncured photopolymer resin to drain. The integrated "spray tube" is connected to a supply of a solvent like isopropyl alcohol (IPA). It features a series of narrow, high-velocity nozzles. The system sprays solvent into the internal cavities of the prints to flush them thoroughly before a final UV cure. The entire rack, with its integrated spray system, can be moved from the solvent bath to a UV curing chamber.

  • Mermaid.js Diagram:

    flowchart TD
    Start(Place Resin-Coated Part on Rack) --> A{Position part on inclined supports};
    A --> B[Move Rack to Cleaning Station];
    B --> C{Dock Spray Tube with IPA Supply};
    C --> D[Activate High-Velocity Solvent Spray];
    D --> E{Flush Internal Cavities};
    E --> F[Move Rack to Curing Station];
    F --> End(UV Cure);

2.4 Integration with Emerging Tech

Derivative 2.4.1: Machine Vision Guided Cleaning

  • Enabling Description: A dishwasher is equipped with an internal, water-proof camera. When the glassware rack is loaded and in the "treating position," the camera captures an image. A machine vision algorithm identifies (a) which slots in the rack are occupied and (b) the type of glassware in each slot (e.g., wine glass vs. heavy tumbler) based on its profile. The integrated spray tube is mounted on a rotational motor. The AI controller directs the spray tube to orient its nozzles specifically towards each detected glass and modulates the spray pressure and duration based on the glass type (e.g., lower pressure for delicate stemware). Nozzles corresponding to empty slots are deactivated.

  • Mermaid.js Diagram:

    sequenceDiagram
    participant Camera;
    participant AI_Controller;
    participant Spray_Tube_Motor;
    participant Nozzle_Valves;
    Camera->>AI_Controller: Send Rack Image;
    AI_Controller->>AI_Controller: Identify Glass Type & Position;
    AI_Controller->>Spray_Tube_Motor: Rotate to Target Glass #1;
    AI_Controller->>Nozzle_Valves: Open Valve for Glass #1;
    AI_Controller->>Spray_Tube_Motor: Rotate to Target Glass #2;
    AI_Controller->>Nozzle_Valves: Open Valve for Glass #2;

2.5 The "Inverse" or Failure Mode

Derivative 2.5.1: Fail-Safe Pressure-Actuated Docking

  • Enabling Description: The docking mechanism that connects the rack's spray tube to the dishwasher's water supply incorporates a mechanical, pressure-sensitive bypass valve. If the rack is not fully latched into its rearmost position, the fluidic connector is misaligned, and the valve remains closed, preventing water from being pumped. Furthermore, a secondary flow sensor is placed within the spray tube itself. If the controller detects pressure from the main pump but the flow sensor in the tube reads zero (indicating a clog or disconnection), the controller immediately shuts down the recirculation pump and flags a maintenance error. This prevents the system from spraying a high-pressure jet of water into the tub if the spray tube becomes detached from its mount.

  • Mermaid.js Diagram:

    stateDiagram-v2
    state "Not Docked" as NotDocked
    state "Docked" as Docked
    state "Washing" as Washing
    state "Fault" as Fault

    [*] --> NotDocked
    NotDocked --> Docked : Rack Pushed In & Latched
    Docked --> Washing : Cycle Start
    Washing --> Docked : Cycle End

    Washing --> Fault : Pressure_OK AND Flow_Zero
    Docked --> NotDocked : Rack Pulled Out
    Fault --> [*] : User Reset

Part 3: Combination with Open-Source Standards

3.1 Combination with MQTT for Smart Home Integration:

  • Enabling Description: The specialized glassware rack is equipped with an embedded ESP32 microcontroller and a flow sensor (e.g., YF-S201) at the water inlet of the spray tube. This microcontroller communicates over Wi-Fi using the lightweight, open-source MQTT protocol. The rack publishes real-time flow rate data to a topic such as dishwasher/rack/glass_sprayer/flow_rate on a local MQTT broker (e.g., Mosquitto). The dishwasher's main controller, or a separate home automation system (e.g., Home Assistant), can subscribe to this topic. This allows for verification of proper operation, detection of clogged nozzles (indicated by reduced flow), and logging of water usage for that specific zone, all using a widely adopted open standard for IoT communication.

3.2 Combination with OPC UA for Industrial Automation:

  • Enabling Description: An industrial parts washer, designed for cleaning items like fuel injectors using the rack geometry of Claim 13, is controlled by a Programmable Logic Controller (PLC). The PLC manages the movement of the rack, docking, and activation of the high-pressure solvent spray. This PLC runs an OPC UA server. OPC UA (Open Platform Communications Unified Architecture) is the prevailing open standard for machine-to-machine communication in industrial settings. A central factory control system (SCADA/MES) can connect to the washer as an OPC UA client to monitor cycle status, solvent pressure, and receive fault codes, allowing the patented rack system to be integrated seamlessly into a standardized, interoperable "Industry 4.0" environment.

3.3 Combination with KiCad/Gerber Open Hardware Design:

  • Enabling Description: The design for the printed circuit board (PCB) that powers the "AI/Machine Vision Guided Cleaning" derivative (Derivative 2.4.1) is created using KiCad, an open-source electronics design automation suite. The schematic, board layout, and bill of materials are made publicly available. The manufacturing output files are generated in the Gerber and Excellon formats, which are the de facto open standards for PCB fabrication. This disclosure provides a complete, open-source, and manufacturable blueprint for the electronic intelligence of the smart rack, teaching a person skilled in the art how to build the control system and integrate it with the mechanical rack, thus placing the specific electronic implementation in the public domain.

Generated 5/1/2026, 1:36:35 PM