Patent 12232681

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 and Prior Art Publication

Title: Dish Rack and Utensil Containment Systems with Multi-Zonal Geometries and Integrated Technologies
Publication Date: May 1, 2026
Reference Patent: U.S. Patent 12,232,681

Preamble: This document describes various embodiments, modifications, and applications of a dish and utensil rack system featuring a multi-level or multi-angled bottom wall structure. The purpose of this disclosure is to place these concepts into the public domain, thereby establishing prior art against future patent applications that may seek to claim these or obvious variations thereof. The following descriptions are intended to be enabling for a person having ordinary skill in the art (POSA) of appliance design, mechanical engineering, and integrated systems.

Derivative 1: Material and Component Substitution

1.1. Shape-Memory Alloy (SMA) Actuated Tines

  • Enabling Description: The static "spaced pins" of claim 1 are replaced with active tines fabricated from a Nickel-Titanium (Nitinol) shape-memory alloy. In its martensitic state at room temperature, the tines are malleable or retracted, allowing for easy loading of bulky utensils. During the wash cycle, the heated water (above the SMA's austenite transition temperature, e.g., >60°C) causes the tines to revert to a pre-programmed "memory" shape. This shape is an upright, rigid position that securely separates utensils for optimal cleaning. As the rack cools post-cycle, the tines return to their malleable state. The tines are electrically isolated and mounted into a high-temperature thermoplastic base (e.g., PEEK) integrated into the angled portion of the rack.

  • Mermaid Diagram: State Transition

    stateDiagram-v2
    [*] --> Malleable
    Malleable: Low Temperature (<60°C) - Easy Loading
    Malleable --> Rigid: Apply Heat (Wash Cycle >60°C)
    Rigid: High Temperature (>60°C) - Utensil Separation
    Rigid --> Malleable: Remove Heat (Cooling Phase)
    Rigid --> [*]

1.2. Magnetorheological Polymer Rack with Adaptive Damping

  • Enabling Description: The entire dish rack frame is constructed from a composite polymer impregnated with magnetorheological (MR) fluid particles. The dishwasher tub is lined with a grid of individually addressable electromagnets. A controller, using input from an accelerometer on the rack, detects vibrations caused by water jets or user interaction. By selectively energizing the electromagnets, the controller can instantly and locally increase the stiffness of the rack's polymer structure. This actively damps vibrations, preventing delicate glassware in the "cup seat" depression from rattling against utensils in the "planar portion" and reducing overall operational noise.

  • Mermaid Diagram: Control Flow

    graph TD
    A[Accelerometer Detects Vibration] --> B{Vibration > Threshold?};
    B -- Yes --> C[Controller Identifies Vibration Zone];
    C --> D[Energize Corresponding Electromagnets];
    D --> E[MR Fluid Stiffens Rack Locally];
    E --> F[Vibration Damped];
    F --> A;
    B -- No --> A;

Derivative 2: Operational Parameter Expansion

2.1. Cryogenic Cleaning Rack for Medical Implants

  • Enabling Description: This embodiment adapts the dual-geometry rack for use in a cryogenic cleaning chamber utilizing liquid nitrogen (-196°C) and pressurized CO2 pellets for precision de-burring and sterilization of medical implants (e.g., titanium hip joints). The rack is machined from a single billet of cryo-treated 316L stainless steel to prevent thermal shock-induced fracturing. The "planar portion" features machined grooves for securing femoral stems, while the angled "depression portion" is shaped to cradle the acetabular cup component, ensuring all surfaces are exposed to the cleaning medium.

  • Mermaid Diagram: Component Diagram

    graph TD
    subgraph Cryogenic Cleaning Chamber
        A[Liquid Nitrogen Inlet] --> R;
        B[Pressurized CO2 Pellet Injector] --> R;
    end
    subgraph Cryo-Treated 316L Steel Rack
        P[Planar Portion with Grooves for Femoral Stems]
        D[Angled Depression for Acetabular Cups]
    end
    R[Rack Assembly] --> P;
    R --> D;

2.2. Microfluidic Lab-on-a-Chip Cleaning Cassette

  • Enabling Description: The invention is scaled down to a microfluidic cassette for cleaning and preparing multiple "lab-on-a-chip" devices simultaneously. The cassette, molded from transparent polycarbonate, is approximately 10cm x 10cm. It features a flat section where up to five standard-sized glass slides (the "utensils") are held by spring-loaded clips. An adjacent depressed, angled section holds custom-shaped microfluidic chips (the "cups"), orienting their input/output ports towards integrated fluid channels within the cassette. A peristaltic pump flushes reagents and cleaning solutions through these channels, performing a parallelized wash cycle at the microliter scale.

  • Mermaid Diagram: Flowchart

    graph LR
    A[Load Glass Slides onto Planar Section] --> C;
    B[Load Microfluidic Chips into Angled Depression] --> C;
    C[Place Cassette in Cleaning Apparatus] --> D[Engage Fluidic Manifold];
    D --> E[Pump Reagent 1 through Cassette];
    E --> F[Pump Wash Solution through Cassette];
    F --> G[Pump Drying Agent through Cassette];
    G --> H[Eject Cleaned Devices];

Derivative 3: Cross-Domain Application

3.1. Aerospace: Turbine Blade Inspection and Cleaning Jig

  • Enabling Description: A robust jig for use in automated Nondestructive Testing (NDT) and cleaning stations for jet engine turbine blades. The jig is made from a carbon-fiber-reinforced polymer. The planar section securely holds the blade's root and airfoil using custom-fitted clamps. The angled, depressed section is contoured to support the delicate tip and shrouded sections of the blade, preventing stress and ensuring precise orientation for robotic ultrasonic probes and high-pressure cleaning nozzles.

  • Mermaid Diagram: System Architecture

    graph TD
    Jig[Turbine Blade Jig]
    subgraph Jig
        P[Planar Section - Clamps Blade Root/Airfoil]
        D[Angled Depression - Supports Blade Tip/Shroud]
    end
    Jig --> P & D
    Blade[Turbine Blade] --> Jig
    subgraph NDT & Cleaning Cell
        RoboticArm[Robotic Arm] -- Mounts --> Probe[Ultrasonic Probe] & Nozzle[Cleaning Nozzle]
    end
    RoboticArm -- Interacts with --> Blade

3.2. AgTech: Vertical Farm Seed Pod Germination and Sanitization Tray

  • Enabling Description: A tray for use in an automated vertical farming system. The tray is molded from antimicrobial, food-grade polypropylene. A large planar area is perforated to allow even water flow and holds a nutrient film or substrate. An integrated, depressed channel (the angled section) features precisely spaced conical seats ("cup seats") that hold biodegradable seed pods. This dual-geometry allows a single tray to serve as both a germination station for new pods and a hydroponic bed for mature, substrate-grown leafy greens, optimizing space within a vertical farming rack. The entire tray can be run through an industrial washer between growth cycles.

  • Mermaid Diagram: Functional Diagram

    graph LR
    T[Dual-Function Tray]
    subgraph Tray
        PS[Planar Section - Perforated]
        DS[Depressed Channel with Conical Seats]
    end
    T --> PS & DS
    Substrate[Nutrient Film for Mature Plants] --> PS
    Pods[Seed Pods] --> DS
    Water[Water/Nutrient Flow] --> T

3.3. Consumer Electronics: Post-Soldering PCB Defluxing Cassette

  • Enabling Description: A cassette for an automated batch cleaning system for removing solder flux from Printed Circuit Boards (PCBs). The cassette is made from an ESD-safe polymer (e.g., carbon-filled ABS). The main planar area holds a motherboard via adjustable edge guides. A secondary, angled portion contains a series of fine-pitched slots ("spaced pins") designed to hold smaller daughterboards or flexible PCBs at a 45-degree angle. This orientation prevents fluid pooling and ensures the cleaning solvent effectively penetrates under dense BGA and QFN components on the smaller boards.

  • Mermaid Diagram: PCB Cassette Layout

    graph BT
    subgraph ESD-Safe Cassette
        direction LR
        A[Planar Section] -- Holds --> B(Main PCB);
        C[Angled Section with Slots] -- Holds --> D(Daughterboards at 45°);
    end
    E[Cleaning Solvent Spray] --> A;
    E --> C;

Derivative 4: Integration with Emerging Tech

4.1. IoT-Enabled Rack with Load-Sensing Tines

  • Enabling Description: The dish rack is equipped with piezoelectric sensors embedded at the base of the tines in both the planar and angled sections. These sensors measure the weight and distribution of the dish load. This data is transmitted wirelessly (via LoRaWAN or Bluetooth Low Energy) to the dishwasher's central controller. An AI algorithm uses this real-time load map to dynamically adjust water pressure, spray arm rotation speed, and cycle duration for maximum efficiency. The data is also sent to a cloud service, allowing the system to learn optimal loading patterns and provide feedback to the user via a mobile app ("Tip: Unblock the lower spray arm by rearranging plates").

  • Mermaid Diagram: Data Flow

    sequenceDiagram
    participant User
    participant RackSensors
    participant DishwasherECU
    participant CloudAI
    participant MobileApp

    User->>+RackSensors: Loads Dishes
    RackSensors->>+DishwasherECU: Transmit Weight & Distribution Data
    DishwasherECU->>+CloudAI: Send Load Data for Analysis
    CloudAI-->>DishwasherECU: Return Optimized Cycle Parameters
    DishwasherECU->>DishwasherECU: Adjust Water Pressure & Duration
    CloudAI-->>MobileApp: Send Loading Feedback/Tips
    MobileApp-->>User: Display Notification

4.2. Blockchain-Verified Sterilization for Commercial Kitchens

  • Enabling Description: For commercial or healthcare applications, the rack is given a unique, cryptographically secure identity (e.g., a PUF-based ID). Integrated temperature, pH, and turbidity sensors monitor the wash cycle. Upon successful completion of a validated sterilization cycle (e.g., reaching 82°C for 30 seconds), the rack's onboard microcontroller signs a data packet containing the cycle parameters, a timestamp, and the rack's unique ID. This packet is broadcast to a distributed ledger (blockchain). This creates an immutable, auditable record of sanitation compliance for health inspections, associating a specific batch of utensils with its verified cleaning event.

  • Mermaid Diagram: Blockchain Transaction Flow

    graph TD
    A(Start Wash Cycle) --> B{Sensors Monitor Parameters};
    B --> C{Cycle Meets Sterilization Criteria?};
    C -- Yes --> D[Microcontroller Signs Data Packet];
    D -- Packet: {RackID, Timestamp, Temp, pH} --> E[Broadcast to Blockchain Network];
    E --> F[Transaction Added to Ledger];
    F --> G(Immutable Record Created);
    C -- No --> H(Cycle Fails - Log Error);

Derivative 5: The "Inverse" or Failure Mode

5.1. Frangible, Color-Indicating Safety Tines

  • Enabling Description: The utensil-holding pins on the angled rack portion are molded from a brittle, engineered polymer with a low shear strength threshold. If a heavy object is improperly placed or dropped onto the rack, these pins are designed to snap off cleanly, preventing transfer of the damaging force to the main rack structure or the object itself. The polymer is also doped with a thermochromic pigment. If the dishwasher malfunctions and overheats, the pins permanently change color (e.g., from grey to bright red), providing a clear visual indicator that the rack's integrity may be compromised and that it should be inspected or replaced.

  • Mermaid Diagram: State Diagram

    stateDiagram-v2
    state "Normal Operation (Grey)" as Normal
    state "Structurally Compromised (Broken)" as Broken
    state "Heat Damaged (Red)" as Damaged

    [*] --> Normal
    Normal --> Broken: On Overload Event
    Normal --> Damaged: On Overheat Event (>100°C)
    Broken --> [*]
    Damaged --> [*]

Combination with Open-Source Standards

Scenario 1: MQTT for Smart Home Integration
The IoT-enabled rack (Derivative 4.1) can be configured to publish its data using the ISO/IEC 20922 (MQTT) protocol. A user could integrate the dishwasher into an open-source home automation platform like Home Assistant. This would enable custom automations, such as flashing smart lights in the kitchen when a cycle is complete or sending a notification to a family message group if the AI detects a suboptimal load that requires rearranging.

Scenario 2: RISC-V Embedded Controller
The onboard microcontroller used in the Blockchain-Verified Sterilization rack (Derivative 4.2) is based on the open-source RISC-V instruction set architecture. This allows for a transparent, auditable, and low-cost hardware implementation, which is critical for security applications. The firmware for signing and broadcasting transactions could be open-sourced to allow third-party security audits, building trust in the verification system.

Scenario 3: 3D-Printable Custom Inserts via STEP/3MF Files
The rack's planar and angled sections are designed with a standardized grid of mounting points. An open-source library of CAD files in standard formats like STEP (ISO 10303) or 3MF is provided for various custom inserts: a holder for baby bottle parts, a secure mount for reusable straws, or a delicate-wine-glass stem holder. Users can download and 3D print these inserts using standard FDM or SLA printers with food-safe materials like PETG or specialized resins, enabling infinite customization of the rack's layout.

Generated 5/1/2026, 3:17:45 AM