Derivative works — US Patent 12543922

Defensive Disclosure and Prior Art Generation

RE: U.S. Patent 12,543,922 “Dishwasher with a dish rack”
Publication Date: May 1, 2026
Author: Senior Patent Strategist and Research Engineer

This document discloses a series of derivative works, alternative embodiments, and cross-domain applications of the core mechanisms described in U.S. Patent 12,543,922 (the '922 patent). The purpose of this disclosure is to place these variations into the public domain, thereby establishing prior art against future patent applications that may claim these or similar concepts as novel inventions.

Derivative 1: Material & Component Substitution

Variation 1.1: Shape-Memory Alloy (SMA) Actuated Rack

Enabling Description: The upper dish rack's utensil holders and cup seat tines are fabricated from a shape-memory alloy, such as Nitinol (Nickel-Titanium). In its martensitic state at room temperature, the holders are in an extended, item-securing position. During the heated drying cycle of the dishwasher, the temperature rises above the alloy's austenite transition temperature (e.g., >85°C). This phase change causes the holders and tines to controllably retract or pivot to a pre-programmed "flat" or "open" geometry. This automated action facilitates easier unloading of dishes and can convert the specialized rack into a general-purpose flat surface for larger items in a subsequent wash cycle. The SMA components are electrically insulated and integrated into the rack's polymer-coated wireframe.

Mermaid Diagram:

stateDiagram-v2
    [*] --> Martensite_Phase: Room Temperature (<85°C)
    Martensite_Phase: Holders & Tines Extended
    Martensite_Phase: Securely hold utensils and cups

    Martensite_Phase --> Austenite_Phase: Apply Heat (Drying Cycle >85°C)
    Austenite_Phase: Phase Transition Occurs
    Austenite_Phase: Holders & Tines Retract
    Austenite_Phase: Releases items, creates flat surface

    Austenite_Phase --> Martensite_Phase: Cool Down (<85°C)

Variation 1.2: Modular Piezoelectric Transducer Integration

Enabling Description: The planar portion and the angled walls of the rack are constructed with integrated docking ports for modular piezoelectric transducer units. These units, encapsulated in waterproof titanium housings, snap into the rack frame. When activated by the dishwasher's controller, they generate high-frequency ultrasonic vibrations (e.g., 40 kHz) directly conducted through the rack's metallic frame. This induces cavitation in the wash water, creating micro-scrubbing actions on the surfaces of utensils and cups in direct contact with the rack, significantly enhancing the cleaning of stubborn food residues. The system uses a low-voltage power connection established when the rack is docked inside the dishwasher tub.

Mermaid Diagram:

graph TD
    A[Dishwasher Controller] -- Low Voltage Power --> B{Rack Docking Port};
    B -- Power & Signal --> C{Modular Piezoelectric Units};
    C -- 40 kHz Vibration --> D[Rack Wireframe];
    D -- Conducted Vibration --> E[Utensils & Cups];
    E -- Induces Cavitation in Water --> F[Enhanced Micro-Scrubbing Action];

Derivative 2: Operational Parameter Expansion

Variation 2.1: Industrial Scale Conveyor Washing System

Enabling Description: The patented rack geometry is implemented as a series of interlocking, modular pallets on an industrial conveyor-based warewashing system. Each pallet, measuring 500mm x 500mm, features the planar utensil section and the depressed cup section. These pallets form a continuous, moving surface through a multi-stage washing tunnel. The system operates with high-pressure spray nozzles delivering water at 80 PSI and a final sanitizing rinse at 185°F (85°C). This application is intended for high-throughput environments like hospitals, cafeterias, and institutional food service operations. The pallets are made from glass-filled polypropylene for high durability and chemical resistance.

Mermaid Diagram:

sequenceDiagram
    participant Pallet as Modular Rack Pallet
    participant Conveyor as Conveyor Belt
    participant Stage1 as Pre-Wash Stage (60 PSI)
    participant Stage2 as Main Wash Stage (80 PSI)
    participant Stage3 as Sanitize Rinse (185°F)

    Pallet->>Conveyor: Loaded with dishes
    Conveyor->>Stage1: Transport Pallet
    Stage1->>Pallet: High-pressure spray
    Conveyor->>Stage2: Transport Pallet
    Stage2->>Pallet: Detergent wash
    Conveyor->>Stage3: Transport Pallet
    Stage3->>Pallet: High-temp sanitize
    Conveyor-->>Pallet: Emerge clean

Variation 2.2: Microfluidic Lab-on-a-Chip Sterilizer

Enabling Description: A micro-scale version of the invention is used for cleaning and sterilizing laboratory pipette tips and sample vials on a microfluidic chip. The "rack" is a 50mm x 75mm silicon wafer. The "planar portion" is an array of micro-etched channels (1mm width) that hold pipette tips horizontally. The "depression" consists of micro-machined wells with angled walls (30-degree slope) designed to hold 0.5mL microcentrifuge tubes. A programmable syringe pump flushes a sequence of cleaning solvents, deionized water, and finally sterilizing agents (e.g., peracetic acid) through a sealed flow cell containing the chip, ensuring high-purity cleaning of micro-liter scale laboratory equipment.

Mermaid Diagram:

graph LR
    subgraph Microfluidic Chip
        A[Planar Micro-Channels for Pipette Tips]
        B[Depressed Micro-Wells for Vials]
    end
    C[Syringe Pump Controller] --> D{Flow Sequencer};
    D -- Step 1 --> E[Solvent Flush];
    D -- Step 2 --> F[DI Water Rinse];
    D -- Step 3 --> G[Sterilizing Agent];
    E --> Chip;
    F --> Chip;
    G --> Chip;
    Chip --> H[Waste Outlet];

Derivative 3: Cross-Domain Application

Variation 3.1: Aerospace Microgravity Tool and Sample Rack

Enabling Description: A rack for use aboard the International Space Station (ISS) for organizing and sterilizing geological sample containers and maintenance tools. The entire assembly is fabricated from PEEK (Polyether ether ketone) to minimize weight and prevent off-gassing. The planar portion uses spring-loaded clips instead of simple holders to positively lock tools (e.g., wrenches, sample scoops) in place, preventing them from floating away in microgravity. The depressed section features deeper, more steeply angled (45-degree) walls with integrated twist-lock mechanisms to secure sample vials during sterilization cycles using vaporized hydrogen peroxide (VHP).

Mermaid Diagram:

classDiagram
    class Rack_Aerospace {
        +material: PEEK
        +planar_section: PlanarSurface
        +depression_section: Depression
    }
    class PlanarSurface {
        +spring_loaded_clips[]
        +lockTool(Tool)
        +releaseTool(Tool)
    }
    class Depression {
        +wall_angle: 45_degrees
        +twist_lock_seats[]
        +secureVial(Vial)
        +releaseVial(Vial)
    }
    Rack_Aerospace *-- PlanarSurface
    Rack_Aerospace *-- Depression

Variation 3.2: AgTech Hydroponic System Cleaning Rack

Enabling Description: An automated cleaning rack for equipment in a vertical farming facility. The depression's "cup seats" are dimensioned to hold standard 2-inch and 3-inch net pots used in hydroponics, orienting them for high-pressure spray cleaning and sterilization to prevent root rot pathogens between growth cycles. The planar portion is fitted with specialized holders for horizontally securing delicate environmental sensors, pH probes, and nutrient injectors, protecting them from damage during the cleaning process. The system is integrated into a larger robotic workflow that automates the harvesting, cleaning, and replanting of hydroponic modules.

Mermaid Diagram:

graph TD
    subgraph AgTech Cleaning System
        A[Robotic Arm] --> B(Load Rack);
        B --> C{Hydroponic Rack};
        C -- holds --> D[2" & 3" Net Pots in Depression];
        C -- holds --> E[pH/EC Probes in Planar Section];
        B --> F[Move Rack to Cleaning Bay];
        F --> G[High-Pressure Wash & Sterilize];
        G --> H[Move Rack to Drying Bay];
        H --> I[Robotic Arm Unloads Clean Items];
    end

Derivative 4: Integration with Emerging Tech

Variation 4.1: AI-Optimized Wash Cycle via IoT Load Sensing

Enabling Description: Each utensil holder and cup seat in the rack is embedded with a passive waterproof RFID tag containing a unique ID. A multi-antenna RFID reader integrated into the dishwasher tub scans the rack upon insertion. The system's edge AI processor queries a database to identify the item type in each location based on pre-registration (e.g., user scans a QR code on a new set of plates). The AI analyzes the specific load composition (e.g., "6 glass cups, 4 ceramic mugs, 12 stainless steel spoons, 1 nylon spatula") and soil level data from a turbidity sensor to dynamically generate an optimal wash cycle, precisely controlling water temperature, pressure, and spray arm choreography to maximize cleaning efficiency and minimize energy and water consumption.

Mermaid Diagram:

sequenceDiagram
    participant User
    participant Rack as RFID-Tagged Rack
    participant Reader as Dishwasher RFID Reader
    participant AI as Edge AI Processor
    participant Controller as Dishwasher Controller

    User->>Rack: Loads dishes and utensils
    Rack->>Reader: Rack is inserted; Reader scans tags
    Reader->>AI: Sends array of tag IDs
    AI->>AI: Queries item database & turbidity sensor
    AI->>Controller: Generates & sends optimized wash cycle parameters
    Controller->>Controller: Executes dynamic wash cycle

Derivative 5: The "Inverse" or Failure Mode

Variation 5.1: Fusible Link Safety Collapse Mechanism

Enabling Description: The angled walls forming the rack's depression are attached to the planar sections via hinges incorporating a "fusible link." This link is a structural component made from a bismuth-tin alloy with a precise melting point of 138°C, well above normal operating temperatures but below temperatures indicative of a critical heating element malfunction. If the dishwasher dangerously overheats, these links melt, causing the entire depression structure to collapse downward. This collapse is mechanically coupled to a lever that actuates the dishwasher's main anti-flood water valve, physically shutting off the water supply as a redundant, non-electrical safety measure to prevent further damage or flooding.

Mermaid Diagram:

stateDiagram-v2
    state "Normal Operation (<138°C)" as Normal {
        [*] --> Deployed
        Deployed: Depression structure is intact
    }

    state "Overheat Failure (>138°C)" as Failure {
        Deployed --> Collapsed: Fusible links melt
        Collapsed: Depression structure collapses
        Collapsed --> Water_Off: Mechanical lever actuates anti-flood valve
    }

Combination Prior Art with Open Standards

Combination with MQTT for Smart Home Integration: The AI & IoT enabled rack (Derivative 4.1) is configured as an MQTT client. It publishes its scanned load data to an MQTT broker on a local network (e.g., a Home Assistant server). The data is published to a topic such as home/kitchen/dishwasher/rack_content with a JSON payload like {"cups": 8, "plates": 4, "utensils": 20}. This allows for platform-agnostic integration with any smart home system, enabling open-source automations like "Send a notification to my phone when the dishwasher is full" or "Log dishwasher energy usage per load type to a database."
Combination with OPC UA for Industrial Automation: The Industrial Scale Conveyor Washing System (Derivative 2.1) uses the OPC UA (IEC 62541) open standard for machine-to-machine communication. Each modular rack pallet has an OPC UA server that exposes variables for its contents, position on the conveyor, and status (clean/dirty). A central SCADA system acts as an OPC UA client to monitor and control the entire washing line, allowing for interoperability with other factory equipment (e.g., robotic loaders, packaging machines) from different vendors.
Combination with glTF for Robotic Interoperability: The manufacturer of a dishwasher featuring this rack geometry publishes a detailed, royalty-free 3D model of the rack in the open glTF (GL Transmission Format). This allows third-party robotics companies and developers to easily import the precise digital twin of the rack into their simulation and programming environments (e.g., ROS, Isaac Sim). This open standard enables any compliant robotic arm to be programmed for loading and unloading tasks without requiring proprietary CAD data or physical access to the appliance, fostering an open ecosystem of automation solutions.