APPLIANCE PUMP ASSEMBLY
A pump assembly for an appliance, an appliance, and a dishwasher appliance are provided. The pump assembly has features for isolating the noise of a pump of the assembly, including a unitary pump housing comprising structural layer and an acoustic layer. The appliance includes a pump assembly and features for isolating noise from a pump of the assembly without requiring insulation for a substantial portion of the appliance. The dishwasher appliance includes a pump assembly and features for isolating the noise of a pump of the assembly such that a substantial portion of the dishwasher appliance need not be insulated to isolate the pump noise.
1 . A pump assembly for an appliance, comprising:
an impeller;
a motor connected to the impeller and operable to rotate the impeller; and
a unitary pump housing including a structural layer and an acoustic layer, the unitary pump housing integrally formed of a continuous piece of material such that the structural layer and the acoustic layer are integrally formed of the continuous piece of material,
wherein the unitary pump housing defines a motor portion surrounding the motor and an impeller portion surrounding the impeller, and
wherein the structural layer is formed inward of the acoustic layer and is adjacent the impeller and motor.
2 . The pump assembly of claim 1 , wherein the unitary pump housing is constructed using an additive process.
3 . The pump assembly of claim 1 , wherein the unitary pump housing further comprises a sealing layer integrally formed of the continuous piece of material, wherein the sealing layer is formed outward of the acoustic layer.
4 . The pump assembly of claim 1 , wherein the acoustic layer is formed of a noise insulating material.
5 . The pump assembly of claim 1 , wherein the continuous piece of material comprises a first material and a second material, and where the structural layer is formed of the first material and the acoustic layer is formed of the second material.
6 . The pump assembly of claim 1 , wherein the unitary pump housing is integrally formed of a plurality of structural layers and a plurality of acoustic layers.
7 . The pump assembly of claim 1 , wherein the structural layer is fused with the acoustic layer.
8 . The pump assembly of claim 1 , wherein the structural layer and acoustic layer are structurally different.
9 . The pump assembly of claim 8 , wherein the acoustic layer is a plurality of cone-shaped elements and the structural layer is a solid layer of material.
10 . The pump assembly of claim 8 , wherein the acoustic layer is a plurality of wedge-shaped elements and the structural layer is a solid layer of material.
11 . A method for forming a unitary pump housing of an appliance, comprising:
establishing three-dimensional information of the unitary pump housing;
converting the three-dimensional information of the unitary pump housing from the established three-dimensional information into a plurality of segments, each segment of the plurality of segments defining a respective cross-sectional slice of the unitary pump housing; and
successively forming each cross-sectional slice of the unitary pump housing with an additive process;
wherein, after each cross-sectional slice is successively formed, the unitary pump housing is formed such that (1) the unitary pump housing is integrally formed of a structural layer and an acoustic layer and (2) the unitary pump housing defines a motor portion and an impeller portion.
12 . The method of claim 11 , wherein the additive process comprises at least one of fused deposition modeling, selective laser sintering, stereolithography, and digital light processing.
13 . The method of claim 11 , wherein the unitary pump housing is a continuous piece of material after each cross-sectional slice is successively formed.
14 . The method of claim 11 , wherein the unitary pump housing is integrally formed of a plurality of structural layers and a plurality of acoustic layers.
15 . The method of claim 11 , wherein the unitary pump housing is integrally formed of a continuous piece of material after each cross-sectional slice is successively formed.
16 . The method of claim 11 , wherein the unitary pump housing is the structural layer formed of a first material and the acoustic layer formed of a second material, the first material and the second material forming a continuous piece of material.
17 . The method of claim 11 , wherein the unitary pump housing is integrally formed of the structural layer, the acoustic layer, and a sealing layer after each cross-sectional slice is successively formed, wherein the sealing layer is formed outward of the acoustic layer.
18 . The method of claim 17 , wherein the unitary pump housing is integrally formed of a plurality of structural layers, a plurality of acoustic layers, and a plurality of sealing layers.
19 . The method of claim 11 , wherein the acoustic layer is formed of a noise insulating material.
20 . The method of claim 11 , wherein the acoustic layer is formed of a plurality of elements shaped to attenuate the noise of the pump assembly, the plurality of elements fused with the structural layer to integrally form the unitary pump housing.