US20160258107A1

US20160258107A1 - Dryer with air flow management

Info

Publication number: US20160258107A1
Application number: US15/061,685
Authority: US
Inventors: Ralph F. HAKE; Thomas E. Gill
Original assignee: Hg Laundry Systems LLC
Current assignee: Hg Laundry Systems
Priority date: 2015-03-06
Filing date: 2016-03-04
Publication date: 2016-09-08
Also published as: US20160258097A1; WO2016144882A1; WO2016144794A2; US20190194850A1; WO2016144757A1; US20160258098A1; WO2016144794A3; US20160258101A1; WO2016144759A1; US20160258100A1; WO2016144758A1

Abstract

A drying apparatus having an airflow management system for recycling heated air and providing two forced air streams within a drum to effectively and efficiently dry one or more articles are contained.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of U.S. Provisional Patent Application 62/129,137 filed Mar. 6, 2015, which is hereby incorporated herein by reference.

BACKGROUND

Laundry generally has been cleaned with the application of three forms of cleaning action: chemical action, such as with detergents and other cleaning chemicals; mechanical action, such as by agitation, tumbling, rubbing the clothes by hand; and heat, typically applied by heated water. Typically drying is accomplished by circulating heated air around tumbling clothes in a drum.
Some global home laundry markets are “laundry pair” markets where much of the sales are of a matched washer and dryer set (the United States is such a “laundry pair” market). In Europe and in Asia, the separate sale of dryers is a fraction of the number of washers. This is because of the limited space in the home, limited drain and vent infrastructure, higher energy costs, and the inefficiency of small drum or condensing dryers which take hours to dry clothes. Combination washer/dryers are sold worldwide in small volumes because drying efficiency is poor resulting in limited capacity and long drying times.
Most washer machines sold are either top loader machines or front loader machines. A top loader washer machine design is shown in U.S. Pat. No. 5,829,277 of Wunderlich. The basic modern day top loading automatic washer consists of an outer drum, an inner basket with agitator, a drive motor, a suspension system, controls, a hot and a cold water fill, a drain pump and a lid. Many consumers consider the top loader to be more convenient than the front loader for loading and unloading. Typically, the outer and inner tubs (drums) are set on a vertical axis. Moreover, a type of combination top loader combination washer/dryer machine is shown in U.S. Pat. No. 5,457,969 of Roaf.
In a modern front load (horizontal) washer, the same sorts of elements are found as in the top load washer, but typically turned sideways on a horizontal axis. A type of front loader washer machine is shown in U.S. Pat. No. 4,819,459 of Keith.
Most washer/dryer combination machines sold are front loading and consist of an outer drum, an inner basket, drive motor, a suspension system, controls, a hot and cold water fill, a drain pump a heater and a blower and a door. Typically the outer and the inner tubs (drums) are set on a horizontal axis. Some dryers are “vented” expelling heated air to the exterior of the house while a second type is a condensing dryer which recirculates heated air through a condenser and collects the moisture in a receptacle in the dryer. A type of combined washer dryer machine is shown in U.S. Patent Application Publication Number US 2006/0086001 to Jeonq et al.
Typically, whether washing clothes or other garments in the top loader or the horizontal washer/dryer combination machine, the inner drum rotates at high speeds such that a centripetal force is applied to the saturated garments within the drum, thereby causing the moisture within the garments to escape through holes of the inner drum for draining out to the outer drum. However, the centripetal force in current machines can only take out so much moisture from the garments, leaving a substantially moist garment requiring more drying time and ultimately more energy to dry the clothes.
Known washer/dryer combination machines commonly lack the ability to sufficiently remove moisture from the clothes during the rinse cycles, and thus, leave the clothes saturated with moisture before starting the drying cycle(s). For example, since the clothes remain so full of moisture after the washing process, the drying cycles must be extended sufficiently and/or a portion of the washed clothes must be removed before the dry cycle. In either case, the long dry cycle consumes more energy. Furthermore, the drying efficiency and effectiveness of known washer/dryer combination machines is generally discourages consumers from purchasing the machines.

SUMMARY OF THE INVENTION

In a first example form, the present invention relates to a dryer having an airflow management system for effectively and efficiently drying one or more article(s). According to other example embodiments, the present invention relates to a combination washer/dryer apparatus in which the washer and the dryer occupy (and share) a single housing. This saves space, material, and cost.
Preferably, the dryer comprises a housing, a drum rotatably mounted within the housing, a blower for producing a first forced air stream, a heating element for heating air in the first forced air stream, a forced air element for producing a second forced air stream. Preferably, the second forced air stream being routed to be mixed with the first forced air stream.
Preferably, a first fluid conduit is provided between the blower and the drum, and wherein the heating element is positioned along the first fluid conduit between the blower and the drum.
Preferably, the blower provides the first forced air stream through the first fluid conduit, across the heating element, and within the drum for inputting heated air within the drum.
Optionally, the dryer comprises a second fluid conduit extending from the drum to the intake of the blower, wherein the second fluid conduit receives warm air exhausted from the drum, which is directed across the heating element, and back within the drum. Optionally, the dryer comprises a third fluid conduit extending from the second fluid conduit to an external portion of the housing. Optionally, the dryer comprises a control valve positioned at a junction between the second fluid conduit and the third fluid conduit.
Preferably, the control valve is movable within the junction to selectively direct the second forced air stream of the second fluid conduit to either the second fluid conduit, the third fluid conduit, or a combination of both the second and third fluid conduits.
Optionally, the dryer comprises a heat exchange unit positioned within the second fluid conduit for removing moisture contained in the air exhausted from the drum.
Preferably, the forced air element is generally provided by compressed air or a high velocity blower, and wherein the direction of the flow of the second forced air stream is generally different than the direction of the flow of the first forced air stream.
According to another example form, the invention relates to a drying apparatus comprising a main body, a drum rotatably mounted within the main body and configured for receiving at least one garment, a hot air generation apparatus for providing a first forced air stream of hot air into the drum, and a forced air element for producing a second forced air stream, the first and second forced air streams being generally configured for mixing with each other and amongst the at least one garment.
Preferably, the apparatus comprises a reclaim mechanism for recycling hot air from the hot air generating apparatus. Preferably, the apparatus comprises a heat exchange apparatus for removing moisture contained in the air exhausted from the drum. Preferably, the heat exchange apparatus comprises a condenser. Preferably, the heat exchange apparatus comprises a water reservoir with a recycling pump. Optionally, the heat exchange apparatus comprises a heat sink.
Preferably, the hot air generating apparatus comprises a blower and a heating element. Preferably, the forced air element is generally positioned near the drum for outputting high velocity air within at least a portion of the drum, thereby mixing the second forced air stream with the first forced air stream. Preferably, the drum is rotatably mounted about an axis offset at an angle relative to a horizontal axis.
According to another example form, the invention relates to a drying apparatus for drying articles comprising a main body, a drum rotatably mounted within the main body, a hot air generating apparatus for providing hot air into the drum, a reclaim mechanism for recycling hot air exhausted from the drum, and a high velocity air generating apparatus. Preferably, the apparatus comprises an output nozzle generally positioned near the drum for outputting high velocity air within at least a portion of the drum. Preferably, rotation of the drum in combination with the hot air generating apparatus and the high velocity air generating apparatus actively and aggressively causes tumbling of the articles within the drum. Preferably, the apparatus comprises a temperature sensing unit for determining the temperature of the air being output from the reclaim mechanism, the temperature sensing unit further in communication with the hot air generating apparatus to adjust the same based on the temperature of the air being output from the reclaim mechanism.
Preferably, the drum is generally rotatably mounted to rotate about a horizontal axis. Optionally, the drum is generally rotatably mounted to rotate about an axis that is generally angled relative to a horizontal axis.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a schematic sectional view of a dryer apparatus according to an example embodiment of the present invention.

FIG. 1A is a detailed view of a portion of the air duct system of FIG. 1, and showing a switch for directing the airflow therethrough.

FIG. 2 is a schematic sectional view of a dryer apparatus according to another example embodiment of the present invention.

FIG. 3 is a schematic sectional view of a combination washer/dryer apparatus according to another example embodiment of the present invention.

FIG. 4 is a schematic sectional view of a combination washer/dryer apparatus according to another example embodiment of the present invention.

FIG. 5 is a schematic sectional view of a combination washer/dryer apparatus according to another example embodiment of the present invention.

FIG. 6 is a schematic sectional view of a combination washer/dryer according to another example embodiment of the present invention.

DESCRIPTION OF EXAMPLE EMBODIMENTS

Referring now to the drawing figures, in which like numerals refer to like elements throughout the several views, FIGS. 1-2 show particular aspects of a dryer apparatus according to example embodiments of the present invention. In some example embodiments (as will be described below), the present invention relates to a combination washer/dryer apparatus.
In a first example form, the present invention relates to a dryer apparatus 10 in which a drum 20 occupies a single housing (typically, a metal cabinet) 12. This saves space, material, and money. Preferably, the housing 12 is box-like, with front and rear sides, left and right sides, and a top and bottom 14. The bottom 14 is adapted for supporting the apparatus upon a support surface, such as a floor, a cabinet, or other generally flat, horizontal surface. Typically, the sides and top and bottom are generally flat panels.
In the particular illustrative example shown in FIG. 1, the drum 20 is fitted within the housing 12 and configured to rotate about a generally horizontal axis X in either of the clockwise or counter-clockwise directions. In example forms, the drum 20 generally rotates relative to a rear plate 24, which has an opening 26 extending therethrough, for example, for inputting heated air or a first forced air stream within the drum 20 such that the clothes or other article(s) therein can tumble amongst the heated air being input through the opening 26 to remove the moisture therefrom.
According to one example form, a motor 30 is mounted within the housing 12 and a belt 32 is provided for movably engaging a shaft of the motor 30 so that rotation of the motor shaft can effect rotational movement of the drum 20 in either of the clockwise or counter-clockwise directions. In one example form, a blower 34 is generally configured for cooperative operation with the motor 30, for example, so that rotation of the motor drive shaft causes rotation of the blower 34 to force air within a first fluid conduit or duct 50 from the blower 34 to a heating element 36. In example forms, air is moved from the blower 34 through the first conduit 50 and through or generally across the heating element 36, and further through a delivery conduit 52 extending from the heating element 36 to the opening 26 in the rear plate 24. According to some example forms, the air moving from the blower 34 to the heating element 36 and further through the delivery conduit 52 is generally defined as the first forced air stream.
According to one example form, an air return duct or second fluid conduit 54 is provided from an end of the drum 20, which generally extends from an opening 60 thereof back to the heating element 36. In example forms, a second and a third fluid conduit 54, 56 are provided for recirculating the air, and a junction is generally positioned at the intersection of the second and third fluid conduits 54, 56, for example, so that at least a portion of the airflow can be exhausted outside through opening 62. For example, according to one example form, the return air moving through the opening 60 (and optional filter) is connected to the second fluid conduit 54, which further extends to the junction.
According to one example form, a valve or switch 70 is generally pivotally mounted within the second fluid conduit 54 beyond the junction that the second fluid conduit 54 forms with the third fluid conduit 56, for example, so that the flow of air being exhausted from the system is controllable and adjustable as desired. According to some example forms, a portion of the air exhausted from the drum (e.g., generally warm moist air) is reheated and reused to be put back in the drum, while another portion of the air exhausted from the drum is generally exhausted outside.
For example, according to some example forms and as shown in FIG. 1A, the switch 70 is in a flow position wherein air moving through the second fluid conduit 54 is going to generally be exhausted through opening 62. However, movement of the switch 70 causes the seals or other sealing or engagement members of the switch 70 to be positioned closer to and in sealing contact or engagement with interior surfaces 54 a, 54 b of the second fluid conduit 54, thus substantially eliminating airflow through the opening 62 and forcing the air to flow in the third fluid conduit 56, and further through the heating element 36 and out the opening 26 back into the drum 20.
Optionally, according to other forms, the invention can be configured such that only one of the blowers 35, 35 is utilized for drawing warm moist air from the drum 20 to be reheated and further injected back into the drum 20. Thus, the fluids conduits may be configured as desired, and one or more switches, junctions, etc. can be provided as desired. Further optional, one or more lint filters and moisture extraction devices can be positioned within the conduits as desired.
In example forms, a condensing unit or other moisture removal device 40 can be provided within a fluid conduit for removing a substantial amount of moisture from the warm moist air being returned in the air return duct 54 through opening 60. The warm moist air is generally dried via the moisture removal device 40 so that the warm air (e.g., after moisture is removed) can be input through the heating element 36 and back into the drum 20. In some example forms, a blower 35 can be provided for pulling warm moist air from the drum (via opening 60), across the moisture removal device 40, within the heating element 36, and back into the drum. In example forms, the blowers 34, 35 can be controllable such that maximum efficiency can be achieved. For example, both blowers 34, 35 can be active, or one can be disabled, for example, depending on the control parameters and efficiency of the system. Preferably, the position of the optional filter, the blower 35 and the condenser 40 can be chosen as desired. In some example forms, the moisture from the warm moist return air is generally extracted prior to being filtered by the optional lint filter and passing by the blower 35. Preferably, one or more valves, switches, gates, etc. can be incorporated with the conduits as desired to control the flows of the air as desired.
Preferably, by recycling air from the air return duct 54 to be reheated, the dryer apparatus 10 is substantially more efficient, for example, since the recycled return air is already heated, and thus, requiring less energy to reheat to a desired heating temperature. For example, according to some example forms of the invention, one or more sensors can be employed with the apparatus such that the temperatures of the air flows are generally monitored continuously, and whereby the resulting temperatures of the air flows determine the position of the switch 70 and other factors, for example, the temperature of the heating element 36, controlling the blowers 34, 35, rotation/oscillation of the drum, etc. In example forms, the drum 20 comprises one or more baffles 27 for providing the clothing therein with a lifting, tumbling action when the drum is in rotation or oscillation.
According to example forms, as will be described in more detail below, a high velocity blower 80 can be provided for injecting a high velocity forced air stream into the drum 20 to be mixed with the warm air from the opening 26. In example forms, the high velocity blower 80 enhances the effectiveness and efficiency of the drying cycle, and provides for accelerated drying by aggressively freeing the water molecules from the article(s) or clothing. According to one example form, a nozzle and/or conduit thereof cam be movable between an operating position and a stored position. For example, when the high velocity blower 80 is desired to be used, the nozzle, conduit, etc. can be moved from its stored position within the housing to a position where the nozzle can be positioned for directing a flow of high velocity air within the drum 20.
FIG. 2 shows a dryer apparatus 100 according to another example embodiment of the present invention. As depicted, the dryer apparatus 100 is generally similar to the dryer apparatus 10 as described above, for example, having a housing (unshown), a drum 120 pivotally mounted within the housing, a drive motor 130, blower 134 and a heating element 136. In example forms, the drum 120 is generally pivotally mounted to rotate about a pivot axis X. According to some example forms, the drum 120 is generally configured such that the pivot axis X is generally horizontal, or for example, generally parallel to a support surface supporting the housing. According to other example forms, the pivot axis can be angled relative to the horizontal axis or support surface.
In example embodiments, a pair of ducts are positioned within the housing and relative to the drum 120 to permit air to be exhausted from the drum 120. According to example forms, a first fluid conduit 140 is provided between an end of the drum assembly and an opening 144 extending within a generally opposite end of the drum assembly. For example, in example forms, the first fluid conduit 140 generally comprises an air return opening 142 (and optional filter) for receiving warm moist air from the drum assembly. In example forms, the warm moist air generally moves within the first fluid conduit 140, across a condensing unit 160 or other moisture extraction device, which is further moved across the blower 134, the heating element 136, and then into the drum 120 through the opening 144, for example, to provide heat within the drum assembly for drying the clothes or article(s) therein.
In example forms, the moisture extraction device 160 is generally in the form of a condenser. Typically, a fluid, for example, tap water 162 (or ambient unheated air), can be provided for flowing through the coils of the condenser such that the condenser is substantially effective at removing moisture from the warm moist air moving through the first fluid conduit 140. In example forms, a collection basin 164 can be provided for collecting the moisture being removed from the warm moist air, for example, which is eventually generally routed through conduit 166 to drain out of the apparatus 100. Optionally, water collected in the collection basin 164 can be utilized for optionally outputting into the drum at a later period in time.
For example, according to some example forms of the present invention, a water jet or nozzle can be positioned for spraying water into the inner drum 120 b and generally in contact with one or more article(s) therein, so that the dryer can then begin drying the article(s). In example forms, when one or more article(s) are generally substantially dry or generally show wrinkles, the dryer apparatus 100 can optionally run a freshening cycle, for example, where water of the collection basin 164 or water elsewhere (tap water, heated tap water, etc.) is applied to one or more article(s) within the drum assembly or inner drum 320 b. The amount of water applied to the article(s) can vary, but will generally depend on the size of the load, for example, the weight of the articles, which can be measured with sensors or other weight devices.
According to one example form, an imaging system may be incorporated into the dryer apparatus 100 such that the size, fluffiness, etc. can be measured by looking at the one or more article(s) therein, for example, after generally short-spanned cycles, or between cycles as the articles are tumbling therein and/or when the drum is not rotating and the article(s) are generally at rest within the inner drum. The imaging system can comprise one or more cameras, lights, etc. as desired to provide for monitoring the article(s) within the drum.
In example forms, the drum 120 comprises one or more baffles 121 for providing the clothing therein with a lifting, tumbling action when the drum is in rotation or oscillation. Preferably, the baffles can be shaped and sized as desired. According to one example form, the baffles comprise a mounted side and a free side, and wherein the mounted side generally comprises a surface for flush engagement with in interior portion of the drum.
Optionally, as will be described in more detail below, a high velocity blower 180 can be provided for injecting a high velocity forced air stream into the drum 120 to be mixed with the warm air from the opening 144. In example forms, the high velocity blower 180 enhances the effectiveness and efficiency of the drying cycle, and provides for accelerated drying by aggressively freeing the water molecules from the article(s) or clothing.
FIG. 3 shows a combination washer/dryer machine 200 according to another example embodiment of the present invention. In example forms, the washing/drying apparatus 200 comprises an outer drum 220 a and an inner drum 220 b, for example, wherein the outer drum 220 a rotatably encases the inner drum 220 b. In example forms, the inner drum 22 b rotatably mounts about a pivot axis X that is oriented at an angle α, which is generally between about 10 and 40 degrees relative to a generally horizontal axis, or for example, relative to a support surface. Generally, the outer drum 220 a substantially encases the inner drum 220 b but preferably allows for rotation thereof relative thereto in both the clockwise and counter-clockwise directions. The lower portion of the inner drum can be perforated. The perforations allow air and water to flow in and out of the inner drum. The actual amount of perforations are dictated by performance results from further testing.
In example forms, the inner drum 220 b is connected to a conduit shaft (pipe shaft) that allows warm air (e.g., a first forced air stream) to enter the inner drum 220 b. The shaft is connected to a drive belt, gear, pulley or other suitable drive mechanism connected to a drive motor 230 that will turn the inner drum 220 b. The conduit shaft is ultimately in communication with a heating conduit 240. The heating conduit 240 preferably comprises a heating element 236 positioned therein or at least along a portion thereof such that a blower 234 provides an airflow across the heating element 236 and supplies heated air through the conduits to within the inner drum 220 b.
According to some example forms, the drive motor 230 preferably provides input to the blower 234, for example so that the drive of the motor also drives the blower 234. Optionally, the drive motor 230 is generally separate from the drive of the blower 234. Preferably, according to some example embodiments, the outer drum 220 a comprises a water and detergent input 247, a drain coupling 246 (and conduit extending therefrom). An air exhaust conduit 250 is provided generally near an end of the inner drum 220 b for permitting generally warm moist air from the drum assembly to be exhausted. An opening 252 is positioned generally near the open end of the inner drum 220 b. Optionally, a lint filter 254 can be coupled to the conduit 250 to filter the air moving through the opening 252.
A door 222 is provided for permitting access to the inner drum 220 b, for example, wherein the door 222 is movable between an open position providing access to the opening of the drum assembly and a closed position generally covering the opening and preventing access within the inner drum 220 b. In example forms, when the door is in the closed position, at least a portion of the door 222 (e.g., facing, gasket, seal surface, etc.) provides for sealing engagement with the drum assembly and/or housing of the machine 200. In example forms, the door 222 is generally movably mounted to at least a portion of the housing or support structure of the machine 200. Optionally, the door 222 can be mounted to the drum assembly. Typically, the door 222 can be configured for providing movement relative to the machine 200 in a front-to-back or up-and-down manner (see arrows), or may be configured for pivotal movement, or for example, a combination or two or more movements relative to the housing of the machine 200 between an open position for providing access to within the inner drum 220 b and a closed position for preventing access within the inner drum 220 b.
After the drum has been loaded with the article(s), clothes or other objects to be washed, and an appropriate amount of water and detergent is in the drum, the drum will oscillate, for example, in a similar manner as the inner drum of current front load machines. While the drum is oscillating/rotating, air is being blown through the pipe shaft creating a jacuzzi-like turbulence, hastening the wash cycle. When the wash cycle is complete, water is drained or evacuated by activating a drain pump or vacuum pump (via the drain 246), simultaneously closing the blast gate (or other suitable valve) and a bag or bladder or bellow will deploy from the top of the tank or door 222, using fluid (air/water) or other mechanical means pressing against the clothes and squeezing the water from the clothes. The vacuum or drain pump will pull the washing wastewater into the drain 246, and ultimately into a receiving tank until the water is further drained from the machine 200. According to some example forms, when the liquid has exited the drum, the drain pump will be activated and the water is exited to the drain in the home.
Upon draining the liquid, the bag is recalled into the top/lid 222 and the machine is ready for the rinse cycle. The drum rotates/oscillates for a shorter time together with the blower action, for example, as the same as the wash cycle, to rinse the clothes. Again, the bag deploys, pressing against the clothes, thereby allowing the water being removed therefrom. Optionally, the rinsing and water removal process may be repeated again to ensure most (if not all) of the cleaning agent is removed from the clothes.
When the rinse cycle(s) are completed and the bag has deployed for the last time pressing against the clothes to remove as much water as possible, the bag is recalled and the blower 234 and heating element 236 are activated, and the drum rotates/oscillates, causing the clothes to tumble within the inner drum. The blower 234 forces air across the heater and injects first forced air stream through the conduit and opening 244 into the drum assembly.
In example forms, the inner drum 220 b comprises one or more baffles 221 for providing the clothing therein with a lifting, tumbling action when the drum is in rotation or oscillation. Preferably, the baffles 221 can be shaped and sized as desired. According to one example form, the baffles 221 comprise a mounted side and a free side, and wherein the mounted side generally comprises a surface for flush engagement with in interior portion of the drum.
According to preferred example embodiments, the washer/dryer machine 200 comprises a high speed blower or forced air element 260 for producing a second forced air stream to be mixed with the heated air (e.g., first forced air stream) entering the inner drum 220 b from the heating conduit 240. According to example forms, a high speed blower, compressor, or other forced air device 262 is provided for generating the second forced air stream into the inner drum 220 b. In example forms, the forced air element 260 preferably comprises a nozzle having or more openings extending therethrough, for example, for injecting high speed air into the inner drum 220 b in two or more directions. In other forms, a nozzle generally having one opening can be provided for injecting a single directional flow of high speed air. Further optional, multiple nozzles having one or more openings can be provided as desired, for example, to spread the high velocity air in a plurality of directions as desired to further the drying effectiveness and efficiency. Preferably, the second forced air stream of the forced air element 260 provides for accelerated drying by aggressively freeing the water molecules from the article(s) or clothing.
In example forms, the combination of the first forced air stream and the second forced air stream being input into the inner drum 220 b provides for a much more efficient drying process. According to example forms, the second forced air stream generally pushes air through the bottom interior of the inner drum 220 b and the top interior of the inner drum 220 b at high velocity. Preferably, the high velocity accelerates evaporation and separation of water molecules from the surfaces of the article(s) construct (e.g., fabric, etc.). In preferred example forms, pivotal movement of the inner drum 220 b in addition to the first and second forced air stream preferably provides for a substantially more effective and efficient drying cycle. In some example forms, the span of the drying cycle of the present invention is between about 65-78% the span of known drying cycles.
According to one example embodiment as depicted in FIG. 3, the forced air element 260 is generally positioned within a portion of the door 222 such that the flow direction of the second forced air stream is substantially opposite the flow of warm air from the first forced air stream. As recited above, a high speed blower, compressor, or other forced air device 262 is provided for generating the second forced air stream into the inner drum 220 b, and a conduit is connected therebetween. In some example forms, the device 262 is generally fixed within the housing and the conduit therebetween is configured to permit movement of the door 222. Optionally, the forced air device 262 is provided in the door 222, rather than in the housing.
Optionally, the air exhaust conduit 250 can be sufficiently larger and comprise a valve therein for example, such that the warm moist air exhausted from the drum does not exceed an airflow rate not exceeding the recommended standard rate for air exhausted from the machine 200. For example, according to one example form, the standard rate for air being exhausted from the machine 200 is about 137 cubic feet per minute (CFM).
FIG. 4 shows a combination washer/dryer machine 300 according to another example embodiment of the present invention. According to example forms, the machine 300 comprises a housing (unshown), a drum assembly (outer drum 320 a, inner drum 320 b) pivotally mounted within the housing, a drive motor 330, blower 334 and a heating element 336. In example forms, the inner drum 320 b is generally pivotally mounted to rotate within the outer drum 320 a about a pivot axis X that is oriented at an angle α, which is generally between about 10 and 40 degrees relative to a generally horizontal axis, or for example, relative to a support surface. Generally, the outer drum 320 a substantially encases the inner drum 320 b but preferably allows for rotation thereof relative thereto in both the clockwise and counter-clockwise directions. The lower portion of the inner drum can be perforated. The perforations allow air and water to flow in and out of the inner drum. The actual amount of perforations are dictated by performance results from further testing.
Preferably, according to some example embodiments, the outer drum 320 a comprises a water and detergent input 345 b, and a drain coupling 345 a (and conduit extending therefrom). During the washing and rinsing cycles, the water and detergent input 345 b is activated for saturating the clothes. The drain 345 a is generally positioned near the lowest portion of the outer drum 320 a so that a substantial majority of the water to be drained therefrom is generally forced by gravity to flow within the drain 345 a.
In example embodiments, a pair of ducts are positioned within the housing and relative to the drum assembly (outer drum 320 a and inner drum 320 b) to permit air to be exhausted from the inner drum 320 b. According to example forms, a first fluid conduit 340 is provided between an end of the drum assembly and an opening 344 extending within a generally opposite end of the drum assembly. For example, in example forms, the first fluid conduit 340 generally comprises an air return opening 342 (and optional filter 346) for receiving warm moist air from the drum assembly.
In example forms, the warm moist air generally moves within the first fluid conduit 340, across a condensing unit or other moisture extraction device 360, which is further moved through the blower 334 across the heating element 336, and then back into the inner drum 320 b, for example, to provide heat within the drum assembly for drying the clothes or article(s) therein. According to some example forms, the rate at which the warm moist air is returned through the first fluid conduit 340 can be varied depending upon a valve 382 and the speed of the blower 330.
In one example form, the valve 382 is positioned within the first fluid conduit 340 to control the size of the opening thereof, and thus, control the flow of air moving therethrough. In some example forms, the speed of the blower 334 can be adjusted to provide more of a vacuum effect to the air moving through the first fluid conduit 340.
According to one preferred example form, an air exhaust conduit 350 can be provided for permitting a portion of the warm moist air within the drum assembly to be exhausted from the inner drum 320 b, and out of the machine for connecting to an exhaust coupling generally found in the home or other building, for example, for further exhausting the warm moist air outdoors. Generally, an opening 352 (and optional filter 354) are provided near an end of the inner drum 320 b for receiving air from the inner drum 320 b. As similarly described with respect to the valve 382 of the first fluid conduit 340, the air exhaust conduit 350 can comprise a valve 380 therein for controlling the flow of air moving therethrough.
In example forms, the moisture extraction device 360 is generally in the form of a condenser. Optionally, other devices can be utilized, for example, an intercooler, radiator-like device, etc. In the example at hand, a fluid, for example, tap water 362, can be provided for flowing through the coils of the condenser such that the condenser is substantially effective at removing moisture from the warm moist air moving through the first fluid conduit 340. Optionally, ambient moist air can be provided for flowing through the coils of the condenser. In example forms, a collection basin can be provided for collecting the moisture being removed from the warm moist air, for example, which is eventually generally routed through conduit 364 to drain out of the machine 300. Optionally, water collected in the collection basin can be utilized for optionally outputting into the drum at a later period in time.
As similarly described with respect to the washer/dryer machine 200, the washer/dryer machine 300 comprises a high speed blower or forced air element 370 for producing a second forced air stream to be mixed with the heated air (e.g., first forced air stream) entering the inner drum 320 b from the heating conduit 340. According to example forms, a high speed blower, compressor, or other forced air device 372 is provided for generating the second forced air stream and injecting it into the inner drum 320 b. In example forms, the forced air element 370 preferably comprises a nozzle having or more openings extending therethrough, for example, for injecting high speed air into the inner drum 220 b in two or more directions. In other forms, a nozzle generally having one opening can be provided for injecting a single directional flow of high speed air. Further optional, multiple nozzles having one or more openings can be provided as desired, for example, to spread the high velocity air in a plurality of directions as desired to further the drying effectiveness and efficiency.
As described above, the combination of the first forced air stream and the second forced air stream being input into the inner drum 320 b provides for a much more efficient drying process. According to example forms, the second forced air stream generally pushes air through the bottom interior of the inner drum 320 b and the top interior of the inner drum 320 b at high velocity. Preferably, the high velocity accelerates evaporation and separation of water molecules from the surfaces of the article(s) construct (e.g., fabric, etc.). In preferred example forms, pivotal movement of the inner drum 320 b in addition to the first and second forced air stream preferably provides for a substantially more effective and efficient drying cycle. In some example forms, the span of the drying cycle of the present invention is between about 65-78% the span of known drying cycles.
According to one example embodiment as depicted in FIG. 4, the forced air element 370 is generally positioned within a portion of the door 322 such that the flow direction of the second forced air stream is substantially opposite the flow of warm air from the first forced air stream. As recited above, a high speed blower, compressor, or other forced air device 362 is provided for generating the second forced air stream into the inner drum 320 b, and a conduit is connected therebetween. In some example forms, the device 372 is generally fixed within the housing and the conduit therebetween is configured to permit movement of the door 222. Optionally, the forced air device 262 is provided in the door 222, rather than in the housing.
In example forms, with the combination of the first and second forced air streams being injected within the inner drum 320 b, the valves 380, 382 can work together to ensure that proper airflow throughout the conduits is provided. According to one example form, the valve 380 is to ensure that the air exhausted from the drum to be exited outdoors is generally not exceed an airflow rate within the recommended standard rate for air exhausted from the machine 200.
Optionally, according to additional example embodiments of the present invention, the drum assembly as described above can be replaced with a single rotatable drum, for example, and include a back plate or bulkhead manifold generally fixedly mounted to the housing and whereby the single drum pivotally mounts to the bulkhead. One or more openings can be provided through the bulkhead for passing air and/or water therethrough and into the single drum.
FIG. 5 shows a combination washer/dryer machine 400 according to another example embodiment of the present invention. As depicted, the combination machine 400 is generally similar to the machines as described above. According to one example form, a stationary plate or bulkhead 424 is fixedly mounted within a housing 412, and a drum 420 is generally pivotally mounted to the plate 424 and rotatable about an axis X. In example forms, the machine 400 and housing thereof 412 can be mounted to a support or auxiliary structure 416, for example, for permitting the machine 400 to be offset an angle a relative to the support 416. In example forms, a pair of conduits generally extend from an exhaust ring 456, which is generally movably mounted to a portion of the drum 420, for example such that the ring 456 can generally remain substantially fixed while allowing rotation of the drum 420 relative thereto.
Preferably, the plate 424 comprises one or more openings extending therethrough for inputting first and second forced air streams. For example, a main blower penetration or first opening 444 is generally provided at a lower portion of the plate 424, and a high speed penetration 470 can be provided at a central portion of the plate 424. Optionally, the penetrations can be positioned as desired.
According to one example form, a first fluid conduit 440 extends from the exhaust ring 456 to the first opening 444. According to example forms, the first fluid conduit 440 can comprise a lint filter 437, a blower 434, and a heating element 436. Optionally, a condensing unit or other moisture extraction device 460 can be provided for assisting in removing moisture from the moist exhaust air entering the first fluid conduit 440.
According to example forms, a second fluid conduit 450 is provided for extending from the exhaust ring 456 to an exterior portion of the machine 400, for example, to provide for exhausting the at least a portion of the warm moist air outdoors.
Preferably, a forced air element having a high speed blower, compressor, or other forced air device 472 is provided for generating the second forced air stream (e.g., generally high speed air) and injecting it through the plate 424 via penetration 470 and into the drum 420. In example forms, the forced air element preferably comprises a nozzle having one or more openings extending therethrough, for example, for injecting high speed air into the drum 420 in two or more directions. In other forms, a nozzle generally having one opening can be provided for injecting a single directional flow of high speed air. Further optional, multiple nozzles having one or more openings can be provided as desired, for example, to spread the high velocity air in a plurality of directions as desired to further the drying effectiveness and efficiency.
In example forms, the mixture of the first and second forced air streams within the drum 420 causes a positive pressure within the drum 420. In example forms, the air drawn into the first fluid conduit 440 is generally equal to the air output into the drum 420 through the blower penetration 444. Thus, the addition of the second forced air stream by the forced air device 472 of the forced air element, causes a positive pressure within the drum 420. In some example forms, the excess pressure within the drum 420 is generally relieved by air flow out of the exhaust fluid conduit 450, for example, to be exited outdoors. As recited above, the flow of air exhausted through the exhaust conduit 450 generally has a flow rate of about 137 CFM. Optionally, other flow rates can be chosen as desired.
As similarly described above, the drum 420 optionally comprises one or more baffles 421 for providing the clothing therein with a lifting, tumbling action when the drum is in rotation or oscillation. Preferably, the baffles 421 can be shaped and sized as desired. According to one example form, the baffles 421 comprise a mounted side and a free side, and wherein the mounted side generally comprises a surface for flush engagement with in interior portion of the drum.
FIG. 6 shows a combination washer/dryer machine 500 according to another example embodiment of the present invention. In example forms, the machine 500 is substantially similar to the machine 400 as described above. According to one example form, the machine 500 comprises a center axial drum 520, for example, which is generally an integrally formed drum having a generally large opening and one end thereof and a generally smaller opening at an opposite end thereof. In example forms, the generally smaller opening is defined within a central pipe shaft, which acts as a central rotational axis for the drum 520.
In example forms, the drum 520 is generally pivotally mounted to rotate about an axis X. In example forms, the machine 500 and housing thereof 512 can be mounted to a support or auxiliary structure 516, for example, for permitting the machine 500 to be offset an angle a relative to the support 516.
As similarly described above, the machine preferably comprises first and second fluid conduits 540, 550. Further, the first fluid conduit 540 is connected from the exhaust ring (e.g., communicating with the interior of the drum 520) and extends to the central pipe shaft of the drum 520, for example, which is in communication with opening 544. As similarly described above, a blower 534, a heating element 536, a lint filter 537 and optional condenser or moisture extraction apparatus 560 can be in communication with the first fluid conduit 540.
Preferably, a forced air element 570 having a high speed blower, compressor, or other forced air device 572 is provided for generating the second forced air stream (e.g., generally high speed air) and injecting it into the drum 520 to be mixed with the first forced air stream entering the drum through opening 544. In example forms, the forced air element preferably comprises a nozzle having one or more openings extending therethrough, for example, for injecting high speed air into the drum 520 in two or more directions. In some example forms, the nozzle is generally positioned such that the flow of the second forced air stream is generally directed in a direction substantially opposite the direction of the flow of the first forced air stream. Optionally, the flow of the second forced air stream can be directed as desired. In some forms, a nozzle generally having one opening can be provided for injecting a single directional flow of high speed air. Further optional, multiple nozzles having one or more openings can be provided as desired, for example, to spread the high velocity air in a plurality of directions as desired to further the drying effectiveness and efficiency.
Further optional and as similarly described above, the drum 520 optionally comprises one or more baffles 521 for providing the clothing therein with a lifting, tumbling action when the drum is in rotation or oscillation. Preferably, the baffles 521 can be shaped and sized as desired. According to one example form, the baffles 521 comprise a mounted side and a free side, and wherein the mounted side generally comprises a surface for flush engagement with in interior portion of the drum.
In example forms, the machines 400, 500 preferably recapture heated air and utilize an active blower system. In example embodiments, the machine lifts and moves (via tumbling and baffles) the article(s) or clothing, recaptures heated air, exhaust air, all while drying the clothes or article(s) within the drum. Furthermore, the second forced air stream preferably accelerates the drying by aggressively freeing the water molecules from the article(s) or clothing. As described, a condenser or other moisture extraction device can be provided for removing moisture from the warm moist air that is being recirculated. In some example forms, the condenser is a high speed condenser in that the recaptured warm moist air is not required to slow down in it rate of flow as the moisture is extracted from the warm moist air. Optionally, the machine can be convertible to a ventless condensing dryer.
In example forms, the blower pulls the main volume of moist heated air from the drum and passes (blows) the air over the heater. Since this blower generally withdraws the same volume of air that it is inputting in the drum, a secondary source of air is provided, for example, which is accomplished with the smaller high velocity blower. As shown in FIG. 5, the high velocity blower provide for injecting a second forced air stream into the drum in a similar direction as the direction of the first forced air stream. In example forms, the volume of air of the second forced air stream added to the drum is generally equal the volume of air that is exhausted out of doors, which generally carries the warm moist air out of doors. The overall volume is adjusted to approximate what a standard home dryer system accommodates. In example forms, the main blower recaptures the heated air to improve efficiencies and energy saving, and the high speed blower provides for accelerated drying by aggressively freeing the water molecules from the clothing.
According to one preferred form, it is desired to control the rate of the air being exhausted to be equivalent to the amount of exhaust that is produced by the standard dryer. Typically, dryer vent systems are designed to handle the volumes and speeds produced by standard dryers. Early testing shows this should not be a problem. However, a common device regulating device can be utilized to regulate the volume to an appropriate amount with sufficient boost and a back pressure regulator to exhaust the air.
In example forms, the condenser will generally be placed before the lint filter to remove as much moisture before passing through the lint filter (to minimize moist sticky lint). Preferably, the condenser is positioned before the main blower so as to remove moisture before being reheated and sent back into the machine. Preferably the condenser would be positioned before the main blower and the out of doors exhaust duct, for example, to provide that the driest air would be recirculated and exhausted.
According to example forms, the volume and speed of the air passing over the condenser can be adjusted so as to optimize the amount of condensate formed. This would be accomplished by splitting the air drawn into the main blower channeling a portion through the condenser and the balance through the main blower, and thus, consequently only a portion of the air recycled is passed through the condenser and a portion of the moist air is sent back into the drum. Preferably, the overall performance and efficiency is improved by the amount of condensate produced. The benefit is faster drying times and less moisture passing through the house hold duct system.
It is to be understood that this invention is not limited to the specific devices, methods, conditions, or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only. Thus, the terminology is intended to be broadly construed and is not intended to be limiting of the claimed invention. For example, as used in the specification including the appended claims, the singular forms “a,” “an,” and “one” include the plural, the term “or” means “and/or,” and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. In addition, any methods described herein are not intended to be limited to the sequence of steps described but can be carried out in other sequences, unless expressly stated otherwise herein.
While the invention has been shown and described in exemplary forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein without departing from the spirit and scope of the invention as defined by the following claims.

Claims

What is claimed is:

1. A dryer comprising:

a housing;

a drum rotatably mounted within the housing;

a blower for producing a first forced air stream;

a heating element for heating air in the first forced air stream;

a forced air element for producing a second forced air stream; and

the second forced air stream being routed to be mixed with the first forced air stream.

2. The dryer of claim 1, wherein a first fluid conduit is provided between the blower and the drum, and wherein the heating element is positioned along the first fluid conduit between the blower and the drum.

3. The dryer of claim 2, wherein the blower provides the first forced air stream through the first fluid conduit, across the heating element, and within the drum for inputting heated air within the drum.

4. The dryer of claim 3, further comprising a second fluid conduit extending from the drum to the heating element, the second fluid conduit receiving warm air exhausted from the drum, which is directed across the heating element, and back within the drum.

5. The dryer of claim 4, further comprising a third fluid conduit extending from the second fluid conduit to an external portion of the housing.

6. The dryer of claim 5, further comprising a control valve positioned at a junction between the second fluid conduit and the third fluid conduit.

7. The dryer of claim 6, wherein the control valve is movable within the junction to selectively direct the second forced air stream of the second fluid conduit to either the second fluid conduit, the third fluid conduit, or a combination of both the second and third fluid conduits.

8. The dryer of claim 7, further comprising a heat exchange unit positioned within the second fluid conduit for removing moisture contained in the air exhausted from the drum.

9. The dryer of claim 8, wherein the forced air element is generally provided by compressed air or a high velocity blower, and wherein the direction of the flow of the second forced air stream is generally different than the direction of the flow of the first forced air stream.

10. A drying apparatus comprising:

a main body;

a drum rotatably mounted within the main body and configured for receiving at least one garment;

a hot air generation apparatus for providing a first forced air stream of hot air into the drum; and

a forced air element for producing a second forced air stream, the first and second forced air streams being generally configured for mixing with each other and amongst the at least one garment.

11. The drying apparatus of claim 10, wherein the apparatus comprises a reclaim mechanism for recycling hot air from the hot air generating apparatus.

12. The drying apparatus of claim 11, further comprising a heat exchange apparatus for removing moisture contained in the air exhausted from the drum.

13. The drying apparatus of claim 12, wherein the heat exchange apparatus comprises a condenser.

14. The drying apparatus of claim 12, wherein the heat exchange apparatus comprises a water reservoir with a recycling pump.

15. The drying apparatus of claim 12, wherein the heat exchange apparatus comprises a heat sink.

16. The drying apparatus of claim 10, wherein the hot air generating apparatus comprises a blower and a heating element.

17. The drying apparatus of claim 10, wherein the forced air element is generally positioned near the drum for outputting high velocity air within at least a portion of the drum, thereby mixing the second forced air stream with the first forced air stream.

18. The drying apparatus of claim 17, wherein the drum is rotatably mounted about an axis offset at an angle relative to a horizontal axis.

19. A drying apparatus for drying articles comprising:

a main body;

a drum rotatably mounted within the main body;

a hot air generating apparatus for providing hot air into the drum;

a reclaim mechanism for recycling hot air exhausted from the drum; and

a high velocity air generating apparatus, the apparatus comprising an output nozzle generally positioned near the drum for outputting high velocity air within at least a portion of the drum,

wherein rotation of the drum in combination with the hot air generating apparatus and the high velocity air generating apparatus actively and aggressively causes tumbling of the articles within the drum.

20. The drying apparatus of claim 17, further comprising a temperature sensing unit, the temperature sensing unit determining the temperature of the air being output from the reclaim mechanism, the temperature sensing unit further in communication with the hot air generating apparatus to adjust the same based on the temperature of the air being output from the reclaim mechanism.

21. The drying apparatus of claim 17, wherein the drum is generally rotatably mounted to rotate about a horizontal axis.

22. The drying apparatus of claim 17, wherein the drum is generally rotatably mounted to rotate about an axis that is generally angled relative to a horizontal axis.