US20250320655A1

US20250320655A1 - Laundry appliance and ventilation assembly for the same

Info

Publication number: US20250320655A1
Application number: US18/632,876
Authority: US
Inventors: David Scott Dunn; Bystrik Cervenka; Jivko Ognianov Djerekarov
Original assignee: Haier US Appliance Solutions Inc
Current assignee: Haier US Appliance Solutions Inc
Priority date: 2024-04-11
Filing date: 2024-04-11
Publication date: 2025-10-16

Abstract

An impeller may be in mechanical communication with a motor to motivate rotation of the impeller about an axial direction. The impeller may be rotatable along a rotational direction about the axial direction to urge a flow of air from the chamber of the laundry basket. The impeller may include a baseplate and a plurality of radially accurate vanes supported on the baseplate. The plurality of radially arcuate vanes may each extend rearward relative to the rotational direction from an inner end proximal to the axial direction to an outer end distal to the axial direction.

Description

FIELD OF THE DISCLOSURE

The present subject matter relates generally to laundry appliances, such dryer or combined washer/dryer appliances, and ventilation assemblies for circulating air through the same.

BACKGROUND OF THE DISCLOSURE

Laundry appliance, such as dryers or drying appliances, generally include a cabinet with a drum mounted therein. For dryers, a heater or heater assembly is also often provided to pass heated air through the chamber of the drum in order to dry moisture-laden articles disposed within the chamber. This may be provided in the context of a dedicated drying appliance or a combination washing and drying appliance, which may greatly increase the ease and convenience for cleaning clothing articles.
In order to circulate heated air, certain dryer appliances include an impeller to rotate about a drive rod within a housing. During operation of the dryer appliance, the impeller urges a flow of heated air into the chamber of the drum. Such heated air absorbs moisture from articles disposed within the chamber. The impeller also urges moisture laden air out of the chamber through a vent. The vent can be connected to household ductwork that directs the moisture laden air outdoors.
In typical appliances, the impeller is provided as a “squirrel cage” impeller design having multiple relatively short straight or forward-swept fan blades disposed thereon. When assembled, the squirrel-cage impeller may be placed within a larger housing having flat front and rear plates bounding the impeller. Such impeller designs may be inexpensive or easy to produce. However, they may suffer from a number of drawbacks.
In particular, existing designs may be especially susceptible to the detrimental airflow effects of use over time. As an example, a relatively large load of articles or clothes within the drum may generate a pressure drop that significantly changes the volumetric airflow produced by the impeller during, for instance, a drying cycle. As an additional or alternative example, lint may accumulated along the ventilation assembly or within the laundry appliance generally may generate a pressure drop that significantly changes the volumetric airflow produced by the impeller during, for instance, a drying cycle.
Accordingly, a laundry appliance with features for improving air flow through the laundry appliance would be useful.

BRIEF DESCRIPTION OF THE DISCLOSURE

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one exemplary aspect of the present disclosure, a laundry appliance is provided. The laundry appliance may include a cabinet, a tub, a laundry basket, a motor, an impeller. The tub may be positioned within the cabinet. The tub may define a tub outlet and a tub inlet. The laundry basket may be rotatably mounted within the tub. The laundry basket may define a chamber for receipt of articles for washing or drying. The motor may be mounted within the cabinet. The impeller may be in mechanical communication with the motor to motivate rotation of the impeller about an axial direction. The impeller may be rotatable along a rotational direction about the axial direction to urge a flow of air from the chamber of the laundry basket. The impeller may include a baseplate, and a plurality of radially accurate vanes supported on the baseplate. The plurality of radially arcuate vanes may each extend rearward relative to the rotational direction from an inner end proximal to the axial direction to an outer end distal to the axial direction.
In another exemplary aspect of the present disclosure, a ventilation assembly for a laundry appliance is provided. The ventilation assembly may include a motor and an impeller. The impeller may be in mechanical communication with the motor to motivate rotation of the impeller about an axial direction. The impeller may be rotatable along a rotational direction about the axial direction to urge a flow of air. The impeller may include a baseplate and a plurality of radially accurate vanes supported on the baseplate. The plurality of radially arcuate vanes may each extend rearward relative to the rotational direction from an inner end proximal to the axial direction to an outer end distal to the axial direction.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a perspective view of a laundry appliance in accordance with exemplary embodiments of the present disclosure.

FIG. 2 provides a side sectional view of the exemplary laundry appliance of FIG. 1 .

FIG. 3 provides a schematic diagram of an exemplary laundry appliance and a conditioning system thereof in accordance with exemplary embodiments of the present disclosure.

FIG. 4 provides a perspective view of an impeller assembly for a laundry appliance according to exemplary embodiments of the present disclosure.

FIG. 5 provides a cross-sectional perspective view of a portion of an impeller assembly according to exemplary embodiments of the present disclosure.

FIG. 6 provides a sectional view of a portion of an impeller assembly according to exemplary embodiments of the present disclosure.

FIG. 7 provides a plan view of an impeller according to exemplary embodiments of the present disclosure.

FIG. 8 provides a graph illustrating data correlating pressure values and airflow rates for various ventilation assemblies.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations.
As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). In addition, here and throughout the specification and claims, range limitations may be combined or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components or systems. For example, the approximating language may refer to being within a 10 percent margin (i.e., including values within ten percent greater or less than the stated value). In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction (e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, such as, clockwise or counterclockwise, with the vertical direction V).
The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows.
Except as explicitly indicated otherwise, recitation of a singular processing element (e.g., “a controller,” “a processor,” “a microprocessor,” etc.) is understood to include more than one processing element. In other words, “a processing element” is generally understood as “one or more processing element.” Furthermore, barring a specific statement to the contrary, any steps or functions recited as being performed by “the processing element” or “said processing element” are generally understood to be capable of being performed by “any one of the one or more processing elements.” Thus, a first step or function performed by “the processing element” may be performed by “any one of the one or more processing elements,” and a second step or function performed by “the processing element” may be performed by “any one of the one or more processing elements and not necessarily by the same one of the one or more processing elements by which the first step or function is performed.” Moreover, it is understood that recitation of “the processing element” or “said processing element” performing a plurality of steps or functions does not require that at least one discrete processing element be capable of performing each one of the plurality of steps or functions.
Referring now to the figures, an exemplary laundry appliance that may be used to implement aspects of the present subject matter will be described. Specifically, FIG. 1 is a perspective view of an exemplary horizontal axis washer/dryer appliance 100 (e.g., washer and condenser dryer combination appliance), referred to herein for simplicity as laundry appliance 100. FIG. 2 is a side sectional view of laundry appliance 100. As illustrated, laundry appliance 100 generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined. Laundry appliance 100 includes a cabinet 102 that extends between a top 104 and a bottom 106 along the vertical direction V, between a left side 108 and a right side 110 along the lateral direction, and between a front 112 and a rear 114 along the transverse direction T.
Referring to FIG. 2 , a laundry basket 120 is rotatably mounted within cabinet 102 such that it is rotatable about an axis of rotation A. According to the illustrated embodiment, axis of rotation A is substantially parallel to a horizontal direction (e.g., the transverse direction T), as this exemplary appliance is a front load appliance. A motor 122, such as a pancake motor, is in mechanical communication with laundry basket 120 to selectively rotate laundry basket 120 (e.g., during an agitation or a rinse phase of laundry appliance 100). Motor 122 may be mechanically coupled to laundry basket 120 directly or indirectly (e.g., via a pulley and a belt—not pictured). Laundry basket 120 is received within a tub 124 that defines a (e.g., laundry or drying) chamber 126 that is configured for receipt of articles for washing or drying.
As used herein, the terms “clothing” or “articles” includes but need not be limited to fabrics, textiles, garments, linens, papers, or other items from which the extraction of moisture is desirable. Furthermore, the term “load” or “laundry load” refers to the combination of clothing that may be washed together or dried together in laundry appliance 100 (e.g., the combination washer and dryer) and may include a mixture of different or similar articles of clothing of different or similar types and kinds of fabrics, textiles, garments and linens within a particular laundering process.
The tub 124 holds wash and rinse fluids for agitation in laundry basket 120 within tub 124. As used herein, “wash fluid” may refer to water, detergent, fabric softener, bleach, or any other suitable wash additive or combination thereof. Indeed, for simplicity of discussion, these terms may all be used interchangeably herein without limiting the present subject matter to any particular “wash fluid.”
Laundry basket 120 may define one or more agitator features that extend into chamber 126 to assist in agitation, cleaning, and drying of articles disposed within chamber 126 during operation of laundry appliance 100. For example, as illustrated in FIG. 2 , a plurality of baffles or ribs 128 extend from basket 120 into chamber 126. In this manner, for example, ribs 128 may lift articles disposed in laundry basket 120 and then allow such articles to tumble back to a bottom of drum laundry basket 120 as it rotates. Ribs 128 may be mounted to laundry basket 120 such that ribs 128 rotate with laundry basket 120 during operation of laundry appliance 100.
Referring generally to FIGS. 1 and 2 , cabinet 102 may include a front panel 130 which defines an opening 132 that permits user access to laundry basket 120 and tub 124. More specifically, laundry appliance 100 includes a door 134 that is positioned over opening 132 and is rotatably mounted to front panel 130. In this manner, door 134 permits selective access to opening 132 by being movable between an open position (not shown) facilitating access to a tub 124 and a closed position (FIG. 1 ) prohibiting access to tub 124. Laundry appliance 100 may further a latch assembly 136 (see FIG. 1 ) that is mounted to cabinet 102 or door 134 for selectively locking door 134 in the closed position or detecting the door 134 in the closed position. Latch assembly 136 may be desirable, for example, to ensure only secured access to chamber 126 or to otherwise ensure and verify that door 134 is closed during certain operating cycles or events.
In some embodiments, a window 138 in door 134 permits viewing of laundry basket 120 when door 134 is in the closed position (e.g., during operation of laundry appliance 100). Door 134 may include a handle (not shown) that, for example, a user may pull when opening and closing door 134. Further, although door 134 is illustrated as mounted to front panel 130, it should be appreciated that door 134 may be mounted to another side of cabinet 102 or any other suitable support according to alternative embodiments.
Referring again to FIG. 2 , laundry basket 120 may also define a plurality of perforations 140 in order to facilitate fluid communication between an interior of basket 120 and tub 124. A sump 142 is defined by tub 124 at a bottom of tub 124 along the vertical direction V. Thus, sump 142 is configured for receipt of and generally collects wash fluid during operation of laundry appliance 100. For example, during operation of laundry appliance 100, wash fluid may be urged by gravity from basket 120 to sump 142 through plurality of perforations 140.
In some embodiments, a drain pump assembly 144 is located beneath tub 124 and is in fluid communication with sump 142 for periodically discharging soiled wash fluid from laundry appliance 100. Drain pump assembly 144 may generally include a drain pump 146 which is in fluid communication with sump 142 and with an external drain 148 through a drain hose 150. During a drain cycle or phase (e.g., as a portion of a wash cycle), drain pump 146 urges a flow of wash fluid from sump 142, through drain hose 150, and to external drain 148. More specifically, drain pump 146 includes a motor (not shown) which is energized during a drain cycle such that drain pump 146 draws wash fluid from sump 142 and urges it through drain hose 150 to external drain 148.
A spout 154 is configured for directing a flow of fluid into tub 124. For example, spout 154 may be in fluid communication with a water supply 155 (FIG. 2 ) in order to direct fluid (e.g., clean water or wash fluid) into tub 124. Spout 154 may also be in fluid communication with the sump 142. For example, pump assembly 144 may direct wash fluid disposed in sump 142 to spout 154 in order to circulate wash fluid in tub 124.
As illustrated in FIG. 2 , a detergent drawer 156 may be slidably mounted within front panel 130. Detergent drawer 156 receives a wash additive (e.g., detergent, fabric softener, bleach, or any other suitable liquid or powder) and directs the fluid additive to wash chamber 126 during operation of laundry appliance 100. According to the illustrated embodiment, detergent drawer 156 may also be fluidly coupled to spout 154 to facilitate the complete and accurate dispensing of wash additive.
In optional embodiments, a bulk reservoir 157 is disposed within cabinet 102 and is configured for receipt of fluid additive or detergent for use during operation of laundry appliance 100. Moreover, bulk reservoir 157 may be sized such that a volume of fluid additive sufficient for a plurality or multitude of wash cycles of laundry appliance 100 (e.g., five, ten, twenty, fifty, or any other suitable number of wash cycles) may fill bulk reservoir 157. Thus, for example, a user can fill bulk reservoir 157 with fluid additive and operate laundry appliance 100 for a plurality of wash cycles without refilling bulk reservoir 157 with fluid additive. A reservoir pump (not shown) may be configured for selective delivery of the fluid additive from bulk reservoir 157 to tub 124.
A water supply valve or control valve 158 may provide a flow of water from a water supply source (such as a municipal water supply 155) into detergent dispenser 156 or into tub 124. In this manner, control valve 158 may generally be operable to supply water into detergent dispenser 156 to generate a wash fluid (e.g., for use in a wash cycle) or a flow of fresh water (e.g., for a rinse phase). It should be appreciated that control valve 158 may be positioned at any other suitable location within cabinet 102.
A control panel 160 including a plurality of input selectors 162 (e.g., buttons, knobs, toggles, touch screens, etc.) is coupled to front panel 130. Control panel 160 and input selectors 162 collectively form a user interface input for operator selection of machine cycles and features. For example, in one embodiment, a display 164 indicates selected features, a countdown timer, or other items of interest to machine users.
Operation of laundry appliance 100 is controlled by a controller or processing device 166 (FIG. 1 ) that is operatively coupled to control panel 160 for user manipulation to select laundry cycles and features. In response to user manipulation of control panel 160, controller 166 operates the various components of laundry appliance 100 to execute selected machine cycles and features.
Controller 166 may include a memory and microprocessor, such as a general or special purpose microprocessor operable to execute programming instructions or micro-control code associated with a cleaning cycle. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 166 may be constructed without using a microprocessor (e.g., using a combination of discrete analog or digital logic circuitry-such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software. Control panel 160 and other components of laundry appliance 100 may be in communication with controller 166 via one or more signal lines or shared communication busses.
During operation of laundry appliance 100, laundry items are loaded into laundry basket 120 through opening 132, and a washing or wash/dry operation (e.g., having discrete wash and dry cycles) is initiated through operator manipulation of input selectors 162. Tub 124 is filled with water, detergent, or other fluid additives (e.g., via spout 154 and or detergent drawer 156). One or more valves (e.g., control valve 158) can be controlled by laundry appliance 100 to provide for filling laundry basket 120 to the appropriate level for the amount of articles being washed or rinsed. By way of example for a wash cycle, once laundry basket 120 is properly filled with fluid, the contents of laundry basket 120 can be agitated (e.g., with ribs 128) for washing of articles in laundry basket 120.
After an agitation phase of the wash cycle is completed, tub 124 can be drained. Laundry articles can then be rinsed by again adding fluid to tub 124, depending on the particulars of the cleaning cycle selected by a user. Ribs 128 may again provide agitation within laundry basket 120. One or more spin cycles or phases may also be used. In particular, a spin phase may be applied after the wash cycle or after the rinse phase in order to wring wash fluid from the articles being washed. During a final spin cycle, basket 120 is rotated at relatively high speeds and drain pump assembly 144 may discharge wash fluid from sump 142. Following the wash cycle, a dry cycle may be executed, as will be described in greater detail below.
While described in the context of a specific embodiment of horizontal axis laundry appliance 100, using the teachings disclosed herein it will be understood that horizontal axis laundry appliance 100 is provided by way of example only. Other laundry appliances having different configurations, different appearances, or different features may also be utilized with the present subject matter as well (e.g., vertical axis laundry appliances). For instance, aspects of the present subject matter may be applicable to dedicated dryers or drying appliances, as would be understood. Indeed, it should be appreciated that aspects of the present subject matter may further apply to other laundry appliances. In this regard, the same methods as systems and methods as described herein may be used to implement dry cycles for other appliances, as described in more detail below.
Referring again to FIG. 2 , a conditioning system 200 is provided to facilitate heating or moisture removal for tub 124. In turn, conditioning system 200 generally includes one or more heaters or heating assemblies 202 and air handlers (e.g., provided as part of a ventilation assembly, described in greater detail below) in an open or closed loop assembly.
As shown in FIG. 2 , conditioning system 200 may be provided as part of a closed loop assembly. Conditioning system 200 may include a return duct 220 that is mounted to tub 124 for circulating air within chamber 126 to facilitate a dry cycle. For example, according to the illustrated exemplary embodiments, return duct 220 is fluid coupled to tub 124 proximate a top of tub 124. Return duct 220 receives heated air that has been heated or dehumidified by a conditioning system 200 and provides the heated air to laundry basket 120 via one or more holes defined by rear wall 206 or cylindrical wall 208 of laundry basket 120 (e.g., such as perforations 140).
During a dry cycle, moisture laden, heated air is drawn from laundry basket 120 by an air handler, such as a blower fan 222, which may generate a negative air pressure within laundry basket 120. As the air passes from blower fan 222, it enters an intake duct 224 and then is passed into conditioning system 200. In some embodiments, the conditioning system 200 may have a heater 202 that includes or is provided as an electric heating element (e.g., a resistive heating element) or a gas-powered heating element (e.g., a gas burner), as would be understood. According to the illustrated exemplary embodiment, laundry appliance 100 is a heat pump dryer appliance and thus conditioning system 200 may be or include a heater including a heat pump having a sealed refrigerant circuit, as described in more detail below with reference to FIG. 3 . Heated air (with a lower moisture content than was received from laundry basket 120), exits conditioning system 200 and returns to laundry basket 120 by a return duct 220. As air is heated and circulated through the chamber 126, the basket 120 may be rotated (e.g., as motivated by the motor 122), such as at a set tumble speed, to permit agitation (e.g., at non-plastering or sub-plaster speeds), as is understood. After the clothing articles have been dried (e.g., following completion of the dry cycle), the articles may be removed from the laundry basket 120 via opening 132.
As shown, laundry appliance 100 may further include one or more lint filters 230 (FIG. 3 ) to collect lint during drying operations. The moisture laden heated air passes through intake duct 224 enclosing screen filter 230, which traps lint particles. More specifically, filter 230 may be placed into an air flow path 232 defined by laundry basket 120, conditioning system 200, intake duct 224, and return duct 220. Filter 230 may be positioned in the process air flow path 232 and may include a screen, mesh, other material to capture lint in the air flow 232. The location of lint filters in laundry appliance 100 as shown in FIG. 3 is provided by way of example only, and other locations may be used as well. According to exemplary embodiments, lint filter 230 is readily accessible by a user of the appliance. As such, lint filter 230 should be manually cleaned by removal of the filter, pulling or wiping away accumulated lint, and then replacing the filter 230 for subsequent drying or dry cycles.
According to optional embodiments, laundry appliance 100 may facilitate a steam dry process. In this regard, laundry appliance 100 may offer a steam dry cycle, during which steam is injected into chamber 126 (e.g., to function similar to a traditional garment steamer to help remove wrinkles, static, etc.). Accordingly, as shown for example in FIG. 3 , laundry appliance 100 may include a misting nozzle 234 that is in fluid communication with a water supply 236 (e.g., such as water supply 155) in order to direct mist into chamber 126. Laundry appliance 100 may further include a water supply valve or control valve 238 for selecting discharging the flow of mist into chamber 126. It should be appreciated that control valve 238 may be positioned at any other suitable location within cabinet 102.
FIG. 3 provides a schematic view of laundry appliance 100 and depicts conditioning system 200 in more detail. In the illustrated exemplary embodiments, laundry appliance 100 is a heat pump dryer appliance and thus conditioning system 200 includes a sealed system 250. Sealed system 250 includes various operational components, which can be encased or located within a machinery compartment of laundry appliance 100. In some embodiments, the operational components are operable to execute a vapor compression cycle for heating process air passing through conditioning system 200. The operational components of sealed system 250 include an evaporator 252, a compressor 254, a condenser 256, and one or more expansion devices 258 connected in series along a refrigerant circuit or line 260. Refrigerant line 260 is charged with a working fluid, which in this example is a refrigerant. Sealed system 250 depicted in FIG. 3 is provided by way of example only. Thus, it is within the scope of the present subject matter for other configurations of the sealed system to be used as well. As will be understood by those skilled in the art, sealed system 250 may include additional components (e.g., at least one additional evaporator, compressor, expansion device, or condenser). For instance, sealed system 250 may include two evaporators.
In performing a dry cycle, one or more laundry articles LA may be placed within the chamber 126 of laundry basket 120. For instance, following a wash cycle, articles may remain within the chamber 126. Hot dry air HDA may be supplied to chamber 126 via return duct 220. The hot dry air HDA enters chamber 126 of laundry basket 120 via a tub inlet 264 defined by laundry basket 120 (e.g., the plurality of holes defined in rear wall 206 or cylindrical wall 208 of laundry basket 120 as shown in FIG. 2 ). The hot dry air HDA provided to chamber 126 causes moisture within laundry articles LA to evaporate. Accordingly, the air within chamber 126 increases in water content and exits chamber 126 as warm moisture laden air MLA. The warm moisture laden air MLA exits chamber 126, such as through a tub outlet 266 defined by laundry basket 120 and flows into intake duct 224.
After exiting chamber 126 of laundry basket 120, the warm moisture laden air MLA may flow downstream to conditioning system 200. Blower fan 222 moves the warm moisture laden air MLA, as well as the air more generally, through a process air flow path 232 defined by laundry basket 120, conditioning system 200, intake duct 224, and return duct 220. Thus, generally, blower fan 222 is operable to move air through or along the process air flow path 232. The duct system includes all ducts that provide fluid communication (e.g., airflow communication) between tub outlet 266 and conditioning system 200 and between conditioning system 200 and tub inlet 264. Although blower fan 222 is shown positioned between laundry basket 120 and conditioning system 200 along intake duct 224, it will be appreciated that blower fan 222 can be positioned in other suitable positions or locations along the duct system.
As further depicted in FIG. 3 , the warm moisture laden air MLA flows into or across evaporator 252 of the conditioning system 200. As the moisture-laden air MLA passes across evaporator 252, the temperature of the air is reduced through heat exchange with refrigerant that is vaporized within, for example, coils or tubing of evaporator 252. This vaporization process absorbs both the sensible and the latent heat from the moisture-laden air MLA-thereby reducing its temperature. As a result, moisture in the air is condensed and such condensate water may be drained from conditioning system 200 (e.g., using a drain line 262, which is also depicted in FIG. 3 ).
In optional embodiments, a condenser tank or a condensate collection tank 270 is in fluid communication with conditioning system 200 (e.g., via drain line 262). Collection tank 270 is operable to receive condensate water from the process air flowing through conditioning system 200, and more particularly, condensate water from evaporator 252. A sensor 272 may be operable to detect when water within collection tank 270 has reached a predetermined level. Sensor 272 can be any suitable type of sensor, such as a float switch as shown in FIG. 3 . Sensor 272 can be communicatively coupled with controller 166 (e.g., via a suitable wired or wireless communication link). A drain pump 274 is in fluid communication with collection tank 270. Drain pump 274 is operable to remove a volume of water from collection tank 270 and, for example, discharge the collected condensate to an external drain. In some embodiments, drain pump 274 can remove a known or predetermined volume of water from collection tank 270. Drain pump 274 can remove the condensate water from collection tank 270 and can move or drain the condensate water downstream (e.g., to a gray water collection system). Particularly, in some embodiments, controller 166 is configured to receive, from sensor 272, an input indicating that water within the collection tank has reached the predetermined level. In response to the input indicating that water within collection tank 270 has reached the predetermined level, controller 166 can cause drain pump 274 to remove the predetermined volume of water from collection tank 270.
Air passing over evaporator 252 becomes cooler than when it exited laundry basket 120 at tub outlet 266. As shown in FIG. 3 , cool air CA (cool relative to hot dry air HDA and moisture laden air MLA) flowing downstream of evaporator 252 is subsequently caused to flow across condenser 256 (e.g., across coils or tubing thereof), which condenses refrigerant therein. The refrigerant enters condenser 256 in a gaseous state at a relatively high temperature compared to the cool air CA from evaporator 252. As a result, heat energy is transferred to the cool air CA at the condenser 256, thereby elevating its temperature and providing warm dry air HDA for resupply to laundry basket 120 of laundry appliance 100. The warm dry air HDA passes over and around laundry articles LA within the chamber 126 of the laundry basket 120, such that warm moisture laden air MLA is generated, as mentioned above.
With respect to sealed system 250, compressor 254 pressurizes refrigerant (i.e., increases the pressure of the refrigerant) passing therethrough and generally motivates refrigerant through the sealed refrigerant circuit or refrigerant line 260 of conditioning system 200. Compressor 254 may be communicatively coupled with controller 166 (communication lines not shown in FIG. 3 ). Refrigerant is supplied from the evaporator 252 to compressor 254 in a low pressure gas phase. The pressurization of the refrigerant within compressor 254 increases the temperature of the refrigerant. The compressed refrigerant is fed from compressor 254 to condenser 256 through refrigerant line 260. As the relatively cool air CA from evaporator 252 flows across condenser 256, the refrigerant is cooled and its temperature is lowered as heat is transferred to the air for supply to chamber 126 of laundry basket 120.
Upon exiting condenser 256, the refrigerant is fed through refrigerant line 260 to expansion device 258. Although only one expansion device 258 is shown, such is by way of example only. It is understood that multiple such devices may be used. In the illustrated example, expansion device 258 is an electronic expansion valve, although a thermal expansion valve or any other suitable expansion device can be used. In additional embodiments, any other suitable expansion device, such as a capillary tube, may be used as well. Expansion device 258 lowers the pressure of the refrigerant and controls the amount of refrigerant that is allowed to enter the evaporator 252. Importantly, the flow of liquid refrigerant into evaporator 252 is limited by expansion device 258 in order to keep the pressure low and allow expansion of the refrigerant back into the gas phase in evaporator 252. The evaporation of the refrigerant in evaporator 252 converts the refrigerant from its liquid-dominated phase to a gas phase while cooling and drying the moisture laden air MLA received from chamber 126 of laundry basket 120. The process is repeated as air is circulated along process air flow path 232 while the refrigerant is cycled through sealed system 250, as described above.
In the case of a tumble dry cycle, the heater (e.g., sealed system 250) remains inactive such that heat is not actively generated or, alternatively, the heater may be directed to a relatively low heat setting (i.e., a first heat setting that is lower in power, voltage, duty cycle, or temperature than a second heat setting of the dry cycle). For instance, the compressor 254 may be directed to a reduced state. Optionally, compressor 254 may be held inactive to restrict the flow of refrigerant through sealed system 250. Nonetheless, air may be cycled through chamber 126 along the same path as air circulated during a dry cycle (e.g., as described above).
Turning now to FIGS. 4 through 7 , various views are provided of an impeller assembly 400 of a ventilation assembly (e.g., provided as or as part of blower fan 222) according to exemplary embodiments of the present disclosure. Generally, impeller assembly 400 includes an impeller 410 and a housing 412. Impeller assembly 400 may be used in any suitable appliance. For example, impeller assembly 400 may be used in laundry appliance 100 (e.g., as blower fan 222-FIG. 2 ). Thus, impeller assembly 400 may be positioned within cabinet 102 such that impeller assembly 400 draws and receives moisture laden air from chamber 126 of tub 124.
In some embodiments, impeller 410 is positioned within a housing cavity 414 defined by housing 412. In some such embodiments, housing 412 includes a front panel 416 and a rear panel 418 (e.g., at least partially defining the housing cavity 414). When assembled, the front panel 416 and the rear panel 418 may be spaced apart (e.g., along an axial direction X by the housing cavity 414). Additionally or alternatively, impeller 410 may be placed in mechanical communication with a motor 420 that selectively rotates impeller 410 about an axial direction X within housing 412. For example, impeller 410 may be fixed to a shaft or drive rod 422 of motor 420 such that impeller 410 rotates along a rotational direction E about the axial direction X within housing 412 with motor 420. In some embodiments, the drive rod 422 extends (e.g., along an axial direction X) from the motor 420 to the impeller 410 through the rear panel 418.
As shown, front panel 416 is mounted to rear panel 418 (e.g., via one or more sidewalls positioned about or at least partially defining the housing cavity 414). Front panel 416 defines an entrance 424 for receiving the flow of air F into housing 412. In some embodiments, rear panel 418 also defines an exhaust exit 426 for directing the flow of air F out of housing cavity 414. As an example, during operation of impeller assembly 400, impeller 410 may rotate on the axial direction X within housing 412 such that impeller 410 draws the flow of air F into housing 412 via entrance 424 of front panel 416. In addition, impeller 410 may urge the flow of air F through rear panel 418 to exhaust exit 426 of housing 412 during operation of impeller assembly 400. In such a manner, impeller 410 may urge or draw the flow of air F through housing 412 during operation of impeller assembly 400.
In some embodiments, housing 412 includes a volute portion 428 and a transition duct 430. Volute portion 428 defines a portion of housing cavity 414 (e.g., as a cylindrical, radially expanding, or spiraled portion) of housing 412 that is sized and configured for receiving impeller 410—and receiving air from impeller 410. Thus, impeller 410 may be positioned within volute portion 428 (e.g., at the volute portion of housing cavity 414). A cutoff 432 may be disposed within housing cavity 414 and delineate at least a portion of volute portion 428. The cutoff 432 may include a curved interior face 436 (e.g., proximal to the axial direction X) and a flat or planar exterior face 438 (e.g., distal to the axial direction X) along which air flows and which are separated by an acute-angle transition tip 434 serving as a cut point for the flow of air. As shown, the cutoff 432 may be disposed above the impeller 410 (e.g., such that a plane on which the exterior face 438 lies is optionally parallel to, or otherwise fails to intersect, the entirety of the impeller 410 and, thus, does not extend through any portion of the impeller 410).
From the cutoff 432, a transition duct 430 extends between cavity 414 of volute portion 428 and exhaust exit 426 (e.g., in an L-shape). Exhaust exit 426 may define an exit axis. The flow of air F may thus exit housing 412 at exhaust exit 426 flowing along a direction that is parallel to exit axis. In optional embodiments, exit axis is, for example, substantially parallel to the axial direction X. The flow of air F may flow into housing 412, flowing along a direction that is parallel to the axial direction X. Within cavity 414 of volute portion 428, the flow of air F may be urged radially outward from the axial direction X (e.g., perpendicular to the axial direction X) or along a tangential direction relative to the perimeter or circumference of the impeller 410. Transition duct 430 may redirect or turn the flow of air F within housing 412 (e.g., such that the flow of air F enters and exits housing 412 along directions that are parallel to each other).
As discussed above, housing 412 may be positioned within cabinet 102 of laundry appliance 100. As an example, housing 412 may be positioned within cabinet 102 at a front duct or intake duct 224 (FIG. 2 ). Entrance 424 of front panel 416 may be positioned for receiving moisture laden air MLA from intake duct 224. In addition, front panel 416 may be mounted to volute portion 428 and positioned over the volute of housing cavity 414. Entrance 424 of front panel 416 may also be positioned for directing the flow of air F into cavity 414 of volute portion 428. The flow of air F flows through housing 412 from cavity 414 of volute portion 428 to exhaust exit 426. From exhaust exit 426, the flow of air F exits housing 412. In laundry appliance 100, supply duct 220 may extend between and fluidly couple exhaust exit 426 of housing 412 and tub inlet 264 (FIG. 2 ).
As noted above, in exemplary embodiments, the impeller 410 is a centrifugal impeller 410 configured to rotate about the axial direction X. Multiple vanes 442 may be provided on the impeller 410 and may extend generally outward in or along a radial direction R that is perpendicular to the axial direction X. For example, the vanes 442 may each extend along a generally-radial arcuate path as a plurality of radially accurate vanes 442 (as shown). Thus, although the vanes 442 may curved relative to the radial direction R (i.e., not strictly parallel to the radial direction R). Moreover, the vanes 442 may be formed according to a prismatic shape, formed such as to incline each vane relative to the axial direction X (or baseplate 444).
The vanes 442 may be supported (e.g., formed) on a baseplate 444 proximal to rear panel 418 (i.e., distal to front panel 416). Moreover, the vanes 442 may each extend rearward (e.g., relative to the rotational direction E and, thus, opposite the rotational direction E) from an inner end 446 proximal to the axial direction X to an outer end 448 distal to the axial direction X. Thus, as tracked inside to outside along a radial path from the inner end 446 to the outer end 448, each vane 442 will also rearward away from the rotational direction E. It is noted that although the inner ends 446 may each be proximal to the axial direction X, in some embodiments a central gap 450 is defined (e.g., on the baseplate 444) to separate or space apart the inner ends 446 from the axial direction X. In some embodiments, the circumferential spacing between each pair of adjacent vanes 442 varies (e.g., expands) along the radial path from the inner end 446 to the outer end 448. For instance, the circumferential distance between adjacent outer ends 448 may be greater than the circumferential distance between the corresponding adjacent inner ends 446.
In certain embodiments, the impeller 410 provides a faceplate 452 supported on the plurality of vanes 442 opposite of the baseplate 444 (e.g., relative to the axial direction X). In particular, the faceplate 452 may extend radially (e.g., as a solid disk) from an inner edge 486 proximal to the axial direction X to an outer edge 488 distal to the axial direction X. The inner edge 486 may be spaced apart from the axial direction X. The outer edge 488 may cover or extend radially to the outer ends 448 of the vanes 442.
In exemplary embodiments, the impeller 410 has or defines a circular perimeter 454 (e.g., at the outer edge 488 or outer ends 448 of vanes 442). The impeller 410 may thus provide a generally circular profile (e.g., as defined on a plane perpendicular to the axial direction X). Across the circular perimeter 454 (e.g., perpendicular to the axial direction X), the impeller 410 extends to an outer impeller diameter 456 (i.e., with an outer impeller radius 458 that extends from the axial direction X and is half the outer impeller diameter 456). As shown, the outer impeller diameter 456 may be defined as a radially-outermost portion of the impeller 410 (e.g., outermost as measured from the axial direction X). In some such embodiments, the outer impeller diameter 456 is defined at a radial tip of the baseplate 444, outer edge 488 of faceplate 452, or outer ends 448 of vanes 442.
As shown, the impeller 410 may define an impeller inlet 460 (e.g., through the faceplate 452) along the axial direction X. In some such embodiments, the inner edge 486 serves to define the impeller inlet 460. Radially spaced apart from the impeller inlet 460, an impeller outlet 462 may be defined. For instance, the impeller outlet 462 may be defined as the circumferential spacing between the outer ends 448 of the vanes 442. Thus, as the impeller 410 rotates, air may be drawn axially toward and through the impeller inlet 460 before being directed radially outward through the impeller outlet 462.
In certain embodiments, the faceplate 452 defines a curved outer surface 464. The faceplate 452 may be generally convex (e.g., when viewed along the axial direction X opposite of the vanes 442). Additionally or alternatively, the impeller width of the outer surfaces of the impeller 410 may vary (e.g., along the radial direction R). In some such embodiments, a maximum impeller width 466 is defined (e.g., along the axial direction X) at the inner edge 486 while a minimum impeller width 468 is defined (e.g., along the axial direction X) at the outer edge 488. Thus, the width or axial height of the vanes 442 may decrease along the radial direction R from the inner ends 446 to the outer ends 448. Optionally, the portion of baseplate 444 along the radial direction R from inner edge 486 to outer edge 488 may be generally flat or parallel to the radial direction R.
As shown, especially in FIG. 6 , at least a portion of the housing 412 may be formed to closely match or complement the impeller 410. Specifically, at least a portion of the front panel 416 may define an inner panel surface 470 that is directed toward or faces the impeller 410. The inner panel surface 470 of the front panel 416 may define at least part of the volute portion 428. In some such embodiments, the inner panel surface 470 is complementary to the curved outer surface 464. For instance, the inner panel surface 470 may hold a substantially constant axial distance with or between the faceplate 452.
Separate from or in addition to the front panel 416, at least a portion of the rear panel 418 may define an inner panel surface 472 that is directed toward or faces the impeller 410. The inner panel surface 472 of the rear panel 418 may define at least part of the volute portion 428. In some such embodiments, the inner panel surface 472 is complementary to an outer surface 464 of the baseplate 444. For instance, the inner panel surface 472 may hold a substantially constant axial distance with or between the baseplate 444.
As noted above, the front panel 416 may define the entrance 424 to the housing 412. As shown, the entrance 424 may be concentric with the impeller inlet 460. Thus, the impeller inlet 460 may extend concentrically with the entrance 424 along the axial direction X. In some embodiments the housing 412 further includes an interior lip 474 disposed at the entrance 424. The interior lip 474 may extend, for instance, along the entrance 424 toward the housing cavity 414 or impeller 410. The interior lip 474 may even define a smaller radial diameter than the impeller inlet 460. In some such embodiments, the interior lip 474 extends into the impeller inlet 460 and thus occupies a common radial plane with at least a portion of the impeller 410. Notably, turbulence or flow losses into the impeller 410 may be prevented.
In certain embodiments, the housing 412 includes an impeller guide 476 within at least a portion of the housing cavity 414. Specifically, the impeller guide 476 may provide one or more ridge walls (e.g., extending axially from the front panel 416 or rear panel 418) about at least a portion of the impeller 410 (e.g., radially inward from the cutoff 432 relative to the axial direction X). In the illustrated embodiments, a front ridge wall 490 and a rear ridge wall 492 extend about the impeller 410 and axially from the front panel 416 and the rear panel 418, respectively. Although the impeller guide 476 extends about the impeller 410, a radial guide outlet 478 is defined (e.g., as an axial space between the front and rear ridge walls 490, 492). When assembled, the guide outlet 478 may be radially aligned with the impeller outlet 462. In some embodiments, the impeller outlet 462 has an axial guide-outlet (GO) width 480 that is less than some or all of the impeller width(s). For instance, the GO width 480 may be less than the impeller width (e.g., minimum impeller width 468) defined at the outer surface 464 of the impeller 410 at the impeller outlet 462.
Returning especially to FIG. 5 , the cutoff 432 may be maintained in relatively close proximity to the impeller 410. In certain embodiments, a minimum radial gap 482 is defined between the impeller 410 and the cutoff 432. For instance, from a portion of the outer impeller perimeter 454 (e.g., most proximate to the cutoff 432) relative to the radial direction R, the minimum radial gap 482 may be defined as a positive distance (i.e., greater than 0) to the exterior face 438 (e.g., the plane on which the exterior face 438 lies) along a direction perpendicular to the axial direction X. In some embodiments, the minimum radial gap 482 is less than 10% (e.g., less than 5%) of the outer impeller radius 458. Thus, although the cutoff 432 may be positioned above the impeller 410, the cutoff 432 may be close to the upper tangent extending from the impeller 410. Separately from or in addition to the radial gap 482, the cutoff 432 may define a relatively small radial distance 484 to the axial direction X. For instance, a radial distance 484 may be defined from the cutoff 432 (e.g., at the tip 434) to the axial direction X about which the impeller 410 rotates. The radial distance 484 may, specifically be the minimum distance measurable from the cutoff 432 (e.g., at the tip 434) to the axial direction X along the radial direction R. In some embodiments, the radial distance 484 is less than 15% (e.g., less than 10%) of the outer impeller radius 458.
Turning now to FIG. 8 , present embodiments of the impeller or ventilation assembly 400 (FIGS. 4 through 7 ) may advantageously reduce impacts to volumetric flowrate reduction with pressure resistance increase (e.g., as may be caused by a relatively large load within a chamber 126—FIG. 2 —or the accumulation of lint). For instance, using the exemplary system curve (line 8-1) as a reference, impacts of pressure resistance variations (e.g., drops) to the performance of exemplary ventilation assemblies can be observed. Specifically, pressure at a fan outlet may increase, at the same operating speed, as system resistance is increasing. As shown, exemplary embodiments of the present disclosure (line 8-2) provide a relatively steep negative slope across most airflow rates, especially in comparison to existing squirrel-cage impeller assemblies (e.g., lines 8-3 and 8-4). In turn, modifications to the system curve 8-1, such as would occur if airflow were restricted (e.g., transforming to the line 8-1-1, as may be caused by a relatively large load within a chamber 126—FIG. 2 —or the accumulation of lint), would not greatly decrease the possible airflow rate to the exemplary embodiments of the present disclosure 8-2 in comparison to the existing assemblies 8-3, 8-4.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

What is claimed is:

1. A laundry appliance comprising:

a cabinet;

a tub positioned within the cabinet, the tub defining a tub outlet and a tub inlet;

a laundry basket rotatably mounted within the tub, the laundry basket defining a chamber for receipt of articles for washing or drying;

a motor mounted within the cabinet; and

an impeller in mechanical communication with the motor to motivate rotation of the impeller about an axial direction, the impeller being rotatable along a rotational direction about the axial direction to urge a flow of air from the chamber of the laundry basket, the impeller comprising

a baseplate, and

a plurality of radially accurate vanes supported on the baseplate, the plurality of radially arcuate vanes each extending rearward relative to the rotational direction from an inner end proximal to the axial direction to an outer end distal to the axial direction.

2. The laundry appliance of claim 1, further comprising a housing positioned within the cabinet, the housing defining

a housing cavity within which the impeller is positioned,

an entrance upstream from the impeller to permit air thereto,

a cutoff disposed above the impeller, and

a transition duct extending between the cutoff and an exhaust exit of the housing.

3. The laundry appliance of claim 2, wherein the impeller defines an outer impeller diameter, and

wherein a minimum radial gap is defined between an outer impeller perimeter and the cutoff, the minimum radial gap being greater than 0 and less than 10% of the outer impeller diameter.

4. The laundry appliance of claim 2, wherein the impeller defines an outer impeller radius extending from the axial direction, and

wherein the cutoff defines a radial distance to the axial direction, the radial distance being less than 15% of the outer impeller radius.

5. The laundry appliance of claim 2, wherein the impeller defines an impeller outlet and an impeller width along the axial direction at the impeller outlet, wherein the housing further comprises an impeller guide extending about the impeller within the housing cavity and radially inward from the cutoff, the impeller guide defining a guide outlet radially aligned with the impeller outlet, the guide outlet having a GO width less than the impeller width.

6. The laundry appliance of claim 2, wherein the impeller defines an impeller inlet extending concentrically with the entrance along the axial direction, and wherein the housing further comprises an interior lip extending axially along the entrance into the impeller inlet.

7. The laundry appliance of claim 2, wherein the impeller further comprises a faceplate supported on the plurality of radially arcuate vanes opposite of the baseplate, the faceplate extending radially from an inner edge proximal to the axial direction to an outer edge distal to the axial direction.

8. The laundry appliance of claim 7, wherein the impeller defines a maximum impeller width along the axial direction at the inner edge and a minimum impeller width along the axial direction at the outer edge.

9. The laundry appliance of claim 7, wherein the faceplate defines a curved outer surface, wherein the housing further comprises a front panel defining an inner panel surface directed toward the impeller, and wherein the inner panel surface is complementary to the curved outer surface.

10. A ventilation assembly for a laundry appliance, the ventilation assembly comprising:

a motor; and

an impeller in mechanical communication with the motor to motivate rotation of the impeller about an axial direction, the impeller being rotatable along a rotational direction about the axial direction to urge a flow of air, the impeller comprising

a baseplate, and

11. The ventilation assembly of claim 10, further comprising a housing defining

a housing cavity within which the impeller is positioned,

an entrance upstream from the impeller to permit air thereto,

a cutoff disposed above the impeller, and

12. The ventilation assembly of claim 11, wherein the impeller defines an outer impeller diameter, and

13. The ventilation assembly of claim 11, wherein the impeller defines an outer impeller radius extending from the axial direction, and

14. The ventilation assembly of claim 11, wherein the impeller defines an impeller outlet and an impeller width along the axial direction at the impeller outlet, wherein the housing further comprises an impeller guide extending about the impeller within the housing cavity and radially inward from the cutoff, the impeller guide defining a guide outlet radially aligned with the impeller outlet, the guide outlet having a GO width less than the impeller width.

15. The ventilation assembly of claim 11, wherein the impeller defines an impeller inlet extending concentrically with the entrance along the axial direction, and wherein the housing further comprises an interior lip extending axially along the entrance into the impeller inlet.

16. The ventilation assembly of claim 11, wherein the impeller further comprises a faceplate supported on the plurality of radially arcuate vanes opposite of the baseplate, the faceplate extending radially from an inner edge proximal to the axial direction to an outer edge distal to the axial direction.

17. The ventilation assembly of claim 16, wherein the impeller defines a maximum impeller width along the axial direction at the inner edge and a minimum impeller width along the axial direction at the outer edge.

18. The ventilation assembly of claim 16, wherein the faceplate defines a curved outer surface, wherein the housing further comprises a front panel defining an inner panel surface directed toward the impeller, and wherein the inner panel surface is complementary to the curved outer surface.