Combination Laundry Appliance and Induction Heater

The present subject matter relates generally to laundry appliances and heating systems therefor.

Laundry appliances, such as washing machine appliances and dryer appliances, generally include components for generating heated air. Combination laundry appliances, sometimes also referred to as washer/dryer appliances, provide both washing and drying functions in a single unit. Combination laundry appliances are therefore advantageous for added convenience and space saving.

Laundry appliances generally may include expansion devices, compressors, condensers, and various gas or electric heater assemblies for generating heated air for removing moisture from laundry articles. For combination laundry appliances, such components, and further in conjunction with washing machine components, may result in bulky, heavy, and complex assemblies.

Accordingly, a laundry appliance including improved heating systems would be beneficial and advantageous. Additionally, a combination laundry appliance including an improved heating system would be beneficial and advantageous.

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.

An aspect of the present disclosure is directed to a laundry appliance. A cabinet defines an interior volume, A tub is mounted within the interior volume of the cabinet. A laundry basket is rotatably mounted within the tub. The laundry basket defines a chamber for the receipt of laundry articles. A heat exchanger system is in thermal communication with the chamber. The heat exchanger system includes a vessel forming a plenum at which a refrigerant is receivable. The vessel includes a ferrous material. A sleeve at least partially surrounds the vessel. The sleeve includes a non-ferrous material. The sleeve has a conductive structure extending at least partially surrounding the vessel. A volume is formed between the vessel and the sleeve.

An aspect of the present disclosure is directed to a combination washer and dryer laundry appliance. A cabinet defines an interior volume. A tub is mounted within the interior volume of the cabinet. A laundry basket is rotatably mounted within the tub. The laundry basket defines a chamber for the receipt of laundry articles. A heat exchanger system is in thermal communication with the chamber. The heat exchanger system includes a vessel forming a plenum at which a refrigerant is receivable. The vessel includes a ferrous material. A sleeve at least partially surrounds the vessel. The sleeve includes a non-ferrous material. The sleeve has a conductive structure extending at least partially surrounding the vessel. A volume is formed between the vessel and the sleeve.

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.

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 or spirit 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.

As used herein, terms of approximation, such as “substantially,” “generally,” or “about” include values within ten percent greater or less than the stated value. 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. For example, “generally vertical” includes directions within ten degrees of vertical in any direction, e.g., clockwise or counter-clockwise.

Turning now to the figures,provides a perspective view of a laundry applianceaccording to exemplary embodiments of the present disclosure. In some embodiments, the laundry applianceis a washing machine appliance. In still some embodiments, the laundry appliance is a dryer appliance. In various embodiments, the laundry applianceis a combination laundry appliance, and may also be referred to as a multifunction laundry appliance or washer/dryer combination appliance.provides a section view of laundry appliance. The laundry appliancegenerally 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 defined. While described in the context of a specific embodiment of laundry appliance, using the teachings disclosed herein, it will be understood that laundry applianceis provided by way of example only. Other laundry appliances having different appearances and different features may also be utilized with the present subject matter as well.

As used herein, the terms “articles,” “clothing,” or “laundry” include but need not be limited to fabrics, textiles, garments, linens, papers, or other items which may be cleaned, dried, and/or otherwise treated in a laundry appliance. Furthermore, the term “load” or “laundry load” refers to the combination of clothing that may be washed together in a washing machine appliance or dried together in a dryer appliance (e.g., clothes dryer), including washed and dried together in a combination laundry appliance, 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.

Cabinetincludes a front panel, a rear panel, a left side panelsand a right side panelspaced apart from each other by front and rear panelsand, a bottom panel, and a top cover. As used herein, terms such as “left” and “right” or “front” and “back” refer to directions from the perspective of a user facing the laundry appliancefor accessing and/or operating the laundry appliance. For example, a user stands in front of the laundry appliance, e.g., at or near the front panel, to access doorand/or inputs(the doorand inputsare described in more detail below). Within cabinet, an interior volumeis defined. A drum or tubis mounted within the interior volume. A laundry basketis mounted within the tub. The laundry basketdefines a chamberfor receipt of articles of clothing for treatment, e.g., washing, rinsing, spinning, tumbling, and/or drying.

In some embodiments, one or more selector inputs, such as knobs, buttons, touchscreen interfaces, etc., may be provided or mounted on the cabinet, e.g., on a control panelthereof and are in operable communication (e.g., electrically coupled or coupled through a wireless network band) with a processing device or controller. The control panelmay also include a display. Controllermay also be provided in operable communication with various components of the washer/dryer appliance, such as the motor, blower, and/or heat exchanger system. In turn, signals generated in controllerdirect operation of such components in response to the position of inputs. As used herein, “processing device” or “controller” may refer to one or more microprocessors, microcontroller, ASICS, or semiconductor devices and is not restricted necessarily to a single element. The controllermay be programmed to operate laundry applianceby executing instructions stored in memory (e.g., non-transitory media). The controllermay include, or be associated with, one or more memory elements such as RAM, ROM, or electrically erasable, programmable read only memory (EEPROM). For example, the instructions may be software or any set of instructions that when executed by the processing device, cause the processing device to perform operations. It should be noted that controllers as disclosed herein are capable of and may be operable to perform any methods and associated method steps as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in the memory and executed by the controller.

Tubextends between a front portionand a back portion. Tubis generally cylindrical in shape, having an outer cylindrical walland a front flange or wallthat defines an openingof tub, e.g., at front portionof tub, for loading and unloading of articles into and out of a chamberdefined by and within a laundry basketinside of the tub. Tubincludes a rear wallopposite the front flange. A doorprovides for closing or accessing tubthrough opening. A window() may be provided in doorfor viewing of the chamberand/or laundry articles therein, e.g., during operation of the laundry appliance.

Laundry basketis rotatably mounted within tubsuch that the laundry basketis rotatable about an axis of rotation CL. According to the illustrated embodiment, the axis of rotation is substantially parallel to the transverse direction T. In this regard, laundry applianceis generally referred to as a “horizontal axis” or “front load” laundry appliance. However, it should be appreciated that aspects of the present subject matter may be used within the context of a vertical axis or top load laundry appliance as well.

Laundry applianceincludes a motor assembly (not shown) that is in mechanical communication with laundry basketto selectively rotate laundry basket. The motor assembly may be a pancake motor or any other suitable type, size, or configuration of motor may be used to rotate laundry basketaccording to various embodiments.

Laundry basketincludes a rear wallextending along the vertical direction V and a sidewallextending from the rear wallalong the transverse direction T. Laundry basketmay define one or more agitator features that extend into chamberto assist in agitation and cleaning of articles disposed within laundry chamberduring operation of laundry appliance. For example, as illustrated in, a plurality of ribsextends from laundry basketinto chamber. In this manner, for example, ribsmay lift articles disposed in laundry basketduring rotation of laundry basket, such as during an agitation or rinse portion of a wash operation of the laundry appliance. During a drying operation of the laundry appliance, the ribsmay also lift articles in the chamberof the laundry basketand then allow such articles to tumble back to a bottom of laundry basketas laundry basketrotates.

A sumpis defined by tuboutside of laundry basketat a bottom of the tubalong the vertical direction V. For instance, sumpmay be defined between the cylindrical walland the sidewallof the laundry basket. Thus, sumpis configured for receipt of, and generally collects, wash liquid (the wash liquid may include, e.g., water, and may also includes additives such as detergents, etc.) during wash operations of laundry appliance. For example, during a wash operation of laundry appliance, wash liquid may be urged (e.g., by gravity) from the chamberwithin the laundry basketto sumpthrough the plurality of perforations,. A pump assemblyis located beneath tubfor gravity assisted flow when draining tub(e.g., via a drain). Pump assemblyis also configured for recirculating wash liquid within tub.

In some embodiments, laundry applianceincludes an additive dispenser or spout. For example, spoutmay be in fluid communication with a water supply (not shown) in order to direct fluid (e.g., clean water) into tub. Spoutmay also be in fluid communication with the sump. For example, pump assemblymay direct wash liquid disposed in sumpto spoutin order to circulate wash liquid in tub.

As illustrated, a detergent drawermay be slidably mounted within front panel. Detergent drawerreceives an additive (e.g., detergent, fabric softener, bleach, or any other suitable liquid or powder) and directs the additive to chamberduring operation of laundry appliance. According to the illustrated embodiment, detergent drawermay also be fluidly coupled to spoutto facilitate the complete and accurate dispensing of the additive.

Referring now to, schematic embodiments of the laundry applianceare provided. Laundry applianceincludes a heat exchanger systemconfigured to add or remove thermal energy from a fluid provided to the chamber.

Referring to, embodiments of the heat exchanger systemare provided. Heat exchanger systemincludes a vesselforming a plenumat which a refrigerant is receivable. Vesselis formed, at least in part, from a ferrous material, such as iron, an iron-based material or alloy, ferrite, etc. Vesselmay form a pressure vessel having a sidewall. For instance, the vesselincluding the sidewallforms a substantially cylindrical structure having closed ends. The vesselmay form the plenumas a substantially closed volume.

The heat exchanger systemincludes a sleeveat least partially surrounding the vessel. The sleeveis formed from a non-ferrous material, such as, but not limited to, a plastic material, a silicone material, a ceramic material, or other appropriate insulative or non-conductive material.

The sleeveincludes a conductive structureextending at least partially surrounding the vessel. For instance, the conductive structuremay include a conductive wire (e.g., a copper wire, or other desired conductor) extending substantially circumferentially at the sleeveand around the vessel. For instance, the conductive structuremay include a helical, spiral, or braided extension around the vessel.

A gap or volumeis formed between the vesseland the sleeve. In various embodiments, the sleevepositions the conductive structurein substantially uniform distance away from the sidewall, such as depicted inschematically via arrowextending between sidewalland conductive structure. As such, sleeveinhibits direct contact of the conductive structurefrom the vessel. The inhibited direct contact may mitigate circuit shortage and promote generation of an electromagnetic field for generating heat at or within the vessel.

In still various embodiments, the sleeveis positioned in concentric arrangement to the vessel. For instance, sleevesurrounds the sidewalland positions the sleeveconcentric to the vessel. Sleevemay further position the conductive structureconcentric to the sidewall.

In some embodiments, vesselmay include a first opening(e.g., inlet opening) and a second opening(e.g., outlet opening) in fluid communication with the plenum. One or more valvesmay be positioned at the vesselto selectively permit and inhibit flow of refrigerant into, or egress from, the plenum.

In various embodiments, the refrigerant at the plenumis a water or water-based solution, an ammonia or ammonia-based solution, or other desired refrigerant. In some embodiments, the refrigerant is water or a water-based solution, such as may provide desirably high latent heat of vaporization, desired cooling effectiveness, and mitigate corrosion or undesired odors.

Referring back toand, in various embodiments, the laundry applianceincludes a power supplyoperably coupled to the conductive structure. The power supplymay include any appropriate power supply, or components for power distribution, for a laundry appliance as may generally be understood. A conductive lead, such as a conductive wire, electrically couples the power supplyto the conductive structureto transmit energy through the conductive structureto generate heat at the vessel. For instance, power supply, conductive lead, and conductive structuremay form an induction heating device at which the electrically conductive vesselis heated through heat transfer from an electromagnetic field formed from energy transferred at the conductive structure. Heat is generated within the vessel, such as at plenumand refrigerant received thereat.

Controlleris operably coupled to the power supplyto selectively transmit energy through the conductive structureto selectively generate heat. Referring to, the vesselis positioned in thermal communication with a flow of fluid provided in fluid communication with the chamberof the tub.

Referring to, in some embodiments, vesselis configured to receive a flow of fluid, such as water or water-based solution depicted schematically via arrows, into plenum. Controllertransmits energy through the conductive structureto heat the water. Valvemay form a check valve, one-way valve, or other appropriate flow control device. For instance, valvemay be configured to articulate open to permit egress of water from the plenum, such as depicted via arrows. Valvemay be configured to open corresponding to a temperature of water and corresponding pressure at plenumto egress water to chamber. A flow of heated fluid is provided to the chamberas a heated wash fluid, such as depicted schematically via arrows.

Referring to, in still some embodiments, vesselis configured to receive a flow of fluid, such as air, in thermal communication with the vessel. Air, depicted schematically via arrow, is provided in thermal communication with vessel. Controllertransmits energy through the conductive structureto generate heat at the vessel. Vessel, or heated refrigerant from the vessel, is provided in thermal communication with the flow of air, such as depicted schematically via arrows. Heated air is provided in fluid communication to chamber, such as depicted schematically via arrows.

In operation, one or more laundry articlesmay be placed within the chamber, and heated water or water-based solution may be provided to the chamberfor washing the laundry articles. A supply ductmay be mounted to tuband may extend between tuband heat exchanger system. The tubis downstream of the heat exchanger systemalong the supply ductsuch that the heat exchanger systemsupplies heated fluid to the tubvia the supply duct. A return ductmay also be mounted to the tuband may extend between tuband the heat exchanger system. The tubis upstream of the heat exchanger systemalong the return ductsuch that the heat exchanger systemreceives relatively moist, humid, air from the tubvia the return duct, e.g., air returns to the heat exchanger systemfrom the tub, e.g., after flowing over and around articles within the chamber, through the return duct. The supply ductmay be mounted to the tub, e.g., at the rear wallthereof as in the illustrated example, or the supply ductmay be mounted to the cylindrical wallof the tub, such as above the basket, similar to the return ductin the illustrated example embodiment.

Embodiments of the laundry appliancemay include the schematic embodiment depicted in, such as to form the laundry applianceas a washing machine appliance including the heat exchanger systemto provide heated water for washing laundry articleswhile removing or obviating various components generally associated with heating water.

Embodiments of the laundry appliancemay include the schematic embodiment depicted in, such as to form the laundry applianceas a dryer appliance including the heat exchanger systemto heat air for removing moisture from laundry articleswhile removing or obviating various components generally associated with heating air, such as expansion devices and condensers.

In still various embodiments, laundry appliancemay include schematic embodiments such as depicted in, such as to form the laundry applianceas a combination washer-dryer appliance utilizing a common heat exchanger systemfor heating water and air.

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.