Three-Dimensional Steam Generating System for Performing a Steam Cycle Within a Laundry Appliance

This application is a continuation of U.S. application Ser. No. 17/709,951 filed Mar. 31, 2022, entitled THREE-DIMENSIONAL STEAM GENERATING SYSTEM FOR PERFORMING A STEAM CYCLE WITHIN A LAUNDRY APPLIANCE, which claims priority to and the benefit under 35 U.S.C. § 119 (e) of U.S. Provisional Patent Application No. 63/189,289, filed on May 17, 2021, entitled THREE-DIMENSIONAL STEAM GENERATING SYSTEM FOR PERFORMING A STEAM CYCLE WITHIN A LAUNDRY APPLIANCE, the entire disclosures of which are hereby incorporated herein by reference.

The device is generally in the field of laundry appliances, and more specifically, a laundry appliance including a plurality of fluid-directing nozzles that are operable to perform a variety of steam functions that can be adjusted based upon various parameters.

According to one aspect of the present disclosure, a laundry appliance includes a blower that delivers process air through an airflow path. A rotating drum defines a processing chamber. The processing chamber is part of the airflow path. A steam generating system disposes steam into the processing chamber. A plurality of fluid nozzles direct the steam into the processing chamber according to an operating pattern. The plurality of fluid nozzles include a first nozzle that is positioned within an upper portion of the processing chamber and a second nozzle that is positioned in a lower portion of the processing chamber.

According to another aspect of the present disclosure, a laundry appliance includes a cabinet having an access aperture defined within a front panel of the cabinet. A drum rotates within the cabinet. The access aperture provides selective access to a processing chamber defined within the drum. A steam generating system delivers steam to the processing chamber. A first nozzle is coupled to the front panel and above the access aperture. A second nozzle is positioned within a rear panel of the processing chamber. A steam generator delivers steam to the first nozzle and the second nozzle according to an operating pattern. The operating pattern is determined by a plurality of sensors that are positioned in communication with the processing chamber. The steam generator generates steam in the absence of a dedicated heating element.

According to yet another aspect of the present disclosure, a laundry appliance includes a cabinet having an access aperture. A drum rotates within the cabinet to process a load of articles. The access aperture provides selective access to a processing chamber defined within the drum. A steam generating system delivers steam to the processing chamber. A first nozzle is coupled to a front panel and above the access aperture. A second nozzle is positioned within a rear panel of the processing chamber. The steam generating system delivers steam to the first nozzle and the second nozzle according to an operating pattern. The operating pattern is determined by a plurality of sensors that are positioned in communication with the processing chamber. The first nozzle is oriented to direct a first jet of fluid in a downward direction toward a rear panel of the processing chamber and the second nozzle is positioned within the rear panel and is oriented to direct a second jet of fluid in an upward direction toward the access aperture. The first and second jets of fluid define a three-dimensional pattern of steam that engages the load of articles from above and below, respectively.

These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.

The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a team generating system for a laundry appliance that operates according to a sequence that is adjustable based upon various parameters. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in. Unless stated otherwise, the term “front” shall refer to the surface of the element closer to an intended viewer, and the term “rear” shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The terms “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

Referring now to, reference numeralgenerally refers to a steam generating system for a laundry appliancethat generates steamwithin a processing chamberof the appliance, typically within a rotating drum. A steam generating systemincludes a plurality of fluid nozzlesthat are used to generate steamwithin the processing chamber. According to various aspects of the device, the applianceincludes a blowerthat delivers process airthrough an airflow path. The rotating drumdefines the processing chamber. The processing chamberis included within the airflow pathfor receiving process airthat dehumidifies articlescontained within the processing chamber. The steam generating systemoperates to dispose steamwithin the processing chamber. The plurality of fluid nozzlesoperate to direct the steaminto and through the processing chamberaccording to a predetermined operating pattern. According to various aspects of the device, the predetermined operating patterncan be based upon various factors. These factors can include, but are not limited to, the type of articleor fabric that is being processed within the processing chamber, an amount of articlesthat are being processed within the processing chamber, combinations thereof and other factors.

Typically, the predetermined operating patterncan vary depending upon various parameters relating to the selected operating cycleand the articlesbeing processed within the processing chamber. These predetermined operating patternstypically include selective operation of the steam generating system. This selective operation is in the form of activationsand deactivationsof the plurality of fluid nozzles. These activationsand deactivationscan be sequential, alternating, combinations thereof and other operating patternsof activationsand deactivationsof one or more of the plurality of fluid nozzles. The activationsand deactivationsof the operating patterncan be modified or adjusted based upon the measurements taken by one or more sensors, and typically a plurality of sensors. The sensors are configured to take measurement of the process air, the conditions within the processing chamberand the conditions of the articlesbeing processed. Using these measurements, the controllercan assess whether any of the activationsor the deactivationsof the operating patternneed to be extended, suspended or otherwise modified.

According to various aspects of the device, the steam generating systemincludes a steam generator that generates steamwithin the processing chamberwithout the use of a dedicated heat source within the steam generating system. Accordingly, the steam generating systemgenerates steamhaving a temperature that is similar to that of the air temperature of the process airwithin the processing chamber. In this manner, fluidis delivered to the fluid nozzlesand is sprayed into the processing chamberin the form of a fine mist. Various differences in humidity levels, dew points, and other environmental factors between areas outside of the processing chamberand the areas inside of the processing chambercooperate to generate steamwithin the processing chamber. Various air handlers can be used to move the steamthat is generated within the processing chamberaround and through the articlesto be processed in the laundry appliance.

Referring now to, the plurality of fluid nozzlescan include a front fluid nozzle, also referred to herein as the first nozzle, that is positioned to generate steamwithin an upper portionof the processing chamber, and a rear fluid nozzlethat is positioned to generate steamwithin a lower portionof a processing chamber. The front fluid nozzlecan be positioned near or within a front panelof the applianceso that the fluid nozzleis directed to inject or otherwise dispose a first jetof fluidin a generally downward direction into the access apertureand toward a rear panelof the rotating drum. The rear fluid nozzle, also referred to herein as the second nozzle, is typically positioned within the rear panelfor the rotating drumthat is generally stationary as a perimetrical wallof the rotating drumrotates about a rotational axis. The rear fluid nozzleis adapted to direct a second jetof fluidin a generally upward direction and toward the access aperture. When both the front and rear fluid nozzles,are activated, steamis generated within a front portionand the upper portionof the processing chamberand a rear portionand the lower portionof the processing chamber. In this manner, the steamgenerated by a plurality of fluid nozzlescan be moved throughout the entire processing chamberfor penetrating within, around and through the articlesbeing processed within the rotating drum. This configuration of the steam generating systemalso allows the articlesto tumble through areas of steamthat are generated in the processing chamber.

Referring again to, the steam generating systemincludes a fluid delivery manifoldthat directs a fluidto the front and rear fluid nozzles,. Various valvesare attached to the fluid delivery manifoldand/or the front and rear fluid nozzles,for selectively operating the front and rear fluid nozzles,(first and second nozzles). This selective operation of the front and rear fluid nozzles,is used to perform the various activationsand deactivationsof the steam generating systemand the plurality of fluid nozzles. The front and rear fluid nozzles,of the steam generating systemoperate to define a three-dimensional patternof steamthat engages the articleswithin the processing chamberfrom the front and from the rear as well as from above and below, as described more fully herein.

Referring now to, a user interfacefor the appliancecan include dedicated controls for operating the steam generating systemduring performance of any one or more operating cyclesof the appliance. Certain operating cyclescan include a built-in steam functionthat automatically operates within a portion of the operating cycle. It is also contemplated that various steam functionscan be specifically selected utilizing the user interface. These specific selections can activate or deactivate a steam function, increase or decrease the amount of steamgenerated during a processing chamber, set various parameters regarding the amount of steamto be generated, and other similar factors that are described more fully herein.

Referring now to, the front fluid nozzleis typically positioned at a 12-o'clock position of a rotating drumand near a top portionof the access apertureof the rotating drum. The front fluid nozzlemay be attached to the outer cabinetor attached to a structural member of the appliancenear the outer cabinet. In this manner, the front fluid nozzleis stationary as the drumrotates about the rotational axis. The front fluid nozzledirects the fluidthrough the access apertureand into the processing chamberso that steamcan be generated within the processing chamber. In various aspects of the device, the door panelfor the appliancecan include a window so that a user can view the generation of steamwithin the processing chamber.

Referring now to, the steam generating systemcan include an automatic activation sequencethat can be used to determine the appropriate amount of steamto be generated within the processing chamber. While various sensors and data points can be utilized for estimating the amount of articlesbeing processed or the type of articlesbeing processed, an exemplary aspect of the device includes rear and front temperature probes,that are positioned at an upstream locationof the processing chamberand a downstream locationof the processing chamber, respectively. As exemplified in, the front temperature probeis positioned at the downstream locationso that process airleaving the processing chambercan be monitored by the front temperature probefor determining temperature of the process airleaving the processing chamber. The rear temperature probemonitors the temperature of the process airentering into the processing chamber, and is typically positioned behind the rotating drumwithin a portion of the airflow pathproximate a back wallof the appliance.

The rear and front temperature probes,monitor a change or “A” of the temperature for the process airas it moves through the processing chamberand engages the various articlesto dehumidify the articlesduring the laundry cycle. The change in temperature, or the temperature difference, of the process aircan have a predictable temperature change depending upon the amount of articlesbeing processed within the processing chamber. Utilizing this temperature difference between the temperature of the process airentering the processing chamberand the temperature of the process airleaving the processing chamber, the amount of articlesbeing processed can be estimated and categorized between a small load, medium load and large load. It is also contemplated that the load sizes can be sorted into fewer categories, such as large load and small load. Greater numbers of categories can also be used depending upon the sensitivity of the rear and front temperature probes,and the desired accuracy of the various steam functions.

Referring again to, when the size of the load is estimated, the amount of steamto be generated within the processing chambercan be increased for larger loads and decreased for smaller loads. The amount of steamto be generated is intended to be an appropriate amount for refreshing or de-wrinkling clothing without causing an undesirable accumulation of moisture within the processing chamberthat may cause the articlesto become over saturated with fluid.

As exemplified in, the amount of moisture to be generated within the processing chamberis a value that can be calculated by a controllerfor the appliance. The performance of generating steamwithin the processing chamberis undertaken by the various activationsand deactivationsof the front and rear fluid nozzles,. By way of example, and not limitation, a greater amount of steamthat is to be generated within the processing chambercan result in a greater amount of activationsor longer periods of activationbetween the front and rear fluid nozzles,. Where lesser amounts of steamare intended to be generated, there may be a greater degree of deactivationsor longer period of deactivationbetween the front and rear fluid nozzles,for the steam generating systems. Stated another way, more activationsand/or longer activationsgenerally result in a greater amount of steamthat is generated within the processing chamber.

Referring now to, depending upon the amount of articlesthat are estimated to be present within the processing chamber, the operating patternthat includes various configurations of activationsand deactivationsof the front and rear fluid nozzles,can vary. As exemplified in, three separate small-load configurationsfor the front and rear fluid nozzles,are presented in an exemplary and non-limiting fashion. The differences in the operating patternof activationsand deactivationscan vary depending upon the length of the activationor deactivation, the operating patternof activationsand deactivations, and the alternating and simultaneous activationof the front and rear fluid nozzles,. Similarly, as exemplified in, three separate large-load configurationsof the steam generating systemare presented in an exemplary and non-limiting fashion.

As exemplified in, the various activationsand deactivationsof the front fluid nozzleand rear fluid nozzletends to be longer in the large-load configurationsso that greater amounts of steamcan be generated within the processing chamber. Additionally, the operating patternof activationsand deactivationsof the front and rear fluid nozzles,can vary between simultaneous activation, sequential activation, prolonged activation or deactivation, and combinations of these variations between the activationsand deactivationsof the plurality of fluid nozzles.

As exemplified in, the difference between the small-load configurationsand large-load configurationfor the steam generating systemcan be in the form of a number of cycles performed in a recurring fashion during a particular drying cycle. As shown in, the small-load configurationis repeated ten times where the large-load configurationis repeated 20 times.

As exemplified in, the estimation of load size using the rear and front temperature probes,can change the configuration of the steam cycle so that more steamis generated when larger loads of articlesare present. It is also contemplated that the estimation of load size performed by the rear and front temperature probes,and the controllercan extend the time of the cycle so that the additional activationswithin a large-load configurationcan be performed to completion. Alternatively, where a smaller load of articlesis being processed, a particular laundry cycle may be shortened after the requisite number of activationsand deactivationsof the front and rear fluid nozzles,has been performed to completion.

According to various aspects of the device, the rear and front temperature probes,can also be utilized for determining a garment type or fabric type of the articlesthat are being processed within the processing chamber. Typically, users of laundry appliancestend to group articlesto be processed within particular categories. Such categories can include delicates, whites (typically cotton), darks, sheets, linens and other similar fabric-type categories. Article-type categories can include bulky items, non-clothing items (such as shoes), and others. The user interfacefor the laundry appliancecan be configured to provide a selection of garment type. It is also contemplated that the various sensors can be used to estimate a garment type that is being processed. These estimations can be automatically selected or can be part of a confirmation sequence used when selecting a laundry cycle. The confirmation can be related to the particular fabric type or articlebeing processed. The various steam functionspresented herein for large and small loads of articlescan also vary depending upon the fabric type. Delicates may require lesser amounts of steamwhere cottons may require larger amounts of steam. These various parameters can be adjusted based upon garment type, load size, selected dryness level and other similar parameters that may be hardwired or programmed within the controllerfor the applianceor selected by a user, or both.

Referring now to, various mechanisms can be utilized for assessing an amount of steamthat has been generated within a laundry appliance. By way of example, and not limitation, a conductivity sensor, in the form of a conductivity strip, can be positioned within the processing chamber. This conductivity sensorcan be attached to an inner surfaceof the drum. The amount of humidity within the processing chamber, in the form of steam, can be sensed by the conductivity sensorfor estimating an amount of steamcontained within the environment of the processing chamber. When an appropriate amount of steamhas been achieved within the processing chamber, the conductivity sensorsenses this amount and communicates with a controllerto initiate a deactivationof one or both of the front and rear fluid nozzles,. The conductivity sensorcan also communicate with the controllerto modify the activationsand deactivationsto provide more or less steamwithin the processing chamber.

By way of example, and not limitation, over the course of a drying cycle, the amount of steamrequired within the processing chambermay change over time. As these steam generating needs change, the conductivity sensorcan adjust the activationsand deactivationsof front and rear fluid nozzles,to provide a corresponding increase or decrease in the amount of steamgenerated therein.

Referring now to, it is contemplated that the conductivity sensoris used to measure a moisture level in relation to a maximum predefined moisture level. Typically, the conductivity sensoris disposed on an inner surfaceof the drumand measures an amount of moisture or a humidity level of process airwithin the processing chamber. In this manner, when the amount of steamgenerated within the processing chamberreaches a predefined maximum amount of moisture, the conductivity sensorcan communicate with the front and rear fluid nozzles,, via the controller, to initiate a deactivationof the front and rear fluid nozzles,. If the amount of moisture within the processing chamberdips below the predefined maximum amount or below a predefined minimum amount, the conductivity sensorcan measure this decrease in moisture and communicate with the controllerto initiate an activationof the front and rear fluid nozzles,to provide additional amounts of steam, as needed.

Having described various aspects of the steam generating system, a methodis disclosed for generating steamwithin a processing chamber. The methodincludes selecting a drying function, steam functionor other operating cycle(step). As discussed herein, the process of selecting an operating function is typically initiated by a user via a user interface. In certain aspects of the device, it is contemplated that a drying appliancecan automatically select certain operating cyclesbased upon various sensor readings of the articlesbeing processed within the drum. According to the method, the operating cycleis activated (step). When activated, a load size of the articlesbeing processed is estimated (step). The process of estimating load size can be initiated during the typical performance of a particular operating cycle. It is also contemplated that the estimating function can be performed during a dedicated estimation routine that is performed before the selected operating cycleis initiated. Once the load size is estimated, a steam functionis initiated based upon the load size (step). During performance of the steam functionand the operating cycle, an amount of steamgenerated within the processing chamberis monitored (step). As discussed herein, this monitoring function is typically performed by a conductivity sensorthat is positioned within the processing chamber. According to the method, an amount of steamis maintained within a preferred steam or moisture range that is below a maximum predetermined amount and above a minimum predetermined amount of moisture (step). In this manner, the conductivity sensorcommunicates with the controllerto modify the activationsand deactivationsof the plurality of fluid nozzlesto adjust an amount of steamgenerated within the processing chamber. The operating cycleis then completed (step).

According to various aspects of the device, the steam generating systemis used to provide an automated steam functionthat can be adjusted on the fly and in real time during performance of various laundry cycles. The steam generating systemgenerates steamwithin the processing chamberand provides a desired amount of moisture within the processing chamberfor performing various refreshing and dewrinkling type steam functionsupon articlescontained within the processing chamber.

As discussed herein, the steam generating systemgenerates steamwithin the processing chamberwithout the aid of a dedicated heating element within the steam generating system. It is contemplated that the various algorithms and steam generating cycles discussed herein can be utilized with steam generating systemsthat do utilize a heating element for generating steamand injecting jets of steaminto the processing chamber. It is also contemplated that a combination of heated steam generating elements and non-heated fluid nozzlescan be used in combination for generating various amounts of steamwithin the processing chamber.

The plurality of fluid nozzlesdisclosed herein can include the front fluid nozzleand the rear fluid nozzle. It is also contemplated that additional fluid nozzlescan be incorporated within the drumfor providing other configurations of a three-dimensional steam generating function of the steam generating system. Where additional fluid nozzlesare provided in a steam generating system, the configuration of activationsand deactivationsof the plurality of fluid nozzlescan be adjusted to provide the desired amounts of steamand configurations of steamwithin the processing chamber. The configurations of steamprovided by the plurality of fluid nozzlesare intended to provide steamthroughout the processing chamberso that the articlesreceive steamfrom below via the rear fluid nozzlesand also tumbles through a generated section of steamwithin an upper portionof the processing chamber. This combination of fluid nozzlesis configured to provide sufficient steamto allow steamto move within, around and through various articlesbeing processed.

According to another aspect of the present disclosure, a laundry appliance includes a blower that delivers process air through an airflow path. A rotating drum defines a processing chamber. The processing chamber is part of the airflow path. A steam generating system disposes steam into the processing chamber. A plurality of fluid nozzles direct the steam into the processing chamber according to an operating pattern. The plurality of fluid nozzles include a first nozzle that is positioned within an upper portion of the processing chamber and a second nozzle that is positioned in a lower portion of the processing chamber.

According to another aspect, the operating pattern is based upon a fabric type that is being processed in the processing chamber.

According to yet another aspect, the operating pattern is based upon an amount of articles that are being processed in the processing chamber.

According to another aspect of the present disclosure, the operating pattern includes activations and deactivations of the plurality of fluid nozzles.

According to another aspect, the rotating drum operates within the cabinet and includes an access aperture that provides selective access to the processing chamber. The first nozzle is positioned above the access aperture and is oriented to direct a first jet of fluid in a downward direction toward a rear panel of the processing chamber.

According to yet another aspect, the second nozzle is positioned within the rear panel and is oriented to direct a second jet of fluid in an upward direction toward the access aperture.

According to another aspect of the present disclosure, a steam generator generates steam having a temperature that is similar to an air temperature of the process air within the processing chamber. The steam generator delivers fluid to the first nozzle and the second nozzle according to the operating pattern.

According to another aspect, the operating pattern includes selective activation of valves for the first nozzle and the second nozzle, respectively. The steam generator includes the first nozzle and the second nozzle.

According to yet another aspect, a conductivity sensor is in communication with the steam generator and the valves. The conductivity sensor measures a humidity level within the processing chamber. The operating pattern and the selective activation of the valves are operated at least partially according to the humidity level within the processing chamber as measured by the conductivity sensor.

According to another aspect of the present disclosure, a rear temperature probe is positioned within the airflow path and proximate the rear panel of the processing chamber. The rear temperature probe measures an air temperature of the process air entering the processing chamber. A front temperature probe is positioned within the airflow path and proximate a front panel of the processing chamber. The front temperature probe measures the air temperature of the process air exiting the processing chamber. The rear and front temperature probes measure a temperature change of the process air. The operating pattern and the selective activation of the valves are operated at least partially according to the temperature change of the process air.

According to another aspect, a laundry appliance includes a cabinet having an access aperture defined within a front panel of the cabinet. A drum rotates within the cabinet. The access aperture provides selective access to a processing chamber defined within the drum. A steam generating system delivers steam to the processing chamber. A first nozzle is coupled to the front panel and above the access aperture. A second nozzle is positioned within a rear panel of the processing chamber. A steam generator delivers steam to the first nozzle and the second nozzle according to an operating pattern. The operating pattern is determined by a plurality of sensors that are positioned in communication with the processing chamber. The steam generator generates steam in the absence of a dedicated heating element.

According to yet another aspect, the operating pattern includes selective operation of the first and second nozzles.

According to another aspect of the present disclosure, the first nozzle is positioned within an upper portion of the processing chamber and a second nozzle is positioned in a lower portion of the processing chamber. The second nozzle is positioned within the rear panel and is oriented to direct steam in an upward direction toward the access aperture.

According to another aspect, the steam generating system includes a steam generator that generates steam having a temperature that is similar to an air temperature of process air within the processing chamber. The steam generator delivers steam to the first nozzle and the second nozzle according to the operating pattern.

According to yet another aspect, the steam generating system includes valves that are positioned between the steam generator and the first and second nozzles. The operating pattern includes selective activation of the valves for the first nozzle and the second nozzle, respectively.

According to another aspect of the present disclosure, a conductivity sensor is in communication with the steam generator and the valves. The conductivity sensor is disposed on a surface of the drum and measures a humidity level of process air within the processing chamber. The operating pattern and the selective activation of the valves are operated at least partially according to the humidity level, as measured by the conductivity sensor.

According to another aspect, a laundry appliance includes a cabinet having an access aperture. A drum rotates within the cabinet to process a load of articles. The access aperture provides selective access to a processing chamber defined within the drum. A steam generating system delivers steam to the processing chamber. A first nozzle is coupled to a front panel and above the access aperture. A second nozzle is positioned within a rear panel of the processing chamber. The steam generating system delivers steam to the first nozzle and the second nozzle according to an operating pattern. The operating pattern is determined by a plurality of sensors that are positioned in communication with the processing chamber. The first nozzle is oriented to direct a first jet of fluid in a downward direction toward a rear panel of the processing chamber and the second nozzle is positioned within the rear panel and is oriented to direct a second jet of fluid in an upward direction toward the access aperture. The first and second jets of fluid define a three-dimensional pattern of steam that engages the load of articles from above and below, respectively.