The invention relates to a capacitive sensor for detecting a fluid level within a movable fluid tank of a domestic appliance, for example a detergent tank of a washing machine.
As household appliances continue to become more sophisticated, the need for modern components increases. Dishwashers, washing machines, ovens, refrigerators, and more are all providing more and more functions to users, many of which are automated. One consequence of this trend is the need of household appliance manufacturers for sophisticated sensing elements within their products to facilitate these automated functions. In the case of water-based devices like dishwashers, embedded liquid level sensors are especially important.
Fluid level sensors are typically designed to detect, measure and regulate levels of a particular free-flowing substance within a contained area, level sensors are predominantly a tool used to monitor liquid levels. They can also be used to monitor solids such as powders. Liquid or fluid level sensors have advanced significantly over the years, and today, a variety of technologies can be used for the process of level measurement, including, for example, float sensors, hydrostatic sensor, radar sensors, ultrasonic sensors radiometric sensors and capacitive sensors.
Capacitive sensors are particularly suitable for heavy duty applications as they are easy to install and highly reliable in a contact or non-contact setup. When used in a non-contact setup, the sensor is simply attached to a (non-conductive) vessel or tank while establishing an electric field that penetrates into the vessel or tank. When there is no fluid in the in the vicinity of the sensor, the sensor will measure a predetermined capacitance (e.g. to a ground). When the fluid level rises into the filed of the sensor, the static capacitance of the sensor is disturbed or changed indicating the presence of a fluid or liquid.
Such sensors usually require a precise setup and arrangement with the fluid tank in order to provide accurate measurement or detection of precise fluid levels during use. Also, for household appliances, it is often the case that fluid tanks or vessels are removed or at least retracted to allow access for filling the tank or vessel (e.g. with detergent or conditioner). These tanks of vessels are repeatedly opened and closed over a long period of time, thus, they optimally include a hard-wearing and simplistic design that is very easy to use during the lifespan of the appliance. However, available sensors typically require a relatively precise placement or positioning in order to allow for reproducible and reliable measurements. This, in turn, requires mechanisms for the moveable tank or vessel that provide movement with low tolerances, thus increasing complexity and costs.
Therefore, it would be desirable to provide an improved fluid level sensor that is adapted to prevent or at least mitigate the problems associated with the prior art. In particular, it is an object of the present invention to provide a capacitive fluid level sensor for household appliances adapted to determine the fluid level of a removable fluid tank, that is hardwearing and reliable, and has an improved ease of use.
According to a first aspect of the present invention, there is provided a capacitive sensor assembly for detecting a fluid level within a removable tank of a domestic appliance along an axis, mountable within the domestic appliance, comprising at least one fluid level electrode comprising a resiliently deformable contact member adapted to contactingly engage with the removable tank received in the domestic appliance and convey at least one electrical field generated by the capacitive sensor into the removable tank.
This provides the advantage that any possible gaps between the sensor electrodes and the removable tank (once inserted) are avoided, or at least minimised, thus providing an assembly with improved ease of use and wear and tear resistance, as well as, an improved accuracy due to the optimised contact between the inserted tank and the sensor assembly.
Advantageously, the resiliently deformable contact member is made from a material having a relative permittivity adapted to convey the at least one electrical field generated by the capacitive sensor assembly into the removable tank.
Advantageously, the resiliently deformable contact member is made from an electrically conductive material adapted to convey the at least one electrical field generated by the capacitive sensor assembly into the removable tank.
Advantageously, the removable tank is slidable in an insertion direction through an opening in the domestic appliance, and wherein the capacitive sensor assembly is mountable opposite to the opening such that the at least one resiliently deformable contact member is directed oppositely to the insertion direction so as to contactingly engage with a wall of the removable tank when inserted.
Advantageously, the resiliently deformable contact member matches the footprint of the at least one fluid level electrode.
Advantageously, the capacitive sensor assembly comprises a single fluid level electrode and wherein the single fluid level electrode extends substantially the height of the fluid tank. This provides the advantage of using one electrode in a continuous fluid level measuring mode so as to allow precise fluid level measurements using one electric field of the capacitive sensor.
Alternatively, the capacitive sensor assembly comprises a plurality of fluid level electrodes spaced apart from one another along the axis, each one comprising one of the resiliently deformable contact member. In yet another alternative embodiment, the capacitive sensor assembly comprises a plurality of fluid level electrodes arranged so as to form a first row of spaced apart fluid level electrodes along the axis, and a second row of spaced apart fluid level electrodes along the axis parallel to and axially offset from the first row of the spaced apart fluid level electrodes.
This provides the advantage of discrete fluid level measurements, where the precision of the fluid level measurement (resolution) is determined by the number of fluid level electrodes, as well as the distance between them. Additionally, a combination of continuous measurement and discrete measurement (hybrid) may be applied by measuring the discrete fluid levels when “jumping” from one electrode to the next one, and continuous fluid levels within each one of the fluid electrodes.
Advantageously, the capacitive sensor assembly comprises at least one reference electrode configured for compensating variations in environmental parameters.
Advantageously, the capacitive sensor assembly further comprises a housing having an interior configured to receive a printed circuit board (PCB) comprising at least one contact pad operably coupleable with the at least one fluid level electrode. Preferably, the housing comprises a wall with the at least one resiliently deformable contact member mounted to an outside surface of the wall, and wherein the at least one contact pad is operably coupled to the resiliently deformable contact member through the wall.
Alternatively, the housing comprises a wall having at least one aperture, and wherein the at least one resiliently deformable contact member is operably coupled to the at least one contact pad through the aperture of the wall.
Advantageously, the at least one resiliently deformable contact member comprises any one of: a sponge, for example an electrically conductive sponge, a silicone, for example an electrically conductive silicone, a rubber, for example an electrically conductive rubber, or a thermoplastic elastomer.
Alternatively, the at least one resiliently deformable contact member comprises an electrically conductive spring member. Preferably, the electrically conductive spring member is made from metal.
Example embodiment(s) of the invention are illustrated in the accompanying drawings, in which:
Certain terminology is used in the following description for convenience only and is not limiting. The words right, ‘lower’, ‘upper’, ‘front’, ‘rear’, ‘upward’, ‘down’ and ‘downward’ designate directions in the drawings to which reference is made and are with respect to the described component when assembled and mounted. The words ‘inner’, ‘inwardly’ and ‘outer’, ‘outwardly’ refer to directions toward and away from, respectively, a designated centreline or a geometric centre of an element being described (e.g. central axis), the particular meaning being readily apparent from the context of the description.
Further, as used herein, the terms ‘connected’, ‘attached’, ‘coupled’, ‘mounted’ are intended to include direct connections between two members without any other members interposed therebetween, as well as, indirect connections between members in which one or more other members are interposed therebetween. The terminology includes the words specifically mentioned above, derivatives thereof, and words of similar import.
Further, unless otherwise specified, the use of ordinal adjectives, such as, “first”, “second”, “third” etc. merely indicate that different instances of like objects are being referred to and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking or in any other manner.
Like reference numerals are used to depict like features throughout.
In other examples, the domestic appliance 1 may be a tumble dryer and the fluid tank 4 may hold condensate from the drying process, or any other household appliance that requires a removable fluid tank.
As shown, an embodiment (e.g. the single full range fluid electrode 102c of
In particular, the capacitive sensor assembly 100 of
As illustrated in
In particular, the capacitive sensor assembly 100 measures a capacitance of an electric field generated through the fluid electrode 102 (i.e. any one of the different embodiments 102a, 102b, 102c) (the field is conveyed via its resiliently deformable contact member or pad 104a, 104b, 104c). This electric field is “disturbed” by any object moving into that field, changing the capacitance measured at that particular fluid electrode 102c. Thus, the change of the measured capacitance indicates, for example, a fluid 7 presence at that fluid electrode 102c, allowing the fluid level within the tank 4 to be determined continuously (e.g. when using a full range single fluid electrode 102e) or discretely (e.g. when using relatively narrow spaced apart fluid electrodes 102a, each one indicating a discrete fluid level). Alternatively or additionally, the fluid electrodes 102b may be shaped so as to allow a hybrid measurement, i.e. a discrete fluid level detection when reaching a particular fluid electrode 102b and a continuous fluid level measurement within the range of that particular fluid electrode 102b. Discrete measurements may be made by simply detecting a “disturbance” of the capacitance of a particular fluid electrode 102b, wherein continuous measurements may be made by detecting a change of that capacitance when the fluid rises up or lowers down within the range of the fluid electrode 102b (e.g. calibrating the change to a particular fluid level).
Accordingly, the capacitive sensor assembly 100 can detect a fluid level in the fluid tank 4 without contacting the fluid 7 or having any components within, or attached to, the fluid tank 4.
The resiliently deformable contact member or pad 104 (including any embodiment 104a, 104b, 104c) ensures suitable contact is made with the fluid tank 4 even if the position of the fluid tank 4 varies in the insertion direction 8, for example, due to tolerances or loosening of latches over time. Advantageously, eliminating or reducing air gaps between the capacitive sensor assembly 100 and the fluid tank 4 will improve detection of a changing level of the fluid 7 within the fluid tank 4, because air has an extremely low relative permittivity.
Referring now to
The resiliently deformable contact member or pad 104 may be an insulator having a relative permittivity that is suitable to convey the electric field of the fluid electrode 102 of the capacitive sensor assembly 100 into the fluid tank 4. For example, the relative permittivity may be in the range of 2 to 20. Example materials may include a polymer, such as silicone or silicone rubber, a sponge material and the like.
On the other hand, the resiliently deformable contact member or pad 104 may be electrically conductive, so as to electrically extend the electrode pad 102 of the PCB 108 to the fluid tank 4. The resiliently deformable contact member or pad 104 may be made from a conductive polymer, such a silicone or silicone rubber compound mixed with conductive material (e.g. metal particles or filaments).
Alternatively, the resiliently deformable contact member or pad 104 may be made from a spring (not shown) made from a conductive metal. In these examples, the spring may be embedded within a polymer, for example rubber or silicone. In other examples, the spring may act between the housing 106 and the fluid electrode pads 102 of the PCB 108. In other examples, the deformable contact pad(s) 104 may comprise a spring in isolation, without any other material.
In other examples, the resiliently deformable contact member or pad(s) 104 may comprise a thermoplastic elastomeric material or may be made from a Graphene material or graphene rubber compound or a rubber or polymer comprising graphene or a graphene material such as graphene oxide, so as to make the compound electrically conductive.
It is understood by the person skilled in the art that any number and any suitable arrangement of fluid electrodes 9 may be provided so as to improve the resolution of fluid level detection, i.e. by providing more discrete levels of penetrating fields form the capacitive sensors. Further sensing electrodes may be provided to improve the resolution of fluid level detection. In both cases, fluid entering the electrical field will change (or disturb) a capacitance measured at a discrete electrode so as to determine a fluid level in the fluid tank 4. The capacitive sensor assembly 100 can be calibrated by measuring the detected capacitance (changes) for different fluid levels.
Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
Features, integers, characteristics, or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
Number | Date | Country | Kind |
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EP22184942.5 | Jul 2022 | EP | regional |
EP22186119.8 | Jul 2022 | EP | regional |
EP23184704.7 | Jul 2023 | EP | regional |