Patent Application
20250230602
The present subject matter relates generally to condenser-type dryer appliances, or more specifically, to systems and methods for operating a condenser dryer appliance.
Certain conventional closed loop airflow circuit dryer appliances, such as condenser dryers, include a closed loop airflow circuit (e.g., a hot air circuit) along which process air is moved. The process air passes through a drum of the dryer appliance to extract hot, moist air before the process air loop directs that flow through a conditioning system, e.g., passing the process air over a condenser to remove moisture from the process air after the air has absorbed water from articles. These appliances may also include a cooling air loop (e.g., a cool air circuit) that is used to cool the condenser to facilitate the condensation process.
Notably, the ambient air that is used to cool the condenser is typically recirculated from within the laundry room where the appliance is located. This may result in undesirable heating of the laundry room over time. In addition, condenser dryers may operate at an efficiency that is limited based on the temperature of the air in the cooling air loop. In this regard, for example, a lower temperature of ambient air may result in a cooler condenser and increased condensate generation, whereas a higher temperature of ambient air may result in a warmer condenser and decreased condensate generation.
Accordingly, a condenser dryer appliance with features for improved efficiency would be desirable. More specifically, a condenser dryer appliance that can quickly and effectively dry clothes without overheating the laundry room would be particularly beneficial.
Aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
In one exemplary embodiment, a condenser dryer is provided including a cabinet defining an indoor air vent and an external air vent, a drum rotatably mounted within the cabinet, the drum defining a chamber for receipt of articles for drying, the drum being fluidly coupled to a supply duct and a return duct, a conditioning system positioned within the cabinet, wherein the conditioning system is fluidly coupled to the supply duct and the return duct to define a process air flow path and is fluidly coupled to the indoor air vent and the external air vent to define a cooling air flow path, a blower fan fluidly coupled to the process air flow path for urging a flow of process air along the process air flow path, and a cooling air fan fluidly coupled to the cooling air flow path for urging a flow of cooling air along the cooling air flow path, wherein the cooling air fan is operable in a first mode of operation to draw the flow of cooling air in through the indoor air vent and discharge the flow of cooling air through the external air vent and in a second mode of operation to draw the flow of cooling air in through the external air vent and discharge the flow of cooling air through the indoor air vent.
In another exemplary embodiment, a conditioning system for a condenser dryer is provided including a process air flow path comprising a supply duct and a return duct fluidly coupled to a drum of the condenser dryer, a cooling air flow path comprising an indoor air duct fluidly coupled to an indoor environment and an external air duct fluidly coupled to an outdoor environment, a condenser fluidly coupled to the supply duct, the return duct, the indoor air duct, and the external air duct such that the process air flow path and the cooling air flow path are in thermal communication with each other while remaining in fluid isolation, and a cooling air fan fluidly coupled to the cooling air flow path for urging a flow of cooling air along the cooling air flow path, wherein the cooling air fan is operable in a first mode of operation to draw the flow of cooling air in from the indoor environment and in a second mode of operation to draw the flow of cooling air in from the outdoor environment.
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.
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.
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.
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, 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 and/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 and/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, e.g., 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.
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. Moreover, 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.
Referring now to the figures,
According to exemplary embodiments, dryer appliance 100 includes cabinet 102 that is generally configured for containing and/or supporting various components of dryer appliance 100 and which may also define one or more internal chambers or compartments of dryer appliance 100. In this regard, as used herein, the terms “cabinet,” “housing,” and the like are generally intended to refer to an outer frame or support structure for dryer appliance 100, e.g., including any suitable number, type, and configuration of support structures formed from any suitable materials, such as a system of elongated support members, a plurality of interconnected panels, or some combination thereof. It should be appreciated that cabinet 102 does not necessarily require an enclosure and may simply include open structure supporting various elements of dryer appliance 100. By contrast, cabinet 102 may enclose some or all portions of an interior of cabinet 102. It should be appreciated that cabinet 102 may have any suitable size, shape, and configuration while remaining within the scope of the present subject matter.
As illustrated, dryer 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. Cabinet 102 includes a front panel 104 and a rear panel 106 spaced apart along the transverse direction T, a pair of side panels 108 and 110 spaced apart from each other along the lateral direction L (e.g., extending between front panel 104 and rear panel 106), and a bottom panel 112 and a top panel 114 spaced apart along the vertical direction V.
Within cabinet 102 is a container or drum 120 which defines a chamber 122 for receipt of articles, e.g., clothing, linen, etc., for drying. Drum 120 extends between a front portion and a back portion, e.g., along the transverse direction T. In example embodiments, drum 120 is rotatable, e.g., about an axis that is parallel to the transverse direction T, within cabinet 102. A door 124 is rotatably mounted to cabinet 102 for providing selective access to drum 120.
An air handler 126, such as a blower or fan, may be provided to motivate an airflow through chamber 122, e.g., in order to dry articles located therein, as discussed in greater detail below. In this regard, air handler 126 may generally include a motor 128 which may be in mechanical communication with a blower fan 130, such that motor 128 rotates blower fan 130. In alternative example embodiments, dryer appliance 100 may include an additional motor (not shown) for rotating fan 130 of air handler 126 independently of drum 120.
As best shown in
Process air flow path 134 may include drum 120 and the duct system that provides fluid communication (e.g., airflow communication) between a return opening 136 of drum 120 and a supply opening 138 of drum 120. In addition, process air flow path 134 may include a conditioning system 140 operably coupled to the duct system between return opening 136 and supply opening 138. More specifically, process air flow path 124 may include a supply duct 142 that extends between and fluidly couples conditioning system 140 to supply opening 138. Similarly, process air flow path 124 may include a return duct 144 that extends between and fluidly couples conditioning system 140 to return opening 136. Although blower fan 130 is shown positioned between drum 120 and conditioning system 140 along return duct 144, it will be appreciated that blower fan 130 can be positioned in other suitable positions or locations along the duct system.
In exemplary embodiments, return duct 144 may be in the form of a trap duct which may include a filter portion 146 which includes a screen filter or other suitable device for removing lint and other particulates as internal air is drawn out of chamber 122. The internal air is drawn through filter portion 146 by blower fan 130 before being passed through return duct 144. After the clothing articles have been dried (or a drying cycle is otherwise completed), the clothing articles are removed from drum 120, e.g., by accessing chamber 122 by opening door 124. The filter portion 146 may further be removable such that a user may collect and dispose of collected lint between drying cycles.
In performing a drying and/or tumbling cycle, one or more laundry articles LA may be placed within the chamber 122 of drum 120. Hot dry air HDA is supplied to chamber 122 via supply duct 142. The hot dry air HDA enters chamber 122 of drum 120 via a supply opening 138 defined by drum 120. The hot dry air HDA provided to chamber 122 causes moisture within laundry articles LA to evaporate. Accordingly, the air within chamber 122 increases in water content and exits chamber 122 as warm moisture laden air MLA. The warm moisture laden air MLA exits chamber 122 through a return opening 136 defined by drum 120 and flows into return duct 144. After exiting chamber 122 of drum 120, the warm moisture laden air MLA flows downstream to conditioning system 140. In other words, blower fan 130 moves the warm moisture laden air MLA, as well as the air more generally, through process air flow path 134 defined by drum 120, conditioning system 140, return duct 144, and supply duct 142.
According to example embodiments, laundry appliance 100 is a condenser dryer. Therefore, as further depicted in
For this embodiment, a condenser tank or a condensate collection tank 154 is in fluid communication with conditioning system 140, e.g., via drain line 152. Collection tank 154 is operable to receive condensate water from the process air flowing through conditioning system 140, and more particularly, condensate water from condenser 150. A sensor 156 is operable to detect when water within collection tank 154 has reached a predetermined level. Sensor 156 can be any suitable type of sensor, such as a float switch as shown in
Process air 132 passing over condenser 150 becomes cooler than when it exited drum 120 at return opening 136. As shown in
Notably, conditioning system 140 may further include a cooling air flow path (e.g., identified herein generally by reference numeral 170) that is used to remove heat from condenser 150 and conditioning system 140. In this regard, cooling air flow path 170 may be fluidly isolated but thermally coupled to process air flow path 134, e.g., through condenser 150. As illustrated, dryer appliance 100 may include an indoor air vent 172 that defined on front panel 104 of cabinet 102 and fluidly coupled to conditioning system 140 through an indoor air duct 174. In addition, dryer appliance 100 may include an external air vent 176 defined on rear panel 106 of cabinet 102 and fluidly coupled to conditioning system 140 through an external air duct 178.
Although example vent positioning and duct configurations are described and illustrated herein, it should be appreciated that these positions and configurations may vary while remaining within the scope of the present subject matter. For example, although external air duct 178 is illustrated as terminating at rear panel 106 of cabinet 102, it should be appreciated that external air duct 178 may be routed outside of the laundry room or the home (or may be coupled with a duct that is so routed), such that external air duct 178 is coupled to a source of outside air. In general, indoor air vent 172, indoor air duct 174, conditioning system 140, external air duct 178, and external air vent 176 may generally define the cooling air flow path 170.
As best illustrated in
Notably, conventional condenser dryer appliances simply recirculate indoor air to cool the heat exchanger and remove condensate. However, this recirculated indoor air may increase in temperature over time, which may result in undesirable heating of the laundry room, poor heat exchanger efficiency, reduced moisture extraction, and longer dry times. Accordingly, aspects of the present subject matter are directed to a condenser dryer with features to reduce the undesirable heat soaking of the indoor space and improve the system efficiency, both when it is relatively hot outside (e.g., in the summer) and when it is relatively cold outside (e.g., in the winter).
Referring specifically to
Referring specifically to
In some embodiments, controller 204 can automatically select or toggle between the first and second mode of operation. For instance, in some embodiments, controller 204 can be communicatively coupled with one or more temperature sensors 194, e.g., via a suitable wired or wireless communication link. In some embodiments, these temperature sensors 194 are operable to sense a temperature of the air within outdoor environment 190 and/or indoor environment, respectively. Controller 204 may be programmed to toggle between operating modes based on the measured indoor temperature, the measured outdoor temperature, or a difference between the two.
In some example embodiments, controller 204 is configured to receive an input indicative of a temperature of the air within outdoor environment 190. Controller 204 can then determine whether the temperature of the air within outdoor environment 190 has passed a threshold temperature. As one example, the threshold temperature can be an upper threshold temperature, e.g., seventy degrees Fahrenheit (70° F.) or (21° C.). In this example, if the sensed temperature has passed or is greater than seventy degrees Fahrenheit (70° F.), then controller 204 determines that the temperature of the air within outdoor environment 190 has passed the threshold temperature. As another example, the threshold temperature can be a lower threshold temperature, e.g., thirty-two degrees Fahrenheit (32° F.) or (0° C.). In this example, if the sensed temperature has passed or is less than thirty-two degrees Fahrenheit (32° F.), then controller 204 determines that the temperature of the air within outdoor environment 190 has passed the threshold temperature. In such embodiments, when the temperature of the air within outdoor environment 190 has passed the threshold temperature, controller 204 can cause dryer appliance 100 to switch or toggle to either the first or second mode of operation depending on the temperature threshold passed.
For example, if the sensed outdoor temperature has passed or is greater than the upper threshold temperature, then controller 204 can automatically switch to or operate in the second mode of operation, where the cooling air is drawn from indoor environment 192. By contrast, if the sensed outdoor temperature has passed or is greater than the lower threshold temperature, then controller 204 can automatically switch to or operate in the first mode of operation, where the cooling air is drawn from outdoor environment 190. According to still other embodiments, controller may switch the mode of operation based on the sensed indoor temperature relative to predetermined thresholds or may instead toggle based on an indoor/outdoor temperature differential.
One or more selector inputs 200, such as knobs, buttons, touchscreen interfaces, etc., may be provided on a user interface panel 202 and may be in communication with a processing device or controller 204. Signals generated in controller 204 operate motor 128, heating assembly 160, and other system components in response to the position of selector inputs 200. Additionally, a display 206, such as an indicator light or a screen, may be provided on cabinet user interface panel 202. Display 206 may be in communication with controller 204 and may display information in response to signals from controller 204.
As used herein, “processing device” or “controller” may refer to one or more microprocessors or semiconductor devices and is not restricted necessarily to a single element. The processing device can be programmed to operate dryer appliance 100. The processing device may include, or be associated with, one or more memory elements (e.g., non-transitory storage media). In some such embodiments, the memory elements include electrically erasable, programmable read only memory (EEPROM). Generally, the memory elements can store information accessible processing device, including instructions that can be executed by processing device. Optionally, the instructions can be software or any set of instructions and/or data that when executed by the processing device, cause the processing device to perform operations. For certain embodiments, the instructions include a software package configured to operate appliance 100 and execute certain cycles or operating modes.
In some embodiments, dryer appliance 100 also includes one or more sensors that may be used to facilitate improved operation of dryer appliance. For example, dryer appliance 100 may include one or more temperature sensors which are generally operable to measure internal temperatures in dryer appliance 100 and/or one or more airflow sensors which are generally operable to detect the velocity of air (e.g., as an air flow rate in meters per second, or as a volumetric velocity in cubic meters per second) as it flows through the appliance 100. In some embodiments, controller 204 is configured to vary operation of heating assembly 160 based on one or more temperatures detected by the temperature sensors or air flow measurements from the airflow sensors.
Referring again to
External communication system 210 permits controller 204 of dryer appliance 100 to communicate with external devices either directly or through a network 212. For example, a consumer may use a consumer device 214 to communicate directly with dryer appliance 100. For example, consumer devices 214 may be in direct or indirect communication with dryer appliance 100, e.g., directly through a local area network (LAN), Wi-Fi, Bluetooth, Zigbee, etc. or indirectly through network 212. In general, consumer device 214 may be any suitable device for providing and/or receiving communications or commands from a user. In this regard, consumer device 214 may include, for example, a personal phone, a tablet, a laptop computer, or another mobile device.
In addition, a remote server 216 may be in communication with dryer appliance 100 and/or consumer device 214 through network 212. In this regard, for example, remote server 216 may be a cloud-based server 216, and is thus located at a distant location, such as in a separate state, country, etc. In general, communication between the remote server 216 and the client devices may be carried via a network interface using any type of wireless connection, using a variety of communication protocols (e.g., TCP/IP, HTTP, SMTP, FTP), encodings or formats (e.g., HTML, XML), and/or protection schemes (e.g., VPN, secure HTTP, SSL).
In general, network 212 can be any type of communication network. For example, network 212 can include one or more of a wireless network, a wired network, a personal area network, a local area network, a wide area network, the internet, a cellular network, etc. According to an exemplary embodiment, consumer device 214 may communicate with a remote server 216 over network 212, such as the internet, to provide user inputs, transfer operating parameters or performance characteristics, receive user notifications or instructions, etc. In addition, consumer device 214 and remote server 216 may communicate with dryer appliance 100 to communicate similar information.
External communication system 210 is described herein according to an exemplary embodiment of the present subject matter. However, it should be appreciated that the exemplary functions and configurations of external communication system 210 provided herein are used only as examples to facilitate description of aspects of the present subject matter. System configurations may vary, other communication devices may be used to communicate directly or indirectly with one or more laundry appliances, other communication protocols and steps may be implemented, etc. These variations and modifications are contemplated as within the scope of the present subject matter.
As explained herein, aspects of the present subject matter are generally directed to a condenser dryer that has fan which is capable of reversing the air flow direction depending upon the indoor and the outdoor temperature. In this regard, a cooling air circuit passes between the laundry room and the ambient environment for access to outdoor air. The direction of this air exchange may be dependent on the indoor and outdoor temperatures. For example, in the summer, the air may be sucked from indoors (e.g., from within the laundry room) and waste heat is rejected outdoors in order to keep the laundry room cool. By contrast, in the winter, the air may be sucked from outdoors and the waste heat is released indoors to keep the laundry room warm. For example, this may be achieved with the help of an outside vent. This also, in turn, can provide the coolest air to the heat exchanger leading to higher efficiency and faster drying performance.
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 language of the claims.
