Patent Application
20180105971
The device is in the field of laundry appliances, and more specifically, laundry appliances having a heat pump system for operating a filterless air-handling system.
In at least one aspect, a laundry appliance includes a blower that directs process air along an airflow path. A condensing heat exchanger heats the process air to define heated process air. A drum receives the heated process air to dry laundry. A pump directs fluid along a fluid path. An evaporating heat exchanger cools the fluid to define a cooled fluid. A refrigerant circuit directs a refrigerant between the condensing and evaporating heat exchangers. A shower area in which the cooled fluid is showered through the heated process air after the heated process air exits the drum to wash particulate matter out of the heated process air. The pump directs the fluid towards the evaporating heat exchanger in order to cool the fluid, and directs the cooled fluid to the shower area.
In at least another aspect, a thermal exchange system for an appliance includes a first heat exchange loop having condensing and evaporating heat exchangers. A second heat exchange loop heats process air at the condensing heat exchanger for delivery through a drum and a shower area, sequentially. A third heat exchange loop cools a fluid at the evaporating heat exchanger for delivery to the shower area. The shower area is defined by an interaction of the fluid with the process air leaving the drum to wash particulate matter from the process air leaving the drum and to cool and dehumidify the process air leaving the drum.
In at least another aspect, an air-handling system for an appliance includes an airflow path that directs process air through a condensing heat exchanger to define heated process air that is delivered through a rotating drum. A fluid path selectively directs a fluid through an evaporating heat exchanger to define cooled fluid, wherein the evaporating heat exchanger is in thermal communication with the condensing heat exchanger. A shower area defined by an intersection of the airflow path and the fluid path. The cooled fluid is delivered through the heated process air within the fluid shower to cool and dehumidify the heated process air and warm the cooled fluid. The cooled fluid washes particulate matter from the heated process air. The heated process air increases a fluid temperature of the cooled fluid.
These and other features, advantages, and objects of the present device will be further understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
In the drawings:
For purposes of description herein the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the device as oriented in
As illustrated in
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According to the various embodiments, it is contemplated that the heated return fluid 66 can be transmitted to a fluid tank 84 for recycling back through the evaporating heat exchanger 36 to be cooled into the cooled fluid 38 and subsequently pumped back to the shower area 40. It is also contemplated that during or after the performance of various laundry functions, the heated return fluid 66 containing the condensate and particulate matter 82 from the moisture-laden process air 62 can be removed from the appliance 12 through a drain 86 and/or drain pump or through removal of a removable compartment having the particulate matter 82 and fluid 18 contained therein. Through this operation of the particulate filtration mechanism 80, the cooled return air is substantially free of particulate matter 82 that may adhere to the condensing heat exchanger 28.
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According to the various embodiments, as exemplified in
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According to the various embodiments, it is contemplated that the condensing and evaporating heat exchangers 28, 36 can be connected through a refrigerant circuit 50 that selectively delivers a refrigerant 52 between the condensing and evaporating heat exchangers 28, 36. Such a refrigerant circuit 50 can include a compressor 120, an expansion device 122, and the refrigerant 52 that can include a phase change material, such as Freon, water, and other similar phase change materials.
According to the various embodiments, in order to move the process air 16 through the airflow path 24 and the fluid 18 through the fluid path 32, the airflow path 24 can include a blower 26 that selectively recirculates process air 16 sequentially through the rotating drum 20, the shower area 40 and the condensing heat exchanger 28. The fluid path 32 can include a fluid pump 34 that selectively delivers fluid 18 from the second heat exchanger and to the shower area 40. It is contemplated that the fluid 18 can be delivered from the shower area 40 back to a fluid tank 84 and/or the evaporating heat exchanger 36 through the force of gravity or a secondary pump positioned within the fluid path 32.
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According to the various embodiments, the third heat exchanger 42 is defined by the intersection of the second and third thermal transfer materials 136, 142. Additionally, the third thermal transfer material 142 is adapted to condense and precipitate the retained moisture 60 within the second thermal transfer material 136 and to remove at least a portion of the particulate matter 82 sequestered or otherwise retained within the second thermal transfer material 136.
It is contemplated that the second thermal transfer material 136 of the second heat exchange loop 134 can be process air 16 that is directed through the process chamber 138. The third thermal transfer material 142 can be the fluid 18 that is directed through the fluid sprayer 144 disposed proximate the third heat exchanger 42. In this embodiment, the second heat exchange loop 134 passes through the first heat exchanger, which again corresponds to the condensing heat exchanger 28. This condensing heat exchanger 28 heats the process air 16 to define the heated process air 30 that is delivered through the process chamber 138, typically in the form of the rotating drum 20. As the heated process air 30 moves through the third heat exchanger 42, this third heat exchanger 42 at least partially performs an evaporating function to cool the process air 16 and also condense moisture 60 contained within the process air 16. Accordingly, with respect to the second heat exchange loop 134, the third heat exchanger 42 acts as an evaporator 150 for the second heat exchange loop 134.
With respect to the third heat exchange loop 140, the fluid 18 pumped therethrough is cooled by the second heat exchanger, which typically corresponds to the evaporating heat exchanger 36. This cooled fluid 38 is directed to the fluid sprayer 144 of the third heat exchanger 42. With respect to the third heat exchange loop 140, the third heat exchanger 42 performs certain condensing functions such that the cooled fluid 38 is heated as it passes through the third heat exchanger 42. Accordingly, with respect to the third heat exchange loop 140, the third heat exchanger 42 is a condenser 152 that operates in conjunction with the evaporating heat exchanger 36 of the first heat exchange loop 130. In this manner, the third heat exchanger 42 of the thermal exchange system 14 of the appliance 12 simultaneously performs both condensing functions with respect to the third heat exchange loop 140 and evaporating functions with respect to the second heat exchange loop 134. In such an embodiment, the condensing, evaporating and third heat exchangers 28, 36, 42 of the thermal exchange system 14 transfer heat energy 110 in the form of heating and cooling to perform various processing functions of the appliance 12.
Stated another way, the condensing and third heat exchangers 28, 42 of the thermal exchange system 14 define a heater 160 and a cooling module 162, respectively, of the second heat exchange loop 134. Simultaneously, the evaporating and third heat exchangers 36, 42 define a cooling module 162 and a heater 160, respectively, of the third heat exchange loop 140.
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According to the various embodiments, this removal of moisture 60 within the third heat exchanger 42 is possible through the separation of the process air 16 from direct contact with the evaporating heat exchanger 36. Instead, cooling, in the form of cooled fluid 38, from the evaporating heat exchanger 36 is delivered to the fluid sprayer 144 of the third heat exchanger 42. The cooled fluid 38 performs the evaporating functions to remove moisture 60 and particulate matter 82 with respect to the moisture-laden process air 62. Additionally, this condensing operation is also possible through the separation of the fluid path 32 from direct engagement with the condensing heat exchanger 28. Accordingly, the moisture condensation functions and particulate filtration, with respect to the moisture-laden air, as discussed above, are physically separated from both of the condensing and evaporating heat exchangers 28, 36.
According to the various embodiments, by separating the moisture condensation and particulate removal functions of the appliance 12 with respect to the moisture-laden process air 62 from each of the condensing and evaporating heat exchangers 28, 36, the particulate filtration mechanism 80 of the laundry appliance 12 can also be contained within the third heat exchanger 42, and physically separated from the condensing and evaporating heat exchangers 28, 36. By removing the particulate matter 82, such as lint, fluff, and other fibrous material obtained from the items 22 being processed within the rotating drum 20, this material is removed from the process air 16 before the process air 16 is returned to the condensing heat exchanger 28. This particulate matter 82 can also be removed from the fluid 18 before the fluid 18 is returned to the evaporating heat exchanger 36. Accordingly, this heat pump system 10 described herein allows for the absence of a screen-type filter while also unifying the filtration and moisture condensing functions of the appliance 12 within a single location of the third heat exchanger 42. In this manner, the third heat exchanger 42 is a compartment or area within the appliance 12 where process air 16 and fluid 18 can be combined to transfer heat energy 110 therebetween.
According to the various embodiments, the thermal exchange system 14 described herein can be incorporated within various appliances 12. These appliances 12 can include, but are not limited to, washers, dryers, combination washers and dryers, refrigerators, dish washers, freezers, and other similar appliances 12 that include a heat pump system 10 or other refrigerant-based thermal exchange system 14.
It will be understood by one having ordinary skill in the art that construction of the described device and other components is not limited to any specific material. Other exemplary embodiments of the device disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.
For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.
It is also important to note that the construction and arrangement of the elements of the device as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present device. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present device, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
The above description is considered that of the illustrated embodiments only. Modifications of the device will occur to those skilled in the art and to those who make or use the device. Therefore, it is understood that the embodiments shown in the drawings and described above is merely for illustrative purposes and not intended to limit the scope of the device, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents.
