Floating Drum and Clutch for Top-Loading Washing Machine

Abstract

“FLOATING BASKET AND CLUTCH APPLIED TO THE TOP LOADING WASHING MACHINE”, more particularly, the basket floating (1) and clutch (2) are applied to top loading washing machines (M), equipped with motor (M) and drive system which includes a drive shaft (E), pulley (P) and belt (Cr) and sealing device (V), assembled between the shaft (E) and the base of the tub (T); more precisely, the clutch (2) is responsible for commanding the operation of the oscillating movement of the agitator or “impeller” (AG), when in the washing operation (OPL) of fabrics and operating the high-speed spinning of the agitator (AG) and basket (1), when operating in centrifugation operation (OPC) of fabrics; the floating basket (1) is coupled and fixed to the tub (5) of the upper sector (S1) of the clutch (2) and the tub is fixed to the female lower crown (4) of the lower sector (S2) of the clutch (2); the floating basket (1) has vertical displacement (x) in relation to the tub (T), along the drive shaft (E) and according to presence or absence of water (A) in the tub (T) of the washing machine (ML); the upper sector (S1) of the clutch (2) is made up of a male upper crown (3) and fixed in the stationary end (E1) of the drive shaft (E) and an female upper crown (6) is fixed to the tub (5) with screws (P2); the lower sector (S2) of the clutch (2) comprises the male lower crown (7), fixed to the tub (5) with screws (P3) and the female lower crown (4) fixed and stationary in the tub (T) by screws (P).

Description

FIELD OF THE INVENTION

The present invention relates to a floating basket and clutch applied to top loading washing machines and more particularly, the object of this application includes the combination of a floating basket coupled to a set of clutch parts which moves vertically and along the drive shaft, depending on the presence or absence of water in the basket of the machine; the floating basket and clutch set allows that the functions of washing and centrifugation are performed with a reduced number of parts and a high efficiency when compared to conventional models.

INVENTION BACKGROUND

It is known that “top loading” washing machines are devices with a top door that includes a tub, a basket and an agitator or “impeller”, mounted on a vertical shaft. Most models of “top loading” washing machines have a vertical shaft that is coupled to a drive system consisting of a motor, transmission (gearbox) and clutch.

In general, the clutch work of a washing machine is that of allowing the motor and the transmission to operate, as programmed, within certain variations in the output rotational speed of the vertical shaft, to which the agitator and basket are bound in order to carry out, on its program, the washing operation, i.e., the oscillating movement of the agitator in relation to the basket, and where soap and water are stirred between fabrics, removing the dirt from them. After some periods of stirring, the agitator and basket are stopped, which allows the washing water to be drained, so that in a final operation the agitator and basket are driven in a manner that they spin together, and at high speed, characterizing the operation of centrifugation that expels the excess water retained in clothes and fabrics.

Most of conventional clutches use a gear mechanism and springs for changing the transmission of the motor power between the washing and dewatering steps. The conventional clutch springs provide a way of carrying out power transmission among the motor and the agitator and the basket.

Each conventional clutch spring requires high precision in their laps, and depends on calculations relating to its inner diameter, among others. In addition, to control the movement of the clutch springs, electro-magnet, actuators, lever arms and other components are required. Therefore, the conventional clutch mechanism has a complicated construction, resulting in an increased production cost.

Currently there are several types of clutches for different types of “top loading” machines and most of them are somewhat complex, even for simpler applications.

Analysis of the State-of-the-Art

Some manufacturers of washing machines have already had technical solutions that use floating clutches based on the principle of presence or absence of water in the tub to promote the movement of washing and centrifugation.

A brief survey in databanks revealed solutions included in the scope of this application, i.e., a floating movement of some parts assembled on the drive shaft of the automatic washing machine in order to perform the washing and spinning movement. However, as it will be explained, the present invention shows a new and inventive solution against the traditional clutch systems, i.e., the vertical displacement of the floating basket associated to a clutch mechanism which does not require the employment of the transmission system, and therefore, having significant advantages in terms of efficiency and reliability for performing the washing machine innovative operations of washing and centrifugation, as well as it proved to be more affordable to manufacturing and assemble and, consequently, to reduce the cost of the final product.

An example of a system that uses floating clutch and requires transmission system, unlike the object of this document, is the Brazilian document No. PI 0605507-9 (Mabe) that refers to a floating clutch with two concentric shafts, where through a movable body it is possible to transmit energy from one shaft to another, through an indented disc which engages or disengages by vertical displacement in a cylindrical part, fixed to the agitator, due to the presence of some fluid, transmitting the torque of the inner shaft coupling, and from this one to the other parts. The motor is DD (direct drive) type and transmits power to the set of shafts through the transmission system.

Another American document No. U.S. Pat. No. 5,661,990 (DAEWOO) has no transmission system, but uses the gearing of a set of floating pieces and the floating impeller whose drive shaft has a DD motor assembled directly on it, producing the stress directly, differing from the proposal exposed as follows.

BRIEF DESCRIPTION OF THE INVENTION

Based on the above considerations, the floating basket and clutch assembly applied to a washing machine with agitator has as its main objective, to provide that a top loading washing machine has specific constructiveness in order to engage, in a specific and efficient way, the mechanism of the floating basket and the gear assembly to perform the functions of washing and centrifugation.

For this, the set of floating basket and clutch includes a drive shaft that (i) at the lower end it receives the rotation command from the motor, (ii) at the upper end it is coupled to the base of the agitator or the impeller, and the this requires the oscillating movement and, (iii) in the middle area, it provides ways that allow a vertical displacement of the basket in order to perform the operation of centrifugation.

In order to achieve the above objectives, at the very end of the shaft, a first gearing mechanism is fixed, composed of a cylindrical bearing with external radial dents, while in the middle area of that shaft, other cylindrical bearing with internal dents is placed which, in turn, is fixed at the base inside the tub.

This time, between the fixed upper and lower bearings, a floating mechanism operates, made up by the floating basket that can be coupled to a set of three floating parts of clutch, movable vertically, where two of them are called ‘crown’, upper and lower, each provided with internal and external dents, which may engage in the upper and lower bearings mentioned above. The central part of the floating set comprises of a chamber or inverted cup whose upper base is fixed with screws to the upper floating crown and the lower base of this cup is also fixed with screws to the floating basket and to the lower crown, forming thereby a floating set that can be engaged and disengaged from the fixed bearing fixed.

The driving of the washing function or centrifugation is carried out by the presence or absence of water in the floating set. Therefore, when water is present in the wash tub, the basket moves upwards vertically along the drive shaft, by disengaging the fixed upper bearing assembly, however engaging it to the fixed lower bearing assembly, stopping, this way, the basket and allowing the shaft to impose the oscillating movement to the agitator, and washing the clothes.

When water is drained from the tube, the whole floating set moves down, i.e., displaces down along the drive shaft, allowing the set to be engaged to the fixed upper bearing and disengaged from the lower fixed bearing, which allows the shaft, the agitator and the basket forms a single piece capable to spin together and at high speed, performing the function of centrifugation.

This innovation is simple and eliminates the need to employ several other conventional components, thereby reducing costs without compromising the operation of agitation and centrifugation.

The sets of upper and lower gearing are easy to produce and avoid or reduce considerably the labor for maintenance, not to mention that, in there is a need for replacement of any parts of the gearing sets, the cost is low in the market, since parts are made of plastic.

BRIEF DESCRIPTION OF THE DRAWINGS

To complement this description in order to obtain a better understanding of the characteristics of the present invention, and according to a preferred practical presentation, a set of schematic drawings with description are attached and showed below, where in an exemplified manner, among others, the following has been represented:

FIG. 1 is a perspective view of a top loading washing machine, illustrating the basket and the agitator in evidence, and the driving system formed by the motor, pulley, belt and drive shaft;

FIG. 2 is a side view, in enlarged section of the whole innovative assembly, i.e., floating basket, drive shaft, fixed bearings and small motor;

FIG. 2A is a perspective view and partial section of the elements that make up the clutch and the fixed bearings;

FIGS. 3A and 3B show a lower view (bottom) of the basket and an enlarged side sectional view of the base of the basket, illustrating the floating chambers;

FIGS. 4A, 4B and 4C respectively show the fixed upper bearing and the upper crown in perspective and lateral view of both in the assembled position;

FIGS. 5A, 5B and 5C respectively show the fixed lower bearing and the lower crown in perspective and the side view of both in the assembled position;

FIGS. 6A, 6B and 6C represent, in detail and in upper and lower perspective, the intermediate floating chamber that integrates the clutch relating to the base of the basket;

FIG. 7 is a side view and in section of a washing machine with enough water to proceed with the washing operation, illustrating in enlarged detail the upper gearing assembly engaged and the lower gearing in disengaged position, which allows the agitator to oscillate and that the basket remains stationary, and

FIG. 8 illustrates another view as presented in the previous Figure, but the washing machine is without water, in a position to start the centrifugation procedure, where it can be noted in more details, the upper gearing set disengaged and the lower gearing set engaged, allowing that the agitator and the basket agitate together and at high speed.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawings, the present invention refers to “FLOATING BASKET AND CLUTCH APPLIED TO TOP LOADING WASHING MACHINE, more particularly, the floating basket (1) and the clutch (2) are applied to top loading washing machines (ML), equipped with a motor (M) and drive system which includes a drive shaft (E), pulley (P) and belt (Cr) as well as a sealing device (V) assembled between the shaft (E) and the base of the tub (T); more precisely, the clutch (2) is responsible for commanding the operation of the agitator oscillating or “impeller” (AG), when in washing operation (LGA) (FIG. 7) of fabrics and operating at high-speed rotation of the agitator (AG) and basket (1), when in centrifugation operation (OPC) of clothes (FIG. 8).

According to the present invention, the floating basket (1) is coupled and fixed to the tube (5) of the upper sector (S1) of the clutch (2) with screws (PI) and the tub is fixed to the female lower crown (4) of the lower sector (S2) of the clutch (2), so that the basket moves vertically (x) in relation to the tub along the drive shaft (E) in the presence or absence of water (A) in the tub (T) of the washing machine (ML) (FIGS. 7 and 8).

The upper sector (S1) of the clutch (2) is made up of a male upper crown (3) fixed and stationary at the end (E1) of the drive shaft (E), which allows axial and external displacement of a female upper crown (6), duly attached to the tub (5) with screws (P2).

The lower sector (S2) of the clutch (2) is composed of a male lower crown (7) fixed to the tub (5) with screws (P3) and a female lower crown (4), as already mentioned, fixed and stationary in the tub (T).

The vertical displacement (x) between the basket (1) and the clutch (2) is based on the fact that the male upper crown (3), fixed to the end (E1) of the shaft (E) and the female lower crown (4), being fixed to the tub (T), determines an optimum spacing for the vertical displacement (x) of the set of parts made up by the floating basket (1), female upper crown (6), tub (5) and male lower crown (7) the presence or absence of water (A) in the tub.

The basket (1) is composed of cylindrical side wall part (1a), multiperforated (1b) and lower base (1c) provided with central hole (1d) for the drive shaft passing over (E). The lower surface of the base (1c) is provided with multiple small orthogonal walls arranged radially (1e) and concentric (1f), forming multiple floating chambers (1g). The internal wall of the central hole (1d) has a directional lock in jut (1h) for assembling and coupling to the lowering (5b) provided on the tub (5) (explained later), whereas the area around the central hole wall (1d) provides other multiple floating chambers (1g′), to a lesser extent in relation to the chambers (1g); in the area near the central hole (1d), threaded holes are provided (1i) for the fixation of the basket (1), with screws (P1), to the tub (5).

Eventually, the floating basket (1) may provide floating element (8) in its side, preferably on the external surface, which can be configured by an air bag (8a) obtained with the provision of a sector of double wall (8b), parallel to the wall (1a), or even, an alternative constructive option, one or more floats can be assembled (9) in low density material, such as EPS (Expanded Polystyrene), PU (Polyurethane), among others.

The male upper crown (3) (FIG. 4B), in a preferred construction, comprises a number of engineering plastic, with a cylindrical central sector whose side wall (3a) and orthogonal branching (3b) in “L” where multiple equidistant radial dents (3c), preferably cylindrical step, and an upper base (3d) with a central hole where it accommodates a bushing (B) with an opening grooved (B1) that can be coupled to the ribbed edge (E1) of the drive shaft (E). The branch (3b), in the shape of skirt, presents a peripheral radius defined to allow the stability of the male upper crown (3) within the female upper crown (6), at its vertical displacement.

The female upper crown (6) (FIG. 4A), also made of engineering plastics, presents a cylindrical central sector (6a), covering the upper base (6b) with sized central hole to serve as a cylindrical fitting seat (SC) of the agitator (AG) which, in turn, struts the upper base (3d) of the crown (3), preventing its movement; the lower face of the base (6b) is provided with multiple radial equidistant dents (6c), preferably of cylindrical steps and compatible with the dents (3c) of the crown (3). The lower base (6d) of the part (6) comprises a cylindrical tab provided with hollow holes (6e) which can be passed over by the screws (P2) used for the fixation of the part (6) to the tub (5) (FIG. 2A). The part (6) is provided with external lifting strake of bracing (6f).

The female lower crown (4) (FIG. 5A), also made of engineering plastic is constituted by a discoid body, made up by the peripheral skirt (4a) with multiple holes (4b), passed over by screws (P) for fixing this part to the base of the tub (T) and provides, to the center, a cylindrical sector (4c), braced to the skirt (4a) through the walls (4d); this cylindrical sector (4c) is provided with upper flange (4e) whose inner face is coated with multiple equidistant radial dents (4f), preferably cylindrical steps.

The male lower crown (7) (FIG. 5B) also cylindrical and made of engineering plastic and comprises a central sector (7a) with the lower base in the shape of a surrounding skirt (7b), whose upper surface is provided with multiple equidistant radial dents (7c), preferably of cylindrical and sized steps so as to couple in the dents (4f) of the female lower crown (4); the upper base (7d) of the cylindrical central sector (7a) has multiple small holes (7e) distributed in a equidistant way and around a central hole (7f), sized to allow the housing, with displacement, of the middle sector of the shaft (E). Between the inner surface of the upper base (7d) and the inner wall of the sector (7a) are applied the bracing fins (7g).

The tub (5) (FIGS. 6A, 6B and 6C) is designed to act as the main element of the clutch (2), once it is fixed to it the female upper crown (6) with screws (P2), the male lower crown (7) with screws (P3), and the floating basket (1), with screws (P1). The tub (5) is made, preferably, of aluminum and is configured by a cylindrical central sector (5a) whose side wall includes a longitudinal lowering (5b) for engaging and sliding of the latch (1h) of the floating basket (1). The upper base (5c) of the cylindrical sector (5a) is provided with multiple holes (5d) that, at the upper sector it fixes the female upper crown (6) with screws (P2) and, in the lower sector, it fixes the male lower crown (7) with screws (P3). The lower base (5e) is formed by a skirt also provided with holes (5f) for assembling and fixing the floating basket (1). All the internal area of the tube (5) is provided with micro air chambers (5g) made up of walls and fins, orthogonal to each other (5h).

Therefore, for the washing operation (OPL) (FIG. 7), the tub (T), on principle, contains water (A), the floating basket (1) must be stationary to the tub (T) and the agitator (AG) may fluctuate by imposition of the drive shaft (E) and motor (M). In the case of the present invention, the floating basket (1), according to the floating chambers (1g)/(5g) and, possibly, the floating element (8) is moved upward (x), carrying the tub with it (5) and consequently, causing the female upper crown (6) to disengage the male upper crown (3) fixed to agitator and the male lower crown (7) also moves upward engaging the female lower crown (4), fixed to the tub (T).

This displacement (x) upwards (floating) causes the floating basket (1) to remain fixed to the tub (T) (stationary position), while the agitator (AG) is free to perform the oscillating movement, in the washing operation, through the drive shaft (E).

Once the washing water is drained from the tub (T) (see FIG. 8), the floating basket (1) moves vertically (x) and downwards; the tub (5) also moves down carrying with it the female upper crown (6) which engages the male upper crown (3) fixed to the shaft (E), and the male lower crown (7) which disengages the female lower crown (4). Since these parts (3)/(6) are engaged and the parts disengaged from each other (4)/(7), the basket (1) is coupled to the agitator (AG). As the agitator (AG) starts rotating, the basket is dragged along by the clutch arrangement (2), so that the operation is performed by centrifugation (OPC) by the washing machine.

It is true that when the invention is put into practice, modifications may be made with regard to certain details of construction and shapes, without incurring depart from the principles that are clearly substantiated in the set of claims, where it is understood that the terminology used has had the purpose of no limitation.

Claims

1) “FLOATING BASKET AND CLUTCH APPLIED TO A WASHING MACHINE WITH TOP LOADING”, more specifically, the floating basket (1) and the clutch (2) are of the kind applied to a washing machine (M) with top loading, equipped with motor (M) and movement system which includes a drive shaft (E), pulley (P) and belt (Cr), as well as a sealing device (V) assembled between the shaft (E) and the tank base (T); more specifically, the clutch (2) is responsible for commanding the floating operation of the agitator or “impeller” (AG) during the washing operation (OPL) of the clothes, and the high speed rotating operation of the agitator (AG) and the basket (1) during the centrifugation operation (OPC) of the clothes; characterized by the fact that the floating basket (1) is connected and fastened to the hub (5) of the top section (S1) of the clutch (2) and the tank is fastened to the lower grooved crown (4) of the bottom section (S2) of the clutch (2); the floating basket (1) has a vertical displacement (x) if compared to the tank (T) along the drive shaft (E) due to the presence or absence of water (A) in the washing machine (ML) tank (T); the top section (S1) of the clutch (2) is constituted of a fixed and stationary upper tongued crown (3) in the edge (E1) of the drive shaft (E) and an upper grooved crown (6) fastened to the hub (5) through screws (P2); the bottom section (S2) of the clutch (2) is constituted of an upper tongued crown (7) fastened to the hub (5) through screws (P3) and a lower grooved crown (4) in the tank (T) fixed and fastened through screws (P).

2) “FLOATING BASKET”, according to the claim 1, characterized by the fact that the basket (1) is constituted of a cylindrical part with a multi-perforated (1b) side wall (1a) and a lower base (1c) provided of a central hole (1d) for the crossing of the drive shaft (E); the lower surface of the base (1c) is provided of multiple small orthogonal walls, arranged in a radial (1e) and concentric (1f) manner, creating many floating chambers (1g); the internal wall of the central hole (1d) has a directional lug lock (1h), whereas the section which involves the central hole wall (1d) presents other multiple floating chambers (1g′), in a smaller dimension if compared to the chambers (1g); the internal wall of the central hole (1d) has a directional lug lock (1h), whereas the section which involves the central hole wall (1d) presents other multiple floating chamber (1g′), in a smaller dimension if compared to the chamber (1g); in the section next to the central hole (1d), screwed holes (1i) are provided to fasten the referred basket (1) through screws (P1), to the hub (5).

3). “FLOATING BASKET”, according to claim 1 and one complementary option, characterized by the fact that the floating basket (1) is equipped with a floating element (8) in its side part.

4) “FLOATING BASKET”, according to claim 1, characterized by the fact that the floating element (8) of the floating basket (1) is constituted of an air bag (8a) obtained by the provision of a section with a double wall (8b), parallel to the wall (1a).

5) “FLOATING BASKET”, according to claim 1, characterized by the fact that the floating element (8) of the floating basket (1) is constituted of one or more floats (9) made of low density materials, such as EPS (Expanded polystyrene), PU (Polyurethane), among others.

6) “CLUTCH”, according to claim 1, characterized by the fact that the upper grooved crown (3) presents a cylindrical central section (3a) and an “L” orthogonal ramification (3b), where multiple equidistant radial teeth (3c) is provided, besides an upper base (3d) with central hole where a bushing (B) with a splined hole (B1) connects the splined edge (E1) of the drive shaft (E).

7) “CLUTCH”, according to claim 1, characterized by the fact that the external perimeter of the base (3d) of the upper tongued crown (3) represents a means of stability for the vertical displacement of the upper grooved crown (6).

8) “CLUTCH”, according to claim 1, characterized by the fact that the upper grooved crown (6) presents a cylindrical central section (6a), with top base (6b) with central hole for connection of the agitator (AG) cylindrical seat (SC;) the bottom face of the base (6b) is provided of multiple radial teeth (6c) equidistant and compatible with the crown (3) teeth (3c); the bottom base (6d) of the item (6) is comprised of a cylindrical flange provided of vented holes (6e) that may be crossed by the screws (P2); the piece (6) is provided of external bracing blades (6f).

9) “CLUTCH”, according to the claim 1, characterized by the fact that the upper grooved crown (4) is constituted of a discoid body, formed by a peripheral skirt (4a) with multiple holes (4b) crossed by screws (P) for fastening of this piece to the tank base (T) and presents, in the center, a cylindrical section, (4c), braced in comparison to the skirt (4a) through walls (4d); such cylindrical section (4c) is provided of an upper flange (4e), whose internal face presents multiple equidistant radial teeth (4f).

10) “CLUTCH”, according to claim 1, characterized by the fact that the lower tongued crown (7) presents a cylindrical shape and a central section (7a) with bottom base in the format of a circular skirt (7b) whose top surface is provided of multiple radial teeth (7c), equidistant and measured as to connect to the teeth (40 of the lower grooved crown (4); the top base (7d) of the cylindrical central section (7a) presents multiple small holes (7e) arranged in an equidistant manner and around the central hole (70, measured to allow the housing, with displacement, of the median shaft section (E); between the internal surface of the top base (7d) and the internal wall of the section (7a) bracing blades (7g) are applied.

11) “FLOATING BASKET AND CLUTCH”, according to the claim 1, characterized by the fact that the hub (5) is made up of a central cylindrical section (5a) whose side wall includes a longitudinal rabbet (5b) for placement and sliding of the floating basket (1) lock; (1h) the top base (5c) of the cylindrical section (5a) is provided of multiple holes (5d) that in the top section fasten the upper grooved crown (6) through screws (P2) and in the bottom section fasten the lower tongued crown (7) through screws (P3); the bottom base (5e) is made up of a skirt with holes (5f) for assembling and fastening of the floating basket (1); all internal section of the hub (5) is provided of micro inner tubes (5g) made up of walls and orthogonal blades among themselves (5h).

12) “FLOATING BASKET AND CLUTCH”, according to claim 1, characterized by the fact that the hub (5) is the drive element of the clutch (2), having the upper grooved crown (6) assembled and fastened through screws (P2), the lower tongued crown (7) through screws (P3) and the floating basket (1) through screws (P1).

13) “CLUTCH”, according to claim 1, characterized by the fact that the radial teeth (3c), radial teeth (6c), radial teeth (40 and radial teeth (7c) present pitch in round format.

14) “CLUTCH”, according to claim 1, characterized by the fact that the upper tongued crown (3), the upper grooved crown (6), the lower grooved crown (4), and the lower grooved crown (7) are made of plastic.

15) “CLUTCH”, according to claim 1, characterized by the fact that the hub (5) is made of aluminum.

16) “FLOATING BASKET AND CLUTCH APPLIED TO THE WASHING MACHINE WITH TOP LOADING”, according to claim 1 wherein the washing machine (ML) presents water in the tank (T) for the washing operation (OPL), characterized by the fact that the floating basket (1) provided of floating chambers (1g)/(5g) and, eventually, a floating element (8), is in vertical displacement (x) upwards, pulling the hub along (5); the upper grooved crown (6) is disconnected from the upper tongued crown (3) fastened to the agitator, and the lower tongued crown (7) is connected to the lower grooved crown (4), that, for its turn, is fastened to the tank (T).

17) “FLOATING BASKET AND CLUTCH APPLIED TO THE WASHING MACHINE WITH TOP LOADING”, according to claim 1 wherein the washing machine (ML) is not provided with water in its tank (T) for the centrifugation operation (OPL), characterized by the fact that the floating basket (1) presents vertical (x) displacement downwards; the hub (5) moves downward in the same path pulling the upper grooved crown (6) along, which is connected to the upper tongued crown (3), whereas the lower tongued crown (7) disconnects from the lower grooved crown (4); and the pieces (3)/(6) are connected and the pieces (4)/(7) are disconnected among themselves, the basket (1) follows the movement of the agitator (AG).

18) “FLOATING BASKET AND CLUTCH APPLIED TO THE WASHING MACHINE WITH TOP LOADING”, according to claim 1, characterized by the fact that the washing machine (ML) with top loading presents a floating basket (1), floating chambers (1g)/(5g) and, eventually, a floating element (8).