Laundry treating appliances, such as clothes washers, refreshers, and non-aqueous systems, may have a configuration based on a cabinet within which is housed the components of the appliance, including a tub. The tub may house a rotating drum that defines a treating chamber in which laundry items are placed for treating. The tub is dynamically connected to the suspension system to support the drum. The tub is dimensioned to accommodate tub movement within the cabinet, movement of the drum within the tub, and to support forces generated by the weight and rotation of the drum.
The tub dynamically connects to a suspension system to support the movement of the tub within the cabinet, dampening any movement or vibrational transmission from the tub. Supporting the movement of the tub within the cabinet necessarily limits capacity of the tub, thus limiting the capacity of the drum within the tub and the volume of laundry which can be treated within the treating chamber.
A laundry treating appliance configured to treat laundry according to a cycle of operation, comprising a chassis defining an interior. A tub is located within the interior and is statically mounted to the chassis, the tub further defining a liquid chamber. A rotatable drum is located within the liquid chamber and is rotatable about a horizontal axis. An electric motor, having a drive shaft operably coupled to the rotatable drum, effects rotation of the drum with rotation of the drive shaft. An exoskeleton located within the liquid chamber has a rear support directly supporting at least one of the rotatable drum and the electric motor. A suspension, comprising at least one suspension component, couples to the exoskeleton and extends through an opening in the tub, permitting dynamic movement of the exoskeleton. One or more seals, associated with each of the at least one suspension components, prevents liquid flow from the liquid chamber to the interior through the opening in the tub.
A laundry treating appliance configured to treat laundry according to a cycle of operation, comprising a chassis defining an interior. A tub located within the interior statically mounts to the chassis, the tub further defining a liquid chamber. The tub further comprises at least one opening fluidly coupling the interior to the liquid chamber. An exoskeleton is located within the liquid chamber and is coupled to the chassis. A suspension comprises at least one suspension component coupling the exoskeleton to the chassis. A seal associated with the at least one suspension components, prevents liquid flow from the liquid chamber to the interior through the opening.
In the drawings:
As may best be seen in
A liquid chamber 26 is defined by a tub 28, which is supported by the chassis. The tub 28 is statically mounted to the chassis 12. Alternatively, the tub 28 may be at least partially mounted to the front wall 14 and the opposing side walls 18 and 20. The tub 28 may also be integrally formed with the opposing side walls 18 and 20 as seen in
A laundry holding assembly is disposed at least partially within the liquid chamber 26 and is defined by an exoskeleton 100, a drum 32 provided within the exoskeleton 100, and a laundry treating chamber 34 at least partially defined by the drum 32. The exoskeleton 100 physically supports the drum 32 and a suspension system 30 extends between the exoskeleton 100 and the chassis 12 to provide suspension directly to the exoskeleton 100. In turn, the suspension system 30 indirectly provides suspension for the drum 32. The suspension system 30 is configured to reduce the movement and vibration of the laundry holding assembly during a cycle of operation.
The drum 32 may include a plurality of perforations 36 such that liquid may flow between the tub 28 and the drum 32 through the perforations 36. A plurality of baffles 38 may be disposed on an inner surface of the drum 32 to lift the laundry load received in the treating chamber 34 while the drum 32 rotates.
The laundry holding assembly may further include a door 40 which may be movably mounted to the chassis 12 to selectively close the drum 32. A bellows 42 may couple a front opening in the exoskeleton 100 with the chassis 12, with the door 40 sealing against the bellows 42 when the door 40 closes the drum 32.
The washing machine 10 also includes a drive system for rotating the drum 32 and may include an electric motor 44 physically supported by the exoskeleton 100, which is directly coupled with the drum 32 through an output shaft or drive shaft 46 to rotate the drum 32 about a longitudinal axis 48 of the drum 32 during a cycle of operation. The electric motor 44 may be a brushless permanent magnet (BPM) motor having a stator and a rotor. Alternately, the electric motor 44 may be coupled to the drum 32 through a belt and a drive shaft to rotate the drum 32, as is known in the art. Other motors, such as an induction motor or a permanent split capacitor (PSC) motor, may also be used. The electric motor 44 may rotate the drum 32 at various speeds in either rotational direction.
The washing machine 10 may include additional features typically found in a conventional washing machine, the details of which are not germane to the present invention. For example, the washing machine 10 may include a liquid supply system for supplying water to the washing machine 10 for use in treating laundry during a cycle of operation and a dispensing system for dispensing treating chemistry to the treating chamber 34 for use in treating the laundry according to a cycle of operation. The washing machine 10 may also include a recirculation and drain system for recirculating liquid within the laundry holding assembly and draining liquid from the washing machine 10. Liquid supplied to the drum 32 or tub 28 enters a space between the tub 28 and the drum 32 and may flow by gravity to a drain conduit, which may drain the liquid from the washing machine 10, or to a recirculation conduit to direct liquid into the drum 32. In this manner, liquid provided to the drum 32 or tub 28, with or without treating chemistry may be recirculated into the treating chamber 34 for treating the laundry within. The liquid supply and/or recirculation and drain system may be provided with a heating system which may include one or more devices for heating laundry and/or liquid supplied to the drum 32 or tub 28, such as a steam generator and/or a sump heater, the details of which are not germane to the present invention. Any suitable liquid supply system, dispensing system, recirculation system and/or drain system may be used with the embodiments of the present invention, the details of which are not germane to the present invention.
The washing machine 10 also includes a control system for controlling the operation of the washing machine 10 to implement one or more cycles of operation. The control system may include a controller 60 located within the chassis 12 and a user interface 62 that is operably coupled with the controller 60. The user interface 62 may include one or more knobs, dials, switches, displays, touch screens and the like for communicating with the user, such as to receive input and provide output. The user may enter different types of information including, without limitation, cycle selection and cycle parameters, such as cycle options.
The controller 60 may include the machine controller and any additional controllers provided for controlling any of the components of the washing machine 10. For example, the controller 60 may include the machine controller and a motor controller. Many known types of controllers may be used for the controller 60. The specific type of controller is not germane to the invention. It is contemplated that the controller 60 is a microprocessor-based controller that implements control software and sends/receives one or more electrical signals to/from each of the various working components to affect the control software. As an example, proportional control (P), proportional integral control (PI), and proportional derivative control (PD), or a combination thereof, a proportional integral derivative control (PID control), may be used to control the various components. The controller 60 may be provided with a memory for storing control software that is executed by a central processing unit of the controller 60 in completing a cycle of operation using the washing machine 10 and any additional software.
The controller 60 may be operably coupled with one or more components of the washing machine 10 for communicating with and controlling the operation of the component to complete a cycle of operation. For example, the controller 60 may be operably coupled with the electric motor 44 and any other additional components that may be present such as a steam generator, a treating chemistry dispenser, and a sump heater (not shown) to control the operation of these and other components to implement one or more of the cycles of operation. The controller 60 may also be coupled with one or more sensors provided in one or more of the systems of the washing machine 10 to receive input from the sensors, which are known in the art and not shown for simplicity. Non-limiting examples of sensors that may be communicably coupled with the controller 60 include: a treating chamber temperature sensor, a moisture sensor, a weight sensor, a chemical sensor, an optical sensor, a conductivity sensor, a turbidity sensor, a position sensor and a motor torque sensor, which may be used to determine a variety of system, laundry and liquid characteristics, such as laundry load inertia or mass.
The suspension system 30 comprises at least two springs 70 and at least two struts or dampers 72 attached to the front support 102 and rear support 104 of the exoskeleton 100. As illustrated, two springs 70 are attached to the upper portion of both the front support 102 and rear support 104 and two dampers 72 attached to the lower portion of both the front support 102 and rear support 104. Alternatively, the springs 70 and dampers 72 may attach to the stringers 106 or a combination of the front support 102, rear support 104 and stringers 106.
Referring again to
The tub 28 at least partially surrounds the exoskeleton 100 and retains liquid within the liquid chamber 26. The tub 28 and front panel wall 14 enclose the front side of the liquid chamber 26. The rear support 104 and a flexible rear seal 31 coupled between a rear portion of the tub 28 and the rear support 104 enclose the rear side of the liquid chamber 26.
The tub 28 also includes a plurality of apertures defining suspension openings 29 between the interior 24 and the liquid chamber 26. The suspension openings 29 are aligned with the suspension system 30 such that the springs 70 and dampers 72 pass through the suspension openings 29 to couple the exoskeleton 100 to the chassis 12.
The electric motor 44 is mounted to the motor mount 112 on the rear side of the rear support 104 such that the electric motor 44 is physically supported by the rear support 104. The drive shaft 46 extends from the electric motor 44 through a bearing assembly mounted in the bearing mount 108 formed in the rear support 104 and is coupled to the rear drum wall 54 of the drum 32. The bearing assembly may comprise a friction reducing surface or friction reducing devices such as roller bearings and is configured to aid in rotation of the drive shaft 46 by reducing friction between the drive shaft 46 and the rear support 104. Alternatively, the at least one counterweight 101 may be coupled to the stringers 106, or a combination of being attached to front support 102 and stringers 106.
The washing machine 10 may also include at least one counterweight 101 provided on the exoskeleton 100. The counterweight 101 may be coupled with the front support 102 or may be integrally formed with the front support 102. The density of the front support 102 may also be configured such that the front support 102 functions as a counterweight 101.
Referring to
The washing machine disclosed herein provides a plurality of benefits including that the size of the drum can be maximized to increase washing capacity of the drum without increasing a size of the chassis or cabinet. This is achieved by isolating the tub from the suspension system, supporting the drum with the exoskeleton and allowing the suspension system to extend between the exoskeleton and the chassis through the tub. Isolating the tub from the suspension system eliminates the clearance needed between a moving tub and the chassis. Extending the suspension system through the tub minimizes the space needed between the tub and the chassis to house the suspension system. Supporting the drum generated forces with the exoskeleton allows the tub to function solely as a liquid retainer and not as a structural support for the drum which also allows the tub wall thickness to be reduced. Eliminating clearances needed between the tub and the chassis, minimizing interior space needed to house the suspension system, and reducing the tub wall thickness allow for a larger drum with increase washing capacity without increasing a size of the chassis or cabinet.
Turning now to
The bellows 120 has a somewhat sinusoidal profile common to bellows 120, while any profile shape, such as an “S” shaped bellows 120, is contemplated. The bellows 120 further comprises a bellows top 128, coupled to the suspension mount 126, and a bellows bottom 130, coupled to a wall 142 defining the suspension opening 29. The bellows 120 can mount to suspension mount 126 and the wall 142 by any method known in the industry, such as welding, adhesives, or fasteners. The bellows 120 is generally annular and surrounds the damper 72 to define a bellows space 134 between the bellows 120 and the damper 72, which is in fluid communication with the interior 24. As can be appreciated, any fluid within the liquid chamber 26 can contact the bellows 120, but cannot flow into bellows space 134, preventing any liquid from escaping into the interior 24 from the liquid chamber 26.
Turning now to
Turning to
The cap 144 is illustrated with a flat surface transitioning to rounded edges. However, any suitable shape is contemplated. The passage 146 can be the same size as the damper 72, or slightly smaller or larger, permitting the sealed insertion of the damper 72. In many instances, the cap 144 need not form a liquid-tight seal relative to the damper 72. In some implementations, it will be sufficient that the cap 144 essentially functions as a splash guard, which would permit a gap between the cap 144 and the damper 72. In other implementations a liquid-tight seal is contemplated. In such cases, the cap 144 would contact the damper 72. The cap 144 can be rubber, malleable plastic, or any other expandable or compressible material such that the cap 144 can expand or compress with the actuation of the damper rod 124, movement of the exoskeleton 100, or movement of the damper 72.
The cap 144 also has a plurality of slits 150 extending from the exterior of the cap 144 to the damper 72. The slits 150 can be shaped as holes, ellipses, or otherwise, in non-limiting examples, and can be disposed in an annular fashion around the entirety of the cap 144. The slits 150 provide a gap in the cap 144 such that flexion of the cap 144 is enhanced during dynamic movement of the damper 72 or the exoskeleton 100. The slits 150 permit the expansion of the cap 144 about the slits 150 or compression of the cap 144 at the slits 150, providing a greater range of flexion of the caps 144 to support the dynamic movements. The increased range of flexion further prevents the suspension seals 118 from tearing or breaking during movement of the dampers 72 or exoskeleton 100. Additionally, the slits 150 can divide the cap 144 into sections where the cap 144 can expand independently of each section, permitting greater movement of the cap 144 in maintaining the seal.
Turning now to
Turning now to
The umbrella 156 further comprises an umbrella top 158 disposed at the upper portion of the umbrella 156, the umbrella top 158 coupling to the damper body 122 at the umbrella passage 154. Extending from the umbrella top 158 is an umbrella peripheral wall 160. As shown, the umbrella peripheral wall 160 extends downward at a distance sufficient to surround a portion of the wall 142, while the end of the umbrella peripheral wall 160 remains spaced from the tub 28 at a distance sufficient to permit movement of the exoskeleton 100 or damper 72.
An umbrella gap 162 is defined between the umbrella peripheral wall 160 and the wall 142. As such, the umbrella 156 creates a labyrinth seal between the liquid chamber 26 and the interior 24. The labyrinth seal retards liquid flow and splashing that can occur during movement of the exoskeleton 100 or the damper 72, preventing leakage. Liquid 164 disposed within the liquid chamber 26, can comprise a volume such that the liquid 164 can rise to a level disposed along both the wall 142, the umbrella peripheral wall 160, and within the umbrella gap 162. The umbrella 156 and wall 142 can be sized to anticipate liquid 164 flow into the umbrella gap 162 such that the liquid 164 in the umbrella gap 162 will not rise to a level sufficient to spill over into the interior 24. Furthermore, the umbrella gap 162 can comprise a distance where liquid 164 movement or dynamic movement of the exoskeleton 100 cannot create a wave or splash of liquid 164 sufficient to spill into the interior 24. The gap can be 12 to 20 millimeters (mm) while a gap as great as 30 can be used.
Typical labyrinth seals used in the industry require multiples grooves with associated extensions within the grooves to define a labyrinth path. The umbrella 156 defines a simplified labyrinth without requiring grooves, eliminating the potential for increased machining. Additionally, the vertical orientation of the umbrella 156, which can also be partially submerged in liquid, eliminates issues with escaping water vapor or heat loss typical in common labyrinth seals used in the industry. As such, the umbrella 156 provides increased efficiency in protecting leakage, while reducing costs normally associated with a labyrinth-type seal.
Turning now to
While the embodiments disclosed herein describe three different embodiment of seals utilized within a horizontal-axis, laundry treating appliance with a fixed tub, additional seals are contemplated. Non-limiting examples of seals can include adhesives, rings, heat seals, couplings, hermetic seals, gaskets, plugs, etc.
Additionally, while the embodiment described herein have utilized a damper suspension element toward the bottom of the tub, the embodiments can be utilized with springs or any other suspension element, and can be disposed at the top of the tub where heated vapor can commonly escape.
While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the invention which is defined in the appended claims.
This application is a continuation in part of and claims the benefit of U.S. application Ser. No. 14/574,522 filed Dec. 18, 2014, now U.S. Pat. No. 9,765,467, issued Sep. 19, 2017, which is incorporated herein by reference in its entirety.
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Number | Date | Country | |
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20160177486 A1 | Jun 2016 | US |
Number | Date | Country | |
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Parent | 14574522 | Dec 2014 | US |
Child | 14810851 | US |