The present invention relates to washing machines and more particularly to moving clothes within the wash chamber of an automatic washer.
Known washing machines include vertical axis washers that use an agitator, impeller or some other type of rotor that rotates or oscillates about a vertical axis, such as shown in U.S. Pat. Nos. 5,031,427 and 5,460,018 or horizontal axis machines that input mechanical energy to the clothes load by rotating the wash chamber at a speed less than that which could cause the clothes to be held against the wall of the wash chamber by centrifugal force. Such horizontal axis machines are disclosed in U.S. Pat. Nos. 5,219,370 and 5,974,610.
In such typical horizontal or tilted axis washing machines, the wash chamber rotations or oscillations are symmetric and constant during the majority of a wash cycle. That is, they use a set, non-changing clockwise and counter clockwise wash chamber oscillation. In a vertical axis machine, typically there is a center rotor in the form of an agitator or impeller that rotates to impart mechanical energy to the wash load, and typically those rotations are symmetric and constant during the majority of the wash cycle. The wash chamber may be rotatable, but typically the wash chamber is rotated only during an extraction mode when it is desired to remove water or wash liquid from the clothes load, and then the wash chamber is spun in one direction only.
In U.S. Ser. No. 10/142,345, assigned to Whirlpool Corporation, assignee of the present application, the washer oscillates the clothes load for a plurality of periods of clockwise and counter-clockwise oscillations, wherein the time duration of the oscillations are selected for each period. The oscillations can be symmetrical or asymmetrical, and can have a time duration that is variable. Further, in another embodiment, the time duration of the oscillations varies for consecutive periods.
The tumbling action of the clothes load in a washer results in a flexing of the fabric to loosen and remove dirt and other foreign materials from the fabric load, but it also causes mechanical damage to the fabric in the form of broken threads. A reduction in such damage would be desirable, particularly if the level of dirt and foreign material removal can be maintained or enhanced.
According to the present invention, therefore, methods and apparatuses are provided for maintaining or enhancing the dirt and foreign material removal in a fabric load, while reducing the mechanical damage to the fabric inside a washing machine having a rotatable wash chamber by using randomly selected symmetric or asymmetric clockwise and counter-clockwise wash chamber oscillations that vary in subsequent periods. Conversely, the level of mechanical damage to the fabric may remain the same as in conventional washers while greatly enhancing dirt and foreign material removal. A period is defined as beginning at the onset of a stroke in a first direction and ending at the termination of the opposite direction stroke, the combination of strokes comprising an oscillation. These oscillations reduce the mechanical damage to clothes while improving the cleaning effect of the wash cycle. The stroke speed may vary randomly, the stroke angle, or the angle traversed may vary randomly, and the off time or pause between strokes or oscillations may vary randomly. Stroke speed or angle of a counterclockwise stroke may vary from the stroke speed or angle of a clockwise stroke within a single oscillation. These strokes or oscillations may vary randomly with each subsequent period.
In accordance with methods consistent with the present invention, a method of washing items in an automatic washer is provided, wherein the automatic washer has a wash chamber with a central axis and the wash chamber being rotatable about the central axis. The method comprises the steps of loading items into the wash chamber, supplying wash liquid into the wash chamber, and oscillating the wash chamber about the central axis by speed varying, range varying, offtime varying, ontime varying, or combination thereof, oscillations. The oscillations can comprise rotational movement exceeding a full revolution, or being less than a full revolution.
In an embodiment, the wash chamber oscillates for a plurality of periods of clockwise and counter-clockwise oscillations, wherein the time duration of the speed and time duration of the strokes are selected for each period. The strokes can be symmetrical or asymmetrical, and can have a speed or time duration that is selected randomly or from some predetermined varying pattern. Further, in another embodiment, the time duration of the oscillations vary for consecutive periods. The average or mean speed or time of the time-varying oscillations can be adjusted by the controller responsive to an amount of the items, to a size of the items, or a cloth type (i.e. silk vs. denim).
The items in the wash chamber can move, for example, in a tumbling pattern.
In accordance with apparatuses consistent with the present invention, an automatic washer is provided. The automatic washer comprises a cabinet, a wash chamber with a central axis supported within the cabinet, a motor suspended outside the wash chamber and drivingly connected to the wash chamber, the wash chamber oscillating about the central axis by speed- and time-varying oscillations. The wash chamber may have a horizontal axis or any non-vertical axis. The automatic washer may use aqueous wash liquid, conventional non-aqueous fluids known as dry cleaning fluids, other non-aqueous fluids, some combination of the foregoing or no wash liquid or fluid.
The above-mentioned and other features, utilities, and advantages of the invention will become apparent from the following detailed description of the preferred embodiments of the invention together with the accompanying drawings.
Other systems, methods, features, and advantages of the invention will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying drawings.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an implementation of the invention and, together with the description, serve to explain the advantages and principles of the invention.
In accordance with methods and apparatuses consistent with the present invention, in some embodiments of the invention, the mechanical action inside a washing machine having a wash chamber rotatable about an axis is enhanced by using symmetric clockwise and counter-clockwise wash chamber oscillations that vary with each subsequent period. In other embodiments, the oscillations may be non-symmetric or may vary over time, and not with each subsequent period. In some embodiments, the oscillation periods may be randomly selected, while in other embodiments, the oscillation periods may be selected in accordance with a predetermined pattern.
Within each oscillation, as defined herein, are a series or sequence of steps or actions. There is a stroke in a first direction, followed by a pause, then a stroke in a second direction followed by a second pause. As contemplated in the present invention, each of the aforementioned steps or actions may be randomly selected or may be selected in accordance with a predetermined pattern, within certain preselected ranges of speeds, times or stroke angles.
Methods and apparatuses consistent with the present invention may be embodied in any type of automatic washer in which the wash chamber is oscillated to provide the mechanical energy input to the clothes load, for example, a horizontal axis washer or a nonvertical axis washer. Similarly, methods and apparatuses consistent with the present invention be embodied in a vertical axis machine. In a vertical axis machine, typically there is a center rotor in the form of an agitator or impeller that rotates to impart mechanical energy to the wash load. Some types of vertical axis washers may also use the wash chamber itself, or rotors or other protrusions extending into the wash chamber therefrom, as the mechanism for imputing mechanical energy into the clothes load, as opposed to a separately rotatable agitator, impeller or other rotor, and the present invention can be utilized and realized in such vertical axis washers.
In an example, methods and apparatuses consistent with the present invention may be embodied, in an automatic washer as depicted in
During the wash cycle, the wash chamber is spun at a speed slow enough to effect less than a one gravity centrifugal force on the clothes load, thus resulting in the clothes load tumbling within the wash chamber. The tumbling of the clothes flexes the fabrics and thereby provides mechanical energy input to the clothes load.
The washer 30 of
As shown specifically in the schematic illustration of
As used herein, the term oscillate, as related to wash basket or wash chamber motion, describes motion wherein the wash basket or wash chamber is alternately rotated in a first direction and then in a reverse direction. The wash basket and wash chamber may complete one or many full revolutions, or less than one full revolution, while rotating or spinning in one direction before being reversed to rotate in the opposite direction.
In accordance with methods and apparatuses consistent with the present invention, the mechanical action inside the automatic washer 30, 30′ is enhanced in some embodiments by using symmetric clockwise and counter-clockwise wash chamber oscillations that vary with each subsequent oscillation period. In other embodiments, the oscillations may vary over time, but not necessarily with each successive period. For example, two to ten periods in a row may have the same oscillation before a change is made. Further, as will be described in more detail below, in an embodiment, the variation of the oscillations can be bi-modal, that is, limited to two selected period lengths, switching between these two lengths after every third or more period.
In the illustrative example of
The controller 60′ can receive an input from a user to adjust the oscillation time based on, for example, the load size or the number of items in the load. The controller is provided with, for example, a keypad or operators for this purpose. Using the keypad, the user, for example, selects a small, medium, or large load size or a small, medium, or large item size. The controller 60′ can proportionally adjust the oscillation time based on the received user input, such as proportionally to load size or item size. Alternatively, the controller 60′ can increase or decrease the variation of the oscillation time based on the load size or item size. Instead of or in conjunction with a user-controlled load setting, the washer may detect or sense the load size or item size using known load detection techniques. For example, the controller 60′ can provide oscillation signals having lower average means times for small loads than for large loads.
Experimental test results illustrating the enhanced cleaning action, and reduced mechanical damage, of the present invention are depicted in
Two measurements were recorded in these tests:
Measurement 1) Thread count of damaged threads in the clothes load.
Measurement 2) Amount of a particular “dirt” remaining from the amount that was placed on the test clothes items.
The results of Test 1, in which the “dirt” comprised a common amount of clay on fabric samples, are depicted in
The results of Test 2, in which the “dirt” comprised a common amount of carbon black on fabric samples, are depicted in
In both tests, the mechanical damage to the fabric load was significantly reduced, while the cleaning action was generally as good or better in the random oscillation machine versus the fixed oscillation machine.
In accordance with methods and apparatuses consistent with the present invention, the mechanical action inside the automatic washer 30, 30′ is enhanced in some embodiments by using alternating rotations through a fixed angle, with short pauses between each reversal, and with rotational speeds that vary periodically. The speed may vary from an average speed by a randomly changing amount or by an amount that varies according to some predetermined pattern.
As a specific illustrative example, meant only as an example and not to limit the scope of the invention is as follows. The wash chamber is alternately rotated clockwise and counter-clockwise through an angle of 120°. Following each 120° rotation, the rotation stops and pauses for 0.1 seconds. A reverse rotation of 120° then follows and another 0.1 second pause and the process is repeated. The speed of rotation, in revolutions per minute (RPM) is varied, for example by selecting an “average” or base speed of 70 RPM and varying that speed, by a random amount in the range of ±15 RPM, every 0.2 seconds.
In other embodiments an angle different than 120° can be selected, a different period of time for the pauses can be selected, a different “base” speed of rotation can be selected, a different range of speed variation from the base can be selected, and a different period of time for changing the speed can be selected or the speed could be changed upon the occurrence of an event, such as the reversal of rotation. The speed of rotation could also be varied according to a predetermined pattern rather than randomly. The rotations could be reversed following a given time period rather than a predetermined angle. The various times and angles can either be fixed for the entire wash cycle or can be varied periodically.
Further, one of skill in the art will appreciate that the present invention can be implemented in washing machines having a non-horizontal axis, wherein the wash basket, or protrusions extending inwardly therefrom are used to impart mechanical energy into the clothes load, rather than a separately rotating or oscillating agitator, impeller or other rotor.
While the above-described embodiments of the present invention are presented in terms of symmetric on/pause/on/pause oscillation patterns, the present invention is not limited thereto. The present invention can be implemented with asymmetric oscillation patterns as well. For example, the present invention can be implemented with “random” clockwise and counter-clockwise oscillations with constant motor off times, with “random” clockwise and counter-clockwise oscillations with “random” motor off times, or with constant clockwise and counter-clockwise oscillations with “random” motor off times.
As shown for example in
As further shown for example in
The preferred values within the foregoing ranges, or outside the foregoing ranges, and the ranges themselves may be generated in a “random” manner as desired, guided by a design of experiments for a specific automatic washer type.
An alternative embodiment is shown in
Wash performance according to this invention is shown in
As can be seen in
Sampling was done by running a number of wash loads at the selected RPM means and ranges, and the results vary for each. The varying results are shown in the form of a sloped line, from high to low score, with a horizontal line depicting the mean. Specifically, as shown in
As shown by a horizontal line in each instance, mean wash results range from approximately 1.03 to 1.05, within the IEC A rating range.
Further tests were performed as shown in
For both the Full Random and the Degree Random profiles, the values within the ranges specified were determined using a uniform random generator. The Ratchet Random profile is unique in that the RPM values changed within its range specified every 0.3 seconds no matter the drum direction. The amount in which the RPM value changed was determined using a uniform random generator.
One of skill in the art will appreciate that the present invention can be implemented in washing machines having a non-horizontal axis, wherein the wash basket, or protrusions or rotors extending inwardly therefrom are used to impart mechanical energy into the clothes load, rather than a separately rotating or oscillating agitator, impeller or other rotor.
The foregoing description of an implementation of the invention has been presented for purposes of illustration and description. It is not exhaustive and does not limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practicing the invention. The scope of the invention is defined by the claims and their equivalents.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
This application is a continuation-in-part of U.S. patent application Ser. No. 10/142,345, filed May 9, 2002, now issued as U.S. Pat. No. 7,127,767.
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Child | 10766404 | US |