WASHER AND DRYER COMBINATION LAUNDRY APPLIANCE

FIELD

The present disclosure relates generally to laundry appliances and more particularly to various sub-systems, sub-assemblies, and components of a front-load washer and dryer combination appliance.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure and may not constitute as prior art.

Laundry appliances (i.e., laundry machines, washing machines, and dryers) are prolific in both residential and commercial settings. Traditionally, separate washer and dryer machines have been used in tandem to clean and dry laundry. However, there is a growing market for washer and dryer combination appliances where a single machine performs both the washing and drying functions, thereby eliminating the need for two separate machines. There are a number of different names used to describe washer and dryer combination appliances, including without limitation, “washer/dryer combos” and “all-in-one washer dryers.” While these units save space compared to separate washer and dryer machines, combining the washing and drying functions into a single appliance presents a number of engineering challenges.

Many washer and dryer combination appliances have a front-load appliance configuration, where the washer and dryer combination appliance includes an appliance housing with a front opening that is accessed by a front-mounted appliance door. A drum is positioned in and is rotatable with respect to the appliance housing. During tumbling, a motor housed within the appliance housing rotates the drum. The drum typically has a front end with a drum opening that provides access to a laundry compartment inside the drum.

Washer and dryer combination appliances are gaining in popularity because they save space compared to a set of separate washer and dryer appliances and because they do not require the act of transferring laundry between separate appliances between the wash and drying cycles. This allows consumers to simply load laundry into the washer and dryer combination appliance and select the desired wash and drying cycle settings and they do not have to return again until the laundry is washed and dried. However, performing the drying cycle in the same appliance that performed the wash cycle presents a number of engineering challenges due to the presence of water inside the drum during the wash cycle and the resulting levels of humidity that remain inside the appliance during the drying cycle. Solutions that improve the performance and efficiency of the drying cycle in washer and dryer combination appliances in the face of these challenges are needed.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

In accordance with one aspect of the present disclosure, a laundry appliance is provided that comprises: an appliance housing with a front opening that provides access to a laundry compartment located inside the appliance housing, a front appliance door pivotally mounted with respect to the appliance housing such that the front appliance door is configured to swing between a closed position where the front appliance door closes the front opening in the appliance housing and an open position where the front appliance door is swung away from the front opening, a bowl mounted to the front appliance door at a location such that at least a portion of the bowl extends into the front opening in the appliance housing when the front appliance door is in the closed position, an in-door cavity defined between the front appliance door and the bowl, and an in-door condensing system mounted within the in-door cavity, the in-door condensing system having a condenser positioned in the in-door cavity that includes a water inlet and a water outlet, an air inlet positioned in the bowl to define an air intake flow path along which moist air flows directly from the laundry compartment into the in-door cavity, and an air outlet positioned in the bowl to define a return air flow path along which dry air from inside the in-door cavity flows directly into the laundry compartment.

In accordance with another aspect of the present disclosure, the condenser is a tube that extends helically about a coil axis to form multiple windings that are positioned between the water inlet and the water outlet.

In accordance with another aspect of the present disclosure, the coil axis is arranged in a substantially vertical orientation.

In accordance with another aspect of the present disclosure, each of the windings has a substantially horizontal orientation.

In accordance with another aspect of the present disclosure, the front appliance door has an outer door surface and wherein the coil axis is arranged substantially parallel to the outer door surface.

In accordance with another aspect of the present disclosure, the condenser is a tube that extends in a flat spiral to form multiple loops that are arranged in a condenser loop plane and that gradually increase in radius.

In accordance with another aspect of the present disclosure, the condenser loop plane is arranged in a substantially vertical orientation.

In accordance with another aspect of the present disclosure, the front appliance door has an outer door surface and wherein the condenser loop plane is arranged substantially parallel to the outer door surface.

In accordance with another aspect of the present disclosure, the in-door condensing system includes a condenser fan positioned in the in-door cavity to draw moist air into the in-door cavity along the air intake flow path and expel dry air from the in-door cavity along the return air flow path.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a removable lint screen positioned over the air inlet, wherein the removable lint screen is retained on the bowl by a retaining feature that allows the removable lint screen to be detached from the bowl.

In accordance with another aspect of the present disclosure, the retaining feature is a detachable cover that forms part of the bowl and that includes the holes forming the air inlet into the in-door cavity.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a partition that extends from the bowl towards the condenser to divide at least part of the in-door cavity into an upper zone and a lower zone, wherein the air inlet and the air outlet are positioned in different zones of the in-door cavity such that the partition directs airflow inside the in-door cavity past the condenser before exiting through the air outlet.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a drying air circulation duct mounted inside the appliance housing and including a duct inlet and a duct outlet that are arranged in fluid communication with the laundry compartment, a drying air circulation fan mounted inside the drying air circulation duct that is configured to pull air in through the duct inlet and push air out through the duct outlet to generate a drying air circulation flow path through the drying air circulation duct, and a heater positioned inside the drying air circulation duct for heating air inside the drying air circulation duct upstream of the duct outlet, wherein the air intake flow path into the in-door cavity and the return air flow path out of the in-door cavity are separate and independent of the drying air circulation flow path.

In accordance with another aspect of the present disclosure, the air inlet extends through the bowl at a location that is positioned above the air outlet.

In accordance with another aspect of the present disclosure, the air inlet extends through the bowl at a location that is positioned below the air outlet.

Advantageously, the in-door condensing system described herein improves the drying performance of the washer and dryer combination laundry appliance by reducing the humidity of the air inside the laundry compartment, which is heated and recirculated during a drying cycle. This is because warm dry air provides better drying performance than warm moist air. In addition, the in-door condensing system described herein is self-contained within the bowl of the front appliance door, which is normally wasted space. The disclosed configuration avoids the need to run air ducts between the front appliance door and the appliance housing. As will be explained in further detail below, only a water cooling line and a water drain line in the front appliance door need to connect with corresponding water lines in the appliance housing.

In accordance with yet another aspect of the present disclosure, a laundry appliance is provided that comprises: an appliance housing with a front opening that provides access to a laundry compartment located inside the appliance housing, a front appliance door pivotally mounted with respect to the appliance housing such that the front appliance door is configured to swing between a closed position where the front appliance door closes the front opening in the appliance housing and an open position where the front appliance door is swung away from the front opening, a bowl mounted to the front appliance door at a location such that at least a portion of the bowl extends into the front opening in the appliance housing when the front appliance door is in the closed position, an in-door cavity defined between the front appliance door and the bowl, and an in-door condensing system mounted within the in-door cavity, the in-door condensing system having a condenser positioned in the in-door cavity that includes a water inlet and a water outlet, a cooling water line that is connected in fluid communication with the water inlet of the condenser, and a water drain line with a drain line inlet that is spaced below the water outlet of the condenser and that is arranged in fluid communication with the in-door cavity such that the water drain line is configured to collect cooling water flowing out of the water outlet of the condenser and water condensate from inside the in-door cavity.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a water supply line positioned in the appliance housing, and a water inlet joint including a first water inlet coupling and a second water inlet coupling that are each connected to one of the water supply lines in the appliance housing and the cooling water line in the appliance door, wherein the first and second water inlet couplings are positioned on the appliance housing and the front appliance door to mate with one another and form a fluid tight connection when the front appliance door is in the closed position and disconnect from one another when the front appliance door is swung open towards the open position.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a water return line positioned in the appliance housing, and a water outlet joint including a first water outlet coupling and a second water outlet coupling that are each connected to one of the water return lines in the appliance housing and the water drain line in the front appliance door, wherein the first and second water outlet couplings are positioned on the appliance housing and the front appliance door to mate with one another and form a fluid tight connection when the front appliance door is in the closed position and disconnect from one another when the front appliance door is swung open towards the open position.

In accordance with another aspect of the present disclosure, the first water inlet coupling and the first water outlet coupling are each configured as a male connector that includes a tubular projection terminating at a circular rim and a plug that is concentrically arranged with the tubular projection and that extends longitudinally out from the circular rim of the tubular projection and wherein the plug has an outer diameter that is less than an inside diameter of the tubular projection.

In accordance with another aspect of the present disclosure, the second water inlet coupling and the second water outlet coupling are each configured as a female connector that includes a tubular housing and a spring-biased piston that is slidingly received within the tubular housing for longitudinal movement between a seated position and an unseated position.

In accordance with another aspect of the present disclosure, the tubular housing has an inner diameter that is larger than the tubular projection such that the tubular projection is received in the tubular housing and the plug contacts and pushes the spring-biased piston to the unseated position when the front appliance door is in the closed position.

In accordance with another aspect of the present disclosure, the first water inlet coupling and the second water outlet coupling are positioned on the front appliance door and wherein the second water inlet coupling and the first water outlet coupling are positioned on the appliance housing.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a water cooling loop positioned in the appliance housing, wherein the water supply and return lines are connected in fluid communication with the water cooling loop, wherein the water cooling loop includes a heat exchanger that is configured to cool recirculating water traveling through the water cooling loop from the water return line to the water supply line.

In accordance with another aspect of the present disclosure, the laundry applicant further comprises: a cold water inlet valve positioned in fluid communication with the water supply line, and a sump positioned in the appliance housing, wherein the water return line is arranged to drain into the sump.

In accordance with another aspect of the present disclosure, the coil axis is arranged in a substantially vertical orientation and each of the windings has a substantially horizontal orientation.

In accordance with another aspect of the present disclosure, the front appliance door has an outer door surface and wherein the coil axis is arranged substantially parallel to the outer door surface.

In accordance with another aspect of the present disclosure, the condenser loop plane is arranged in a substantially vertical orientation.

Advantageously, the common water drain line that is arranged in fluid communication with the in-door cavity collects both cooling water that is flowing out of the condenser and water condensate that has accumulated inside the in-door cavity. This open loop configuration eliminates the need for two separate fluid conduit joints-one for the condenser outlet and another for the condensate drain.

In accordance with yet another aspect of the present disclosure, a laundry appliance door assembly is provided that comprises: an appliance housing with a front opening that provides access to a laundry compartment located inside the appliance housing, a front appliance door pivotally mounted with respect to the appliance housing such that the front appliance door is configured to swing between a closed position where the front appliance door closes the front opening in the appliance housing and an open position where the front appliance door is swung away from the front opening, and a water conduit joint including a first water conduit coupling and a second water conduit coupling that are positioned on the appliance housing and the front appliance door to mate with one another and form a fluid tight connection when the front appliance door is in the closed position and disconnect from one another when the front appliance door is swung open towards the open position, wherein the first water conduit coupling is configured as a male connector that includes a tubular projection terminating at a circular rim and a plug that is concentrically arranged with the tubular projection and that extends longitudinally out from the circular rim of the tubular projection, wherein the second water conduit coupling is configured as a female connector that includes a tubular housing and a spring-biased piston that is slidingly received within the tubular housing for longitudinal movement between a seated position and an unseated position, wherein the tubular projection is configured to be received in the tubular housing and the plug is configured to contact and push the spring-biased piston to the unseated position when the front appliance door is in the closed position to open a fluid pathway through the water conduit joint.

In accordance with another aspect of the present disclosure, the spring-biased piston is shaped like a bowling pin and has a stem portion and a head portion.

In accordance with another aspect of the present disclosure, the second water conduit coupling includes a biasing spring that is positioned on and extends helically about the stem portion of the spring-biased piston to bias the spring-biased piston towards a seated position.

In accordance with another aspect of the present disclosure, the tubular housing includes a receptacle portion, an attachment portion, and a seat portion that is positioned longitudinally between the receptacle and attachment portions.

In accordance with another aspect of the present disclosure, the attachment portion of the tubular housing includes a main cavity that holds the stem portion of the spring-biased piston and the biasing spring and a connection port that is disposed in fluid communication with the main cavity and configured to connect to a fluid conduit.

In accordance with another aspect of the present disclosure, the seat portion of the tubular housing defines a seal cavity and receives the head portion of the spring-biased piston in sealing engagement when the spring-biased piston is in the seated position and that is arranged in fluid communication with the main cavity of the attachment portion when the spring-biased piston is in the unseated position.

In accordance with another aspect of the present disclosure, the receptacle portion of the tubular housing defines a receptacle cavity, wherein the plug has an outer diameter that is less than an inside diameter of the tubular projection, and wherein the receptacle cavity has an inner diameter that is larger than an outside diameter of the tubular projection.

In accordance with another aspect of the present disclosure, the tubular projection includes at least one seal that is positioned on the outside diameter of the tubular projection and configured to seal against the inner diameter of the receptacle cavity of the tubular housing when the spring-biased piston is in the seated position.

In accordance with another aspect of the present disclosure, the head portion of the spring-biased piston includes at least one seal that is configured to seal against the seal cavity of the tubular housing when the spring-biased piston is in the seated position.

In accordance with another aspect of the present disclosure, the laundry appliance door assembly further comprises: a shroud positioned around the first water conduit coupling, the shroud including a shroud opening through which the tubular projection of the first water conduit coupling extends.

In accordance with another aspect of the present disclosure, the laundry appliance door assembly further comprises: an alignment feature positioned on or adjacent to the second water conduit coupling, wherein the shroud opening includes at least one ramped surface that is configured to make sliding contact with the alignment feature to guide the tubular projection of the first water conduit coupling into the tubular housing of the second water conduit coupling as the front appliance door is swung towards the closed position.

In accordance with another aspect of the present disclosure, the laundry appliance door assembly further comprises: an electrical continuity sensor positioned in the shroud opening that is configured to detect the presence of water dripping into the shroud opening.

In accordance with another aspect of the present disclosure, the at least one ramped surface of the shroud opening is shaped as a funnel.

In accordance with another aspect of the present disclosure, the first water conduit coupling is positioned on the front appliance door and the second water conduit coupling is positioned on the appliance housing.

In accordance with another aspect of the present disclosure, the first water conduit coupling is positioned on the appliance housing and the second water conduit coupling is positioned on the front appliance door.

In accordance with yet another aspect of the present disclosure, a laundry appliance door assembly is provided that comprises: an appliance housing with a front opening that provides access to a laundry compartment located inside the appliance housing, a front appliance door pivotally mounted with respect to the appliance housing such that the front appliance door is configured to swing between a closed position where the front appliance door closes the front opening in the appliance housing and an open position where the front appliance door is swung away from the front opening, and a water conduit joint including a first water conduit coupling and a second water conduit coupling that are positioned on the appliance housing and the front appliance door to mate with one another and form a fluid tight connection when the front appliance door is in the closed position and disconnect from one another when the front appliance door is swung open towards the open position, the first water conduit coupling being configured as a male connector that includes a tubular projection terminating at a circular rim, the second water conduit coupling being configured as a female connector that includes a tubular housing that is configured to receive the tubular projection of the first water conduit coupling when the front appliance door is in the closed position, a shroud positioned around the first water conduit coupling, the shroud including a shroud opening through which the tubular projection of the first water conduit coupling extends, and an alignment feature positioned on or adjacent to the second water conduit coupling,

wherein the shroud opening includes at least one ramped surface that is configured to make sliding contact with the alignment feature to guide the tubular projection of the first water conduit coupling into alignment with the tubular housing of the second water conduit coupling as the front appliance door is swung towards the closed position.

In accordance with another aspect of the present disclosure, the laundry appliance door assembly further comprises: a sensor positioned in the shroud opening that is configured to detect the presence of water in the shroud opening.

In accordance with another aspect of the present disclosure, the at least one ramped surface of the shroud opening is shaped as a funnel.

Many front load laundry appliances have front appliance doors that exhibit some free play and imprecise tolerances when closed. These characteristics are perfectly acceptable for most laundry appliances, but pose alignment issues if a quick-connect water conduit joint is added between the front appliance door and the appliance housing. Advantageously, the shroud opening with its ramped surface(s) and the corresponding alignment feature(s) described herein help guide the tubular projection of the first water conduit coupling into the tubular housing of the second water conduit coupling to resolve any alignment issues that could lead to the front appliance door not closing properly and/or a leaking water conduit joint.

In accordance with yet another aspect of the present disclosure, a laundry appliance is provided that comprises: an appliance housing with a front opening, a front appliance door configured to open and close the front opening in the appliance housing, a drum housing mounted inside the appliance housing, the drum housing including a drum housing sidewall that extends annularly about a drum housing cavity, a drum positioned inside the drum housing and rotatably supported within the drum housing cavity such that the drum is rotatable relative to the drum housing, the drum having a cylindrical shape and including a front drum end, a rear drum end, a drum sidewall that extends longitudinally between the front and rear drum ends, a laundry compartment located inside the drum, and a drum opening that provides access to the laundry compartment, the drum housing including a front opening positioned in at least partial alignment with the front opening in the appliance housing and the drum opening, the drum sidewall having an outer surface, the drum housing sidewall including a temperature sensor opening, a temperature sensor mounted within a temperature sensor housing that is mounted to the drum housing sidewall, the temperature sensor being configured to remotely measure a temperature of the outer surface of the drum sidewall and having a sensor aperture that is positioned in alignment with the temperature sensor opening in the drum housing sidewall such that the sensor aperture has an unobstructed line of sight to the outer surface of the drum sidewall, and the temperature sensor housing including a sensor air duct that is configured to direct a stream of air past the sensor aperture to prevent steam in the drum housing cavity from passing through the temperature sensor opening in the drum housing sidewall and fouling the sensor aperture.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a track that is fixedly secured to the drum housing sidewall at a location adjacent to the temperature sensor opening in the drum housing sidewall, and a sliding sensor cover that is arranged in sliding engagement with the track for movement between a covered position and an uncovered position along a slide travel direction, wherein the temperature sensor housing is fixedly secured to one of the drum housing sidewall and the track at a location where the sliding sensor cover is positioned radially between the track and the temperature sensor housing.

In accordance with another aspect of the present disclosure, the track includes a first window that is aligned with the temperature sensor opening and the sliding sensor cover includes a second window that is offset and spaced from the temperature sensor opening and the first window, in the slide travel direction, when the sliding sensor cover is in the covered position and that is aligned with the temperature sensor opening and the first window when the sliding sensor cover is in the uncovered position.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a slide controller, electrically connected to the retractor motor, that is programmed to actuate the retractor motor to move the sliding sensor cover to the covered position during a wash cycle of the laundry appliance to protect the temperature sensor from splash and actuate the retractor motor to move the sliding sensor cover to the uncovered position during a drying cycle of the laundry appliance.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a biasing member that is connected to and that biases the sliding sensor cover toward the covered position and a tether that is connected to and extends between the sliding sensor cover and the retractor motor, wherein the retractor motor is configured to pull the sliding sensor cover toward the uncovered position when the retractor motor is energized.

In accordance with another aspect of the present disclosure, the temperature sensor housing includes a collar portion and a barrel portion that extends longitudinally from the collar portion and into the temperature sensor opening in the drum housing sidewall, the collar portion including a through-bore that receives the temperature sensor.

In accordance with another aspect of the present disclosure, the sensor air duct has an annular shape in the collar portion of the temperature sensor housing and is positioned radially outward of and in concentric alignment with the through-bore that receives the temperature sensor.

In accordance with another aspect of the present disclosure, the collar portion of the temperature sensor housing includes an air port that opens into the sensor air duct and that is configured to be connected in fluid communication with an air source.

In accordance with another aspect of the present disclosure, the barrel portion of the temperature sensor housing is externally threaded and configured to screw into the temperature sensor opening in the drum housing sidewall and wherein the through-bore in the collar portion of the temperature sensor housing is internally threaded such that the temperature sensor screws into the through-bore.

In accordance with another aspect of the present disclosure, the temperature sensor is an infrared temperature sensor.

In accordance with another aspect of the present disclosure, the sensor aperture includes a lens and the stream of air prevents the steam from fogging up the lens.

In accordance with another aspect of the present disclosure, the stream of air flowing through the sensor air duct is provided by an air source that is connected in fluid communication with the sensor air duct upstream of the sensor aperture.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a fan, mounted in the sensor air duct upstream of the sensor aperture, that is configured to generate the stream of air flowing through the sensor air duct.

In accordance with another aspect of the present disclosure, the drum sidewall has a emissivity enhancing coating along at least a portion of the outer surface that passes by the temperature sensor opening in the drum housing sidewall as the drum rotates within the drum housing cavity.

Advantageously, the sensor air duct described herein helps to prevent steam from fogging up and condensing (or otherwise fouling) the sensor aperture of the temperature sensor, which improves the accuracy of the temperature readings made by the temperature sensor of the outer surface of the drum sidewall. This occurs because a fog-free temperature sensor accurately measures the outer surface of the drum sidewall instead of the temperature of the fogged up lens of the temperature sensor, which is not the surface whose temperature needs to be measured in order to more accurately control efficient and effective heating during the drying cycle of a washer and dryer combination laundry appliance.

In accordance with yet another aspect of the present disclosure, a laundry appliance is provided that comprises: an appliance housing, a drum housing mounted inside the appliance housing, the drum housing including a drum housing sidewall that extends annularly about a drum housing cavity, a drum positioned inside the drum housing and rotatably supported within the drum housing cavity such that the drum is rotatable relative to the drum housing, the drum having a cylindrical shape and including a front drum end, a rear drum end, a drum sidewall that extends longitudinally between the front and rear drum ends, and a laundry compartment located inside the drum, the drum sidewall having an outer surface, the drum housing sidewall including a temperature sensor opening, a temperature sensor mounted within a temperature sensor housing that is mounted to the drum housing sidewall, the temperature sensor being configured to remotely measure a temperature of the outer surface of the drum sidewall and having a sensor aperture that is positioned in alignment with the temperature sensor opening in the drum housing sidewall, and

a sliding sensor cover that is configured to move relative to the temperature sensor and the drum housing sidewall along a slide travel direction between a covered position and an uncovered position, wherein the sliding sensor cover includes a window that is offset and spaced from the temperature sensor opening when the sliding sensor cover is in the covered position to protect the temperature sensor from splash and that is aligned with the temperature sensor opening when the sliding sensor cover is in the uncovered position to provide the sensor aperture with an unobstructed line of sight to the outer surface of the drum sidewall in the uncovered position.

In accordance with another aspect of the present disclosure, the temperature sensor housing includes a sensor air duct that is configured to direct a stream of air past the sensor aperture to prevent steam in the drum housing cavity from fouling the sensor aperture by passing through the temperature sensor opening in the drum housing sidewall and the window in the sliding sensor cover when the sliding sensor cover is in the uncovered position.

In accordance with another aspect of the present disclosure, the laundry appliance further comprises: a retractor motor that is configured to move the sliding sensor cover relative to the track in the slide travel direction between the covered position and the uncovered position, and a slide controller, electrically connected to the retractor motor, that is programmed to actuate the retractor motor to move the sliding sensor cover to the covered position during a wash cycle of the laundry appliance to protect the temperature sensor from splash and actuate the retractor motor to move the sliding sensor cover to the uncovered position during a drying cycle of the laundry appliance.

Advantageously, the sliding sensor cover described herein helps to protect/shield the temperature sensor from encountering splash and debris while the washer and dryer combination laundry appliance is performing a wash cycle (during which time the temperature sensor is not in use). This enables the use of an infrared temperature sensor to measure the temperature of the outer surface of the drum sidewall in a washer and dryer combination laundry appliance during a drying cycle and improves the durability, reliability, and/or dependability of the temperature sensor in such an application.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present disclosure will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a front perspective view of an exemplary washer and dryer combination laundry appliance that has been constructed in accordance with the present disclosure;

FIG. 2 is a side cross-section view of the exemplary washer and dryer combination laundry appliance shown in FIG. 1;

FIG. 3 is a side perspective view of the exemplary washer and dryer combination laundry appliance shown in FIG. 1 where certain components of the laundry appliance have been made transparent and converted to dashed lines for illustration purposes;

FIG. 4 is another side perspective view of the exemplary washer and dryer combination laundry appliance shown in FIG. 1 where certain components of the laundry appliance have been made transparent and converted to dashed lines for illustration purposes;

FIG. 5 is a side cross-section view of an exemplary front appliance door sub-assembly of the washer and dryer combination laundry appliance shown in FIG. 1;

FIG. 6 is a perspective exploded view of the exemplary front appliance door sub-assembly shown in FIG. 5;

FIG. 7 is a rear elevation view of another exemplary front appliance door sub-assembly having a condenser that has been constructed in accordance with another aspect of the present disclosure;

FIG. 8 is a rear perspective view of the exemplary front appliance door sub-assembly shown in FIG. 7 where the condenser, partition, and condenser fan are shown in dashed lines;

FIG. 9 is a side cross-section view of the exemplary front appliance door sub-assembly shown in FIG. 7;

FIG. 10 is an enlarged side cross-section view of an exemplary water inlet joint of the washer and dryer combination laundry appliance shown in FIG. 1, which is illustrated with the front appliance door in a closed position;

FIG. 11 is an enlarged side cross-section view of the exemplary water inlet joint shown in FIG. 10, which is illustrated with the front appliance door in an open position;

FIG. 12 is an enlarged cross-side section view of an exemplary water outlet joint of the washer and dryer combination laundry appliance shown in FIG. 1, which is illustrated with the front appliance door in the closed position;

FIG. 13 is an enlarged side cross-section view of the exemplary water outlet joint shown in FIG. 12, which is illustrated with the front appliance door in the open position;

FIG. 14 is an enlarged side cross-section view of another exemplary water inlet joint of the washer and dryer combination laundry appliance shown in FIG. 1, which is illustrated with the front appliance door in the open position;

FIG. 15 is an enlarged perspective view of an exemplary temperature sensor sub-assembly of the washer and dryer combination laundry appliance shown in FIG. 1, which includes a sliding sensor cover;

FIG. 16 is an enlarged side cross-section view of the exemplary temperature sensor sub-assembly shown in FIG. 15, which is illustrated with the sliding sensor cover in a covered position;

FIG. 17 is another enlarged side cross-section view of the exemplary temperature sensor sub-assembly shown in FIG. 15, which is illustrated with the sliding sensor cover in an uncovered position;

FIG. 18 is a side cross-section view of another exemplary temperature sensor sub-assembly for the washer and dryer combination laundry appliance shown in FIG. 1; and

FIG. 19 is a perspective section view of the exemplary temperature sensor sub-assembly shown in FIG. 18.

DETAILED DESCRIPTION

Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, various aspects of a washer and dryer combination laundry appliance 20 are illustrated.

Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

For purposes of description herein the terms “up,” “down,” “above,” “below,” “upper,” “lower,” “top,” “bottom,” “front,” “rear,” and derivatives thereof shall relate to the assembly as oriented in FIGS. 1-19. However, it is to be understood that the apparatus and assemblies described herein may assume various alternative orientations. Finally, the term “substantially” as used herein describes angles and/or orientations that can vary plus or minus five degrees from the referenced direction, axis, plane, or orientation.

With reference to FIGS. 1 and 2, a laundry appliance 20 having a front-load configuration is illustrated. The laundry appliance 20 includes an appliance housing 22 that is rectangular in shape and that includes a front opening 24. A front appliance door 26 is pivotally connected to the laundry appliance 20. The front appliance door 26 swings between an open position and a closed position. In the closed position, the front appliance door 26 shuts or closes the front opening 24 in the appliance housing 22. Although other configurations are possible, in the illustrated example, the front appliance door 26 is pivotally mounted to the front of the appliance housing 22 by a hinge 28 and held in the closed position during wash and drying cycles by a latch 29.

The front appliance door 26 includes an outer door surface 30 that faces out away from the front opening 24 in the appliance housing 22 when the front appliance door 26 is in the closed position and an interior door surface 32 that faces the front opening 24 in the appliance housing 22 when the front appliance door 26 is in the closed position. The front appliance door 26 includes a bowl 34, which extends from the interior door surface 32 of the front appliance door 26. At least a portion of the bowl 34 is received in the front opening 24 in the appliance housing 22 when the front appliance door 26 is in the closed position. Among other functions, the bowl 34 prevents laundry inside the laundry appliance 20 from accumulating in the front opening 24 during tumbling and particularly during the wash cycle of the laundry appliance 20. Although other materials can be used, in the illustrated example, the front appliance door 26 is made of metal, while the bowl 34 is made of a molded plastic material. Portions of the bowl 34 are spaced from the front appliance door 26 such that an in-door cavity 35 is defined between the interior door surface 32 of the front appliance door 26 and the bowl 34.

The laundry appliance 20 includes a drum housing 36 with a cylindrical shape that is mounted inside the appliance housing 22 on dynamic mounts 38, which keep the drum housing 36 from rotating, but permit limited degrees of freedom that allow the drum housing 36 to move/oscillate relative to the appliance housing 22 during tumbling. The drum housing 36 includes a front ring 40, a rear drum housing wall 42, and a drum housing sidewall 44 that extends longitudinally from the front ring 40 to the rear drum housing wall 42 to define a drum housing cavity 46 inside the drum housing 36. The front ring 40 of the drum housing 36 includes a drum housing opening 48 positioned in at least partial alignment with the front opening 24 in the appliance housing 22.

A drum 50 is positioned in the drum housing cavity 46 and is supported therein such that the drum 50 is rotatable with respect to the drum housing 36 about a longitudinal axis 52. The drum 50 also has a cylindrical shape and extends longitudinally between a front drum end 54 and a rear drum end 56. The drum 50 includes a drum opening 58 at the front drum end 54, a rear drum wall 60 at the rear drum end 56, and a drum sidewall 62 that extends longitudinally between the front and rear drum ends 54, 56. The drum sidewall 62 includes an outer surface 64 that faces the drum housing sidewall 44. The front drum end 54, the drum sidewall 62, and the rear drum wall 60 cooperate to define a laundry compartment 66 inside the drum 50. The front opening 24 in the appliance housing 22, the drum housing opening 48 in the front ring 40 of the drum housing 36, and the drum opening 58 at the front drum end 54 are at least partially aligned with one another and therefore provide access to the laundry compartment 66 inside the drum 50 when the front appliance door 26 is in the open position. Thus, it should be appreciated that in use, laundry (e.g., clothes, towels, and/or bedding, etc.) is placed inside the laundry compartment 66 where it is first cleaned during the wash cycle and then dried during the drying cycle of the laundry appliance 20.

A drive shaft 68, fixedly coupled to the rear drum end 56, is supported by a bearing pack 70 such that the drive shaft 68 and the drum 50 rotate together as a single unit within the appliance housing 22. An electric motor 72, positioned in the appliance housing 22, operates to drive rotation of the drive shaft 68, which in turn drives rotation of the drum 50 within the drum housing 36 and the appliance housing 22 during operation of the laundry appliance 20, such as during washing and tumbling.

With additional reference to FIG. 3, the laundry appliance 20 includes a drying air circulation duct 74, which is mounted inside the appliance housing 22. The drying air circulation duct 74 includes a duct inlet 76 and a duct outlet 78 that are arranged in fluid communication with the laundry compartment 66. A drying air circulation fan 80 is mounted inside the drying air circulation duct 74. During a drying cycle of the laundry appliance 20, the drying air circulation fan 80 pulls air in the laundry compartment 66 in through the duct inlet 76 and pushes air out through the duct outlet 78 to define a drying air circulation flow path 82 through the drying air circulation duct 74. A heater 84 is also positioned inside the drying air circulation duct 74. Although other configurations are possible, the heater 84 may be an electric resistance heater, for example. During one or more portions of the drying cycle, the heater 84 operates to heat the air inside the drying air circulation duct 74 upstream of the duct outlet 78. When the heater 84 is activated, the temperature of the air expelled into the laundry compartment 66 from the duct outlet 78 is warmer (i.e., is at a higher temperature) than the air that is pulled into the drying air circulation duct 74 through the duct inlet 76. The circulation and heating of air performed by the drying air circulation duct 74 during a drying cycle of the laundry appliance 20 dries the laundry in the laundry compartment 66 as it tumbles within the rotating drum 50. However, as the laundry dries, the air inside the laundry compartment 66 that is re-circulated through the drying air circulation duct 74 because very humid (i.e., moist).

To improve drying performance, the laundry appliance 20 further includes an in-door condensing system 86 that is mounted within the in-door cavity 35. The in-door condensing system 86 operates to remove some of the humidity (i.e., moisture) from the air in the laundry compartment 66 through condensation to improve the drying performance of the laundry appliance 20. The space in the front appliance door 26 that is taken up by the bowl 34 is normally wasted. Advantageously, the in-door condensing system 86 described herein makes use of this otherwise wasted space and does not consume space inside the appliance housing 22.

With additional reference to FIGS. 4-6, the in-door condensing system 86 includes a condenser 88, an air inlet 90, an air outlet 92, and a condenser fan 94. The condenser 88 is positioned in the in-door cavity 35. In the illustrated example, the condenser 88 is formed of a metal tube with a water inlet 96 at one end and a water outlet 98 at an opposite end. The condenser 88 extends helically about a coil axis 100 to form multiple windings that are positioned between the water inlet 96 and the water outlet 98. While other orientations are possible, in the illustrated example, the coil axis 100 is arranged substantially parallel to the outer door surface 30 (i.e., is arranged in a substantially vertical orientation) such that each of the windings has a substantially horizontal orientation.

As shown in FIG. 4, the in-door condensing system 86 also includes a cooling water line 102 and a water drain line 104. The cooling water line 102 includes a cooling water line inlet 106 and a cooling water line outlet 108. The cooling water line inlet 106 is connected in fluid communication with and receives cooling water from a water inlet joint 110 between the front appliance door 26 and the appliance housing 22, which will be explained in greater detail below. The cooling water line outlet 108 is connected in fluid communication with the water inlet 96 of the condenser 88. The water drain line 104 includes a drain line inlet 112 and a drain line outlet 114. The drain line inlet 112 is spaced below the water outlet 98 of the condenser 88 and is arranged in fluid communication with the in-door cavity 35 such that the water drain line 104 is configured to collect cooling water flowing out of the water outlet 98 of the condenser 88 and water condensate from inside the in-door cavity 35. The drain line inlet 112 is not directly coupled to the water outlet 98 of the condenser 88. In other words, there is no connection or coupling between said water outlet 98 of the condenser 88 and the drain line inlet 112. Instead, cooling water freely drains out from the condenser 88 through the water outlet 98 and falls into the in-door cavity 35 under the influence of gravity. The moist air that is drawn into the in-door cavity 35 through the air inlet 90 by the condenser fan 94 condenses inside the in-door cavity 35 as it flows by the cooler condenser 88. The resulting water condensate collects in the in-door cavity 35 and is carried back to the appliance housing 22 with the cooling water that is discharged from the water outlet 98 of the condenser 88 via the water drain line 104. In other words, cooling water is discharged from the water outlet 98 of the condenser 88 into the in-door cavity 35, which is the same volume where the water condensate collects. The drain line outlet 114 is connected in fluid communication with a water outlet joint 116 between the front appliance door 26 and the appliance housing 22, which will be explained in greater detail below.

Still referring to FIG. 4, the laundry appliance 20 includes a cold water inlet valve 118 and a sump 120 that are both positioned inside the appliance housing 22. The cold water inlet valve 118 is connected in fluid communication with a dispenser box 122, which discharges wash water into the laundry compartment 66 during a wash cycle of the laundry appliance 20. That wash water drains into the sump 120, which is located at the bottom of the appliance housing 22, beneath the drum 50. A water supply line 124, positioned in the appliance housing 22, is connected to the cold water inlet valve 118 at one end and the water inlet joint 110 at an opposite end and operates to deliver cold water to the cooling water line 102 of the in-door condensing system 86. A water return line 126, positioned in the appliance housing 22, is connected to the water outlet joint 116 at one end and is arranged to drain into the sump 120. As a result, the water return line 126 carries the cooling water and water condensate draining out of the in-door cavity 35 through the water drain line 104 to the sump 120 of the laundry appliance 20.

FIG. 4 also illustrates an alternative, closed-loop configuration shown in dashed lines, where the water supply and return lines 124, 126 are connected in fluid communication with a water cooling loop 128 positioned in the appliance housing 22, instead of to the cold water inlet valve 118 and the sump 120. In accordance with this configuration, the water cooling loop 128 includes a heat exchanger 130 (such as an air-to-water or water-to-water heat exchanger) that is configured to cool recirculating water traveling through the water cooling loop 128 from the water return line 126 to the water supply line 124. This arrangement provides reduced water consumption and suits applications where the laundry appliance 20 is not connected to a residential or commercial water supply and drain, allowing the laundry appliance 20 to operate as a self-sufficient stand-alone appliance that only requires an electrical connection (i.e., an electrical socket) to operate.

As shown in FIGS. 5 and 6, the condenser fan 94 is positioned in the in-door cavity between the condenser 88 and the bowl 34. When energized, the condenser fan 94 operates to draw moist air into the in-door cavity 35 along an air intake flow path 132 (shown in FIGS. 3 and 5) and expel dry air from the in-door cavity 35 along a return air flow path 134 (also shown in FIGS. 3 and 5). Optionally, a removable lint screen 136 or filter is positioned between the air inlet 90 and the condenser fan 94. The removable lint screen 136 is retained by a retaining feature 138 that allows the removable lint screen 136 to be removed from the bowl 34 and cleaned or replaced. For example, in the example illustrated in FIGS. 5 and 6, the retaining feature 138 is a detachable cover that forms part of the bowl 34 and that includes holes 140a forming the air inlet 90 into the in-door cavity 35.

As best seen in FIG. 5, the air outlet 92 of the in-door condensing system 86 is positioned in an upper half 142 of the bowl 34 and defines the return air flow path 134 along which dry air from inside the in-door cavity 35 flows directly into the laundry compartment 66. The air inlet 90 of the in-door condensing system 86 is positioned in a lower half 144 of the bowl 34 and defines the air intake flow path 132 along which moist air flows directly from the laundry compartment 66 into the in-door cavity 35. While other configurations are possible, in the illustrated examples, the air inlet 90 and the air outlet 92 are provided in the form of a plurality of holes 140a, 140b that extend through the bowl 34 where the group of holes 140a forming the air inlet 90 are positioned below the group of boles 140b forming the air outlet 92. Referring back to FIG. 3, it should be appreciated that the air intake flow path 132 into the in-door cavity 35 and the return air flow path 134 out of the in-door cavity 35 are separate and independent of the drying air circulation flow path 82.

FIGS. 7-9 illustrate another exemplary in-door condensing system 86′, which has a condenser 88′ that is constructed in accordance with an alternative configuration. Many of the elements of the in-door condensing system 86′ shown in FIGS. 7-9 are the same or similar to the elements of the in-door condensing system 86 shown in FIGS. 1-6 and therefore share the same reference numbers, but have been annotated with a prime symbol (′) after the reference numerals. The condenser 88′ shown in FIGS. 7-9 is a tube that extends in a flat spiral to form multiple loops that are arranged in a condenser loop plane 146′ and that gradually increase in radius. The condenser 88′ is mounted to the front appliance door 26′. As such, the condenser loop plane 146′ is arranged in a substantially vertical orientation and is substantially parallel to the outer door surface 30′.

The bowl 34′ in this embodiment has a dome-shaped depression 148′ and a partition 150′, attached to the bowl 34′, that extends from the bowl 34′ towards the condenser 88′ to divide at least part of the in-door cavity 35′ into an upper zone 152′ and a lower zone 154′. The air inlet 90′ and the air outlet 92′ are positioned in different zones 152′, 154′ of the in-door cavity 35′ such that the partition 150′ directs airflow inside the in-door cavity 35′ past the condenser 88′ before exiting through the air outlet 92′. Although other configurations are possible, in the illustrated example, the air inlet 90′ is positioned in fluid communication with the upper zone 152′ of the in-door cavity 35′ and the air outlet 92′ is positioned in fluid communication with the lower zone 154′ of the in-door cavity 35′. In other words, the air inlet 90′ extends through the bowl 34′ at a location that is positioned above the air outlet 92′. Like in the previously described arrangement, the in-door condensing system 86′ shown in FIGS. 7-9 includes a condenser fan 94′, but in this arrangement, the condenser fan 94′ is positioned in the lower zone 154′ of the in-door cavity 35′ adjacent to the air outlet 92′.

More detailed views of the water inlet and outlet joints 110, 116 (i.e., the fluid conduit joints) are provided in FIGS. 10-13.

FIGS. 10 and 11 illustrate the water inlet joint 110 between the front appliance door 26 and the appliance housing 22, the location of which is shown in FIG. 1. The water inlet joint 110 includes a first water inlet coupling 156 that is connected to the cooling water line 102 in the appliance door and a second water inlet coupling 158 that is connected to the water supply line 124 in the appliance housing 22. The first and second water inlet couplings 156, 158 are positioned on the appliance housing 22 and the front appliance door 26, respectively, in such a way that they are generally aligned and configured to mate with one another to form a fluid tight connection when the front appliance door 26 is in the closed position (as shown in FIG. 10) and disconnect from one another when the front appliance door 26 is swung open towards the open position (as shown in FIG. 11).

FIGS. 12 and 13 illustrate the water outlet joint 116 between the front appliance door 26 and the appliance housing 22, the location of which is also shown in FIG. 1. While other configurations are possible, it is intended for water to drain from the in-door cavity under the influence of gravity, so the water outlet joint 116 is naturally positioned below the water inlet joint 110 in the illustrated example. The water outlet joint 116 includes a first water outlet coupling 160 that is connected to the water return line 126 in the appliance housing 22 and a second water outlet coupling 162 that is connected to the water drain line 104 in the front appliance door 26. The first and second water outlet couplings 160, 162 are positioned on the front appliance door 26 and the appliance housing 22, respectively, in such a way that they are generally aligned and configured to mate with one another to form a fluid tight connection when the front appliance door 26 is in the closed position (as shown in FIG. 12) and disconnect from one another when the front appliance door 26 is swung open towards the open position (as shown in FIG. 13). It should be appreciated that the first water inlet coupling 156 and the first water outlet coupling 160 have similar arrangements and may be referred to collectively as first water conduit couplings 156, 160. Similarly, the second water inlet coupling 158 and the second water outlet coupling 162 have similar arrangements and may be referred to collectively as second water conduit couplings 158, 162. Thus, it should be appreciated that, generally speaking, the first and second water conduit couplings 156, 158, 160, 162 of a water conduit joint 110, 116 are configured to provide a quick-connect (i.e., detachable) fluid-tight connection between two water conduits (i.e., water lines) positioned on opposite sides of the closing interface between the appliance housing 22 and the front appliance door 26.

With reference to FIGS. 10-13, the first water inlet coupling 156 and the first water outlet coupling 160 are each configured as a male connector with a tubular projection 164a, 164b that terminates at a circular rim 166a, 166b. The first water inlet coupling 156 and the first water outlet coupling 160 each have a plug 168a, 168b that is concentrically arranged with the tubular projection 164a, 164b and that extends longitudinally out from the circular rim 166a, 166b of the tubular projection 164a, 164b. Each plug 168a, 168b has an outer diameter that is less than an inside diameter of the tubular projection 164a, 164b. Each of the first water inlet coupling 156 and the first water outlet coupling 160 further include an elbow 170a, 170b that connects the first water inlet coupling 156 to the cooling water line 102 and the first water outlet coupling 160 to the water drain line 104, respectively.

The second water inlet coupling 158 and the second water outlet coupling 162 are each configured as a female connector with a tubular housing 172a, 172b and a spring-biased piston 174a, 174b that is slidingly received within the tubular housing 172a, 172b for longitudinal movement between a seated position (as shown in FIGS. 11 and 13) and an unseated position (as shown in FIGS. 10 and 12). Although other configurations are possible, in the illustrated example, the spring-biased piston 174a, 174b is shaped like a bowling pin and has a stem portion 176a, 176b and a head portion 178a, 178b. As shown in FIGS. 10-13, the head portion 178a, 178b of the spring-biased piston 174a, 174b generally has a larger diameter than the stem portion 176a, 176b of the spring-biased piston 174a, 174b. A biasing spring 180a, 180b is positioned on and extends helically about the stem portion 176a, 176b of the spring-biased piston 174a, 174b to bias the spring-biased piston 174a, 174b towards a seated position (as shown in FIGS. 11 and 13).

Each tubular housing 172 includes a receptacle portion 182a, 182b, an attachment portion 184a, 184b, and a seat portion 186a, 186b that is positioned longitudinally between the receptacle portion 182a, 182b and attachment portion 184a, 184b.

The attachment portion 184a, 184b of each tubular housing 172a, 172b includes a main cavity 188a, 188b that holds the stem portion 176a, 176b of the spring-biased piston 174a, 174b and the biasing spring 180a, 180b. The attachment portion 184a, 184b of each tubular housing 172a, 172b also includes a connection port 190a, 190b that is disposed in fluid communication with the main cavity 188a, 188b. The connection port 190a of the second water inlet coupling 158 is connected in fluid communication with the water supply line 124 and the connection port 190b of the second water outlet coupling 162 is connected in fluid communication with the water drain line 104. The seat portion 186a, 186b of each tubular housing 172a, 172b defines a seal cavity 192a, 192b that receives the head portion 178a, 178b of the spring-biased piston 174a, 174b in sealing engagement when the spring-biased piston 174a, 174b is in the seated position (as shown in FIGS. 11 and 13). Each plug 168a, 168b of the first water inlet and outlet couplings 160, 162 is configured to contact and push the spring-biased piston 174a, 174b of each of the second water inlet and outlet couplings 160, 162 to the unseated position when the front appliance door 26 is in the closed position (as shown in FIGS. 10 and 12), which opens a fluid pathway 194a, 194b through the water inlet and water outlet joints 110, 116. The seal cavity 192a, 192b is therefore arranged in fluid communication with the main cavity 188a, 188b of the attachment portion 184a, 184b when the spring-biased piston 174a, 174b is pushed to the unseated position by the plug 168a, 168b (as shown in FIGS. 10 and 12). Although other configurations are possible, in the illustrated example, the head portion 178a, 178b of the spring-biased piston 174a, 174b includes one or more piston seals 196a, 196b that are configured to seal against the seal cavity 192a, 192b of the tubular housing 172a, 172b when the spring-biased piston 174a, 174b is in the seated position (as shown in FIGS. 11 and 13).

The receptacle portion 182a, 182b of each tubular housing 172a, 172b defines a receptacle cavity 198a, 198b. Each receptacle cavity 198a, 198b has an inner diameter that is slightly larger than an outside diameter of the corresponding tubular projection 164a, 164b such that the tubular projections 164a, 164b of the first water inlet and outlet couplings 160, 162 are received in the tubular housings 172a, 172b of the second water inlet and outlet couplings 160, 162, respectively, when the front appliance door 26 is in the closed position (as shown in FIGS. 10 and 12). Furthermore, each plug 168a, 168b has an outer diameter that is less than an inside diameter of the tubular projection 164a, 164b such that the plug 168a, 168b does not obstruct fluid flow across the water inlet and water outlet joints 110, 116. The tubular projections 164a, 164b of the first water inlet coupling 156 and the first water outlet coupling 160 also include two annular seals 200a, 200b that are positioned on the outside diameter of each tubular projection 164a, 164b, which are configured to seal against the inner diameter of the receptacle cavity 198a, 198b when the tubular projections 164a, 164b are received in the respective tubular housings 172a, 172b of the second water inlet coupling 158 and the second water outlet coupling 162 when the front appliance door 26 is in the closed position (as shown in FIGS. 10 and 12).

FIG. 14 illustrates another exemplary water inlet joint 110′, which has first and second water inlet couplings 156′, 158′ that are constructed in accordance with an alternative configuration. Many of the elements of the water inlet joint 110′ shown in FIG. 14 are the same or similar to the elements of the water inlet joint 110 shown in FIGS. 10 and 11 and therefore share the same reference numbers, but have been annotated with a prime symbol (′) after the reference numerals. It should also be appreciated that the alternative configuration shown in FIG. 14 could also be applied to the water outlet joint 116 in a similar fashion.

The water inlet joint 110′ shown in FIG. 14 further includes a shroud 202′ that is positioned around the first water inlet coupling 156′. The shroud 202′ includes a shroud opening 204′ through which the tubular projection 164′ of the first water inlet coupling 156′ extends. The water inlet joint 110′ also includes an alignment feature 206′ that extends from the second water inlet coupling 158′. In the illustrated example, the alignment feature 206′ is a cylinder that extends out from the receptacle portion 182′ of the second water inlet coupling 158′, but other alignment structures positioned on or adjacent to the second water inlet coupling 158′ could also be used. The shroud opening 204′ includes a ramped surface 208′ that is configured to make sliding contact with the alignment feature 206′ and guide the tubular projection 164′ of the first water inlet coupling 156′ into the receptacle portion 182′ of the tubular housing 172′ of the second water inlet coupling 158′ as the front appliance door 26 is swung towards the closed position. While other ramped shapes may be used, in the illustrated example, the ramped surface 208′ of the shroud opening 204′ is shaped like a funnel. Optionally, an electrical continuity sensor 210′ may be positioned in the shroud opening 204′ that is configured to detect the presence of water dripping into the shroud opening 204′.

FIGS. 15-17 illustrate an exemplary temperature sensor assembly 212 for measuring the surface temperature of the drum 50 of the laundry appliance 20. The temperature sensor assembly 212 includes a temperature sensor 214 that is mounted within a temperature sensor housing 216. The temperature sensor housing 216 is mounted on the drum housing 36 at a location adjacent to a temperature sensor opening 218 that extends through the drum housing sidewall 44. The temperature sensor 214 is an infrared temperature sensor 214 that is configured to remotely measure a temperature of the outer surface 64 of the drum sidewall 62. The temperature sensor 214 has a sensor aperture 220 that is positioned in alignment with the temperature sensor opening 218 in the drum housing sidewall 44 such that the sensor aperture 220 has an unobstructed line of sight to the outer surface 64 of the drum sidewall 62. The sensor aperture 220 includes a lens 222, which may be made of glass or another transparent material. During a drying cycle, the temperature sensor 214 measures the surface temperature of the drum sidewall 62 either continuously or at frequent intervals and communicates electronic signals corresponding to temperature measurements to a drying cycle control module (not shown). The drying cycle control module uses the temperature measurements provided by the temperature sensor 214 to control certain parameters of the drying cycle, such as the heat output of the heater 84, the speed of the drying air circulation fan 80, and the duration of the drying cycle, for example.

The temperature sensor assembly 212 further includes a mounting frame 224 and a track 226 that are fixedly secured to the drum housing sidewall 44 at a location adjacent to the temperature sensor opening 218 in the drum housing sidewall 44. The track 226 includes a tray 228 that is received within the mounting frame 224 and that has a bottom wall 230 that abuts the drum housing sidewall 44. The track 226 includes a first window 232 that extends through the bottom wall 230 of the tray 228. The first window 232 in the track 226 is aligned with the temperature sensor opening 218. The temperature sensor assembly 212 also includes a sliding sensor cover 234 that is slidingly engaged with the track 226 and includes a lower wall 236 that is arranged in the tray 228 of the track 226 between the track 226 and the temperature sensor housing 216. As such, the lower wall 236 of the sliding sensor cover 234 is positioned radially between the bottom wall 230 of the track 226 and the temperature sensor housing 216. The sliding sensor cover 234 is configured to move (i.e., slide) relative to the temperature sensor 214 and the drum housing sidewall 44 along a slide travel direction 238 between a covered position and an uncovered position. The temperature sensor housing 216 is fixedly secured to the track 226 and therefore does not move with the sliding sensor cover 234.

The sliding sensor cover 234 includes a second window 240 that extends through the lower wall 236 of the sliding sensor cover 234. When the sliding sensor cover 234 is in the covered position, the second window 240 in the lower wall 236 is offset and spaced from the temperature sensor opening 218 and the first window 232 in the slide travel direction 238, which serves to protect the temperature sensor 214 from splash during a wash cycle, for example, when the surface temperature of the drum 50 does not need to be measured. When a temperature measurement/reading of the drum 50 is desired, such as during a drying cycle, the sliding sensor cover 234 is slid in the slide travel direction 238 to the uncovered position, where the second window 240 in the lower wall 236 is aligned with the temperature sensor opening 218 in the drum housing sidewall 44 and the first window 232 in the bottom wall 230 of the track 226 to provide the sensor aperture 220 with an unobstructed line of sight to the outer surface 64 of the drum sidewall 62, making remote temperature measurements possible.

The sliding sensor cover 234 in the illustrated example also includes a tether attachment arm 242 and a biasing member attachment arm 244 that extend from opposite sides of the sliding sensor cover 234 in the slide travel direction 238. The temperature sensor assembly 212 includes an anchor 246 that is fixedly secured to the drum housing sidewall 44 and a biasing member 248 that extends between and is attached to the anchor 246 at one end and the biasing member attachment arm 244 of the sliding sensor cover 234 at an opposite end. As such, the biasing member 248 applies a biasing force to the sliding sensor cover 234 that biases the sliding sensor cover 234 toward the covered position. While many different types of biasing members 248 may be used, in the illustrated example, the biasing member 248 is a coil spring. The temperature sensor assembly 212 further includes a retractor motor 250 that is configured to move the sliding sensor cover 234 relative to the track 226 in the slide travel direction 238 between the covered position and the uncovered position. Like the biasing member 248, many different types of retractor motors 250 can be used. In the illustrated example, the retractor motor 250 is an electric motor with a stator and a rotor. The rotor is coupled to a spool (not shown) and a tether 252 is attached to the spool of the retractor motor 250 at one end and the tether attachment arm 242 of the sliding sensor cover 234 at an opposite end. As the rotor rotates relative to the stator when the retractor motor 250 is energized, the tether 252 is wound up around the spool, which pulls the sliding sensor cover 234 to the uncovered position. When the retractor motor 250 is de-energized, the biasing member 248 pulls the sliding sensor cover 234 back to the covered position. In another possible arrangement that eliminates the need for the tether 252 and/or biasing member 248, at least part of the sliding sensor cover 234 is magnetic and the retractor motor 250 is configured to generate a magnetic field that applies a force to the sliding sensor cover 234 that changes direction depending on a polarity of the magnetic field to move the sliding sensor cover 234 back and forth between the covered and uncovered positions.

The temperature sensor assembly 212 further includes a slide controller (not shown) that is electrically connected to the retractor motor 250. The slide controller is programmed to actuate the retractor motor 250 to move the sliding sensor cover 234 to the covered position during a wash cycle of the laundry appliance 20 to protect the temperature sensor 214 from splash and move the sliding sensor cover 234 to the uncovered position during a drying cycle of the laundry appliance 20 to allow for temperature measurements of the drum 50.

As explained above, the air inside the laundry compartment 66 of the drum 50 is warm and moist during the drying cycle, particularly during the middle portion of the drying cycle. As a result, steam builds up inside the drum housing 36 and has a tendency to fog up and/or condense on the lens 222 of the temperature sensor 214. When this occurs, the temperature sensor 214 can provide erroneous readings that correspond to the temperature of the lens 222 instead of the surface temperature of the drum sidewall 62. To address this problem, the temperature sensor housing 216 includes a sensor air duct 254 that is configured to direct a stream of air 256 past the sensor aperture 220 to prevent steam in the drum housing cavity 46 from passing through the temperature sensor opening 218 in the drum housing sidewall 44, the first window 232 in the track 226, and the second window 240 in the sliding sensor cover 234 when the sliding sensor cover 234 is in the uncovered position, where it could fog up and/or condense on the lens 222 of the temperature sensor 214. A fan 258 is mounted in the sensor air duct 254 upstream of the sensor aperture 220, which is configured to generate the stream of air 256 flowing through the sensor air duct 254. For example, in the illustrated embodiment, the temperature sensor housing 216 includes an annular duct portion 260 that houses the fan 258 and an outlet channel 262 that houses the temperature sensor 214 and that ends at a duct opening 264, which is aligned with the temperature sensor opening 218 in the drum housing sidewall 44 and the first window 232 in the bottom wall 230 of the track 226. The stream of air 256 flowing through the sensor air duct 254 could alternatively be provided by an air source, such as a compressed air line.

Optionally, the drum sidewall 62 may have an emissivity enhancing coating 266 that is applied along at least a portion of the outer surface 64 to increase the accuracy of the temperature measurements made by the temperature sensor 214. The emissivity enhancing coating 266 is applied to at least the portion of the outer surface 64 of the drum sidewall 62 that passes by the temperature sensor opening 218 in the drum housing sidewall 44 as the drum 50 rotates within the drum housing cavity 46. By way of example and without limitation, the emissivity enhancing coating 266 may be paint or a matte surface finish that is applied to at least a portion of the outer surface 64 of the drum sidewall 62 that can be detected by the infrared temperature sensor 214.

FIGS. 18 and 19 illustrate another exemplary temperature sensor assembly 212′ that is constructed in accordance with an alternative configuration. Some of the elements of the temperature sensor assembly 212′ shown in FIGS. 18 and 19 are the same or similar to the elements of the temperature sensor assembly 212 shown in FIGS. 15-17 and therefore share the same reference numbers, but have been annotated with a prime symbol (′) after the reference numerals. Like in the temperature sensor assembly 212 shown in FIGS. 15-17, the temperature sensor assembly 212′ shown in FIGS. 18 and 19 includes an infrared temperature sensor 214′ for measuring the surface temperature of the drum 50. The temperature sensor 214′ has a sensor aperture 220′ that is covered by a lens 222′ and a temperature sensor housing 216′ that is attached to the drum housing sidewall 44′ and holds the temperature sensor 214′ such that the sensor aperture 220′ is in alignment with the temperature sensor opening 218′ in the drum housing sidewall 44′. In this embodiment, the temperature sensor housing 216′ includes a collar portion 268′ and a barrel portion 270′. The barrel portion 270′ of the temperature sensor housing 216′ extends longitudinally from the collar portion 268′ and into the temperature sensor opening 218′ in the drum housing sidewall 44′. While other configurations are possible, in the illustrated example, the barrel portion 270′ of the temperature sensor housing 216′ is externally threaded and screws into the temperature sensor opening 218′ in the drum housing sidewall 44′. The collar portion 268′ of the temperature sensor housing 216′ includes a through-bore 272′ that is configured to receive the temperature sensor 214′. Again, while other configurations are possible, in the illustrated example, the through-bore 272′ in the collar portion 268′ of the temperature sensor housing 216′ is internally threaded and the temperature sensor 214′ screws into the through-bore 272′. In accordance with this configuration, the temperature sensor housing 216′ includes a sensor air duct 254′ in the collar portion 268′ of the temperature sensor housing 216′ that has an annular shape and that is positioned radially outward of and in concentric alignment with the through-bore 272′. The sensor air duct 254′ and the through-bore 272′ then both open into the barrel portion 270′ of the temperature sensor housing 216′, which is a hollow tube.

A stream of air 256′ flowing through the sensor air duct 254′ is provided during a drying cycle by an air source that is connected in fluid communication with the sensor air duct 254′ upstream of the sensor aperture 220′. For example, the air source may be a compressed air supply line (not shown) that connects to the collar portion 268′ of the temperature sensor housing 216′ through an air port 274′ that opens into the sensor air duct 254′. Alternatively, a fan may be mounted in the sensor air duct 254′ upstream of the sensor aperture 220′. Either way, the stream of air 256′ in the sensor air duct 254′ prevents steam from fogging up or otherwise fouling the lens 222′ of the temperature sensor 214′.

Many modifications and variations of the apparatus and assemblies described in the present disclosure are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims. These antecedent recitations should be interpreted to cover any combination in which the inventive novelty exercises its utility.

WASHER AND DRYER COMBINATION LAUNDRY APPLIANCE

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