Patent Application
20120311794
1. Field of the Invention
The subject matter disclosed herein relates generally to appliances and to methods of operating the appliances with particular emphasis on wash cycles in which washing fluid is dispensed into a wash zone in which objects are positioned to be washed.
2. Description of Related Art
Some appliances such as household washing machines typically include a cabinet that houses an outer tub for containing wash and rinse water, a perforated wash basket within the tub, and an agitator within the basket. A drive and motor assembly is mounted underneath the stationary outer tub to rotate the basket and the agitator relative to one another, and a pump assembly is configured to pump water from the tub to a drain to execute a wash cycle.
These appliances are equipped with various settings, some of which provide selections for the temperature of the washing fluid that is used for washing the objects therein. Typically these temperature settings include hot, warm, and cold. For the hot setting, the washing fluid is often drawn directly from a hot water heater or related fluid heating device (the “hot supply”) into the wash zone. On the other hand, when cold settings are selected, the washing fluid is often drawn directly from a municipal, well, or related supply (the “cold supply”). Warm settings utilize a mixture of fluids from both the hot supply and the cold supply to achieve the temperature of the washing fluid that is dispensed into the wash zone.
Hot washing fluid such as is dispensed by the hot setting is ideal to treat many stains, dirt, and other soils. However, the amount of hot washing fluid that can be utilized during the wash cycle is often limited by energy standards. To address this issue and to facilitate compliance with such standards, many appliances are not equipped to use washing fluid entirely from the hot supply, but rather use a mixture of fluids from the hot supply and the cold supply to meter the temperature of the resultant washing fluid. While this final mixture may be hotter than the washing fluid under the warm setting, the temperature is still less than the ideal treatment conditions provide by “purely” hot washing fluid.
There is therefore a need for an appliance that is configured to provide effective treatment of objects using hot washing fluid, but that meets energy standards without sacrificing quality and effectiveness of treatment of the objects that are washed therein.
In one embodiment, there is described a method implemented on an appliance comprising a wash zone in which objects are positioned to be washed. The method comprises a step for forming a fluid mixture in the wash zone, the fluid mixture comprising a first fluid and a second fluid dispensed during an operational cycle so that the fluid mixture reaches a fill level in the wash zone. In one example, the first fluid is dispensed to a first level that is less than the fill level and has a temperature that is greater than a mixture temperature for the fluid mixture and a secondary operation is initiated in response to the first fluid reaching the first level.
In another embodiment, in a washing machine having a fluid inlet and a wash tub forming a wash zone in which objects are positioned to be washed, there is provided a method implemented on the washing machine that comprises a step for dispensing a first fluid from the fluid inlet into the wash zone and a step for dispensing a second fluid from the fluid inlet into the wash zone. In one example, the first fluid and the second fluid form a fluid mixture with a mixture temperature and that reaches a fill level in the wash zone, the first fluid is dispensed to at least a first level that is less than the fill level and has a temperature that is greater than the mixture temperature, and a secondary operation is initiated in response to the first fluid reaching the first level.
In yet another embodiment, there is described an appliance that comprises a wash zone in which objects are positioned to be washed, a flow regulator in communication with the wash zone, and a controller coupled to the flow regulator. In one example, the controller is operatively configured to execute an operational cycle during which a fluid mixture is formed in the wash zone. The fluid mixture comprises a first fluid and a second fluid dispensed from the flow regulator during the operational cycle, the first fluid is dispensed to at least a first level that is less than a fill level for the fluid mixture and has a temperature that is greater than a mixture temperature for the fluid mixture, and a secondary operation is initiated in response to the first fluid reaching the first level.
Reference is now made briefly to the accompanying drawings, in which:
Where applicable like reference characters designate identical or corresponding components and units throughout the several views, which are not to scale unless otherwise indicated.
For context and to begin the discussion, reference can be had to
In the exemplary embodiment, the vertical-axis washing machine 102 includes a cabinet 104 and a cover 106. A backsplash 108 extends from the cover 106 and a variety of control input selectors 110 are coupled to the backsplash 108. The control input selectors 110 form a user interface input 112 for operator selection of machine cycles and features. Located within the cabinet 104 is a wash zone 114 that is formed inside of a wash tub 116 and more particularly is defined by a wash basket 118, which is movably disposed and rotatably mounted in the wash tub 116 in a spaced apart relationship from wash tub 116. The wash basket 118 has a plurality of perforations 120 to facilitate communication of a washing fluid (not shown) out of the wash basket 118. An agitation device 122 (or impeller or oscillatory basket mechanism) is rotatably positioned in the wash basket 118 on a vertical axis 124, which is substantially aligned and coincident with a center axis (not shown) of the wash basket 118. In one example, the agitation device 122 is configured to impart oscillatory motion to objects (e.g., articles of clothing) and liquid (e.g., the washing fluid) in the wash basket 118. The appliance 100 also includes a spray device 126, which is mounted within the cabinet 104 and through which the washing fluid is dispensed into the wash zone 114.
At a relatively high level, more details being provided in the discussion that follows, the inventors propose concepts that are useful to more effectively leverage the cleaning properties of the washing fluid, while providing configurations for the appliance 100 that meet energy and efficiency standards for, e.g., household washing machines. Embodiments of the appliance 100, for example, are configured to execute an operational cycle by which is formed in the wash zone 114 a fluid mixture that comprises a first fluid and a second fluid. The operational cycle includes a first wash phase in which the first fluid is dispensed to a saturation or first level in the wash zone 114. In one embodiment, the first level is sufficient to wet and in some implementations to submerge the objects disposed therein, but is less than a level for the fluid mixture that is reached by way of a second wash phase in which the second fluid is mixed with the first fluid in the wash zone 114.
To effectuate cleaning of the objects, the first fluid is provided at an elevated temperature that is higher than the temperature of the fluid mixture. In one example, the elevated temperature is consistent with washing fluid that is provided by a hot water heater (also called, “hot tap fluid”) that is present in the location (e.g., house, apartment, office) in which the appliance is positioned. However, whereas certain standards may preclude the use of hot tap fluid such as to fill the wash zone 114 to the fill level, implementation of the first wash phase and the second wash phase and formation of the fluid mixture as discussed below is preferred because the objects are subjected to the elevated temperature of the hot tap fluid during the first wash phase, rather than only to the lower temperature of the fluid mixture during the operational cycle.
These concepts are further illustrated in the discussion of the exemplary embodiment of an appliance 200 that is depicted in schematic form in
In the embodiment of
To effectuate cleaning of objects which are optimally cleaned by a high temperature fluid, the operational washing cycle is performed in two phases. In the first phase, flow of the washing fluid 230 fills the wash zone 214 to a first or saturation level 260 with a first fluid 252 having a first relatively high temperature, TPP, such as is preferably drawn directly from hot water supply 236 via hot fluid portion 242 of regulator 228. However, this first fluid could comprise a mixture of fluid from 236 and 238, as long as the resultant temperature of the first fluid is sufficiently high to efficiently clean the objects in need of a high temperature fluid. The first or saturation level 260 is set at level sufficient to saturate if not totally immerse the objects, but is less than the fill level 258 for the second phase of the operational washing cycle, so as to reduce the amount of hot fluid utilized for the operational washing cycle. On the first fluid reaching the first level, a first wash cycle comprising a secondary operation, such as a agitation cycle and/or other operational cycles as necessary to complete the first phase of the wash cycle intended perform a cleaning operation on the objects while exposed to the relatively high temperature first fluid is performed. On completion of this first phase, the second phase is initiated by supplying a second fluid 254 having a second temperature, TSP, which is less than the first fluid temperature to the wash zone 214, to raise the level of the fluid mixture in the wash zone to the desired fill level 258 and achieve the desired mixture temperature for the ensuing second phase of the wash cycle. This second fluid may be drawn directly from the cold water supply 236 or comprise a mixture of water from drawn from cold supply 238 and hot supply 236. The resulting fluid mixture 250, exhibits a mixture temperature TFM, which is greater than the second fluid temperature and less than the first fluid temperature and which is the desired temperature for the washing fluid for the second phase of the wash cycle. While illustrated in stratified or layered format in
As briefly described above, each of the first fluid 252 and the second fluid 254 can include one or more of the first washing fluid 246 and the second washing fluid 248. That is, in one embodiment, operation of the flow regulator 228 such as by the controller 240 is used to regulate the amount of one or more of the first washing fluid 246 and the second washing fluid 248. Regulating these amounts can, in turn, effectuate the first part temperature TFP, the second part temperature TSP, and ultimately the mixture temperature TFM. In one example, the second fluid comprises a first percentage of the first washing fluid and a second percentage of the second washing fluid, wherein the value of each of the first percentage and the second percentage is selected in response to the mixture temperature TFM.
To further elaborate and to illustrate these concepts, consider in one example that the first fluid supply 236 comprises a hot water heater or related device that provides water at certain temperatures such as from about 32° C. to about 71° C. The second fluid supply 238 comprises a household supply (e.g., a municipal and/or a well-water supply), which provides water that is typically at temperatures of less than about 29° C. In one implementation, the controller 240 activates the hot fluid portion 242, thereby permitting water from the hot water heater to enter the wash zone 214 as the first part 252. Upon expiration of a fill time and/or in response to an indication that the first level 260 is reached, the controller 240 deactivates the hot fluid portion 242. In one embodiment, the controller 240 is operatively configured to activate other portions of the appliance 200 such as motors, pumps, dispensers (e.g., for additives like liquid detergents), and the like.
The controller 240 is also operatively configured to activate the cold fluid portion 244 such as subsequent to either deactivation of the hot fluid portion 242 or the other operations of the appliance 200. This activation permits water from the household supply to enter the wash zone 214 as the second part 254, which mixes with the first part 252 to form the fluid mixture 250 at the fill level 258. Embodiments of the appliance 200 are contemplated in which the cold fluid portion 244 and the hot fluid portion 242 are activated simultaneously, thereby causing to be mixed the water from the hot water heater and the household supply before entering the wash zone 214. Such mixing is effective to regulate one or more of, e.g., the first part temperature TFP, the second part temperature TSP, and the mixture temperature TFM.
The appliance 300 also comprises a pump assembly 362 that is located beneath the wash tub 316 and the wash basket 318 for gravity assisted flow when draining the wash tub 316. The pump assembly 362 includes a pump/motor 364 and in an exemplary embodiment a motor fan (not shown). A pump inlet hose 366 extends from the wash tub 316 to the pump/motor 364 and a pump outlet hose 368 extends from the pump/motor 364 to a drain outlet 370 and ultimately to a building plumbing system discharge line (not shown) in flow communication with the drain outlet 370. In operation, pump assembly 362 can be selectively activated to remove liquid from the wash tub 316 and the wash basket 318 through drain outlet 370 during appropriate points in washing cycles as appliance 300 is used.
The wash basket 318 and the agitation device 322 are driven by a motor 372 through a transmission clutch system 374. A transmission belt 376 is coupled to the motor 372 and the transmission clutch system 374 such as through respective pulleys and shafts. Transmission clutch system 374 facilitates driving engagement of the wash basket 318 and the agitation device 322 through a shaft 378 for rotatable movement within the wash tub 316, and transmission clutch system 374 facilitates relative rotation of the wash basket 318 and the agitation device 322 for selected portions of wash cycles. Motor 372, transmission clutch system 374, and transmission belt 376 can collectively be referred to as a machine drive system, the machine drive system being drivingly connected to the wash basket 318 and the agitation device 322 for rotating the wash basket 318 and/or the agitation device 322.
The flow regulator 328 includes a hot liquid valve 380 and a cold liquid valve 382, which deliver fluid, such as water, to the spray device 326 through a respective hot liquid hose 384 and a cold liquid hose 386. Liquid valves 380, 382 and liquid hoses 384, 386 together form a liquid supply connection for the appliance 300 and, when connected to a building plumbing system (not shown), provide a water supply for use in the appliance 300. Liquid valves 380, 382 and liquid hoses 384, 386 are connected to a basket inlet tube 388, which is coupled to the flow regulator 328, and fluid is dispersed from the basket inlet tube 388 through the spray device 326 as described herein.
In an exemplary embodiment, the appliance 300 also includes an additive dispenser 390, a fluid pressure sensing device 392, and a fluid temperature sensing device 394, which measures the temperature of washing fluid (not shown). The fluid pressure sensing device 392 is configured to monitor the fluid levels 356 of the fluid mixture 350. In one example, the fluid pressure sensing device 392 includes a reservoir/tube assembly 396 and a pressure sensor 398. As fluid such as the washing fluid 330 rises in the wash zone 314, air is trapped in reservoir/tube assembly 396 creating a pressure that is monitored by the pressure sensor 398. Changes in the fluid levels 356 such as the fill level 358 and the first level 360 may therefore be sensed, for example, to facilitate associated control decisions such as the control of hot liquid valve 380 and cold liquid valve 382 during phases of the operational cycle (e.g., the first wash phase and the second wash phase mentioned above).
The fluid temperature sensing device 394 can comprise one or more known devices and/or device configurations that are responsive to, and can provide a signal indicative of, the temperature of fluids such as the fluids discussed herein. Exemplary devices include thermisters, thermocouples, and related devices, which can be coupled via electrical circuitry to, e.g., the controller 340. As depicted in
The additive dispenser 390 is useful to retain and dispense laundry additives for use during the operation of the appliance 300. Dispensing can occur by way of direct injection of the additive into the wash zone 314 and/or injection of the additive into the flow of the washing fluid before, during, and/or after flowing through the spray device 326. Treating chemistry for the additives may be any type of aid for treating fabric. Examples may include, but are not limited to, washing aids, such as detergents and oxidizers (e.g., bleach), and additives such as fabric softeners, sanitizers, de-wrinklers, and chemicals for imparting desired properties to the fabric. These properties include stain resistance, fragrance (e.g., perfumes), insect repellency, and ultra-violet (UV) protection.
Operation of the appliance 300 can be controlled by the controller 340, which is operatively configured to execute an operational cycle and or other instructions (e.g., software and firmware) that instruct the activation and operation of the appliance 300. For example, the controller 340 can be operatively connected to the user interface input (e.g., the user interface input 112 (
Referring next to
It is also depicted in
Focusing on the wash cycle at block 402, it is contemplated that the appliance can be configured to operate in a manner that forms the fluid mixture as discussed in connection with
The method 500 also includes intermediary steps such as, at block 512, executing one or more secondary operations. In one example, these secondary operations can occur between the step for dispensing of the first part (e.g., at block 504 and the step for mixing the second part (e.g., at block 506). In another example, the secondary operations can occur during one of the dispensing steps such as during the step for mixing the second part (e.g., at block 506). Suitable and exemplary secondary operations may include, but are not limited to, soaking objects in the first part of the fluid mixture, agitating the objects and/or the first part of the fluid mixture, and rotating the wash zone and/or the first part of the fluid mixture. Each of the secondary operations may occur in response to a user selected option, which may be part of and/or incorporated in the user interface input.
Noted in the present example is that the first part of the fluid mixture is the result of a hot water fill. That is, the wash zone is filled predominantly with hot water such as from the hot water supply and/or the hot water heater discussed above. In one example, the hot liquid valve (e.g., the hot liquid valve 380) is opened and the cold liquid valve (e.g., the cold liquid valve 382) is closed, thereby causing only hot water to enter the wash zone via the spray device. When the first level is reached, as indicated in one example by a signal from the fluid pressure sensing device 392, then the hot liquid valve is closed and further operation of the appliance can continue. Thus, in one embodiment of the method 500, implementation of one of the secondary operations occurs when the wash zone is only partially-filled with hot water, thereby reducing hot water usage while also leveraging the benefits of higher temperature of the hot water fill.
The second part of the fluid mixture can result from one or more of the hot water fill, a cold water fill, and a warm water fill, as desired. In a cold water fill, the hot liquid valve (e.g., the hot liquid valve 380) is closed and the cold liquid valve (e.g., the cold liquid valve 382) is open, thereby causing only cold water to enter the wash zone via the spray device. When a warm water fill is implemented, each of the hot liquid valve (e.g., the hot liquid valve 380) and the cold liquid valve (e.g., the cold liquid valve 382) is utilized, thereby causing hot water and cold water to enter the wash zone via the spray device. In one example, the hot liquid valve and the cold liquid valve are opened simultaneously so that the cold water mixes with the hot water before entering the wash zone. In another example, the valves are opened and closed in accordance with an algorithm, such as an algorithm that is responsive to signals from the fluid temperature sensing device 394. While examples of this algorithm are not provided herein, it will be recognized by those artisans skilled in control circuitry and related control structures for appliances that the operation of the valves (as between the open state and the closed state) can be used to modify the temperature of the washing fluid that is dispersed by the spray device. Details of such algorithms are therefore not necessary.
Turning next to
Following implementation of the secondary operation at block 618, and in one example as indicated, at block 626, determining whether the secondary operations are complete, the method 600 continues with block 604, dispensing the second fluid. In one embodiment, the method 600 comprises, at block 628, receiving an input indicative of the temperature of the second fluid and, at block 630, opening and closing one or more of the hot inlet valve and the cold inlet valve in response to the input to adjust the temperature of the second fluid. The method 600 also comprises, at block 632, receiving an input indicative of the fill level and, at block 634, determining whether the fluid mixture has reached the fill level. In one example, if the fill level is not reached, then the method 600 continues to dispense the first fluid such as by way of activating one or more of the hot inlet valve and the cold inlet valve (e.g., at block 630). When the fluid mixture reaches the fill level, the method 600 continues to block 636, determining whether the wash cycle is complete and, if not, repeating one or more of the dispensing steps such as at block 602 and/or block 604. On the other hand, if the wash cycle is complete, then the method 600 continues such as, at block 638, entering another part of the operational cycle (e.g., the operational cycle 400).
The method 600 also includes, at block 640, dispensing an additive, which is shown to occur variously as throughout the method 600. The inventors propose, for example, that additive can be dispensed at different times during the operational cycle, thereby subjecting the objects to be washed at one or more additive concentrations. In one embodiment, additive is provided so as to mix with the first part. This mixing creates a high concentration or additive-to-fluid ratio, which is contemplated on the order of 2:1 (e.g., of the normal wash level concentration) and in one example from at least about 2:1 to about 4:3. In another embodiment, additive is also dispensed into the fluid mixture, a step which can occur contemporaneously with and/or subsequently to block 604. In yet another embodiment, the additive can be dispensed as one or more of the secondary operations discussed above and contemplated herein.
A variety of control configurations and schemes can be used to implement the operational cycles, e.g., the operational cycles 400, the wash methods, e.g., the wash methods 500 and 600, and generally the concepts of the present disclosure. The example of
The control scheme 700 further includes valves 722, illustrated in the present example as liquid valve 724 (e.g., the hot liquid valve 380) and liquid valve 726 (e.g., the cold liquid valve 382). The control scheme 700 also includes a motor 728, a pump 730, and an additive dispenser 732. The control scheme 700 also includes one or more sensors 734 such as a fluid pressure sensing device 736 and a fluid temperature sensing device 738.
In one embodiment, the controller 702 is coupled to a control panel 740 that includes one or more wash cycle controls 742. When implemented in the appliances, the controller 702 effectuates operation of various elements of the appliances such as in response to inputs from the sensors 734 and the control panel 740. The timing circuit 718, of which various configurations are contemplated, is provided to indicate times and time periods to, e.g., open and close one or more of the valves 722. These time periods may be selected so as to facilitate the cleanliness of the objects in the appliance as contemplated herein.
At a high level, the control scheme 700 and its constructive components are configured to communicate amongst themselves and/or with other circuits (and/or devices), which execute high-level logic functions, algorithms, as well as firmware and software instructions. Exemplary circuits of this type include, but are not limited to, discrete elements such as resistors, transistors, diodes, switches, and capacitors, as well as microprocessors and other logic devices such as field programmable gate arrays (“FPGAs”) and application specific integrated circuits (“ASICs”). While all of the discrete elements, circuits, and devices function individually in a manner that is generally understood by those artisans that have ordinary skill in the electrical arts, it is their combination and integration into functional electrical groups and circuits that generally provide for the concepts that are disclosed and described herein.
The electrical circuits of the controller 702 are sometimes implemented in a manner that can physically manifest logical operations, which are useful to facilitate the timing of the various cycles of the appliance. These electrical circuits can replicate in physical form an algorithm, a comparative analysis, and/or a decisional logic tree, each of which operates to assign an output and/or a value to the output such as to actuate the valves 722, to activate the motor 728, to activate the pump 730, and/or to activate the additive dispenser 732.
In one embodiment, the processor 704 is a central processing unit (CPU) such as an ASIC and/or an FPGA. The processor 704 can also include state machine circuitry or other suitable components capable of receiving inputs from, e.g. the control panel 740. The memory 706 includes volatile and non-volatile memory and can be used for storage of software (or firmware) instructions and configuration settings. Each of the motor control circuit 710, the pump control circuit 712, the valve control circuit 714, the sensor circuit 716, and the timing circuit 718 can be embodied as stand-alone devices such as solid-state devices. These devices can be mounted to substrates such as printed-circuit boards, which can accommodate various components including the processor 704, the memory 706, and other related circuitry to facilitate operation of the controller 702 in connection with its implementation in the fluid dispensing appliances.
However, although
In view of the foregoing, the above described appliances, methods, and control scheme facilitates reducing hot water usage in appliances such as household washing machines. The reduction in hot water, in turn, facilitates further reductions in energy consumption by the appliance during wash operation. However, although the amount of hot water that is used during the wash cycle may be reduced and/or limited to, e.g., the first level, subjecting the objects to be washed to the hot water (and, in some examples, in combination with high concentrations of laundry additive) can improve cleanliness of the objects realized by the appliance.
Furthermore, it is contemplated that, where applicable in the present disclosure, numerical values, as well as other values that are recited herein are modified by the term “about”, whether expressly stated or inherently derived by the discussion of the present disclosure. As used herein, the term “about” defines the numerical boundaries of the modified values so as to include, but not be limited to, tolerances and values up to, and including the numerical value so modified. That is, numerical values can include the actual value that is expressly stated, as well as other values that are, or can be, the decimal, fractional, or other multiple of the actual value indicated, and/or described in the disclosure.
This written description uses examples to disclose embodiments of the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defied by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
