FLOW DISTRIBUTION VANE FOR THE BASEMENT OF HEAT PUMP DRYER

Description

FIELD

The present disclosure relates to a heat pump drying machine and, more particularly, to a flow distribution vane for a heat pump drying machine that produces an airflow having a more uniform flow velocity through evaporator and condenser coils.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

Laundry appliances are prolific in both residential and commercial settings. The laundry appliance may be a dryer machine that is used to dry laundry after it has been cleaned in a washing machine. In some examples, the laundry appliance may be a washer and dryer combination appliance where a single machine performs both the washing and drying functions. 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.”

Many laundry appliances include a cabinet (i.e., an appliance housing) with an opening that is accessed by an appliance door. A drum is positioned in the cabinet and is rotatable with respect to the cabinet. The drum typically has a drum opening that provides access to a laundry compartment inside the drum. The appliances also include a blower that directs airflow into the drum. In a heat exchanger dryer, that airflow is passed through evaporator and condenser coils prior to entering the drum. The evaporator and the condenser coils remove moisture from and heat the airflow.

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.

A heat pump dryer, in accordance with the present disclosure, includes an evaporator, a condenser, and a blower arranged in fluid communication with both the evaporator and the condenser via an airflow channel. The blower is positioned to direct air through the airflow channel and then through the evaporator and the condenser. At least one flow distribution vane is positioned in the airflow channel downstream of the blower and upstream of both the evaporator and the condenser to distribute airflow across a working area of the evaporator and the condenser. The at least one flow distribution vane extends inwardly from a sidewall of the airflow channel at an oblique angle and terminates at a distal end that is spaced away from the sidewall of the airflow channel.

A heat pump dryer, in accordance with the present disclosure, includes an evaporator, a condenser, and a blower arranged in fluid communication with both the evaporator and the condenser via an airflow channel. The blower being positioned to direct air through the airflow channel and then through the evaporator and the condenser. At least one flow distribution vane is positioned in the airflow channel downstream of the blower and upstream of both the evaporator and the condenser to distribute airflow across a working area of the evaporator and the condenser. The flow distribution vane includes a frontal surface that is angled towards the blower, a backside surface opposite the frontal surface, and a section of reduced height to permit airflow passing along the backside surface of the flow distribution vane.

A method of directing airflow through an evaporator and a condenser in a heat pump dryer includes generating an airflow with a blower, directing the airflow into an airflow channel having a sidewall, passing the airflow across at least one flow distribution vane extending from the sidewall, and channeling the airflow away from the sidewall creating a more uniform flow field entering the evaporator and the condenser.

The flow distribution vane establishes an airflow having a substantially uniform velocity prior to entering the evaporator and condenser. The flow distribution vane directs the air away from non-linear portions of the airflow channel that may adversely affect flow velocity. By creating a more uniform flow velocity, the flow distribution vane increases heat exchange efficiency between the airflow and the evaporator and condenser. The increased heat exchange efficiency reduces the amount of energy required to dry clothes.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

BRIEF DESCRIPTION OF DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure.

FIG. 1 is a front perspective view of a laundry appliance including a basement equipped with a flow distribution vane, in accordance with the present disclosure;

FIG. 2 is a rear perspective view of the exemplary laundry appliance shown in FIG. 1, in accordance with the present disclosure;

FIG. 3 is a partial cross-sectional side view of the exemplary laundry appliance shown in FIG. 1, in accordance with the present disclosure;

FIG. 4 is a perspective view of the basement arranged in the laundry appliance of FIG. 1, in accordance with the present disclosure;

FIG. 5 is a cross-sectional view of the basement of FIG. 4, in accordance with the present disclosure;

FIG. 6 is a cross-sectional top view of the flow distribution vane arranged in an airflow channel at an outlet of a blower, in accordance with the present disclosure;

FIG. 7 is an elevational view of the flow distribution vane on a bottom surface of the airflow channel of FIG. 6, in accordance with the present disclosure; and

FIG. 8 depicts a cross-sectional top view of air flowing over the flow distribution vane into the basement, in accordance with the present disclosure.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

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.

Spatially relative terms, such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below”, or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

With reference to FIGS. 1-3, a laundry appliance 50 is illustrated. The laundry appliance 50 is a dryer machine and more specifically, a heat pump dryer machine. The laundry appliance 50 is illustrated as having a front-load configuration, though may alternatively have a top-load configuration.

The laundry appliance 50 includes a cabinet 52 that is rectangular in shape. The cabinet 52 includes a front cabinet wall 54 having a front cabinet opening 56, a rear cabinet wall 58 opposite the front cabinet wall 54, a set of cabinet sidewalls 60 that extend between the front cabinet wall 54 and the rear cabinet wall 58, a top cabinet wall 62, and a bottom cabinet wall 64. The front cabinet wall 54, rear cabinet wall 58, set of cabinet sidewalls 60, top cabinet wall 62, and bottom cabinet wall 64 cooperate to define a cabinet cavity 68 (FIG. 3) inside the cabinet 52. In accordance with a non-limiting example, front cabinet wall 54 includes a vent 69 that facilitates air flow into cabinet cavity 68 as will be detailed more fully herein.

In some configurations, the laundry appliance 50 may include a control panel 70 that is attached to the front cabinet wall 54. The control panel 70 may be positioned adjacent to the top cabinet wall 62. The control panel 70 may include a display 72, a speaker 74, a control selector 76, and a control module 78. The display 72 may be used to display information, adjust features or settings of the laundry appliance 50, present prompts to users of the laundry appliance 50, and to perform one or more other functions. The display 72 may be a touch screen display. The speaker 74 may be used to output audible sounds and to perform one or more other functions. The control selector 76 may be used to adjust features or settings of the laundry appliance 50 and to perform one or more other functions. The control module 78 may receive input from the user (e.g., via the display 72 or the control selector 76). The control module 78 may be configured to operate a cycle (e.g., a drying cycle) of the laundry appliance 50 according to the user’s input and may perform one or more other functions. Additional functions of the control module 78 will be described below. It should be appreciated that display 72, speaker 74, control selector 76, and control module 78 may be positioned in another suitable location on the laundry appliance 50.

A front appliance door 84 is pivotally connected to the cabinet 52, and more specifically, to the front cabinet wall 54 of the cabinet 52. The front appliance door 84 swings between an open door position and a closed door position. In the open door position, the front appliance door 84 provides access to the front cabinet opening 56. In the closed door position, the front appliance door 84 shuts or closes the front cabinet opening 56. When in the closed door position, the front appliance door 84 may be flush with or positioned adjacent to a front facia 86 of the cabinet 52. Although other materials can be used, in the illustrated example, the front appliance door 84 is composed of metal.

The laundry appliance 50 includes a drum 90 that is positioned in the cabinet cavity 68 and is rotatable with respect to the cabinet 52 about a drum axis 92. The drum 90 has a cylindrical shape and extends between a front drum end 94 and a rear drum end 96. The drum 90 includes a front drum opening 98 at the front drum end 94, a rear drum wall 100 at the rear drum end 96, and a drum sidewall 102 that extends between the front drum end 94 and rear drum end 96. One or more drum outlets 104 extend through the rear drum wall 100.

The front drum end 94, the drum sidewall 102, and the rear drum wall 100 cooperate to define a laundry compartment 110 inside the drum 90. The front cabinet opening 56 in the front cabinet wall 54 and the front drum opening 98 at the front drum end 94 are at least partially aligned with one another and therefore provide access to the laundry compartment 110 inside the drum 90 when the front appliance door 84 is in the open door position. In the illustrated example, the front cabinet opening 56 in the front cabinet wall 54 and the front drum opening 98 at the front drum end 94 are aligned with the drum axis 92. It should be appreciated that in use, laundry (e.g., clothes, towels, and/or bedding, etc.) is placed inside the laundry compartment 110 where it is dried during the drying cycle of the laundry appliance 50.

With additional reference to FIGS. 4-5, the laundry appliance 50 includes an appliance base 116 disposed between the drum 90 and the bottom cabinet wall 64. The appliance base 116 is attached to the bottom cabinet wall 64. The appliance base 116 extends between a front base end 118 and a rear base end 120 that is opposite the front base end 118. The front base end 118 is positioned adjacent to and attached to the front cabinet wall 54. The rear base end 120 is positioned adjacent to and attached to the rear cabinet wall 58. The appliance base 116 extends laterally between a first base end 122 and a second base end 123 opposite the first base end 122. The first base end 122 is positioned adjacent to one of the cabinet sidewalls 60 and the second base end 123 is positioned adjacent to another one of the cabinet sidewalls 60.

The laundry appliance 50 includes a heat exchanger 144 disposed within a basement 146 of the appliance base 116. The heat exchanger is configured to heat air flowing through the appliance base 116. The basement 146 is positioned adjacent to the first base end 122 and between the front base end 118 and rear base end 120 of the appliance base 116. The basement 146 includes a front basement wall 148, a rear basement wall 150, basement sidewalls 152 extending between the front basement wall 148 and rear basement wall 150, and a bottom basement wall 154.

The front basement wall 148 is positioned adjacent to the front base end 118 of the appliance base 116. The rear basement wall is positioned adjacent to the rear base end 120 of the appliance base 116. The basement 146 is arranged in fluid communication with laundry compartment 110 via a first basement opening 156 in the rear basement wall 150. The basement 146 includes a second basement opening 158 (FIG. 5) in the front basement wall 148. The bottom basement wall 154 is inclined such that the bottom basement wall 154 in a position adjacent to the rear basement wall 150 is positioned lower (e.g., closer to the bottom cabinet wall 64) than the bottom basement wall 154 in a position adjacent to the front basement wall 148. In other words, the bottom basement wall 154 in a position adjacent to the front basement wall 148, is positioned higher (e.g., closer to the top cabinet wall 62) than the bottom basement wall 154 in a position adjacent to the rear basement wall 150.

The heat exchanger 144 includes a first heat exchanger 172 and a second heat exchanger 174. In accordance with the present disclosure, first heat exchanger 172 is an evaporator (not separately labeled) and second heat exchanger 174 is a condenser (also not separately labeled). The first heat exchanger 172 and second heat exchanger 174are positioned adjacent to each other. More specifically, the first heat exchanger 172 is positioned adjacent to the front cabinet wall 54, and more specifically, the front basement wall 148. The second heat exchanger 174 is positioned adjacent to the rear cabinet wall 58, and more specifically, the rear basement wall 150. In some examples, the first heat exchanger 172 and second heat exchanger 174 may abut each other.

The first heat exchanger 172 is configured to condense air flowing through vent 69 from ambient. The air is condensed before the air reaches the second heat exchanger 174. The first heat exchanger 172 includes a first pipe 176 extending through the first heat exchanger 172. The first pipe 176 is configured to carry refrigerant or another suitable fluid to aid in condensing the air. Fluid (e.g., water vapor) may be released from the first heat exchanger 172 when the first heat exchanger 172 condenses air passing through the first heat exchanger 172. More specifically, when air is condensed using the first heat exchanger, moisture is removed from the air and fluid gravitationally falls from the first heat exchanger 172 to the bottom basement wall 154 of the basement 146.

The second heat exchanger 174 is configured to heat the air flowing from the first heat exchanger 172 and out the basement 146 of the appliance base 116. The second heat exchanger 174 includes a second pipe 178 extending through the second heat exchanger 174. The second pipe 178 is configured to carry refrigerant or another suitable fluid. Accordingly, air flows through the heat exchanger 144 to first be condensed by the first heat exchanger 172 and subsequently heated by the second heat exchanger 174 to create heated air that is passed into drum 90 via first basement opening 156.

The first pipe 176 and second pipe 178 of the first heat exchanger 172 and second heat exchanger 174 of the heat exchanger 144 are configured to receive refrigerant or another suitable fluid from a compressor 180. The compressor 180 is attached to a compressor base 182 of the appliance base 116. The compressor base 182 is positioned adjacent to the front base end 118 and the first base end 122.

The appliance base 116 includes an airflow channel 210 disposed adjacent to the basement 146. The airflow channel 210 extends between a first channel end 212 and a second channel end 214 that is opposite the first channel end 212. A sidewall 216 extends between and connects the first channel end 212 with the second channel end 214 through a bend portion 217. The first channel end 212 is arranged in fluid communication with the basement 146 via the second basement opening 158. The second channel end 214 is positioned at the front base end 118 the appliance base 116 and adjacent to the second base end 123 of the appliance base 116. More specifically, second channel end 214 is arranged adjacent to vent 69 and received ambient air that is directed into basement 146. Basement 146 is in fluid communication with drum 90 via a connector channel 218. More specifically, first basement opening 156 is fluidically conencted with connector channel 218 which, in turn, is fluidically conencted with drum 90 as will be detailed herein.

The connector channel 218 extends between a first connector end 220 and a second connector end 222 that is opposite the first connector end 220. The first connector end 220 is arranged in fluid communication with first basement opening 156. The second connector end 222 is arranged in fluid communication with the laundry compartment 110 of the drum 90 via one or more drum outlets 104 (shown in FIG. 3). A lint trap 224 is arranged in connector channel 218. Lint trap 224 captures and prevents lint and other debris that may exist in laundry compartment 110 from passing into first heat exchangers 172 and second heat exchanger 174.

A blower 230 (FIG. 4) is configured to blow air through the airflow channel 210, through basement 146 across first heat exchanger 172 and second heat exchanger 174, and back into drum 90. The blower 230 includes a squirrel cage 232 arranged at second channel end 214 of airflow channel 210. Squirrel cage 232 is operatively connected to a blower motor 234 that is positioned in the appliance base 116. The blower motor 234 is positioned adjacent to the front base end 118 and the first base end 122 of the appliance base 116. The blower motor 234 is positioned between the airflow channel 210 and the compressor base 182.

A base cover 238 is sealingly engaged with the appliance base 116 and disposed on top of the appliance base 116. More specifically, the base cover 238 extends over and encloses the basement 146 and the airflow channel 210. The base cover 238 and the basement 146 cooperate to define a basement cavity 240. Blower 230 includes an outlet 242 that directs air through airflow channel 210 into basement cavity 240. The air passes in heat exchange relationship with first heat exchanger 172 and second heat exchanger 174. First heat exchanger 172 removes moisture from the air and second heat exchanger 174 increases a temperature of the air. The air is then directed back into laundry compartment 110.

In accordance with the present disclosure, laundry appliance 50 includes a flow distribution vane 250 arranged in airflow channel 210. Referring to FIGS. 6 and 7, flow distribution vane 250 includes a proximal end 252 connected to sidewall 216, a distal end 254 extending into airflow channel 210, and a curvilinear guide surface 256. Curvilinear guide surface directs air from blower 230 into basement cavity 240 to flow across first heat exchanger 172 and second heat exchanger 274. Flow distribution vane 250 directs the air so as to possess a uniform flow field when passing into basement cavity 240. The uniform flow field presents an airflow having a substantially uniform velocity to first heat exchanger 172. Flow distribution vane 250 also eliminates stagnant air pockets in airflow channel 210.

In accordance with the present disclosure, airflow channel 210 includes a first vertical height “V1”. Distal end 254 of flow distribution vane 250 includes a second vertical height “V2”, and proximal end 252 of flow distribution vane 250 includes a third vertical height “V3”. The second vertical height “V2” of distal end 254 is substantially equal to the first vertical height “V1” of airflow channel 210. That is, distal end 254 extends between and abuts a bottom surface 264 of airflow channel 210 and an inner surface (not separately labeled) of base cover 238. Third vertical height “V3” forms a notch 266 at proximal end 252. With this construction, a first portion of the air passing from blower 230 flows over frontal surface 258 of curvilinear guide surface 256 and a second portion of the air passing from blower 230 passes through notch 266. The second portion of the airflow passes over backside surface 260 of curvilinear guide surface 256 to reduce stagnant air zones or the formation of eddy currents in airflow channel 210.

At this point, it should be appreciated that flow distribution vane 250 establishes an airflow through basement cavity 240 having a substantially uniform velocity such as shown in FIG. 8. Flow distribution vane 250 directs the air away from bend portion 217 and other internal surfaces of airflow channel that may affect flow velocity. By creating a more uniform flow velocity, flow distribution vane increases heat exchange efficiency between the airflow and first heat exchanger 172 and second heat exchanger 174. The increased heat exchange efficiency reduces the amount of energy required for laundry appliance 50 to dry clothes in laundry compartment 110.