PARTICULATE COLLECTION DEVICE FOR LAUNDRY DRYER

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This Application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application 63/712,154, filed on Oct. 25, 2024. The disclosure of this prior application is considered part of the disclosure of this application and is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

This disclosure relates to a particulate collection device, and more particularly, to a particulate collection device for a laundry dryer.

BACKGROUND

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

Laundry drying machines, particularly those used in commercial and industrial settings, are equipped with lint collection systems to capture lint and other debris generated during the drying process. Traditional lint screens, commonly used in these machines, have been found to have relatively low lint collection efficiency. These screens often become clogged, necessitating frequent maintenance and reducing the overall effectiveness of the drying process. The inefficiency of these traditional systems can lead to increased operational costs and potential safety hazards due to lint accumulation.

In response to these challenges, there has been a growing interest in developing high-capacity lint collection systems that can handle larger volumes of lint without frequent clogging. One promising approach is the use of cyclonic lint collection systems, which utilize centrifugal force to separate lint from the airflow. These systems have shown potential in improving lint collection efficiency and reducing maintenance requirements. However, there remains a need for further innovation to optimize these systems for commercial and industrial applications, ensuring they can handle the high demands of such environments.

SUMMARY

One aspect of the present disclosure provides a laundry system. The laundry system includes a cabinet, a particulate hopper, and a particulate collection device. The cabinet includes a tumbler for processing laundry, a bottom panel, and an exhaust. The particulate hopper includes an outer shell, a housing disposed within the outer shell, and a lint containment receptacle. Here, the outer shell, the housing, and the bottom panel of the cabinet collectively define a hopper cavity. The particulate collection device connects the cabinet to the particulate hopper and includes a bleed outlet fluidly connecting the hopper cavity to the exhaust.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, the lint containment receptacle is disposed within the hopper cavity. In some examples, the laundry system further includes a frame disposed within the outer shell. In these examples, the lint containment receptacle surrounds a portion of the frame.

In some implementations, at least a portion of the particulate hopper is one or more of disposable or replaceable. In some examples, the outer shell includes a rear side panel defining an aperture fluidly connecting the hopper cavity to the bleed outlet and a front side panel defining an access window that receives the lint containment receptacle. In these examples, the lint containing receptacle may extend from a first open end disposed at the front side panel to a second closed end adjacent to and spaced away from the rear side panel.

In some implementations, the laundry system further includes a pressure sensor communicatively coupled to data processing hardware of the laundry system. In these implementations, the data processing hardware may be configured to generate a change filter alert alerting a user of the laundry system when pressure data measured by the pressure sensor indicates that the lint containment receptacle is full. In some examples, the particulate collection device includes one or more cyclone filters coupled to a frame of the particulate hopper via respective particulate conduits. In some implementations, the lint containment receptacle includes a mesh material.

Another aspect of the present disclosure provides a laundry system. The laundry system includes a cabinet, a particulate hopper, and a particulate collection device. The cabinet includes a tumbler for processing laundry. The particulate hopper includes an outer shell and a lint containment receptacle. Here, the lint containment receptacle extends from a first open end disposed at a front side panel of the outer shell to a second closed end disposed adjacent to a rear side panel of the outer shell. The particulate collection device connects the cabinet to the particulate hopper and includes a bleed outlet fluidly connected to the rear side pane of the outer shell.

Implementations of this aspect may include one or more of the following optional features. In some implementations, the cabinet further includes an exhaust fluidly connected to the particulate hopper via the bleed outlet. In some examples, the particulate hopper further includes a housing disposed within the outer shell. Here, the outer shell, the housing, and the cabinet collectively define a hopper cavity. In these examples, the lint containment receptacle may be disposed within the hopper cavity. Additionally or alternatively, the laundry system further includes a frame disposed within the outer shell, the lint containment receptacle surrounding a portion of the frame.

In some implementations, at least a portion of the particulate hopper is one or more of disposable or replaceable. In some examples, the second closed end of the lint containing receptacle is spaced away from the rear side panel. In some implementations, the laundry system further includes a pressure sensor communicatively coupled to data processing hardware of the laundry system. In these examples, the data processing hardware may be configured to generate a change filter alert alerting a user of the laundry system when pressure data measured by the pressure sensor indicates that the lint containment receptacle is full. In some implementations, the lint containment receptacle includes a mesh material.

The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a front perspective view of a laundry system including a particulate collection device according to an aspect of the present disclosure.

FIG. 2 is rear perspective view of the laundry system of FIG. 1.

FIG. 3 is a cross-sectional view of the laundry system of FIG. 1, taken along the line 3-3 of FIG. 1.

FIG. 4 is a cross-sectional view of the laundry system of FIG. 1, taken along the line 4-4 of FIG. 1.

FIG. 5 is a perspective view of the particulate collection device of the laundry system of FIG. 1.

FIG. 6 is a top side view of the particulate collection device of the laundry system of FIG. 1.

FIG. 7 is a cross-sectional view of the particulate collection device of FIG. 5, taken along the line 7-7 of FIG. 5.

FIG. 8 is a perspective view of cyclone filters, clean air conduits, and a particulate hopper of the particulate collection device of FIG. 5.

FIG. 9 is an exploded perspective view of the cyclone filters, clean air conduits, and the particulate hopper of the particulate collection device of FIG. 5.

FIG. 10A is a partial cross-sectional view of the particulate hopper of FIG. 8, as taken along line 10A-10A of FIG. 8.

FIG. 10B is a partial cross-sectional view of the particulate hopper of FIG. 8, as taken along line 10B-10B of FIG. 8.

FIG. 11 is a perspective cross-sectional view of the particulate hopper of FIG. 8, as taken along line 10B-10B of FIG. 8.

FIG. 12 is an exploded perspective view of a cyclone filter and lint containment receptacle of FIG. 8.

FIG. 13 is a perspective view of a cyclone filter and a clean air conduit of the particulate collection device of FIG. 8.

FIG. 14A is a cross-sectional perspective view of the cyclone filter and clean air conduit of the particulate collection device of FIG. 8, taken along the line 14-14 of FIG. 13.

FIG. 14B is a cross-sectional plan view of the cyclone filter and clean air conduit of the particulate collection device of FIG. 8, taken along the line 14-14 of FIG. 13.

FIG. 15 is a front elevation view of the cyclone filter of the particulate collection device of FIG. 8.

FIGS. 16A and 16B are perspective views of a particulate conduit of the particulate collection device of FIG. 8.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

Referring to FIGS. 1-4, a laundry system 10 is illustrated and includes a cabinet 100, a particulate collection device 200, and a particulate hopper 300. Briefly, and as described in more detail below, during operation, air 12 is drawn through the cabinet 100 as it processes laundry, through the particulate collection device 200, and to the outside environment or back into the cabinet 100. The particulate collection device 200 separates particulates 14 (such as lint, hair, and other debris) from the air 12 drawn through the cabinet 100 and deposits the particulates 14 into the particulate hopper 300 at a lower portion or region of the cabinet 100 while clean air 12C separated from the particulates 14 is exhausted from the laundry system 10 and/or drawn back through the cabinet 100.

As discussed further below, the particulate collection device 200 includes one or more horizontal cyclone filters 204 disposed at a lower portion or region of the cabinet 100 (e.g., beneath a tumbler 102) to minimize the footprint of the laundry system 10 and maintain a high rate of particulate extraction with low airflow restriction. Further, the particulate collection device 200 deposits the particulates 14 at the particulate hopper 300 at the lower portion or region of the cabinet 100, which is accessible to a user at the front of the cabinet 100 for easier removal of the accumulated particulate 14 from the particulate hopper 300 and easier cleaning of the particulate hopper 300.

Advantageously, the particulate hopper 300 is in fluid communication with the particulate collection device 200 via particulate conduits 242 and a bleed outlet 240 that cooperate to provide a flow of the air 12 through the particulate hopper 300. This flow of air 12 compresses the accumulated particulates 14 within the particulate hopper 300 as air 12 flows between the particulate conduit 242 and the bleed outlet 240, thereby increasing the density of the particulates 14 within the particulate hopper 300 and increasing the number of laundry cycles of the laundry system 10 that can be run before the particulate hopper 300 needs to be emptied. Moreover, at least a portion of the particulate hopper 300 may be easily removed and/or replaced to limit the user's interaction with contaminants and/or damaging components in the accumulated particulate 14 that may be captured by the particulate hopper 300.

As shown, the laundry system 10 includes two (2) cabinets 100 (i.e., vertically stacked tumbler dryers). However, the laundry system 10 may include any number of cabinets 100 enclosing one or more dryer pockets (e.g., tumblers 102). For example, the laundry system 10 may include a single cabinet enclosing a stacked pair of tumblers 102. In other examples, the particulate collection device 200 and particulate hopper 300 may be implemented in conjunction with a cabinet or plurality of cabinets that include a single dryer, a single combined washer/dryer, stacked combined washer/dryers, or a washer stacked with a dryer.

With reference to FIG. 3, the cabinet 100 includes a tumbler 102 for processing laundry and one or more panels 104a-104f. As shown, the cabinet 100 includes a first, front panel 104a, a second, rear panel 104b disposed on an opposite side (i.e., a back side) of the cabinet 100 than the front panel 104a. A third, left panel 104c, a fourth, right panel 104d, a fifth, top panel 104e and a sixth, bottom panel 104f each extend between the front panel 104a and the rear panel 104b such that the panels 104a-104f collectively define a cavity 106 in which the tumbler 102 is disposed.

A door 114 is mounted to an opening in the front panel 104a to provide access to the tumbler 102 for the user. The cabinet 100 additionally includes a control board 116 including a user interface 118. Further, an access panel 120 is disposed at an opening in the front panel 104a below the door 114 and is removable from or movable relative to the cabinet 100 to provide access for the user to the particulate hopper 300 disposed behind the front panel 104a and below the tumbler 102. The access panel 120 may include a lock and/or an actuator for selectively granting access to the particulate hopper 300 to the user. Here, the access panel 120 may be in communication with the control board 116. When the particulate hopper 300 is full and needs to be emptied, the control board 116 may send a signal (e.g., in response to a user selecting a cleanout notification) to the actuator to unlock/open the access panel 120 for opening by a user. In other implementations, a user may manually unlock the access panel 120 using a manual locking or latching device.

The control board 116 includes data processing hardware 122 and memory hardware 124. The data processing hardware 122 can process instructions for execution within the control board 116, including instructions stored in the memory hardware 124 to display information in the user interface 118. In some implementations, the user interface 118 is rendered for display on a screen of the control board 116 and responds to any form of sensory feedback, such as visual feedback, auditory feedback, or tactile feedback, and input from the user can be received in any form including acoustic, speech, or tactile input. Additionally or alternatively, the user interface 118 includes one or more mechanical buttons and/or lights for a user to interact with.

The laundry system 10 also includes air outlets 126 formed in the rear panel 104b that connect the particulate collection device 200 to ductwork of a system exhaust 138 providing a conduit or passageway for airflow from the cabinet 100 and away from the laundry system 10, such as via an exhaust plenum 150 fluidly connecting the system exhaust 138 to the environment. In particular, the particulate collection device 200 is fluidly connected between the cabinet 100 and the system exhaust 138 via the air outlets 126 so that particulates 14 are removed from the air 12 by the particulate collection device 200 prior to (i.e., upstream of) the system exhaust 138 exhausting clean air 12C from the laundry system 10. For example, a fan 130 is disposed behind the rear panel 104b of the cabinet 100 and draws air 12 from within the cabinet 100 toward the particulate collection device 200, the particulate hopper 300, and the exhaust plenum 150. Here, the control board 116 may execute (e.g., via the data processing hardware 122) a fan algorithm to optimize a variable speed of the fan 130 based on the one or more temperature and/or pressure readings measured by sensors located in the laundry system 10. In other words, the control board 116 may increase a speed of the fan 130 in response to determining, using the fan algorithm, that the measured temperature and/or pressure of the laundry system 10 has exceeded an operating threshold.

As shown in FIGS. 3 and 4, during operation of the laundry system 10, air 12 is drawn through the cabinet 100 and into the tumbler 102. As the laundry system 10 processes laundry, particulates 14 such as lint, hair, dust, and other debris are carried with the air 12 out of the tumbler 102, through the particulate collection device 200, and out to the air outlet 126. For example, a series of apertures or through holes 140 are formed through the outer wall of the tumbler 102 and the apertures 140 fluidly connect the interior of the tumbler 102 with a portion of the cavity 106 of the cabinet 100 in fluid communication with the particulate collection device 200. The apertures 140 are configured to allow passage of air 12 and particulates 14 from the tumbler 102 toward the particulate collection device 200 without allowing passage of laundry or larger debris from the tumbler 102.

In the illustrated example, an air conduit or cavity 142 is disposed around or encircles at least a portion of the tumbler 102, such as a forward portion of the tumbler 102 toward the door 114, so that the tumbler 102 rotates or spins within the air cavity 142. A first seal 144 circumscribes the tumbler 102 and fluidly separates the air cavity 142 from a rear portion of the cabinet 100 where the air 12 is drawn into the tumbler 102 so that the air 12 is drawn into the tumbler 102 rather than directly into the air cavity 142. A second seal or flange 146 circumscribes the tumbler 102 and fluidly separates the air cavity 142 from a front portion of the cabinet 100, such as at or near the door 114. Because the air 12 and particulates 14 flow from within the tumbler 102 and through the apertures 140 and the air cavity 142 toward the particulate collection device 200, the first seal 144 and the second seal 146 preclude particulates 14 from entering portions of the cabinet 100 other than the air cavity 142 (where the particulates 14 could clog or damage components of the laundry system 10).

With continued reference to FIGS. 3 and 4, the particulate collection device 200 is fluidly connected to the air cavity 142 and is disposed within the cabinet 100 beneath the tumbler 102. Additionally, the particulate hopper 300 is fluidly connected to the particulate collection device 200 via the particulate conduits 242. The fan 130 draws air 12 through the particulate collection device 200 and the particulate hopper 300 and thus encourages airflow from the tumbler 102, through the apertures 140 and the air cavity 142 through the particulate collection device 200 and the particulate hopper 300. As discussed further below, the particulate collection device 200 separates the particulates 14 from the airflow and directs clean air 12C through a clean air conduit 232 and the particulates 14 to the particulate hopper 300. Moreover, the fan 130 draws (i.e., via the bleed outlet 240) bleed-off air 12C from the particulate hopper 300 into the clean air conduit 232 to compress the particulates 14 within the particulate hopper 300.

As shown, the particulate collection device 200 and the particulate hopper 300 are disposed within the cabinet 100 below the tumbler 102 and thus are integrated with the cabinet 100 to remove particulates 14 from air 12 drawn through the cabinet 100 without the use of a screen or conventional lint trap. The particulate collection device 200 includes one or more cyclone filters 204 that are configured to receive incoming air 12 from the air cavity 142 and separately output particulates 14 and clean air 12C. In the illustrated example, the particulate collection device 200 for each cabinet 100 includes two cyclone filters 204 and a particulate hopper 300, with air 12 drawn through both cyclone filters 204 and the particulate hopper 300 in parallel by the fan 130.

As shown in FIGS. 3, 5-9, and 12-15, the cyclone filter 204 has a substantially cylindrical body 206 that extends between a first end 208 and a second end 210 to define a cyclone cavity 212 of the cyclone filter 204. A central axis A₂₀₄ of the cyclone filter 204 extends along the cylindrical body 206 between the first end 208 and the second end 210. As shown in FIG. 3, the cyclone filter 204 extends substantially horizontally within the cabinet 100 so that the particulate collection device 200 is accommodated within a compact space beneath the tumbler 102. That is, the central axis A₂₀₄ of the cyclone filter 204 extends substantially parallel to a ground surface at which the laundry system 10 is positioned or substantially perpendicular to the front panel 104a and the rear panel 104.

The body 206 of the cyclone filter 204 includes an air inlet 214 disposed at the first end 208 of the body 206 that directs air 12 from the air cavity 142 into a cyclone cavity 212 of the cyclone filter 204, a particulate outlet 216 disposed at the second end 210 of the body 206 that directs particulates 14 removed from the air 12 in the cyclone cavity 212 toward the particulate hopper 300, and a clean air outlet 218 formed at the first end 208 of the body 206 for the clean air 12C to exit the cyclone cavity 212 of the cyclone filter 204. The air inlet 214 provides an inlet conduit 215 configured to introduce the air 12 into the cyclone cavity 212 in a substantially tangential manner relative to the body 206 and the central axis A₂₀₄. Similarly, the particulate outlet 216 directs particulate 14 from the cyclone cavity 212 in a substantially tangential manner relative to the body 206 and the central axis A₂₀₄, while the clean air outlet 218 is coaxial with the central axis A₂₀₄.

In the illustrated example, the air inlet 214 extends tangentially from the cylindrical body 206 and curves upward away from the bottom panel 104f of the cabinet 100 that forms a lower boundary of the air cavity 142. The particulate outlet 216 extends tangentially from the cylindrical body 206 and is spaced away from the bottom panel 104f of the cabinet 100 to direct particulate 14 into the particulate hopper 300 disposed above the bottom panel 104f. The particulate outlet 216 may be oriented at least partially downward toward the bottom panel 104f and connected to a particulate conduit 242 that fluidly connects the cyclone cavity 212 and the particulate hopper 300.

Referring briefly to FIGS. 12, 16A and 16B, the particulate conduit 242 may extend from a conduit inlet 244 fluidly connected to the particulate outlet 216 to a conduit outlet 246 fluidly connected to the particulate hopper 300. As shown, the particulate conduit 242 further includes a transition 248 disposed between the conduit inlet 244 and the conduit outlet 246, which allows the particulate conduit 242 to turn or curve and allow the particulate outlet 216 to be positioned closer to the particulate hopper 300, thereby saving space within the cabinet 100. Further, the air inlet 214 and the particulate outlet 216 may each have a substantially rectangular cross-section, where the cross-section of the air inlet 214 and the conduit 215 is larger than the cross-section of the particulate outlet 216 so that the volume of air 12 entering the cyclone cavity 212 via the air inlet 214 is greater than the volume of particulate 14 exiting the cyclone cavity 212 via the particulate outlet 216. In other words, a cross-section of the air inlet 214 is configured to provide a volume of air 12 to the cyclone cavity 212 sufficient to supply respective portions of the volume of air 12 to each of the particulate outlet 216 (i.e., dirty portion) and the clean air outlet 218 (i.e., clean portion). For example, the air inlet 214 includes a width W₂₁₄ that extends parallel to the central axis A₂₀₄ and the particulate outlet 216 includes a width W₂₁₆ that extends parallel the central axis A₂₀₄, where the width W₂₁₄ of the air inlet 214 is greater than the width W₂₁₆ of the particulate outlet 216.

During operation of the laundry system 10, air 12 is drawn from the air cavity 142 and through the inlet conduit 215 of the air inlet 214 into the cyclone cavity 212. As shown in FIG. 6, the central axes A₂₀₄ of the two cyclone filters 204 are arranged parallel to one another, with the air inlet 214 of one cyclone filter 204 opposing the air inlet 214 of the other cyclone filter 204 so that portions of the air 12 within the air cavity 142 flow into each cyclone filter 204. In other words, the cyclone filters 204 are formed as mirror images of each other and are arranged on opposite sides of the cabinet 100 with the particulate hopper 300 disposed between the cyclone filters 204. The clean air outlet 218 extends axially along the central axis A₂₀₄ from the first end 208 of the body 206 such that air 12 is drawn along the inlet conduit 215 and at least partially around a cylindrical neck or vortex inducer 224 at the clean air outlet 218 when entering the body 206. The width W₂₁₄ of the air inlet 214 may substantially correspond to or equal a length L₂₂₄ of the vortex inducer 224 along the central axis A₂₀₄ of the cyclone filter 204. Thus, the inlet conduit 215 and the vortex inducer 224 cooperate to define a helical conduit for airflow to promote creation of an outer spiral vortex 220 of air 12 flowing from the air inlet 214 toward the particulate outlet 216 and the second end 210 of the cylindrical body 206 (FIG. 14B).

As the air 12 travels into the cyclone body 206 and forms the outer spiral vortex 220 flowing from the air inlet 214 toward the particulate outlet 216, the particulate 14 experiences centrifugal forces that cause the particulate 14 to travel along the interior cylindrical surface of the body 206. As shown in FIG. 14B, the particulate outlet 216 is formed substantially tangential to the body 206 and the central axis A₂₀₄ to promote flow of the particulate 14 out of the outer spiral vortex 220 of air 12 and through the particulate outlet 216 to the particulate hopper 300 via the particulate conduit 242. In other words, because the cyclone filter 204 is oriented substantially horizontal (rather than vertical) and to allow for removal of the particulate 14 at the easy-to-access location of the particulate hopper 300, the tangential particulate outlet 216 relies on the centripetal acceleration of the particulate 14 against the interior surface of the body 206 and the tangential, linear velocity of the particulate 14 when the particulate 14 arrives at the particulate outlet 216. Particulate 14 is directed from the cyclone cavity 212 toward the particulate conduit 242 through the particulate outlet 216 in a generally downward and outward direction relative to the body 206. That is, the particulate outlet 216 directs particulate 14 in a direction that is at least partially downward and away from the cyclone filter 204.

To prevent movement of the outer spiral vortex 220 beyond the particulate outlet 216 at the second end 210 of the body 206 (which could result in recapture of the particulate 14 into the airflow), a vortex diverter 226 extends from the interior surface at the second end 210 of the body 206 and along the central axis A₂₀₄ toward the first end 208. The vortex diverter 226 includes an outer diverter wall 228 that has a length L₂₂₈ extending from a first end attached to the second end 210b of the body 206b to a distal second end. As shown, the length L₂₂₈ of the diverter wall 228 is greater than the width W₂₁₆ of the particulate outlet 216. The diverter wall 228 of the vortex diverter 226 is concentric with the central axis A₂₀₄ and the clean air outlet 218. The diverter wall 228 has an outer diameter D₂₂₆ that tapers from the first end of the diverter wall 228 to the second end of the diverter wall 228, and that is at least slightly larger than an inner diameter D₂₁₈ of the clean air outlet 218 at the second end of the diverter wall 228. A conical concave cap 230 is disposed at the second end of the diverter wall 228. As the airflow of the outer spiral vortex 220 approaches the second end 210 and the vortex diverter 226, the vortex diverter 226 helps to separate the particulate 14 from the airflow and to promote an interior airflow or inner spiral vortex 222 of clean air 12C along the central axis A₂₀₄ and toward the clean air outlet 218.

Thus, instead of using a long, tapered outer cylinder to allow the air vortex to turn and exit the cyclone filter 204, the vortex diverter 226 includes the cylindrical or conical diverter wall 228 that extends within the cyclone cavity 212 from the second end 210 of the body 206 and that has the diameter D₂₂₈ that is slightly larger than the diameter D₂₁₈ of the clean air outlet 218 or vortex inducer 224. This geometry influences the direction of the airflow when entering the air inlet 214 and the cyclone body 206 along the vortex inducer 224. Moreover, the vortex diverter 226 allows the body 206 to be shortened along the central axis A₂₀₄ relative to cyclone designs without a vortex diverter to further reduce the packaging requirements of the particulate collection device 200 within the cabinet 100.

With the fan 130 operating to draw airflow from the cyclone filter 204 through the clean air outlet 218, the inner spiral vortex 222 of clean air 12C flows within (i.e., radially inwardly of) the outer spiral vortex 220 and through the clean air outlet 218 at the first end 208 of the cylindrical body 206. As shown in FIGS. 5-7, a clean air conduit 232 connects the fan 130 and the clean air outlet 218 so that clean air 12C flows from the cyclone filter 204 toward the fan 130 to be exhausted from the laundry system 10 and/or reintroduced to the cabinet 100. The clean air conduit 232 includes a cylindrical mating portion 234 that is at least partially received along the clean air outlet 218 and an angled or curved or twisted portion 236 extending from the mating portion 234 toward the fan 130.

In the illustrated example, the clean air conduit 232 is manufactured separately from the cyclone filter 204 and mated with the filter 204 at the clean air outlet 218 during assembly to provide for simpler manufacturing and easier assembly of the particulate collection device 200. However, it should be understood that the clean air conduit 232 and the filter 204 may be integrally formed with one another. Further, mating the mating portion 234 of the clean air conduit 232 with the cylindrical clean air outlet 218 of the filter 204 allows the axial or rotational position of the end of the vortex inducer 224 to be adjusted and set relative to the vortex divider 226. That is, in some implementations, the mating portion 234 of the clean air conduit 232 may extend into the cavity 212 beyond an end of vortex inducer 224 so that an outer surface of the mating portion 234 operates to extend the vortex inducer 224 into the cavity 212.

Moreover, because the clean air outlet 218 is disposed axially inwardly of the first end 208 of the body 206 along the central axis A₂₀₄ and the mating portion 234 of the clean air conduit 232 extends along the vortex inducer 224 to the clean air outlet 218, the curved portion 236 of the clean air conduit 232 extends from the mating portion 234 at or near the first end 208 of the body 206. That is, the geometry of the body 206 and clean air conduit 232 allows the clean air conduit 232 to turn or curve closer to the body 206 than would be possible with an integrally formed conduit. This allows for a compact airflow solution without adding flow restriction or causing the airflow to turn at sharp angles.

As shown in FIG. 5, the clean air conduits 232 connected to the parallel filters 204 are connected to the fan 130 via a two-way manifold or adapter 238 so that, when the fan 130 is operated to draw airflow through the particulate collection device 200, air 12 is drawn in parallel through the separate filters 204. The particulate outlets 216 of the parallel filters 204 deposit particulate 14 into the shared particulate hopper 300 that is disposed between the filters 204 via opposing particulate conduits 242. It should be understood that the fan 130 may be fluidly connected to any number of filters 204 via a differently configured adapter. For example, the fan 130 may be fluidly connected to a particulate collection device 200 having one or more filters 204 servicing an upper cabinet 100 and a particulate collection device 200 having one or more additional filters 204 servicing a lower cabinet 100.

As shown in FIGS. 8-12, the shared particulate hopper 300 includes an outer shell 302, a housing 304, a frame 306, and a lint containment receptacle 308. The outer shell 302 may be mounted to the bottom panel 104f of the cabinet 100 and the particulate collection device 200 to secure the particulate hopper 300 within the cabinet 100. Moreover, the outer shell 302, the housing 304, and the bottom panel 104f may collectively define a hopper cavity 310 within which the frame 306 and the lint containment receptacle 308 are disposed. As shown, the outer shell 302 includes a first, front side panel 312a, and a second, rear side panel 312b disposed on an opposite side (i.e., a back side) of the outer shell 302 than the front side panel 312a. A third, left side panel 312c and a fourth, right side panel 312d each extend between and connect the front side panel 312a and the rear side panel 312b. The front side panel 312a may include an access window 314 through which the frame 306 and the lint containment receptacle 308 are received to install the frame 306 and the lint containment receptacle 308 into the hopper cavity 310. Additionally, the rear side panel 312b may include an aperture 316 that fluidly connects the hopper cavity 310 to the bleed outlet 240.

As best shown in FIGS. 8, 9, and 11, the housing 304 may extend between the front side panel 312a and the rear side panel 312b and include a top side 318 and sidewalls 320 extending downward from the top side 318 to meet the bottom panel 104f of the cabinet 100. As such, the housing 304, the front side panel 312a, the rear side panel 312b, and the bottom panel 104f collectively define the hopper cavity 310. Each sidewall 320 may be defined by a first portion 346 extending downward from the top side 318 at an oblique angle, and a second portion 348 extending from the first portion 346 at an oblique angle relative to the first portion 346 to a terminal end of the sidewall 320.

Referring to FIG. 12, the frame 306 may extend from a first end 322 to a second end 324 disposed on an opposite side of the frame 306 than the first end 322, and include an outer surface 326 and an inner surface 328. The frame 306 may further include opposing bands 330a, 330b disposed at respective ends 322, 324 of the frame 306, and a plurality of rails 332 extending between and connecting the bands 330a, 330b. The rails 332 and the second band 330b cooperate to define a cage 333 of the frame 306 for attaching the lint containment receptacle 308. A pair of frame apertures 334 may be formed in the first band 330a disposed at the first end 322 of the frame 306 and extend through a thickness of the frame 306 (i.e., from the outer surface 326 to the inner surface 328). Each frame aperture 334 may include a corresponding positioning flange 336 extending from the outer surface 326 and partially circumscribing the outer perimeter of the frame aperture 334.

When the frame 306 is inserted into the hopper cavity 310 (i.e., via the access window 314 in the front side panel 312a), the frame aperture 334 may generally align with and fluidly couple to the conduit inlet 244 of the particulate conduit 242 to allow the flow of air 12 and particulates 14 into the hopper cavity 310 from the cyclone filter 204. To maintain the position of the frame 306 within the hopper cavity 310 during cycles of the laundry system 10, the positioning flanges 336 may engage with the outer circumferences of the respective particulate conduits 242 and dimensionally lock the frame 306 from being over inserted into the hopper cavity 310, while the access panel 120 may prevent the frame 306 from sliding in the opposing direction (i.e., forward and out of the hopper cavity 310).

The lint containment receptacle 308 includes a containment body 350 having a length extending from a first, open end 352 of the lint containment receptacle 308 to a second, closed end 354 of the lint containment receptacle 308. The containment body 350 may generally enclose a containment cavity 356 configured to receive the particulate 14 separated from the clean air 12C by the particulate collection device 200 while allowing clean air 12C drawn by the bleed outlet 240 to flow through the containment body 350 and into the clean air conduit 232. In some implementations, the lint containment receptacle 308 includes a mesh material such as a fabric mesh and/or a metal mesh.

As best seen in FIGS. 8 and 9, the lint containment receptacle 308 is attached to the frame 306 and may encompass the outer surface 326 of the frame 306 and extend beyond the second end 324 of the frame 306. In some instances, the lint containment receptacle 308 surrounds at least a portion of the frame 306. For example, the lint containment receptacle 308 may extend from the first, open end 352 attached to the first band 330a disposed at the first end 322 of the frame 306 to the second, closed end 354 spaced away from the second end 324 of the frame 306. In other words, a length of the lint containment receptacle 308 is greater than the length of the cage 333, whereby a distal portion of the lint containment receptacle 308 defined by the second end 354 hangs from the cage 333 at the second end 324 of the frame 306. While the lint containment receptacle 308 is shown attached to the outer surface 326 of the frame 306, it should be understood that in other implementations, the lint containment receptacle 308 may attach to the frame 306 via the inner surface 328 of the frame 306. Alternatively, where the lint containment receptacle 308 includes a rigid material (e.g., wire mesh), the particulate hopper 300 may omit portions (e.g., the cage 333) of the frame 306 and/or the entire frame 306.

Referring to FIGS. 8 and 10A, the frame 306 and the lint containment receptacle 308 are disposed within the hopper cavity 310 and may extend from the front side panel 312a of the outer shell 302 and towards the rear side panel 312b of the outer shell 302. For example, the lint containing receptacle 308 may extend from the first open end 352 disposed at the front side panel 312a of the outer shell 302 to the second closed end 354 disposed adjacent to the rear side panel 312b. In some implementations, the second closed end 354 is spaced away from the rear side panel 312b to allow clean air 12C pulled through the containment body 350 to flow through the aperture 316 in the rear side panel 312b and into the bleed outlet 240. As should be appreciated, the containment cavity 356 defines a smaller volume than the volume of the hopper cavity 310 to account for an air gap between the lint containing receptacle 308 and the hopper cavity 310 to allow air 12 to flow from the particulate conduit 242, through the lint containing receptacle 308, and out through the bleed outlet 240.

As shown in FIGS. 3, 4, 7, and 11, during operation of the laundry system 10, the fan 130 draws air 12 through the cabinet 100 and into the tumbler 102. As the laundry system 10 processes laundry, particulates 14 such as lint, hair, dust, and other debris are carried with the air 12 out of the tumbler 102 and toward the particulate collection device 200. As described above, the cyclone filter 204 of the particulate collection device 200 separates the particulates 14 from the airflow, directing clean air 12C through the clean air conduit 232 and the particulates 14 through the particulate conduit 242 and into the hopper cavity 310 of the particulate hopper 300. Notably, due to the negative pressure from the fan 130 connected to the hopper cavity 310 via the bleed outlet 240, a mixture of air 12 and particulates 14 may be drawn from the cyclone filter 204, through the particulate conduit 242 and into the containment cavity 356, where the particulates 14 are compressed by the air 12 within the containment cavity 356 as it flows through the containment body 350 and out through the bleed outlet 240. Notably, by compressing the particulates 14 within the containment cavity 356, the bleed outlet 240 increases the capacity of particulates 14 that can be held in the containment cavity 356 between cleanouts of the hopper cavity 310. In other words, rather than containing the particulates 14 in a depressurized containment area where the particulates 14 may accumulate a higher volume quickly (thereby requiring more frequent cleanouts and/or maintenance of the particulate hopper 300), the negative pressure within the containment cavity 356 caused by the bleed outlet 240 fluidly connected to the fan 130 and the exhaust 138 compacts the particulates 14, thereby increasing the density of the particulates 14 before maintenance is needed.

The particulate hopper 300 further includes a pressure sensor 342 communicatively coupled (e.g., via wired or wireless communication) to the data processing hardware 122 of the control board 116. The pressure sensor 342 is configured to measure pressure within respective discrete locations of the particulate hopper 300. For instance, as shown in FIGS. 10A and 10B, the inlet pressure sensor 342 may collect pressure measurements in a first measurement area 344a adjacent to the frame apertures 334 such that the pressure sensor 342 measures the air pressure at the inlet of the hopper cavity 310. Similarly, the pressure sensor 342 may collect pressure measurements in a second measurement area 344b near the bleed outlet 240 (i.e., inside the hopper cavity 310 and/or within the clean air conduit 232) such that that the pressure sensor 342 measures the air pressure at the outlet of the hopper cavity 310. The pressure sensor 342 is configured to communicate the measured pressure data to the control board 116 of the laundry system 10. The control board 116 is configured to evaluate the measured pressure data to determine operating conditions of the laundry system 10 (i.e. the pressure difference across the lint containment receptacle 308). For example, when the pressure data measured by the pressure sensor 342 at the first measurement area 344a and the second measurement area 344b indicates a pressure difference that exceeds a predetermined threshold pressure drop within the hopper cavity 310, the control board 116 may determine that the lint containment receptacle 308 is full and no longer allowing clean air 12C to flow through the containment body 350. Here, the control board 116 may generate a change filter alert alerting the user of the laundry system 10 that the lint containment receptacle 308 is full. Optionally, the particulate hopper 300 may include a respective pressure sensor 342 on each of the particulate conduits 242 such that the pressure sensors 342 measure the pressure difference across the respective particulate conduits 242 that the control board 116 uses to determine whether one or both of the particulate conduits 242 are blocked.

In some implementations, the control board 116 generates the change filter alert when the pressure data measured by the pressure sensors 342, 344 indicates that a capacity of the lint containment receptacle 308 exceeds a fill threshold. The fill threshold may be configured by a user of the user interface 118. For example, a user may select a capacity that is an acceptable threshold for the particulate hopper 300, where the control board 116 generates a notification (e.g., warning light, alarm) in response to detecting the capacity of the lint containment receptacle 308 has exceeded the fill threshold configured by the user. In other examples, the fill threshold is configured by the manufacturer of the laundry system 10 (e.g., on a regular schedule to ensure maximum performance).

In some examples, the user accesses the hopper cavity 310 by removing the access panel 120 on the front of the cabinet 100 to reveal the frame 306 and the lint containment receptacle 308, and can remove the frame 306 and the lint containment receptacle 308 from the hopper cavity 310 to remove particulates 14 from the lint containment receptacle 308 without requiring the user to directly contact the particulates 14. For instance, the user may affix a vacuum to the frame 306 to vacuum the particulates 14 from the lint containment receptacle 308. Optionally, the lint containment receptacle 308 and/or the frame 306 are formed of relatively low-cost materials and are designed to be discarded and replaced. In other words, at least a portion (e.g., the lint containment receptacle 308) of the particulate hopper 300 is disposable and/or replaceable. After the hopper cavity 310 is cleaned, the control board 116 may send a signal to an actuator of the access panel 120 in response to receiving an indication that the user has addressed a cleanout indication displayed on the user interface 118 of the control board 116.

The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “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 features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, 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. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, 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,” “directly attached 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.

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 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 configurations.