EP3124685A1

EP3124685A1 - Laundry dryer

Info

Publication number: EP3124685A1
Application number: EP15178438.6A
Authority: EP
Inventors: Alessandro Vian; Andrea Giovannetti; Rudy Dal Molin
Original assignee: Electrolux Appliances AB
Current assignee: Electrolux Appliances AB
Priority date: 2015-07-27
Filing date: 2015-07-27
Publication date: 2017-02-01

Abstract

The present invention relates to a dryer (1) comprising:
o a casing (10) including a basement (3) having an upper shell (14) and a lower shell (13), said upper (14) and lower shells (13) being apt to be connected together in order to form said basement (3);
o a laundry chamber (6) suitable to receive laundry to be dried;
o a process air circuit (4) for circulating process air into said laundry chamber (6);
o a condensing device (60) for removing moisture from the process air coming from said laundry chamber (6) located within the process air circuit (4);
o a water collecting housing (12) located inside said basement (3) for the collection of condensation water formed by said condensing device (60);
o a water removing unit (18) associable to said water collecting housing (12) for the removal of water therein comprising a pump unit (22) located inside said casing (10); and
o a water protecting cover (40) located above said pump unit (22) apt to protect at least a portion of said pump (22) unit from condensation water condensed outside the process air circuit (4).

Description

FIELD OF THE INVENTION

The present invention concerns the technical field of laundry drying appliances. In particular, the present invention refers to laundry drying machines of the condenser type. The laundry machine of the invention has an improved construction so that the maintenance and safety of the appliance is improved.

BACKGROUND ART

Nowadays the use of laundry drying machines, both "simple" laundry drying machines (i.e. laundry machines which can only dry laundry) and laundry washing-drying machines (i.e. laundry washing machines which can also dry laundry), is widespread.
In the present description the term "laundry drying appliance" or "dryer" will refer to both simple laundry drying machines as well as laundry washing-drying machines.
Dryers capable of carrying out a drying process on laundry generally comprise a casing that houses a laundry chamber, like a rotating drum, where laundry to be dried is received. The dryer comprises a process air circuit for carrying out drying operation by circulating drying air through the laundry chamber. The circulation of process air is obtained for example by means of a fan and preferably also heating means are provided in the air circuit for heating the process air.
In condenser type dryers, condensing means are further provided in the process air circuit for removing moisture from drying air passing through the laundry thereby allowing said air to be recirculated cyclically in the chamber through the air circuit. Condensing means of the known type are usually arranged in the lower part of the dryer. In known condenser type laundry dryers, said means for condensing the moist air coming from the laundry chamber are configured in many different ways. For example, the condensing means may comprise a heat exchanger - an embodiment of which is an air-to-air heat exchanger - arranged in a basement portion of the dryer. The moist air coming from the laundry chamber flows through the heat exchanger and condensation water is formed therein.
Other type of dryers belonging to the art may comprise a heat pump which both dehumidifies and heats the process air. The heat pump typically comprises a closed circuit formed by an evaporator, a condenser and a compressor. The heat pump is typically arranged in the basement portion of the dryer and the moist air coming from the laundry chamber passes the evaporator so that moisture of the process air is removed. Like in the case of a single heat exchanger, condensation water is formed therein.
Condensation water formed in the condensing means is typically collected in a collecting housing, preferably located in the basement. The water in the collecting housing is then conveyed to a moisture tank arranged on the upper portion of the dryer so that it can be easily and periodically emptied by a user. The moisture tank is preferably in the form of a drawer slidably arranged on said upper portion of the dryer. In order to convey the water from the collecting housing to the tank, a water-removing unit is provided at said collecting housing.
The water-removing unit preferably comprises pumping means which are advantageously activated on the base of the water level inside the collecting housing. For this purpose, as an embodiment, a level sensor may also be provided at the collecting housing. Pumping means typically comprises an electric pump and a conveying pipe connecting the pump to the tank. Furthermore, an overflow pipe is usually provided between the tank and the collecting housing which permits the water from the tank to be re-admit into the collecting housing when the tank is full.
However, the removing unit above described belonging to the known art poses some drawbacks.
A drawback posed by the presence of an electric pump inside the casing of the drying machine is that the electrical cable(s) connecting the pump to a power supply or other loads might be subject to condensate water. Indeed, in a dryer appliance, water present outside the process air circuit may condense on any "cold" surface present in the appliance, such as for example on the external surface of the drum. The water that condenses in this external surface, due to the rotation of the drum, may be squirted towards other components present in the appliance, such as the pump. In case water comes into contact with the electrical contacts or cables leading to the pump, a short circuit may take place, causing power interruption.
It is known in the art, to overcome this problem, to realize cables or contacts leading to the pump which are coated with a water resistant coating. However, this requires an additional process to be implemented, in a special environment, for the deposition of the coating, which has a negative impact in terms of costs and rather long time of production.

DISCLOSURE OF THE INVENTION

The aim of the present invention is therefore to solve the noted drawbacks and thus providing a dryer having an improved water-removing unit arrangement, where the possibility of short-circuit due to condensation water are minimized.
It is a further object of the invention to implement a dryer that makes it possible to improve safety without increasing production time and costs. A further object of the present invention is to provide a dryer that makes it possible to simplify maintenance.
It is a further object of the invention to implement a dryer that makes it possible to increase reliability of the dryer.
Applicants have noted that in a dryer in which the basement is formed by the combination of two shells, an upper and a lower shell, which are joined together and defines the outer boundaries of the basement, the optimal place to realize the water removal unit is the upper shell or the lower shell of the basement itself, so that it can be easily accessible. Further, the water removal unit is covered by a cover so that condensation water condensing on any element of the dryer, such as the drum, cannot splash onto the pump and in particular onto its electrical cable(s) and/or connector(s).
According to an aspect, the invention is relative to a dryer comprising:

o a casing including a basement having an upper shell and a lower shell, said upper and lower shells being apt to be connected together in order to form said basement;
o a laundry chamber suitable to receive laundry to be dried;
o a process air circuit for circulating process air into said laundry chamber;
o a condensing device for removing moisture from the process air coming from said laundry chamber located within the process air circuit;
o a water collecting housing located inside said basement for the collection of condensation water formed by said condensing device;
o a water removing unit associable to said water collecting housing for the removal of water therein comprising a pump unit located inside said casing; and
o a water protecting cover located above said pump unit apt to protect at least a portion of said pump unit from condensation water condensed outside the process air circuit.

The dryer of the invention can be either a "single" drying machine or a "combined" washer-dryer machine, therefore including any appliance having laundry drying function. Further, it may be a front-loading dryer, which means that a laundry chamber in which the laundry is located has an axis which is positioned in a horizontal manner or slightly tilted with respect to the horizontal plane, or a top laundry dryer, where the axis of the laundry chamber is substantially vertical.
In a preferred embodiment, the laundry dryer is a front loading laundry dryer.
Preferably, the laundry chamber in which the laundry is located or removed is apt to rotate around its axis, e.g. it is a drum. Further, preferably the laundry chamber is part of a process air circuit in which process air is blown to dry the laundry.
The dryer comprises a casing preferably including a front wall, a rear wall, side walls and a base section or basement. The front wall may comprise a front top panel to command the functioning of the machine by the user. The casing defines the boundary between the internal or inner side of the dryer and the external side of the dryer. Further, preferably, the casing includes a door hinged to the cabinet, e.g. to the front wall in case of a front loading dryer, which is openable in order to introduce the laundry in the laundry chamber.
The basement is divided in an upper and a lower shell. The upper and lower shells define the outer boundaries of the basement, dividing a volume "inside" of the basement and an "outside" to the basement. In the basement a front side, a back side and two lateral sides can be defined as well, which are contiguous to the front, rear and lateral walls of the casing, when the dryer is fully assembled. Between the two shells, upper and lower, a water collecting housing is located, which is apt to collect the water which condenses due to the presence within the air process circuit of a condensing device. Alternatively, the two shells both form a bowl shape wherein the water collecting housing is defined. The condensation water coming from a condensing device is thus collected into the water collecting housing.
The condensing device of the present invention includes preferably a heat exchanger. In an embodiment such a heat exchanger includes an air-to-air heat exchanger. In a different embodiment, the laundry dryer includes a heat pump and the condensing device includes the evaporator of the heat exchanger.
Preferably, a suitable duct or a plurality of ducts connects the location where the condensed water is formed, for example a surface or basin below the condensing device where water drips, to the water collecting housing.
Preferably, the condensing device is located within the basement, that is, between the upper and lower shells. Even more preferably, such duct(s) to channel the condensed water to the water collecting housing is(are) realized integral to said lower or upper shell. Preferably, the surface or basin onto which the condensed water drips positioned below the condensing device is also integral to the lower or upper shell. Preferably, also the water collecting housing in realized integral to the lower or upper shell of the basement.
In the following with the term "realized integral to" means that the element discussed is realized as a single unit together with another element, without discontinuities. A first element realized integral to a second element thus means that the two are a single piece, a unitary body.
The removal of the water from the water collecting housing in the basement takes place by means of a water removing unit.
The water removing unit includes a pump unit which pumps the water out from the water collecting housing. The water can be pumped from the housing for example to a tank positioned in an upper part of the dryer. This tank, in generally, is realized as a drawer, so that the excess water can be removed by the user. However other possibilities are foreseen as well, for example the removal of the water takes place by the pump and it is discharged directly to the drain. In order to pump the water away from the housing, the pump unit is at least for a portion introduced inside the water collecting housing.
As described, condensation water which is formed in the condensing device is collected in the water collecting housing. However, due to the temperature differences within the various elements present inside a dryer and the usually moist ambient conditions, water may condense also outside the air process circuit, for example on any "cool" surface, such as on the outer surface of the drum. When the drum rotates, the water condensed on it is ejected in any possible direction, among which a direction towards the pump unit. In order to protect the electrical contacts and connectors from this condensation water which has condensed outside the process air circuit, a cover has been provided which covers the pump unit itself. A cover located on top of the pump unit, which is located within the basement, covers the pump unit itself at least for a portion and preferably also all the electrical connections and cables which might be damaged by the condensation water drops. The cover is located above the pump unit so as to protect the latter in particular from water drops falling or ejected from above, due to the fact that in a preferred embodiment the drum is located above the basement and thus also above the pump unit.
The cover is preferably easily removable so that easy access is obtained to the pump unit itself.
According to the above mentioned aspect, the dryer of the invention may include in combination or alternatively any of the following characteristics.
Preferably, said water removing unit includes a support body to support said pump unit, said support body being integral in a single piece construction with said upper or lower shell.
The support body supports the pump unit and, in order to limit the number of separated parts to be assembled in the dryer of the invention, the support body is an integral part of the upper or lower shell. Preferably, the support body is an integral part of the upper shell of the basement.
Preferably, said water collecting housing is integral in a single piece construction with said lower or upper shell.
A further minimization of the number of dryer's components is preferably obtained using as a single "multipurpose" unit the lower or upper shell of the basement. The water collecting housing where water is collected thus includes a basin directly formed in the lower or upper shell, without a further introduction of a detached/detachable water collecting housing to be inserted in the basement. Preferably the water collecting housing is integral to the lower shell. More preferably, the water collecting housing includes lateral walls and a bottom wall which are preferably integrally formed in a single piece construction with the lower shell.
Preferably, said basement defines a basement plane parallel to a plane on which the dryer rests and said water removing unit includes a support body to support said pump unit, said support body being formed in a portion of said upper or lower shell which is substantially flat and having a major component parallel to said basement plane.
In a standard operative position, a dryer in a three-dimensional coordinate system defines a substantially horizontal plane which is the basement plane and a vertical axis, which is the vertical direction along which the dryer extends from the floor. Preferably, the upper shell or lower shell includes a flat region, or a region which is for the majority substantially flat, which is substantially parallel to the basement plane itself and defines the support body. In this case, "substantially parallel" means that a projection of the flat region onto the basement plane is the largest projection among the projections of the flat region on the basement plane and on a plane perpendicular to it.
This means that the support body includes a flat portion of the upper or lower shell which in turn comprises a surface that "faces upwards" - at least for most of it - in the basement. This adds simplicity in the mounting and dismounting all elements attached/coupled to the support body because it can be more easily reached.
Advantageously, the water protection cover includes a basin to contain said condensation water.
Preferably, the cover is not only a shield for the water drops, but it can also collect them, so that the drops of water impinging on the cover are not bounced towards another element of the dryer, wetting it. In this way, the water drops are collected and kept inside the basin formed in the cover itself.
More preferably, said basin includes a boundary rim wall having a notch to pour out said condensation water condensed outside the process air circuit.
It is preferred to drain the water which is collected in the cover, to avoid overflows of the same or instability of the cover due to the weight of the collected water. Therefore, preferably, the water can flow in a controlled manner out of the cover by means of an aperture or notch formed in a boundary rim wall of the cover.
In a preferred embodiment, said basement defines a basement plane and said water protecting cover is substantially inclined with respect to said basement plane.
Water flows out of the cover through the notch or aperture on the rim wall by means of gravity due to the inclination of the cover. In this way, the area in which the water outflows is controlled or controllable depending on the inclination of the cover.
Preferably, said water protecting cover includes a projecting arm to anchor the water protecting cover to said upper or lower shell.
The cover is preferably fixed to the basement so that it does not move from its predefined position above the pump unit. The dryer during its standard cycles might vibrate due to the drum rotation and therefore, if not fixed, movements of a loose cover are possible and thus misplacement of the same. In order to obtain a simple and reliable fastening between the cover and the basement, a connecting arm projecting from the cover is foreseen. The arm preferably includes a hook to connect the cover to the upper or lower shell of the basement.
Preferably, said basement includes a channel for guiding said process air, said channel channeling process air from said condensing device to an exit where process air leaves said basement, said water protecting cover including a flap in abutment onto a wall of said channel.
More preferably, the wall is an outer or external wall of the channel, that is, the wall closest to the casing walls of the dryer.
The basement generally includes a portion of the air process circuit, so that the humidity contained in the process air coming from the laundry chamber is removed by the condensing device, preferably also heated and recirculated into the laundry chamber. From the condensing device to the laundry chamber, a channel is present, part of the air process circuit, so that the process air exiting the condensing device can be guided outside the basement in order to be transported back into the laundry chamber. Preferably, this channel is integral to the basement. The channel, together with the casing of the dryer, preferably delimits the volume where the support body is formed in the upper or lower shell. The position of the support body is selected being both easily reachable from the exterior of the dryer (which means with a minimum number of dryer's components to be removed) and also in such a way that the outline of the basement does not have to be excessively modified. Indeed, in the basement generally a plurality of "bulky elements" are present and the repositioning of the same is often very complex and cumbersome.
Changing the outline of the basement, and in particular the positioning of the various components, especially in case of a heat pump dryer, is very complex due to the fact that certain components' dimensions are substantially fixed and the volume of the basement is limited by construction constraints. Therefore, it is preferred to determine the location of the cover so that only minimal changes in the positioning of the components, in particular of the heat pump if present, are needed.
More preferably, said external wall of said channel is integral in a single piece construction with said upper shell or with said lower shell.
Advantageously, the channel itself is formed by the basement's shells, and it is defined by joining together the upper and the lower shell. Preferably an upper half of the channel including the external wall is formed integral to the upper shell and a lower half of the channel is formed integral to the lower shell. Again, the number of elements to be assembled in the laundry dryer of the invention is in this way reduced.
Advantageously, the cover rests on this wall of the channel by means of a flap. This flap is present to avoid vibrations or movement of the cover when the dryer is in an operating position and to give stability and resistance to the cover in case water is present therein.
More preferably, the dryer includes a screw screwing said flap onto said wall on said channel.
In this way, a firm connection between the cover and the basement is realized and there is no or minimal risk of accidental misplacement of the cover from its desired position above the pump unit.
Advantageously, said water removing unit includes a support body to support said pump unit and said water protecting cover is located above said support body and includes a reinforcement wall extending towards said support body.
Preferably, during mounting of the cover above the pump unit, the flap of the cover is placed on the wall of the channel of the process air formed in the basement and fastened therein, for example by means of a screw. However, when the screwing takes place, the cover might rotate due to the applied torque on the screw and the cover itself might be moved from the preferred position. Therefore, preferably, the reinforcement wall abuts against the wall of the channel so that rotations of the cover are avoided. The functionality of a prevention of rotations or shifts tool is present also during the normal dryer functioning; when - as already mentioned - vibrations are possible. Further, the reinforcement wall, in addition to the flap and the arm, has the function to bear the weight of the cover and the water possibly collected therein.
In an embodiment, the water removing unit includes a support body to support said pump unit, said support body comprising a closable access aperture to access said water collecting housing.
According to a preferred embodiment of the invention, the water collecting housing is closed by the support body, so that the condensed water possibly included therein cannot easily come out. The support body is preferably a portion of the upper shell or of the lower shell, more preferably of the upper shell, and it is located substantially on top of the water collecting housing to close the same. The support body comprises a closable access aperture to access said water collecting housing. The aperture can have any desired geometrical shape depending on the position of the same and on the shape of the support body itself. The access aperture can be therefore opened in order to access the housing, and closed when access is not desired. The provision in the support body of a closable access aperture allows an easy access to the water collecting housing when needed without having to dismount the basement. From the access aperture, the water collecting housing can be emptied. Further, from the access aperture, the duct bringing water from the condensing device to the water collecting housing can be accessed as well, passing through the inlet. A tool can be used to move the fluff or lint that may cause a blockage inside such duct.
The access aperture is advantageously closed when access to the water collecting housing is not needed, so that no water can be accidentally spilled. The simple access to the water collecting housing and/or duct from the upper shell of the basement allows an easy mounting and maintenance of the dryer of the invention.
More preferably, said support body further comprises a lead surface to lead condensation water present onto said support body towards said closable access aperture.
The lead surface helps the removal of water from the support body and the flow of the water into the water collecting housing.
Even more preferably, said water protecting cover is apt to pour condensation water collected therein at or in proximity of said closable access aperture and/or said lead surface.
The water collected in the cover and falling onto the support body from the notch or aperture realized in the cover itself, which is also preferably inclined, is preferably not remaining on the support body, where it could still wet the pump unit, but it is directed towards the aperture in the support body and in this way it can flow into the water collecting housing. The possibility of wetting the pump and the electrical connections thereof is therefore minimized. The flow of the water into the water collecting housing is facilitated by the presence of the lead surface, if available.
Advantageously, said water removing unit includes a support body to support said pump unit, said support body comprising a contouring wall defining an elevated border in which said pump unit is hosted.
In order to further minimize the risk of contact between the condensate water collected in the cover and then fallen from the cover to the support unit of the pump unit, the support body includes a perimetral wall contouring the pump unit, so that only in the very remote case of a very large amount of water, the water can flood the pump.
Advantageously, said upper and lower shells are realized in polymeric material.
The usage of polymers allows the molding of the shells and realization of many elements integral to the shells in a simple and relatively economical manner. Polymeric materials are very versatile and easy to manufacture, therefore they are a very good candidate for the realization of the shells which preferably integrate different functionalities and components into themselves.
Preferably the upper and lower shells are molded, more preferably injection molded.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate possible embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings, corresponding characteristics and/or components are identified by the same reference numbers. In particular:

Figure 1 shows a perspective view of a laundry drying machine with a wall removed in order to show a water-removing unit mounted therein according to the invention;
Figure 2 shows a perspective view of a basement and drum of the laundry drying machine illustrated in Figure 1;
Figure 3 shows a perspective view of the basement of figure 2 with the upper shell removed;
Figure 4 and Figure 5 show two perspective views of the basement of Figure 2; and
Figure 6 and Figure 7 show two perspective views of an element of the basement of the laundry drying machine of Figure 2 removed from the remaining of the basement.

DETAILED DESCRIPTION OF THE INVENTION

With initial reference to figure 1, a dryer according to the invention is globally indicated with 1.
In the present detailed description the term "laundry drying machine" or "dryer" will refer to both simple laundry drying machines and combined laundry washing and drying machines. The preferred embodiment is relative to a heat pump laundry drying machine, however the invention can be applied to any type of dryer.
The dryer 1 comprises a casing 10 formed advantageously by a front and a back wall 2a, 2b and a couple of side walls 2c-2d arranged perpendicularly one another. An upper wall 2e closes the top end of the box-like structure formed by the walls 2a-2d. However, some of the mentioned walls need not to be vertical, a one or more tilted wall are foreseen as well. In Figure 1, the lateral side wall 2c has been removed for showing some of the dryer parts accommodated within casing 10.
Further, the casing 10 includes a basement 3, better detailed below, onto which the walls 2a-2d are connected and it represents the lower portion of the dryer 1. The basement also defines a front side, back side and lateral sides which represent the external boundaries of the basement 3 and correspond to the front, back and lateral walls, respectively, of casing 10.
The casing 10 defines in a three-dimensional coordinate system a horizontal plane (X,Y) also called basement plane, and a vertical axis Z, along which the dryer 1 extends from the floor on which is commonly positioned in an operative position. Plane (X, Y) might also be tilted with respect to the horizontal plane if the floor or ground on which the dryer 1 is located is tilted.
A laundry chamber 6, preferably comprising a rotatable drum, is provided within the casing 10. In case of a combined clothes washing and drying machines, the rotatable drum is opportunely contained in a washing tub (not depicted in the attached drawings). The drum 6 is visible in its entirety in figure 2 where the casing 10 has been removed, with the exception of the basement 3. The axis of rotation of the drum 6 is called R, and it can be vertical, horizontal or tilted depending on the type of dryer considered. In a preferred embodiment, the rotational axis R is substantially horizontal or slightly tilted from the basement plane (X, Y).
Casing 10 preferably further includes a front door 8 pivotally coupled to the front upright side wall 2a for allowing access to the drum interior region to place laundry to be dried therein. A user control interface 5 is preferably arranged on the top of the casing 10 for input of laundry drying programs and displaying machine working conditions.
The dryer 1 further comprises a process air circulating circuit 4, depicted as plurality of arrows in figure 2, adapted to circulate a flow of process air in and out of the drum 6. The process air circulating circuit advantageously comprises a fan, not illustrated, which blows a flow of drying air through the drum 6. The air circulating circuit preferably comprises a heating device, adapted to heat up the air at a location upstream of the drum 6. Preferably, in the present embodiment the heating device is included in a heat pump 40, shown in figure 3, for example it includes a condenser 42 of the heat pump. Alternatively, an electric heater can be used as well, when a heat pump is not present, or even in combination with the heat pump.
Circulation of the process drying air inside the drum 6 evaporates the moisture from the wet laundry so as to form a moisture-laden process air, or moist process air. The moist process air then exits the drum 6 preferably at the front side of the dryer 1, as depicted in figure 2. The moist process air enters into the basement 3 where the moisture included in the process air is at least partially removed by means of a condensing device, in this case the evaporator 41 of heat pump 40, or alternatively a heat exchanger, such as an air-to-air heat exchanger. In figure 2, a heat exchanger casing 7 is shown apt to house the condensing device, in the depicted embodiment both heat exchangers (condenser 42 and evaporator 41) of heat pump 40.
In this case moist air passes the evaporator 41 and is cooled by the evaporator itself. The evaporator condenses the water vapor of the moist air and the water formed therein falls in a bottom surface 11, better detailed below.
The process air conduit 4 then exits the basement 3, preferably from the back of the basement, and the process air is fed again to the drum 6.
The basement 3, with now reference to figures 2 and 3, includes a lower shell 13 and an upper shell 14, which are coupled together defining the basement 3. The upper shell 14 forms the upper portion of the basement, while the lower shell 13 forms the lower portion of the basement. Both upper and lower shells form together the front, back and lateral sides of the basement. Preferably, the upper and the lower shell 14, 13 are realized in polymeric material and are preferably formed in a molding process. In the basement, thus as internal volume to the shells can be defined as the "interior" to the basement.
Preferably, the process air conduit 4 includes a basement portion which is formed as a combination of the upper and lower shell 14, 13, that is the basement portion of the process air conduit is divided in two half, a lower half and an upper half, each half realized integral to with the respective shell, defining an air process duct basement portion.
The basement portion of the process air circuit 4 includes the casing 7 for the heat pump 40 and a channel 30, located downstream of the casing 7 in the direction of flow of the process air, which channels the process air exiting the condenser 42 of the heat pump 40 outside the basement 3. Channel 30 and casing 7 are visible for example in figure 2 and are better detailed below.
The casing 7 for the heat exchangers 41, 42 includes a bottom surface, which in turn comprises the bottom surface 11 on which the condensed water drips from the evaporator 41.
Preferably, the bottom surface 11 is realized as an integral part of the lower shell 13.
Further, dryer 1 includes a water collecting housing 12 to collect the condensed water. By means of duct(s) or channel(s), such as duct 50 visible in figure 3, from the bottom surface 11 the condensed water is collected in the water collecting housing 12. The collecting housing 12 is arranged in the interior of the basement 3 of the dryer 1, between upper 14 and lower shell 13. Preferably, the water collecting housing includes lateral walls 12a surrounding the housing and a bottom wall 12b. Water collecting housing 12 is also preferably integral to the lower shell 13, that is bottom wall 12b and lateral walls 12a are a unitary single part with the lower shell 13. More preferably, the water collecting housing 12 is arranged at the rear side of the lower shell 13 of the dryer 1, as illustrated in Figure 3. Preferably, two lateral walls 12a of the housing 12 are adjacent to a corner 16 formed in the basement 3. Preferably, the housing 12 is formed in a corner 16 of the basement 3, so that two lateral walls 12a of the housing 12 are two portions of the back side and of one of the two lateral sides of the basement 3.
Preferably duct 50 is located substantially parallel to one of the lateral sides of the basement. More preferably it is located in proximity of one of the lateral side of the basement 3, that is, between the heat pump 40 and the boundary of the basement 3.
Duct 50 ends in housing 12 defining an inlet 51 for the condensed water. In order to better channel condensed water accumulated in surface 11 to housing 12, preferably duct 50 is slightly vertically tilted, that is a point of a bottom surface of duct 50 at surface 11 is higher in the vertical direction than a point at the inlet 51, so that water flows to water collecting housing 12 by gravity.
Furthermore, in addition to the condensing device - heat pump 40 -, on the basement 3 are preferably arranged other operational devices of the dryer, like air pumping means or electric motors. Advantageously, the upper and lower shells 14, 13 of basement 3 are opportunely shaped so as to create air paths wherein the air is opportunely conveyed. Further, in case of a heat pump dryer, the basement 3 also hosts a compressor 43 of the heat pump. These operational devices or components preferably are arranged in a specific outline within the basement 3, as depicted for example in figure 3.
With reference to the top view of the basement of figure 3, the basement 3 can be divided in four quarters by two substantially parallel centerlines R and H of the basement 3. The centerline R is preferably substantially parallel to the rotational axis R (centerline and axis are indicated with the same reference number) of the laundry chamber or drum 6 in case of a front loading washing machine, and is also parallel to the side walls 2c, 2d of the casing 10. Centerline H is preferably substantially perpendicular to centerline H and it is substantially parallel to the front and back wall 2a, 2b of casing 10. The four quarters so visualized are counted in a clockwise manner from the first quarter which includes a portion of the back side of the basement and a portion of one of the lateral sides (the left side when the drying machine is viewed in a front view) and includes corner 16, the second quarter includes the second portion of the back wall and a portion of the opposite lateral side wall to the one included in the first quarter, and so on.
Further, in a preferred embodiment, preferably the condensing device - heat pump 40 - is located in the fourth quarter of the basement, or at least for the majority of its volume in such fourth quarter, as visible from figure 5. Heat pump 40 might also occupy part of the first quarter. The process air exits the heat pump, preferably the condenser 42 of the heat pump 40 in the first quarter or substantially at the boundary between the first and fourth quarter, and from there it is channeled by means of channel 30 within the basement 3 to an exit 31 of the basement 3, so that it can be returned into the drum 6. The exit 31 is preferably formed in the second quarter and more preferably at the back side of the basement 3 in the second quarter. For this purpose, the channel 30, which is part of the process air circuit 4 above mentioned, is formed in the basement 3, and half of such channel 30 is preferably integral to the upper shell 14 (the upper portion of the channel 30) and the other half (the lower portion) is integral to the lower shell 13. This channel 30 is disposed preferably for the majority of its volume in the first and second quarter of the basement, as depicted in figure 3, so that it can channel the process air exiting the heat pump 40 to the exit 31. The channel 30 has advantageously a concave shape in a top view, the concavity of which is directed towards the center of the basement. Further, the channel 30 includes an external wall 32 which is the wall in top view closer to the boundaries of the basement 3. Preferably, external wall 32 is integral to the upper shell 14.
Preferably, the water collecting housing 12 is realized in the first quarter of basement 3 and even more preferably it includes corner 16 of the lower shell 13. More preferably, the water collecting housing 12 is located between the external wall 32 of the channel 30 and the boundary of the basement 3. Therefore, in this preferred embodiment, the form of the water collecting unit 12 is substantially that of a solid the base of which, i.e. the bottom wall 12b, includes two substantially perpendicular lines, the boundaries of the lower shell at corner 16, and a curved line joining the two perpendicular line, which follows the shape in a top view of the external wall 32 of channel 30. From this base, delimiting the bottom wall 12b, the lateral walls 12a extends substantially orthogonal to bottom wall 12b.
Condensation water from the collecting housing 12 is preferably conveyed to an extractable moisture tank 17 (see figure 1) located at the upper portion of the dryer 1. The moisture tank 17 is preferably in the form of a drawer slidably arranged in a box-shaped housing (not visible) on said upper portion of the dryer 1 so that it can be easily and periodically emptied by a user.
Condensation water from the collecting housing 12 is conveyed to the extractable moisture tank 17 by means of a water-removing unit 18 associated to the collecting housing 12. The water-removing unit 18 preferably comprises a support body 21, a pumping unit 22 and preferably also a water level sensing device 23. The pumping unit 22 and the sensing device 23 are preferably associated to the support body 21 in a removable way so that they can be easily mounted or removed during either manufacturing or maintenance.
The support body 21 preferably includes a flat-shaped member which is more preferably formed substantially parallel to the basement (X, Y) plane. Support body 21 is integral in a single piece construction to upper shell 14, for example is fabricated during the same plastic molding process. Preferably, the support body 21, besides supporting the pump unit 22 and the water level sensing device 23, has also the function of a cover of the water collecting housing 12. Indeed, preferably support body 21 is located above water collecting housing 12 and it engages with lateral walls 12a forming the upper closure of the same.
The flat shaped member defining the support body 21 thus has a first surface facing the interior of the basement 3 - preferably the housing 12 and more preferably bottom surface 12b - and a second surface, opposite to the first, facing the exterior to the basement and substantially facing upwards.
Preferably, in order to strengthen the connection between the flat element defining the support body 21 and the remaining of the upper shell 14, so that the support body does not easily bend, ribs 19 are provided on the external wall 32 of the channel 30 and reaching the flat element defining the support body 21.
The support body 21, covering the housing 12, is preferably substantially flat and, when the basement 3 is positioned in a standard operative position, is substantially horizontal and faces with one of its surfaces upwardly as an integral part of the upper shell (e.g. as a single unit with the upper shell, for example formed in the same molding process). The support body 21 closes as a cover the housing 12 where water condensed from the condensing device 40 can be collected.
Support body 21 further includes an access aperture 60, for example realized as a through hole in support body 21, which renders the inside of the housing 12, normally closed by support body 21, accessible. Access aperture 60 is advantageously openable and closable by means of a shutter 61, which is preferably hinged on support body 21. The hinge of the shutter 61 in the depicted embodiment is formed by a line of thinner material belonging to the support body 21. The shutter 61 can be rotated along a hinging axis, so that the interior of the housing 12 can be reached; or it can be lying on the support body 21 closing the aperture 60. Preferably, in a non-depicted embodiment, the support body in a neighborhood of the access aperture 60 includes a lead surface to lead the water formed or collected onto the support body towards the aperture 60 and in turn into housing 12. The lead surface can include for example a concave surface at the center of which the aperture 60 is formed.
Access aperture 60 is preferably located on support body 21 in proximity of the inlet 51, that is, on an area of the support body 21 which is located adjacent to inlet 51. For example, in case the pump unit 22 is also located on support body 21, in a projection onto the basement plane (X, Y) access aperture 60 is located between pump unit 22 and inlet 51.
A conveying pipe, not shown in the appended drawings, connects the pump unit 22 to the tank 17. The condensed water which comes from the condensing device 40 and reaches the housing 12 is conveyed in turn to the tank 17 through the conveying pipe by means of the pump unit 22. Further, an overflow pipe might be present, also not shown, which preferably connects the tank 17 to the housing 12. When the tank 17 is full, the water flows from the tank 17 to the housing 12 through the overflow pipe. A "full tank" warning alarm is then advantageously emitted for the user, for example an acoustic and/or a visual alarm, so that he/she can remove the excess water from tank 17.
In further embodiments, not depicted, the condensed water from the housing 12 may be conveyed by the pump unit 22 outside through a pipe connected to an external waste water drain. In this case, only the conveying pipe is provided and no further overflow pipes.
However, during the functioning of the dryer, water does not condense only within the process air conduit 4, and in particular not only at the evaporator 41. Some water, due for example to the temperature differences present inside the dryer, may also condense elsewhere and may form droplets. These droplets, if formed in the drum, when the latter rotates may splash other elements present in the basement, among others the pump unit 22 which is connected to a power supply and/or a control unit via electrical contacts or cables (all not shown in the drawings).
With now reference to figs. 4 and 5, the pump unit 22 is preferably covered by a water protecting cover 40 suitable to protect the pump from the water which condenses outside the process air conduit and thus it is not conveyed into housing 12 by channel 50. The water protecting cover 40 is positioned above the pump unit 22 and preferably it is not in contact to the latter. In order to be suspended above the pump unit, the cover 40 includes a protruding arm 44 and a flap 45 to anchor itself onto the basement 3. The protruding arm 44 may include a hook 48 to anchor the cover 40 to the basement, preferably to the rear side of the basement. Further, flap 45 is preferably in abutment to the external wall 32 of the channel 30 and more preferably the flap 45 has a curved shape in order to follow the curved contour of the wall 32 of channel 30. The flap 45 includes a through hole 49 in order to be fixed by means of a screw 47 on the wall 32 of the channel, so that movements of the cover 40 during the drying or washing cycles are prevented or minimized. The mounting of the cover 40 on the basement and its fastening by means of the arm and the flap is realized in such a way that the cover 40 is inclined with respect to the basement plane (X, Y). That is to say that gravity pushes water which might be deposited on the cover 40 towards a given direction, and this direction is given by the inclination of the cover 40. Therefore, water collects on a specific side of the cover 40. Preferably the cover 40 is inclined in such a way that water flows by gravity towards its side which is closer to the access aperture 60.
The water protecting cover 40 is shown in an enlarged view and in details in the figures 6 and 7. The cover 40 preferably includes additionally a basin 41 to collect the water that is accidentally splashed on it. The basin is formed by a rim wall 42 contouring the cover 40. The rim wall 42 includes a notch or aperture 43 on the lower side, that is, on the side which is inclined towards the access aperture 60. The notch 43 allows the water present on the cover 40 which gathers at the inclined side where the notch 43 is formed to fall into the support body 21. In the support body 21, the risk of wetting the pump unit 22 is minimized by the advantageous presence of a contouring wall 26 protruding substantially in a vertical direction from the support body 21 upwards and surrounding the pump unit. The height of the contouring wall 26 is such that the possibility that enough water is collected in the support body 21 so that its level is higher than the contouring wall is highly unlikely. In addition, preferably, due to the construction and position of the cover 40, the water falls onto the support body 21 in proximity or onto the access aperture 60. Water therefore can easily fall into the housing 12, where also the condensate water coming from the process air circuit 4 is collected. In case a lead surface is formed onto the support body, water is even more easily channeled into the housing 12 via access aperture 60.
In addition, cover 40 includes a reinforcement wall 46 protruding from a surface of the cover facing the basement 3. The reinforcement wall preferably abuts against the support body 12 so that the weight of the cover 40 is borne not only by the arm 44 and flap 45, but also by the support body 21 via the reinforcement wall 46. Further, reinforcement wall 46 may have the function of anti-rotation element when the cover is mounted and the flap is fixed to the external wall 32 of channel 30 by means of the screw 47.
The cover 40 therefore protects the pump unit 22 and the electrical connections thereof from water which condenses outside the process air channel and preferably also collects this additional condensate water to channel into towards the housing 12.

Claims

A dryer (1) comprising:
o a casing (10) including a basement (3) having an upper shell (14) and a lower shell (13), said upper and lower shells being apt to be connected together in order to form said basement;

o a laundry chamber (6) suitable to receive laundry to be dried;

o a process air circuit (4) for circulating process air into said laundry chamber (6);

o a condensing device (60) for removing moisture from the process air coming from said laundry chamber (6) located within the process air circuit (4);

o a water collecting housing (12) located inside said basement (3) for the collection of condensation water formed by said condensing device;

o a water removing unit (18) associable to said water collecting housing (12) for the removal of water therein comprising a pump unit (22) located inside said casing (10); and

o a water protecting cover (40) located above said pump unit (22) apt to protect at least a portion of said pump unit from condensation water condensed outside the process air circuit (4).
The dryer (1) according to claim 1, wherein said water removing unit (18) includes a support body (21) to support said pump unit (22), said support body (21) being integral in a single piece construction with said upper or lower shell (13, 14).
The dryer (1) according to claim 1 or 2, wherein said water collecting housing (12) is integral in a single piece construction with said upper or lower shell (13, 14).
The dryer (1) according to any of the preceding claims, wherein said basement (3) defines a basement plane (X, Y) parallel to a plane on which the dryer rests and said water removing unit (18) includes a support body (21) to support said pump unit (22), said support body (21) being formed in a portion of said upper or lower shell which is substantially flat and having a major component parallel to said basement plane.
The dryer (1) according to any of the preceding claims, wherein said water protection cover (40) includes a basin (41) to contain said condensation water.
The dryer (1) according to claim 5, wherein said basin (41) includes a boundary rim wall (42) having a notch (43) to pour out said condensation water condensed outside the process air circuit (4).
The dryer (1) according to any of the preceding claims, wherein said basement (3) defines a basement plane (X, Y) parallel to a plane on which the dryer rests and said water protecting cover (40) is substantially inclined with respect to said basement plane.
The dryer (1) according to any of the preceding claims, wherein said water protecting cover (40) includes a projecting arm (44) to anchor the water protecting cover (40) to said upper or lower shell (14,13).
The dryer (1) according to any of the preceding claims, wherein said basement (3) includes a channel (30) for guiding said process air, said channel (30) channeling process air from said condensing device (60) to an exit (61) where process air leaves said basement (3), said water protecting cover (40) including a flap (45) in abutment onto a wall of said channel (30).
The dryer (1) according to claim 9, including a screw (47) screwing said flap (45) onto said wall on said channel (30).
The dryer (1) according to any of the preceding claims, wherein said water removing unit (18) includes a support body (21) to support said pump unit (22) and said water protecting cover (40) is located above said support body (21) and includes a reinforcement wall (46) extending towards said support body (21).
The dryer (1) according to any of the preceding claims, wherein said water removing unit (18) includes a support body (21) to support said pump unit (22), said support body (21) comprising a closable access aperture (60) to access said water collecting housing (12).
The dryer (1) according to claim 12, wherein said support body (21) further comprises a lead surface to lead condensation water present onto said support body (21) towards said closable access aperture (60).
The dryer (1) according to claim 12 or 13, wherein said water protecting cover (40) is apt to pour condensation water collected therein at or in proximity of said closable access aperture (60) and/or said lead surface.
The dryer (1) according to any of the preceding claims, wherein said water removing unit (18) includes a support body (21) to support said pump unit (22), said support body (21) comprising a contouring wall (26) defining an elevated border in which said pump unit (22) is hosted.
The dryer (1) according to any of the preceding claims, wherein said upper (14) and lower shell (13) are realized in polymeric material.