GB2559559A

GB2559559A - Washing machine counterweights

Info

Publication number: GB2559559A
Application number: GB1702049.6A
Authority: GB
Inventors: Soheil Hamadeh Samer
Original assignee: Tochi Tech Ltd
Current assignee: Tochi Tech Ltd
Priority date: 2017-02-08
Filing date: 2017-02-08
Publication date: 2018-08-15
Also published as: GB201702049D0

Abstract

A washing machine counterweight 202 and method of installation comprising a counterweight used in a washing machine wherein the washing machine consists of a tub, at least one drum disposed in the tub 204, at least one drive unit mechanically coupled to the tub, and at least one refillable hollow counterweight. A second embodiment discloses a method of installation comprising the steps of; positioning the hollow counterweight and tub close together; filling the hollow counter weight; and draining the hollow counterweight. The counter weight may comprise of a filling portion 212, a main body and at least one transition portion, wherein the filling portion may comprise a lid. The counterweight may also have a combined filling portion and transition portion. Filling of the counterweight ballast may be actuated by a valve in the transition portion. The valve may be actuated by either fluid flow or by using parametric data collected from at least one sensor.

Description

(54) Title of the Invention: Washing machine counterweights Abstract Title: Washing machine hollow counterweight (57) A washing machine counterweight 202 and method of installation comprising a counterweight used in a washing machine wherein the washing machine consists of a tub, at least one drum disposed in the tub 204, at least one drive unit mechanically coupled to the tub, and at least one refillable hollow counterweight. A second embodiment discloses a method of installation comprising the steps of; positioning the hollow counterweight and tub close together; filling the hollow counterweight; and draining the hollow counterweight. The counter weight may comprise of a filling portion 212, a main body and at least one transition portion, wherein the filling portion may comprise a lid. The counterweight may also have a combined filling portion and transition portion. Filling of the counterweight ballast may be actuated by a valve in the transition portion. The valve may be actuated by either fluid flow or by using parametric data collected from at least one sensor.

FIG. 2

1/7

FIG. 1

2/7

210

FIG. 2

3/7

FIG. 3

4/7

414

FIG. 4

5/7

522a

514

522d

FIG. 5

6/7

FIG. 6

7/7

700

722

FIG. 7

Manufacturer factory

User site

724

WASHING MACHINE COUNTERWEIGHTS

TECHNICAL FIELD OF INVENTION [0001] The invention relates to washing machines, and particularly to counterweights used in washing machine.

BACKGROUND [0002] Front-load or horizontal-axis washing machines usually comprise an outer tub, inner drum, counterweights, a detergent tray, an electric motor, a drainage pump and a controller. The outer tub and inner drum are concentric cylindrical devices mounted around a horizontal or nearly horizontal axis, and the inner drum loads the clothes through a door provided at the front of the machine. The washing action of the clothes or laundry is achieved through the back-and-forth rotation of the inner drum and outer tub, powered by electric motors. A controller is operatively connected to an electric motor to regulate the motion of the inner drum and washing sequences thereto, based on the user’s commands selected on the user panel.

[0003] During the operation of the front-load washing machine, once the clothes are loaded into the inner drum, water is entered through a detergent tray typically located at the top. This water fills the bottom of the outer tub and inner drum until the desired level is achieved. Subsequently, the electric motor is actuated to agitate the inner drum back and forth on input from the user. In this initial phase of the wash cycle, the inner drum is subjected to rotation, which produces a tumbling motion to move the clothes through the water using inner paddles. In this phase, torque is applied to rotate the inner drum around the horizontal or nearly horizontal axis of rotation. The uneven distribution of clothes and a moment of inertia produces low-frequency vibrations and imbalances in the inner drum during the tumbling motion. As the rotation speed is increased during the subsequent spin cycle, the dynamic random position of the cloth and centrifugal force further increases the imbalance, which could result in undesirable dynamic stress, noise, and component failure. This is particularly exacerbated in high-load conditions and in case of unpredicted impacts caused by various speed rotations. This results in structural malfunctions (such as uneven wear gaps in the inner drum and outer tub), the adjacent supporting frame or wall being damaged and functional defects (such as cloth tears, undesired noise and water puddles at the bottom of the washer due to imbalances or leaks).

[0004] A number of approaches have been proposed to counteract imbalanced forces in the rotating inner drum and increase the efficiency of washing machines.

The most commonly used approach is attaching counterweights to the outer tub, which increases the weight on suspended assembly. Counterweights provide stability to the washing device and reduce the dynamic stress produced during the rotation of the inner drum in the wash cycle. The counterweights, either fully concrete material or hollow shells filled with concrete materials, are usually installed in the machine frame during manufacture. However, such counterweights increase the weight of the washing machine. Such increased assembly weight adds to the effort needed to transport the machine from the factory to the consumer site, which requires more energy and comes with a high cost. Moreover, retailers, technical operators and servicing personnel find it challenging to handle such heavy machines during installations or repairs as concrete is highly vulnerable to breakage. The concrete masses may also undergo secondary pulverisation, which could interfere with the functioning of electric components, leading to repeated failures and higher maintenance cost.

[0005] The counterweights are usually composed of materials such as concrete or cast iron, or other heavy materials moulded into desired shapes. The use of concrete and heavy metals has a number of limitations, such as high carbon life cycle footprint and leakage of toxic metal ions, which result in regulatory risk for manufacturers and users. The recycling value of such pre-installed counterweights, especially concrete material, is less as landfilling is the sole inexpensive method to dispose concrete counterweights.

[0006] A number of approaches have been proposed to deal with the imbalance limitations in horizontal-axis washing machines. Such prior-art devices are based on the deployment of counterweights, such as pre-installed counterweights, at the time that the machine is manufactured. One such apparatus is described in art

EP0812946B1 (Piero Durazzani et. al.). Durazzani et.al. describes a method to manufacture counterweights for washing machines for clothes, particularly of the type used at home. This includes moulding the hollow bodies of the plastic material, immediately followed by the filling process, where it is filled with high specificgravity inert material, such as mill scale of sheet-metal particles, to complete the counterweight manufacturing process. Furthermore, the high-density material is charged and mixed with a liquid additive, and hence provides the pre-installed counterweight that adds excessive load during transportation and installation at the user site. Similar counterweights are disclosed in the prior-art document EP0515874, which describes the method and apparatus for washing machine counterbalances, wherein one or more blocks of heavy material are over-injected with an encased plastic material.

[0007] An impact-absorbing member attached to the plastic shells of counterweights used in a washing machine is disclosed in US Patent 5974839 to reduce transportation damages from the factory to the user site. Counterweights are attached with a foam material to the tab of a counterweight body, pre-installed with a concrete substance at the time of manufacture.

[0008] The process of using one-piece counterweights with at least a foldable member is provided in the prior art. US Patent 7762107 discloses the shell of a moulded plastic material filled with an inert material mixture such as concrete and water. The mixture is passed through a front-open side of the shell. Such constructions are provided to protect the machine by holding the crumbled and cracked material of the ballast mass; however, this does not reduce the overall excessive counterweight before installation and material pulverisation related failure.

b

SUMMARY [0009] The counterweights used in prior art front-load washing machine are preinstalled and adds excess weight to overall assembly. It requires additional manual effort and cost during transportation and installation. It poses environmental risk due to non- recyclable nature after product life cycle.

[0010] The present invention provides a hollow counterweight made of composite materials. The washing machine includes at least one tub, operatively connected driving units, a controller and at least one hollow counterweight. These hollow counterweights comprise at least one filling portion, a main body and one transition portion. The hollow counterweight is formed by moulding the composite material and can be filled following installation at the user site.

[0011] The refillable counterweight for the washing machine uses a recyclable filling substance. The counterweight installation method, according to the present invention advantageously attains the first partially deployed state at the manufacturing facility and first fully deployed state after the machine is installed at the user site.

[0012] The hollow counterweight further attains the second undeployed/deactivated state whenever counterweight is dissembled from the supporting housing during transfer, reinstallation or maintenance. Hence, the counterweight provides balancing action only during the fully deployed state after installation at the user site and only when it is required.

BRIEF DESCRIPTION OF THE DRAWINGS [0013] Various aspects of the invention and its embodiment are better understood by referring to the following detailed description. To understand the invention, the detailed description should be read in conjunction with the drawings, wherein:

[0014] FIG. 1 illustrates an exploded view of a prior art front-load washing machine in general;

[0015] FIG. 2 illustrates an exemplary front-load washing machine with a hollow counterweight, designed in accordance with the present invention;

[0016] FIG. 3 illustrates a perspective view of a hollow counterweight according to the present invention;

[0017] FIG. 4 illustrates an alternative embodiment of a hollow counterweight with a single inlet and drainage portion;

[0018] FIG. 5 illustrates an alternative embodiment of a hollow counterweight with a cubical shell structure;

[0019] FIG. 6 illustrates an alternative embodiment of a cubical hollow counterweight acting as a supporting housing of washing machine;

[0020] FIG. 7, a flow diagram, illustrates exemplary steps for manufacturing and deploying counterweights according to the present invention;

DESCRIPTION [0021] In FIG. 1, a prior art front-load washing machine 100 in general, essentially comprises an outer tub 102 and inner drum 104, counterweights 106, a detergent and softener tray 108, an electric motor 110, a drainage pump 112 and/or a controller 114. The outer tub 102 and inner drum 104 are disposed into a four vertical wall assembly, which forms the supporting housing 116. The front wall 118 is provided with an opening door 120 for the feeding cloth load. A drive shaft 122 is positioned in such a way that it rotates in a horizontal or nearly horizontal axis. The outer tub 102 and inner drum 104 are mounted around the drive shaft 122. The drive shaft 122 is further connected to a variable-speed electric motor 110 which imparts a rotational motion to the outer tub 102.

[0022] The invention, as shown in FIG. 2 and 3, comprises an exemplary embodiment of a front-load washing machine 200 with refillable hollow counterweight in a first partially deployed state at a manufacturer’s factory. The counterweight 202 is a shell structure that at least partially encircles the outer tub 204.

The refillable counterweight is filled through an inlet 212 and drained through an outlet 214. The counterweight 202 and outer tub 204 are fitted onto the supporting housing 206 by engaging means such as screws 210, bolts, nuts, washers and springs through support cylinder 208.

[0023] In another embodiment, the hollow counterweight 300 comprises an inlet 302, a transition portion 304, a main body 306 and a drainage outlet 308. The counterweight is disposed around a rotation axis 322 passing through drive shaft 324.

The inlet portion 302 is positioned to facilitate the flow of counterweight substances into the main body 306. A sealing means 310, such as a lid or cover, is provided on the inlet portion to close it after the introduction of a counterweight substance. The transition portion 304 is positioned in a way that allows the unidirectional flow towards the main body, and is enabled with or without a flow control means 312 such as valves. The flow towards (through inlet 302) and away from (through outlet 308) the main body 306 is facilitated with or without pumps depending on the orientation.

In alternative embodiment of invention, counterweight substances is filled and drained when washing machine is installed or disassembled.

[0024] According to a further aspect of the invention, the main body 306 of the shell comprises a circular opening 314 profiled to accommodate the outer tub 326.

The circular opening 314 is fixedly engaged to the outer tub 326 to provide a ballast mass during high-speed rotations. Inner surface of circular opening 314 comprise additional interconnecting profiles 320 manufactured for additional stability. The interconnecting profiles 320 are interlocked with corresponding elevations 328 on outer tub 326 and provide the rotational stability to the outer tub 326. This interlock arrangement improves the performance of counterweight 300 during tumbling movements in high speed rotation. In the preferred embodiment, the attachment is secured through a slot 316 and fastening means such as threaded bolts 318, screws, nuts, springs and washers, to the vertical walls of the supporting housing.

[0025] The composite materials used for the counterweight are made up of a polymer substance, binding agent and/or plasticising additive. The polymer substance is optionally selected from a group comprising polycarbonate, polyethylene, polyester, polystyrene, polypropylene, polysulfone, polyurethane and ethylene-vinyl5 acetate.

[0026] In an alternative embodiment of the invention, as illustrated in FIG. 4, the counterweight device 400 is provided with a single inlet and drainage outlet 402.

The counterweight is disposed around a rotation axis 410 passing through drive shaft

412. Furthermore, in such an embodiment, the inlet 402 and transition portion 404 are modified to admit the flow of a counterweight substance in both directions, i.e., the fluid is admitted into the main body 406 from a reservoir during the installation of the counterweight, and allows the fluid to exit from the main body after use through the same inlet 402 during uninstallation/undeployment. The unidirectional valve in transition portion 404 is replaced with a bidirectional valve 408, which opens in coordination with a signal received from a processing module (not shown in figure) to open flow path in single inlet and drainage outlet 402. The counterweight main body 406 is molded two semi-circular shells connected to each other through a flow channel 414. Furthermore, additional pocket spaces 416 are moulded onto the main body during the manufacturing process to accommodate the other assembly components, such as the detergent tray, electric motor and drainage pump.

[0027] In an alternative embodiment of the invention, the counterweight device is a cubical shell structure 500 as shown in FIG. 5 comprising four vertical faces i.e front 522b, right side 522a, left side 522c and rear side 522d, one top face

524 and one bottom face 526. The outer surfaces are removably fitted into the supporting housing using attachment frame 528. Similar to previous embodiment in

FIG. 4, counterweight is provided with a single inlet and drainage outlet 502, transition portion 504 and main body 506. The valve in transition portion 504 is preferably a bidirectional valve 508, which opens in coordination with a signal received from a processing module (not shown in figure) to open flow path in single inlet and drainage outlet 502. The counterweight main body 506 is connected to each other through a flow channel 514. The inner circular opening is equipped with interconnecting elevated profiles 516 that engage with the outer tub in a complementary fashion. The interconnecting engagement provides additional mechanical support to the outer tub during rotational imbalances.

[0028] Furthermore, additional pocket spaces 518 are moulded onto the main body during the manufacturing process to accommodate the other assembly components, such as the detergent tray, electric motor and drainage pump as illustrated in FIG. 5. The hollow counterweight, according to the present invention, comprises at least one substantially closed pocket space 518 created to accommodate the detergent tray in middle portion. The main body of the shell is further moulded to accommodate the electric motor, drainage pump and the water heating element in the rear side 522d. The attachment of elements is secured through fastening means such as threaded bolt, screws, nuts, springs and washers, to the vertical walls of the supporting housing with or without shock absorbing elements.

[0029] In another alternative embodiment, cubical counterweight 600 as disclosed in FIG. 6, acts as a supporting housing of washing machine or washing machine components are provided in encastre design. FIG. 6 shows cubical counterweight comprising four vertical faces i.e front 622b, right side 622a, left side

622c and rear side 622d, one top face 624 and one bottom face 626. The inner circular opening is equipped with interconnecting elevated profiles 616 that engage with the outer tub in a complementary fashion. The circular opening optionally engages with outer tub through fastening means 620 such as threaded bolt, screws, nuts, or shock absorbing elements. Similar to previous embodiment in FIG. 5, counterweight is provided with a single inlet and drainage outlet 602, transition portion 604 and main body 606. The valve in transition portion 604 is preferably a bidirectional valve 608. The counterweight main body 606 is connected to each other through a flow channel 614. The cubical counterweight 600 comprises at least one substantially closed pocket space 618 created to accommodate various washing machine assembly components such as detergent tray, electric motor, drainage pump and the water heating element. In another embodiment, an additional air breather or vent is provided on counterweight to allow filling substance to flow in and out. A separate regulating mechanism, such as valves and sensors are provided with breather. In another embodiment of this invention, the main body is partitioned into a plurality of connected hollow counterweight shells. These are assembled onto the outer drum and provide the counterweight of the variable magnitude based on the filling level. The regulating mechanism, such as the valves and sensors, is provided for the fluid level.

[0030] In an alternative embodiment of the invention, washing machine includes least one sensor, the processing module, an indicator module and a valve.

The processing module inputs data from sensors to calculate required amount of counterweight and the indicator module displays the processed data. The size and shape of the counterweight is calculated and specified at the time of manufacturing.

[0031] The invention as illustrated in FIG. 1 to 6, includes at least one sensor, the processing module, indicator module and a valve, according to the present invention. The valves are disposed in the fluid flow path to regulate the substance flow based on output signals from the processing module. The valve structure can be unidirectional or bidirectional based on the presence or absence of a drainage outlet.

The valve is unidirectional in the earlier case, whereas it may be bidirectional to admit fluid flow in the latter case. The valve according to the present embodiment of the invention can be actuated through pneumatic, pressure, hydraulic, electric, electro-mechanical or combination thereof to allow counterweight substance filling.

[0032] In another aspect of the invention, measurement sensors measure the substance level, temperature and impurities using mechanical, chemical and electro13 mechanical sensors, or a combination thereof, to determine the characteristics. In the preferred embodiment, multiple arrays of sensors are disposed to measure the chemical characteristics, pressure and level of the counterweight substance.

[0033] FIG. 7, a flow diagram 700, illustrates the essential assembly deployment steps according to the present invention; the hollow counterweight device, discussed above, is deployed in two state at two different sites. The first partially deployed state is attained at the manufacturer’s factory site 722 and first fully deployed state at the user site after the washing machine has been installed 724.

The hollow counterweight further attains the second undeployed/deactivated state whenever the washing machine needs to be transferred, reinstalled, or during maintenance. Hence, the counterweight provides balancing action only during the fully deployed state after installation at the user site and only when it is required.

[0034] To attain the first deployed state at the manufacturer’s factory, a composite material is taken from the appropriate reservoir and transported to a moulding apparatus 702 on the first station. The moulding apparatus is subjected to optimal processing parameters, such as a desired temperature range, and pressure

704. The hot liquid material is fed to a molten tube 706 and a preform is prepared, which is transported to a moulding apparatus, and subjected to a blowing force that conforms the inside shape of the moulding apparatus 708. The moulding apparatus is cylindrical or semi-cylindrical shape and top inlet position. The blow-moulded counterweight is subsequently cooled to the atmospheric temperature 710 and attains the permanent desired shape as per the present invention. Subsequently, the counterweight is removed from mould. In another aspect of invention, manufacturing method can be selected form additive manufacturing, extrusion, vacuum forming, line bending or combination thereof to produce hollow counterweight.

[0035] The moulded counterweight is transported to the assembly station and positioned inside the supporting housing 712 of the washing machine. Subsequently, the pocket spaces are moulded onto the shell to dispose the assembly components

714, such as the detergent tray, electric motor and drainage pump, to attain the first partially deployed state of the counterweight according to the present invention.

Furthermore, such a washing machine is packaged and transported to the user site through the distributor network.

[0036] The hollow counterweight manufactured according to the present invention is advantageously deployed in two states to reduce the assembly weight.

This reduces effort needed to transport the machine from the factory to the consumer site. It requires less energy and saves additional cost.

[0037] In another aspect of this invention, the hollow counterweight is manufactured from multiple moulded pieces integrated at the machine assembly station or shaped as a unitary structure. The structure can be dissembled into separate moulds and transported easily during shifting home from one place to another, if required optionally. In another embodiment of the invention, the counterweight comprises separate segments, disposed together in the supporting housing of the washing machine and filled through a separate inlet portion for each segment.

[0038] To attain the first fully deployed state according to the present invention, the washing machine, with hollow counterweights positioned into the supporting housing, is mounted on a laundry area at the user site 716. The floor of the laundry area is levelled in a way that maintains the washing cylinder in a balanced position using four or more supporting legs. Once the outer tub and inner drum is mounted permanently, the counterweight is actuated to attain a fully deployed state.

The inlet portion is connected to the counterweight filling substance reservoir, and the substance is passed through the transition portion to fill the main body of the hollow counterweight 718 according to the present invention. The flow is stopped once the desired amount is dispensed 720.

[0039] The counterweight filling is regulated using a manual or automatic method. The processing module, as disclosed in the present invention, begins to register the sensor data from the valve in the transition portion or any another part of the counterweight, once the flow is initiated to fill the counterweight main body. The processing module optionally receives the parametric data on the counterweight substance level (L), temperature (T), chemical quality (Q) or any other parameters.

The data is transmitted to the processing module, wherein an output signal is generated and substance is deployed. The processing includes either assessing data for first time or check earlier stored data about substance parameters. For example, if the substance level and chemical quality at any time, after full deployment of substance, are within the desired threshold levels, the processing module would resume the washing machine function. Alternatively, if the substance level and chemical quality are not within the acceptable threshold values, the washing operation is suspended. Subsequently, the partial or complete counterweight substance volume (VI) is drained out and, fresh counterweight substance volume is refilled from the reservoir.

[0040] According to the preferred embodiment of the present invention, the weight of the filling substance in the preferred embodiment is between 5kg and 20kg or corresponding volume range in a fully deployed state. In an alternative embodiment of this invention, the filling is regulated using manual inputs.

[0041] As a person with ordinary skills in the art may recognise substantially equivalent structures or acts to achieve the same results in the same (or a dissimilar) manner, the exemplary embodiment should not be interpreted as limiting the invention to one embodiment. Various modifications or variations may be in shape of counterweight (cylindrical, semi-cylindrical, cube, rectangular, pentagonal), inlet position (top, bottom, side, front and rear face of counterweight), connecting channels, sealing means (lid, cover, plug, tap, valve), disposal position (cylindrical devices, drive shaft or lower portion of the outer drum) are possible according to scope of invention without departing from the spirit of the invention.

Claims

CLAIMS:

1. A washing machine, comprising:

at least one tub;

at least one drum disposed in the tub;

5 at least one driving unit mechanically coupled to the tub; and at least one refillable hollow counterweight.

2. A washing machine of claim 1, wherein the hollow counterweight includes at least one filling portion, a main body and at least one transition portion.

3. A washing machine of claim 2, wherein the filling portion further comprises a

10 lid.

4. A washing machine of claim 2, wherein the main body of at least one hollow counterweight comprises profiles created on the surface.

5. A washing machine of claim 1, wherein the hollow counterweight is substantially close to the tub.

15

6. A washing machine of claim 1, wherein hollow counterweight is made up of composite material.

7. A washing machine of claim 2, wherein the hollow counterweights is provided with combined filling portion and transition portion.

8. A method of installing at least one refillable hollow counterweight in washing machine comprising:

positioning the hollow counterweight and tub substantially close to each other for attaining a first partially deployed state;

filling the hollow counterweight to attain a first fully deployed state; and draining out the hollow counterweight to attain second undeployed state.

5

9. A method of claim 8, wherein the hollow counterweight is actuated to the first partial deployed state at manufactures’ site.

10. A method of claim 8, wherein the hollow counterweight is actuated to the first fully deployed state at user site after or during installation.

11. A method of claim 8, wherein the hollow counterweight receives a filling

10 substance into the main body through transition portion in the first fully deployed state.

12. A method of claim 8, wherein the hollow counterweight drains out the filling substance from main body to attain the second undeployed state.

13. A method of claim 8, wherein the filling is actuated through a fluidically

15 connected valve in the transition portion.

14. A method of claim 13, wherein the valve is actuated using parametric data collected from at least one sensor.

Intellectual

Property

Office

Application No: GB1702049.6 Examiner: Mr Gary Clements