US20230064924A1

US20230064924A1 - Laundry appliance with adaptive drying cycle based on load size and load type

Info

Publication number: US20230064924A1
Application number: US17/412,902
Authority: US
Inventors: David Scott Dunn; Joshua Reeves; Dimitar Tcholakov; Ionelia Silvia Prajescu; Jivko Ognianov Djerekarov; Daniele Martinello; Gregory Allen Dedow
Original assignee: Haier US Appliance Solutions Inc
Current assignee: Haier US Appliance Solutions Inc
Priority date: 2021-08-26
Filing date: 2021-08-26
Publication date: 2023-03-02

Abstract

A laundry appliance is configured for and/or methods of operating a laundry appliance include determining a load size of articles to be dried in the laundry appliance and determining a load type of the articles to be dried in the laundry appliance. A termination criterion for a dry operation of the laundry appliance is determined based on the load size and the load type. The laundry appliance is further configured for and/or the method further includes performing the dry operation in the laundry appliance. The dry operation is terminated when the termination criterion is reached.

Description

FIELD OF THE INVENTION

The present subject matter relates generally to laundry appliances, and more particularly to laundry appliances with adaptive drying operations.

BACKGROUND OF THE INVENTION

Various laundry appliances include features for drying articles therein. For example, dryer appliance are typically paired with a separate washer appliance such that wet articles from the washer appliance may be loaded into the paired dryer appliance for drying. Combination laundry appliances, sometimes also referred to as washer/dryer appliances, provide both washing and drying functions in a single unit. Both types of laundry drying appliances typically rely on a static termination threshold to terminate a dry cycle, such as a time limit or a static termination threshold for an atmospheric condition where the appliance terminates the dry cycle in response to a measured atmospheric condition reaching the static termination threshold.
The static termination threshold does not change and is the same for each and every load dried. Such static termination thresholds, whether time-based, based on an atmospheric condition, or one or more other bases, are not tailored to the specific load of articles in each drying cycle. For example, the static termination threshold is often designed to perform at a desired level with a specific load such as a test load from regulatory or other testing standards. Such static termination thresholds may over dry loads that are smaller (lighter) and/or less absorptive than the design load, e.g., the test load, and may under dry loads that are larger and/or more absorptive than the design load.
Accordingly, a laundry appliance having improved features for adapting a dry cycle of the laundry appliance to each particular load of laundry articles therein would be advantageous.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
In one aspect of the present disclosure, a method of operating a laundry appliance is provided. The method includes determining a load size of articles to be dried in the laundry appliance and determining a load type of the articles to be dried in the laundry appliance. The method also includes determining a termination criterion for a dry operation of the laundry appliance based on the load size and the load type. The method further includes performing the dry operation in the laundry appliance. The dry operation is terminated when the termination criterion is reached.
In another aspect of the present disclosure, a laundry appliance is provided. The laundry appliance includes a cabinet defining an interior volume with a laundry basket rotatably mounted within the interior volume of the cabinet. The laundry basket defines a chamber for the receipt of articles for treatment. The laundry appliance also includes a heating system. The heating system is in thermal communication with the chamber, and heated air flows from the heating system to the chamber as a result of such thermal communication. The laundry appliance further includes a controller. The controller is configured for determining a load size of articles to be dried in the laundry appliance and determining a load type of the articles to be dried in the laundry appliance. The method also includes determining a termination criterion for a dry operation of the laundry appliance based on the load size and the load type. The method further includes performing the dry operation in the laundry appliance. The dry operation is terminated when the termination criterion is reached.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a perspective view of a laundry appliance in accordance with one or more exemplary embodiments of the present disclosure.

FIG. 2 provides a cross-section view of the example laundry appliance of FIG. 1 .

FIG. 3 provides a perspective view of a washing machine appliance as may be used with one or more additional exemplary embodiments of the present disclosure.

FIG. 4 provides a cross-section view of the example washing machine appliance of FIG. 3 .

FIG. 5 provides a perspective view of a laundry appliance in accordance with one or more further exemplary embodiments of the present disclosure.

FIG. 6 provides a perspective view of the example laundry appliance of FIG. 5 with portions of a cabinet of the laundry appliance removed to reveal certain components of the laundry appliance.

FIG. 7 provides a schematic view of a condensation drying system which may be incorporated into an example laundry appliance, such as an example combination laundry appliance, according to one or more exemplary embodiments of the present disclosure.

FIG. 8 provides a schematic diagram of an exemplary heat exchange heating system which may be incorporated into an example laundry appliance, such as an example combination laundry appliance, according to one or more embodiments of the present disclosure.

FIG. 9 illustrates a method for calculating a load score for a load in a laundry appliance according to an exemplary embodiment of the present subject matter.

FIG. 10 provides a plot of an angular velocity of a basket over time during a load sizing cycle of a washing machine appliance.

FIG. 11 provides a flow chart illustrating a method for operating a laundry appliance in accordance with one or more additional exemplary embodiments of the present disclosure.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
As used herein, terms of approximation, such as “substantially,” “generally,” or “about” include values within ten percent greater or less than the stated value. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction. For example, “generally vertical” includes directions within ten degrees of vertical in any direction, e.g., clockwise or counter-clockwise.
As used herein, the terms “articles,” “clothing,” or “laundry” include but need not be limited to fabrics, textiles, garments, linens, papers, or other items which may be cleaned, dried, and/or otherwise treated in a laundry appliance. Furthermore, the term “load” or “laundry load” refers to the combination of clothing that may be washed together in a washing machine appliance or dried together in a dryer appliance (e.g., clothes dryer), including washed and dried together in a combination laundry appliance, and may include a mixture of different or similar articles of clothing of different or similar types and kinds of fabrics, textiles, garments and linens within a particular laundering process.
As used herein, “temperature sensor” or the equivalent is intended to refer to any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, a “temperature sensor” may be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, a semiconductor-based integrated circuit temperature sensors, etc. In addition, such temperature sensor(s) may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and/or indicative of the temperature being measured. Although exemplary positioning of temperature sensors is described herein, it should be appreciated that a laundry appliance according to the present disclosure may include any other suitable number, type, and position of temperature, humidity, and/or other sensors according to alternative embodiments.
As used herein, the terms “humidity sensor” or the equivalent may be intended to refer to any suitable type of humidity measuring system or device positioned at any suitable location for measuring the desired humidity. Thus, for example, “humidity sensor” may refer to any suitable type of humidity sensor, such as capacitive digital sensors, resistive sensors, and thermal conductivity humidity sensors. In addition, a humidity sensor may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and/or indicative of the humidity being measured. Although exemplary positioning of humidity sensors is described herein, it should be appreciated that a laundry appliance according to the present disclosure may include any other suitable number, type, and position of humidity sensors according to alternative embodiments.
In some embodiments, the laundry appliance may be a combination washer-dryer appliance, such as the example combination appliance 10 illustrated in FIGS. 1 and 2 . FIG. 1 provides a perspective view of a laundry appliance 10 according to exemplary embodiments of the present disclosure. The laundry appliance 10 is a combination laundry appliance, and may also be referred to as a multifunction laundry appliance or washer/dryer combination appliance. FIG. 2 provides a section view of laundry appliance 10. The laundry appliance 10 generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is defined. While described in the context of a specific embodiment of laundry appliance 10, using the teachings disclosed herein, it will be understood that laundry appliance 10 is provided by way of example only. Other laundry appliances having different appearances and different features may also be utilized with the present subject matter as well.
Cabinet 12 includes a front panel 14, a rear panel 16, a left side panels 18 and a right side panel 20 spaced apart from each other by front and rear panels 14 and 16, a bottom panel 22, and a top cover 24. As used herein, terms such as “left” and “right” or “front” and “back” refer to directions from the perspective of a user facing the laundry appliance 10 for accessing and/or operating the laundry appliance 10. For example, a user stands in front of the laundry appliance 10, e.g., at or near the front panel 14, to access door 33 and/or inputs 70 (the door 33 and inputs 70 are described in more detail below). Within cabinet 12, an interior volume 29 is defined. A drum or tub 26 is mounted within the interior volume 29. A laundry basket 130 is mounted within the tub 26. The laundry basket 130 defines a chamber 25 for receipt of articles of clothing for treatment, e.g., washing, rinsing, spinning, tumbling, and/or drying.
In some embodiments, one or more selector inputs 70, such as knobs, buttons, touchscreen interfaces, etc., may be provided or mounted on the cabinet 12, e.g., on a control panel 71 thereof and are in operable communication (e.g., electrically coupled or coupled through a wireless network band) with a processing device or controller 56. The control panel 71 may also include a display 64. Controller 56 may also be provided in operable communication with various components of the dryer appliance, such as the motor, blower, and/or heating system 80, as well as one or more sensors, such as one or more temperature sensors and/or humidity sensors. In turn, signals generated in controller 56 direct operation of such components in response to the position of inputs 70. In this regard, control panel 71, user input devices 70, and display 64 may be in communication with controller 56 such that controller 56 may receive control inputs from user input devices 70, may display information using display 64, and may otherwise regulate operation of combination laundry appliance 10. As used herein, “processing device” or “controller” may refer to one or more microprocessors, microcontroller, ASICS, or semiconductor devices and is not restricted necessarily to a single element. The controller 56 may be programmed to operate laundry appliance 10 by executing instructions stored in memory (e.g., non-transitory media). The controller 56 may include, or be associated with, one or more memory elements such as RAM, ROM, or electrically erasable, programmable read only memory (EEPROM). For example, the instructions may be software or any set of instructions that when executed by the processing device, cause the processing device to perform operations. It should be noted that controllers as disclosed herein are capable of and may be operable to perform any methods and associated method steps as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in the memory and executed by the controller. In particular embodiments where the laundry appliance is a combination appliance such as appliance 10, the controller of the laundry appliance may be capable of and may be operable to perform either or both of the methods 500 and 700 of FIGS. 9 and 11 , among other possible example methods.
Tub 26 extends between a front portion 37 and a back portion 38. Tub 26 is generally cylindrical in shape, having an outer cylindrical wall 28 and a front flange or wall 30 that defines an opening 32 of tub 26, e.g., at front portion 37 of tub 26, for loading and unloading of articles into and out of a chamber 25 defined by and within a laundry basket 130 inside of the tub 26. Tub 26 includes a rear wall 34 opposite the front flange 30. A door 33 provides for closing or accessing tub 26 through opening 32. A window 36 (FIG. 1 ) may be provided in door 33 for viewing of the chamber 25 and/or laundry articles therein, e.g., during operation of the laundry appliance 10.
Laundry basket 130 is rotatably mounted within tub 26 such that the laundry basket 130 is rotatable about an axis of rotation. According to the illustrated embodiment, the axis of rotation is substantially parallel to the transverse direction T. In this regard, laundry appliance 10 is generally referred to as a “horizontal axis” or “front load” laundry appliance 10. However, it should be appreciated that aspects of the present subject matter may be used within the context of a vertical axis or top load laundry appliance as well.
Laundry appliance 10 includes a motor assembly 222 that is in mechanical communication with laundry basket 130 to selectively rotate laundry basket 130. The motor assembly 222 may be a pancake motor, as illustrated, or any other suitable type, size, or configuration of motor may be used to rotate laundry basket 130 according to various embodiments.
Laundry basket 130 may define one or more agitator features that extend into chamber 25 to assist in agitation and cleaning of articles disposed within laundry chamber 25 during operation of laundry appliance 10. For example, as illustrated in FIG. 2 , a plurality of ribs 128 extends from laundry basket 130 into chamber 25. In this manner, for example, ribs 128 may lift articles disposed in laundry basket 130 during rotation of laundry basket 130, such as during an agitation or rinse portion of a wash operation of the laundry appliance 10. During a drying operation of the laundry appliance 10, the ribs 128 may also lift articles in the chamber 25 of the laundry basket 130 and then allow such articles to tumble back to a bottom of laundry basket 130 as laundry basket 130 rotates.
As illustrated for example in FIG. 2 , laundry basket 130 may also include a plurality of perforations 140 extending therethrough in order to facilitate fluid communication between chamber 25 and tub 26, e.g., whereby wash liquid may flow between the tub 26 and the chamber 25 during a wash operation or cycle and/or heated air may flow into the chamber 25 and moisture-laden air may flow out of the chamber 25 during a drying operation or cycle. A sump 142 is defined by tub 26 outside of laundry basket 130 at a bottom of the tub 26 along the vertical direction V. Thus, sump 142 is configured for receipt of, and generally collects, wash liquid (the wash liquid may include, e.g., water, and may also includes additives such as detergents, etc.) during wash operations of laundry appliance 10. For example, during a wash operation of laundry appliance 10, wash liquid may be urged (e.g., by gravity) from the chamber 25 within the laundry basket 130 to sump 142 through the plurality of perforations 140. A pump assembly 40 is located beneath tub 26 for gravity assisted flow when draining tub 26 (e.g., via a drain 41). Pump assembly 40 is also configured for recirculating wash liquid within tub 26.
In some embodiments, laundry appliance 10 includes an additive dispenser or spout 150. For example, spout 150 may be in fluid communication with a water supply (not shown) in order to direct fluid (e.g., clean water) into tub 26. Spout 150 may also be in fluid communication with the sump 142. For example, pump assembly 40 may direct wash liquid disposed in sump 142 to spout 150 in order to circulate wash liquid in tub 26.
As illustrated, a detergent drawer 152 may be slidably mounted within front panel 14. Detergent drawer 152 receives an additive (e.g., detergent, fabric softener, bleach, or any other suitable liquid or powder) and directs the additive to chamber 25 during operation of laundry appliance 10. According to the illustrated embodiment, detergent drawer 152 may also be fluidly coupled to spout 150 to facilitate the complete and accurate dispensing of the additive.
In exemplary embodiments, during operation of laundry appliance 10, laundry items are loaded into laundry basket 130 through opening 32, and an operation is initiated through operator manipulation of input selectors 70. For example, a wash cycle may be initiated such that tub 26 is filled with water, detergent, or other fluid additives (e.g., via spout 150). One or more valves (not shown) can be controlled by laundry appliance 10 to provide for filling laundry basket 130 to the appropriate level for the amount of articles being washed or rinsed. By way of example, once laundry basket 130 is properly filled with fluid, the contents of laundry basket 130 can be agitated (e.g., with ribs 128) for an agitation phase of laundry items in laundry basket 130. During the agitation phase, the basket 130 may be motivated about the axis of rotation at a set speed (e.g., a tumble speed). As the basket 130 is rotated, articles within the basket 130 may be lifted and permitted to drop therein.
After the agitation phase of the washing operation is completed, tub 26 can be drained. Laundry articles can then be rinsed (e.g., through a rinse cycle) by again adding fluid to tub 26, depending on the particulars of the cleaning cycle selected by a user. Ribs 128 may again provide agitation within laundry basket 130. One or more spin cycles may also be used. In particular, a spin cycle may be applied after the wash cycle or after the rinse cycle in order to wring wash liquid from the articles being washed. During a spin cycle, basket 130 is rotated at relatively high speeds. For instance, basket 130 may be rotated at one set speed (e.g., a pre-plaster speed) before being rotated at another set speed (e.g., a plaster speed). As would be understood, the pre-plaster speed may be greater than the tumble speed and the plaster speed may be greater than the pre-plaster speed. Moreover, agitation or tumbling of articles may be reduced as basket 130 increases its rotational velocity such that the plaster speed maintains the articles at a generally fixed position relative to basket 130.
After the spin cycle, a drying operation may begin. A supply duct 82 may be mounted to tub 26 and may extend between tub 26 and a heating assembly or system 80, whereby the tub 26 is downstream of the heating system 80 along the supply duct 82 such that the heating system 80 supplies heated air that has been heated by the heating system 80 to the tub 26 via the supply duct 82. A return duct 84 may also be mounted to the tub 26 and may extend between tub 26 and the heating system 80 whereby the tub 26 is upstream of the heating system 80 along the return duct 84 such that the heating system 80 receives relatively moist, humid, air from the tub 26 via the return duct 84, e.g., air returns to the heating system 80 from the tub 26, e.g., after flowing over and around articles within the chamber 25, through the return duct 84. The supply duct 82 may be mounted to the tub 26, e.g., at the rear wall 34 thereof as in the illustrated example, or the supply duct 82 may be mounted to the cylindrical wall 28 of the tub 26, such as above the basket 130, similar to the return duct 84 in the illustrated example embodiment.
The heating system 80, may include, e.g., a resistance heating element, a gas burner, and/or a heat pump, or any other suitable heat source. Moisture laden, heated air is drawn from tub 26 by an air handler, such as a blower fan, which generates a negative air pressure within the chamber 25. As the air passes from the blower fan, it enters return duct 84 and then is passed into heating system 80. Heated air (with a lower moisture content than was received from tub 26), exits heating system 80 and is supplied to tub 26 by supply duct 82. After the clothing articles have been dried, they are removed from the chamber 25 via opening 32.
In some embodiments, the laundry appliance may be a dryer appliance, such as the example dryer appliance 410 illustrated in FIGS. 5 and 6 . In such embodiments, the laundry appliance, e.g., dryer appliance, may be paired with a separate washing machine appliance, such as the example washing machine appliance 300 illustrated in FIGS. 3 and 4 .
FIG. 3 is a perspective view of an exemplary horizontal axis washing machine appliance 300 and FIG. 4 is a side cross-sectional view of washing machine appliance 300 according to one example embodiment. As illustrated, washing machine appliance 300 generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined. Washing machine appliance 300 includes a cabinet 302 that extends between a top 304 and a bottom 306 along the vertical direction V, between a left side 308 and a right side 310 along the lateral direction L, and between a front 312 and a rear 314 along the transverse direction T.
As may be seen in FIG. 4 , a wash tub 324 is positioned within cabinet 302 and is generally configured for retaining wash fluids during an operating cycle. As used herein, “wash fluid” may refer to water, detergent, fabric softener, bleach, or any other suitable wash additive or combination thereof. Wash tub 324 is substantially fixed relative to cabinet 302 such that it does not rotate or translate relative to cabinet 302.
A wash basket 320 is received within wash tub 324 and defines a wash chamber 326 that is configured for receipt of articles for washing. More specifically, wash basket 320 is rotatably mounted within wash tub 324 such that it is rotatable about an axis of rotation A. According to the illustrated embodiment, the axis of rotation is substantially parallel to the transverse direction T. In this regard, washing machine appliance 300 is generally referred to as a “horizontal axis” or “front load” washing machine appliance 300. However, it should be appreciated that aspects of the present subject matter may be used within the context of a vertical axis or top load washing machine appliance as well.
Wash basket 320 may define one or more agitator features that extend into wash chamber 326 to assist in agitation and cleaning of articles disposed within wash chamber 326 during operation of washing machine appliance 300. For example, as illustrated in FIG. 4 , a plurality of ribs 328 extends from basket 320 into wash chamber 326. In this manner, for example, ribs 328 may lift articles disposed in wash basket 320 during rotation of wash basket 320.
Washing machine appliance 300 includes a motor assembly 322 that is in mechanical communication with wash basket 320 to selectively rotate wash basket 320 (e.g., during an agitation or a rinse cycle of washing machine appliance 300). According to the illustrated embodiment, motor assembly 322 is a pancake motor. However, it should be appreciated that any suitable type, size, or configuration of motor may be used to rotate wash basket 320 according to alternative embodiments.
Referring generally to FIGS. 3 and 4 , cabinet 302 also includes a front panel 330 that defines an opening 332 that permits user access to wash basket 320 of wash tub 324. More specifically, washing machine appliance 300 includes a door 334 that is positioned over opening 332 and is rotatably mounted to front panel 330 (e.g., about a door axis that is substantially parallel to the vertical direction V). In this manner, door 334 permits selective access to opening 332 by being movable between an open position (not shown) facilitating access to a wash tub 324 and a closed position (FIG. 3 ) prohibiting access to wash tub 324.
In some embodiments, a window 336 in door 334 permits viewing of wash basket 320 when door 334 is in the closed position (e.g., during operation of washing machine appliance 300). Door 334 also includes a handle (not shown) that, for example, a user may pull when opening and closing door 334. Further, although door 334 is illustrated as mounted to front panel 330, it should be appreciated that door 334 may be mounted to another side of cabinet 302 or any other suitable support according to alternative embodiments. Additionally or alternatively, a front gasket or baffle 338 may extend between tub 324 and the front panel 330 about the opening 332 covered by door 334, further sealing tub 324 from cabinet 302.
As illustrated for example in FIG. 4 , wash basket 320 may also include a plurality of perforations 340 extending therethrough in order to facilitate fluid communication between an interior of basket 320 and wash tub 324. A sump 342 is defined by wash tub 324 at a bottom of wash tub 324 along the vertical direction V. Thus, sump 342 is configured for receipt of, and generally collects, wash fluid during operation of washing machine appliance 300. For example, during operation of washing machine appliance 300, wash fluid may be urged (e.g., by gravity) from basket 320 to sump 342 through the plurality of perforations 340. A pump assembly 344 is located beneath wash tub 324 for gravity assisted flow when draining wash tub 324 (e.g., via a drain 346). Pump assembly 344 is also configured for recirculating wash fluid within wash tub 324.
In some embodiments, washing machine appliance 300 includes an additive dispenser or spout 350. For example, spout 350 may be in fluid communication with a water supply (not shown) in order to direct fluid (e.g., clean water) into wash tub 324. Spout 350 may also be in fluid communication with the sump 342. For example, pump assembly 344 may direct wash fluid disposed in sump 342 to spout 350 in order to circulate wash fluid in wash tub 324.
As illustrated, a detergent drawer 352 may be slidably mounted within front panel 330. Detergent drawer 352 receives a wash additive (e.g., detergent, fabric softener, bleach, or any other suitable liquid or powder) and directs the fluid additive to wash chamber 326 during operation of washing machine appliance 300. According to the illustrated embodiment, detergent drawer 352 may also be fluidly coupled to spout 350 to facilitate the complete and accurate dispensing of wash additive.
In optional embodiments, a bulk reservoir 354 is disposed within cabinet 302. Bulk reservoir 354 may be configured for receipt of fluid additive for use during operation of washing machine appliance 300. Moreover, bulk reservoir 354 may be sized such that a volume of fluid additive sufficient for a plurality or multitude of wash cycles of washing machine appliance 300 (e.g., five, ten, twenty, fifty, or any other suitable number of wash cycles) may fill bulk reservoir 354. Thus, for example, a user can fill bulk reservoir 354 with fluid additive and operate washing machine appliance 300 for a plurality of wash cycles without refilling bulk reservoir 354 with fluid additive. A reservoir pump 356 is configured for selective delivery of the fluid additive from bulk reservoir 354 to wash tub 324.
A control panel 360 including a plurality of input selectors 362 is coupled to front panel 330. Control panel 360 and input selectors 362 collectively form a user interface input for operator selection of machine cycles and features. For example, in one embodiment, a display 364 indicates selected features, a countdown timer, or other items of interest to machine users.
Operation of washing machine appliance 300 is controlled by a controller or processing device 366 that is operatively coupled to control panel 360 for user manipulation to select washing machine cycles and features. In response to user manipulation of control panel 360, controller 366 operates the various components of washing machine appliance 300 to execute selected machine cycles and features.
Controller 366 may include a memory (e.g., non-transitive memory) and microprocessor, such as a general or special purpose microprocessor operable to execute programming instructions or micro-control code associated with a wash operation. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 366 may be constructed without using a microprocessor (e.g., using a combination of discrete analog or digital logic circuitry, such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software. Control panel 360 and other components of washing machine appliance 300, such as motor assembly 322, may be in communication with controller 366 via one or more signal lines or shared communication busses. It should be noted that controllers as disclosed herein are capable of and may be operable to perform any methods and associated method steps as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in the memory and executed by the controller. In particular, and as will be discussed in more detail below, the method 500 of determining a load score illustrated in FIG. 9 may be performed by the washing machine appliance 300 and/or the controller 366 thereof in some embodiments, and the load score may be communicated, e.g., transmitted, from the washing machine appliance to a paired dryer appliance in some embodiments.
In exemplary embodiments, during operation of washing machine appliance 300, laundry items are loaded into wash basket 320 through opening 332, and a wash operation is initiated through operator manipulation of input selectors 362. For example, a wash cycle may be initiated such that wash tub 324 is filled with water, detergent, or other fluid additives (e.g., via spout 350). One or more valves (not shown) can be controlled by washing machine appliance 300 to provide for filling wash basket 320 to the appropriate level for the amount of articles being washed or rinsed. By way of example, once wash basket 320 is properly filled with fluid, the contents of wash basket 320 can be agitated (e.g., with ribs 328) for an agitation phase of laundry items in wash basket 320. During the agitation phase, the basket 320 may be motivated about the axis of rotation A at a set speed (e.g., a tumble speed). As the basket 320 is rotated, articles within the basket 320 may be lifted and permitted to drop therein.
After the agitation phase of the washing operation is completed, wash tub 324 can be drained. Laundry articles can then be rinsed (e.g., through a rinse cycle) by again adding fluid to wash tub 324, depending on the particulars of the cleaning cycle selected by a user. Ribs 328 may again provide agitation within wash basket 320. One or more spin cycles may also be used. In particular, a spin cycle may be applied after the wash cycle or after the rinse cycle in order to wring wash fluid from the articles being washed. During a spin cycle, basket 320 is rotated at relatively high speeds. For instance, basket 320 may be rotated at one set speed (e.g., a pre-plaster speed) before being rotated at another set speed (e.g., a plaster speed). As would be understood, the pre-plaster speed may be greater than the tumble speed and the plaster speed may be greater than the pre-plaster speed. Moreover, agitation or tumbling of articles may be reduced as basket 320 increases its rotational velocity such that the plaster speed maintains the articles at a generally fixed position relative to basket 320. Plaster speed is also discussed further below with reference to FIG. 10 .
After articles disposed in wash basket 320 are cleaned (or the washing operation otherwise ends), a user can remove the articles from wash basket 320 (e.g., by opening door 334 and reaching into wash basket 320 through opening 332).
Referring now to FIGS. 5 and 6 , in some embodiments, the laundry appliance may be a dryer appliance. For example, FIG. 5 provides a perspective view of dryer appliance 410 according to one or more exemplary embodiments of the present disclosure. FIG. 6 provides another perspective view of dryer appliance 410 with a portion of a cabinet or housing 412 of dryer appliance 410 removed in order to show certain components of dryer appliance 410. Dryer appliance 410 generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is defined. While described in the context of a specific embodiment of dryer appliance 410, using the teachings disclosed herein, it will be understood that dryer appliance 410 is provided by way of example only. Other dryer appliances having different appearances and different features may also be utilized with embodiments of the present subject matter wherein the laundry appliance is a dryer appliance as well.
Cabinet 412 includes a front panel 414, a rear panel 416, a pair of side panels 418 and 420 spaced apart from each other by front and rear panels 414 and 416, a bottom panel 422, and a top cover 424. Within cabinet 412, an interior volume 429 is defined. A drum or container 426 is mounted for rotation about a substantially horizontal axis within the interior volume 429. Drum 426 defines a chamber 425 for receipt of articles of clothing for tumbling and/or drying. Drum 426 extends between a front portion 437 and a back portion 438. Drum 426 also includes a back or rear wall 434, e.g., at back portion 438 of drum 426. A supply duct 441 may be mounted to rear wall 434 and receives heated air that has been heated by a heating assembly or system 440.
A motor 431 is provided in some embodiments to rotate drum 426 about the horizontal axis, e.g., via a pulley and a belt (not pictured). Drum 426 is generally cylindrical in shape, having an outer cylindrical wall 428 and a front flange or wall 430 that defines an opening 432 of drum 426, e.g., at front portion 437 of drum 426, for loading and unloading of articles into and out of chamber 425 of drum 426. A plurality of lifters or baffles 427 are provided within chamber 425 of drum 426 to lift articles therein and then allow such articles to tumble back to a bottom of drum 426 as drum 426 rotates. Baffles 427 may be mounted to drum 426 such that baffles 427 rotate with drum 426 during operation of dryer appliance 410.
Drum 426 includes a rear wall 434 rotatably supported within main housing 412 by a suitable fixed bearing. Rear wall 434 can be fixed or can be rotatable. Rear wall 434 may include, for instance, a plurality of holes that receive hot air that has been heated by a heating assembly or system 440, as will be described further below. Motor 431 is also in mechanical communication with an air handler 448 such that motor 431 rotates a fan 449, e.g., a centrifugal fan, of air handler 448. Air handler 448 is configured for drawing air through chamber 425 of drum 426, e.g., in order to dry articles located therein. In alternative example embodiments, dryer appliance 410 may include an additional motor (not shown) for rotating fan 449 of air handler 448 independently of drum 426.
Drum 426 is configured to receive heated air that has been heated by a heating assembly 440, e.g., via holes in the rear wall 434 as mentioned above, in order to dry damp articles disposed within chamber 425 of drum 426. For example, heating assembly 440 may include any suitable heat source, such as a gas burner, an electrical resistance heating element, or heat pump, for heating air. As discussed above, during operation of dryer appliance 410, motor 431 rotates drum 426 and fan 449 of air handler 448 such that air handler 448 draws air through chamber 425 of drum 426 when motor 431 rotates fan 449. In particular, air is heated within heating assembly 440 and exits heating assembly 440 as heated air. Air handler 448 draws such heated air through supply duct 441 to drum 426. The heated air enters drum 426 through a plurality of outlets of supply duct 441 positioned at rear wall 434 of drum 426.
Within chamber 425, the heated air may accumulate moisture, e.g., from damp clothing disposed within chamber 425. In turn, air handler 448 draws moisture-saturated air through a screen filter (not shown) which traps lint particles. Such moisture-statured air then enters an exit duct 446 and is passed through air handler 448 to a return duct 452. From return duct 452, such moisture-statured air passes from drum 426, e.g., from the chamber 425 therein, back to the heating assembly 440 in a closed loop circulation system. After the clothing articles have been dried, they are removed from the drum 426 via opening 432. A door 433 (FIG. 5 ) provides for closing or accessing drum 426 through opening 432. The door 433 may be movable between an open position and a closed position, the open position for access to the chamber 425 defined in the drum 426, and the closed position for sealingly enclosing the chamber 425 defined in the drum 426.
In some embodiments, the dryer appliance 410 may include one or more sensors, such as temperature sensors and/or humidity sensors, for sensing, detecting, measuring, and/or monitoring one or more atmospheric conditions. For example, the dryer appliance 410 may include a humidity sensor comprising a pair of sensor rods positioned at the entrance of exit duct 446, e.g., proximate the screen filter. In such embodiments, the sensor rods may be operable to detect or measure, etc., electrical resistance between the sensor rods. For example, the sensor rods may be about four inches long and may be spaced apart by about eleven inches. When the remaining moisture content in the laundry articles is relatively high, e.g., about 20% or greater, the resistance between the sensor rods varies with the humidity in the air exiting drum 426, e.g., more moisture in the air corresponds to more conductivity (lower resistance) across the gap between the sensor rods, and the conductivity will decrease and resistance increase as the articles get drier and the humidity of the air from the drum 426 decreases. Also by way of example, the dryer appliance 410 may include one or more temperature sensors and/or humidity sensors in one or more of the ducts, such as return duct 452, as well as or instead of the sensor rods.
In some embodiments, one or more selector inputs 470, such as knobs, buttons, touchscreen interfaces, etc., may be provided or mounted on a cabinet 412 (e.g., on a backsplash 471 of the cabinet 412) and are in operable communication (e.g., electrically coupled or coupled through a wireless network band) with a processing device or controller 490. A display 456 may also be provided on the backsplash 471 and may also be in operable communication with the controller 490. Controller 490 may also be provided in operable communication with motor 431, air handler 448, and/or heating assembly 440, as well as one or more sensors, such as one or more temperature sensors and/or humidity sensors, such as but not limited to sensor rods as described above. In turn, signals generated in controller 490 direct operation of motor 431, air handler 448, and/or heating assembly 440 in response to the position of inputs 470. In the example illustrated in FIGS. 5 and 6 , the inputs 470 are provided as knobs. In other embodiments, inputs 470 may also or instead include buttons, switches, touchpads and/or a touch screen type interface.
Controller 490 is a “processing device” or “controller” and may be embodied as described herein. As used herein, “processing device” or “controller” may refer to one or more microprocessors, microcontrollers, application-specific integrated circuits (ASICS), or semiconductor devices and is not restricted necessarily to a single element. The controller 490 may be programmed to operate dryer appliance 410 by executing instructions stored in memory (e.g., non-transitory media). The controller 490 may include, or be associated with, one or more memory elements such as RAM, ROM, or electrically erasable, programmable read only memory (EEPROM). For example, the instructions may be software or any set of instructions that when executed by the processing device, cause the processing device to perform operations. Controller 490 may include one or more processor(s) and associated memory device(s) configured to perform a variety of computer-implemented functions and/or instructions (e.g. performing the methods, steps, calculations and the like and storing relevant data as disclosed herein). It should be noted that controllers as disclosed herein are capable of and may be operable to perform any methods and associated method steps as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in the memory and executed by the controller. In particular, in embodiments where the laundry appliance is a dryer appliance such as dryer appliance 410, the controller thereof, e.g., controller 490 may be operable to and configured to perform methods such as the method 700 illustrated in FIG. 11 and described in further detail below. Moreover, in such embodiments, the steps 710 and 720 of determining a load size and load type may include receiving load size and load type information, e.g., a load score, from a washer appliance, such as the washing machine appliance 300 illustrated in FIGS. 3 and 4 . Thus, in embodiments where the laundry appliance is a dryer appliance such as dryer appliance 410, the dryer appliance and/or the controller thereof may be coupled to a washing machine appliance, such as communicatively coupled for wired or wireless communication, e.g., of the load information from the washing machine appliance to the dryer appliance.
In some embodiments, the laundry appliance 10 may be a condensation dryer appliance, e.g., the laundry appliance may include condensation drying features as depicted schematically in FIG. 7 . FIGS. 7 and 8 illustrate an example combination appliance, such as the combination appliance illustrated in FIGS. 1 and 2 , however, the condensation drying features described herein may be applied to or incorporated in any suitable laundry appliance which provides drying features, such as the clothes dryer appliance illustrated in FIGS. 5 and 6 . In some embodiments, the laundry appliance 10 may provide ventless drying, e.g., the laundry appliance 10 may not include or require an air vent to direct exhaust or waste air to an ambient environment external to the laundry appliance 10, e.g., an outdoor environment, such that the laundry appliance 10 defines and/or includes a closed-loop air circulation system. In embodiments which include condensation drying features, the laundry appliance 10 may include a condensation surface, e.g., a surface (which may be a cooled surface) on which moisture (water vapor) from the air condenses. For example, a flow of warm saturated air 120 may travel through the return duct 84 from the chamber 25 and then pass over, around, and/or across the condensation surface, which in the illustrated example embodiment is one or more surfaces of an evaporator 102. Condensation collected on the condensation surface may be removed from the interior of the laundry appliance 10 by a drain 85. From the condensation surface, a flow of cool dry air 122 travels through an intermediate duct 83 to a heating element, which may be a heat exchanger such as the condenser 108 in the illustrated example embodiment. The air is heated by the heating element, e.g., condenser 108, in order to supply warm dry air 118 to the chamber 25 via the supply duct 82.
Turning now to FIG. 8 , a schematic view of selected components of one or more exemplary embodiments of laundry appliance 10 is provided. In particular, FIG. 8 illustrates components used during drying operations of the laundry appliance 10. It is understood that, except as otherwise indicated, laundry appliance 10 in FIG. 8 may include some or all of the features described above with respect to FIGS. 1 and 2 and/or 5 and 6 .
In operation, one or more laundry articles 1000 may be placed within the chamber 25 of laundry basket 130 (or chamber 425 of drum 426 in clothes dryer embodiments). Hot dry air 118 may be supplied to chamber 25 whereby moisture within laundry articles 1000 may be drawn from the laundry articles 1000 by evaporation, such that warm saturated air 120 may flow from chamber 25 to an evaporator 102 of the heating system 80, e.g., via the return duct 84 illustrated in FIG. 2 (or return duct 452, as in FIG. 6 , in clothes dryer embodiments). As air passes across evaporator 102, the temperature of the air is reduced through heat exchange with refrigerant that is vaporized within, for example, coils or tubing of evaporator 102. This vaporization process absorbs both the sensible and the latent heat from the moisture-laden air—thereby reducing its temperature. As a result, moisture in the air is condensed and such condensate may be drained from heating assembly 80, as will be understood by those of ordinary skill in the art (such as via the drain 85 depicted in FIG. 7 and described above).
Air passing over evaporator 102 becomes drier and cooler than when it was received from tub 26 of laundry appliance 10. As shown, cool dry air 122 from evaporator 102 is subsequently caused to flow across a condenser 108 (e.g., across coils or tubing of the condenser 108), which condenses refrigerant therein. The refrigerant enters condenser 108 in a gaseous state at a relatively high temperature compared to the air 122 from evaporator 102. As a result, heat energy is transferred to the air at the condenser section 108, thereby elevating the temperature of the air and providing warm dry air 118 for supply to the tub 26 of laundry appliance 10, e.g., via the supply duct 82 illustrated in FIG. 2 . The warm dry air 118 passes over and around laundry articles 1000 within the chamber 25 inside of the tub 26, such that warm saturated air 120 is generated, as mentioned above. For example, the warm dry air may circulate around and through the articles 1000 while the articles 1000 are tumbled within the chamber 25 such as by rotating the basket 130, and the tumbling may be promoted by ribs 128 as well. Because the air is recycled through tub 26 and heating system 80, e.g., in a closed-loop as mentioned above, laundry appliance 10 can have a much greater efficiency than traditional clothes dryers where warm, moisture laden air is exhausted to the environment.
As shown in FIG. 8 , some embodiments of heating system 80 include a compressor 104 that pressurizes refrigerant (i.e., increases the pressure of the refrigerant) supplied by a suction line 110 and generally motivates refrigerant through the sealed refrigerant circuit of heating system 80. Compressor 104 may be in operable communication with controller 56 and is generally designed to pressurize a gas phase refrigerant. Accordingly, in order to avoid damage, refrigerant in suction line 110 is supplied to the compressor 104 in a gas phase from the evaporator section 102. The pressurization of the refrigerant with compressor 104 increases the temperature of the refrigerant (e.g., as directed by controller 56). The compressed refrigerant is fed from compressor 104 to condenser 108 through line 112. As relatively cool air 122 from the evaporator 102 is passed over the condenser 108, the refrigerant is cooled and its temperature is lowered as heat is transferred to the air for supply to tub 26.
Upon exiting condenser 108, the refrigerant is fed through line 114 to an expansion device 106. Although only one expansion device 106 is shown, such is by way of example only. It is understood that multiple such devices may be used. In the illustrated example, expansion device 106 is a thermal expansion valve. In additional embodiments, any other suitable expansion device, such as a capillary tube, may be used as well as or instead of the thermal expansion valve 106. Expansion device 106 lowers the pressure of the refrigerant and controls the amount of refrigerant that is allowed to enter the evaporator 102 via line 116. Importantly, the flow of liquid refrigerant into evaporator 102 is limited by expansion device 106 in order to keep the pressure low and allow expansion of the refrigerant back into the gas phase in the evaporator 102. The evaporation of the refrigerant in the evaporator 102 converts the refrigerant from its liquid-dominated phase to a gas phase while cooling and drying the air 120 from tub 26. The process is repeated as air is circulated through tub 26 and between evaporator 102 and condenser 108 while the refrigerant is cycled through the sealed refrigerant circuit, as described above.
FIG. 9 illustrates a method 500 for operating a laundry appliance according to an exemplary embodiment of the present subject matter. Method 500 can be used to operate any suitable laundry appliance, such as a combination appliance, e.g., combination appliance 10 of FIGS. 1 and 2 , or a washing machine appliance, e.g., washing machine appliance 300 of FIGS. 3 and 4 . For example, method 500 may be used to operate washing machine appliance 300 (FIGS. 3 and 4 ). In particular, controller 366 may be programmed or configured to implement method 500. As another example, method 500 may be used to operate combination appliance 10 (FIGS. 1 and 2 ). In particular, controller 56 may be programmed or configured to implement method 500. Utilizing method 500, a load size of articles within wash chamber 25 of basket 130 (FIG. 2 ) or within wash chamber 326 of basket 320 (FIG. 4 ) can be estimated or measured. In particular, a mass of articles within the wash chamber 25, 326 of the basket 130, 320 can be estimated or measured utilizing method 500. FIG. 10 provides a plot of an angular velocity of basket 130, 320 over time during a load sizing cycle of laundry appliance 10, 300. Method 500 can be performed during the load sizing cycle of combination appliance 10 or washing machine appliance 300 shown in FIG. 10 . Method 500 is discussed in greater detail below in the context of the load sizing cycle illustrated in FIG. 10 .
As may be seen in FIG. 10 , the load sizing cycle includes a plaster step 610. During plaster step 610, controller 56, 366 operates motor 222, 322. In particular, motor 222, 322 can accelerate basket 130, 320 such that an angular velocity of basket 130, 320 increases, e.g., to about a first angular velocity, during the plaster step 610. The first angular velocity can be any suitable angular velocity. For example, the first angular velocity may be greater than a plaster angular velocity of articles within wash chamber 25, 326 of basket 130, 320. Thus, when motor 222, 322 rotates basket 130, 320 at the first angular velocity, articles within wash chamber 25, 326 of basket 130, 320 can be plastered against and/or stick to basket 130, 320 because the angular velocity of basket 130, 320 exceeds the plaster angular velocity of basket 130, 320. With articles within wash chamber 25, 326 of basket 130, 320 plastered against basket 130, 320, articles within wash chamber 25, 326 can be substantially stationary or fixed relative to basket 130, 320 during rotation of basket 130, 320.
At step 510 (FIG. 9 ), controller 56, 366 operates motor 222, 322 in order to rotate basket 130, 320 at the first angular velocity. At step 520, controller 56, 366 determines an average power delivered to motor 222, 322, e.g., during step 510. For example, as shown in FIG. 10 , motor 222, 322 rotates basket 130, 320 at the first angular velocity during a first spin step 620 of the load sizing cycle. At step 520, controller 56, 366 can determine the average power delivered to motor 222, 322 during the entirety of the first spin step 620 or during a portion of the first spin step 620. As will be under stood by those skilled in the art, a power delivered to motor 222, 322 when basket 130, 320 is rotating at a constant angular velocity can correspond to about a power required to overcome friction and other static factors hindering rotation of basket 130, 320, e.g., because basket 130, 320 is not accelerating. Thus, the average power delivered to motor 222, 322 determined at step 520 can be used to estimate or gauge the friction and other steady state losses within motor 222, 322 and other components of washing machine appliance 100 that impede rotation of basket 130, 320.
At step 530, the angular velocity of basket 130, 320 is increased. As an example, controller 56, 366 can operate motor 222, 322 in order to increase the angular velocity of basket 130, 320, e.g., after step 510. In particular, controller 56, 366 can increase the angular velocity of basket 130, 320 from about the first angular velocity to about a second angular velocity with motor 222, 322 at step 530. The second angular velocity can be any suitable angular velocity. For example, the second angular velocity may be greater than the first angular velocity.
At step 540, controller 56, 366 establishes a plurality of instantaneous powers delivered to motor 222, 322, e.g., during step 530. As an example, an instantaneous power may be measured about every ten milliseconds during step 530 in order to establish the plurality of instantaneous powers delivered to motor 222, 322 at step 540. As may be seen in FIG. 10 , motor 222, 322 increases the angular velocity of basket 130, 320 from about the first angular velocity to about the second angular velocity during an acceleration step 630 of the load sizing cycle. At step 540, controller 56, 366 can determine the plurality of instantaneous powers delivered to motor 222, 322 during the entirety of the acceleration step 630 or during a portion of the acceleration step 630. As will be under stood by those skilled in the art, the power delivered to motor 222, 322 when basket 130, 320 is accelerating can correspond to about a power required to overcome friction and other static factors hindering rotation of basket 130, 320 as well as the power required to accelerate basket 130, 320. Thus, each instantaneous power delivered to motor 222, 322 during step 530 can be used to estimate or gauge the power required to accelerate basket 130, 320 after accounting for the friction and other steady state losses within motor 222, 322 and other components of laundry appliance 10, 300 that impede rotation of basket 130, 320.
At step 550, controller 56, 366 calculates a load score of articles within wash chamber 25, 326 of basket 130, 320 based at least in part on the average power delivered to motor 222, 322 during step 520 and the plurality of instantaneous powers delivered to motor 222, 322 during step 530. The load score is, e.g., directly, proportional to a load size of articles within wash chamber 25, 326 of basket 130, 320. As an example, the load score of articles within wash chamber 25, 326 of basket 130, 320 may be calculated with the following at step 550,
$Load Score = \underset{t_{0}}{\sum^{t_{1}}} (P (t) - P_{avg, ss} * \frac{n (t)}{n_{avg, ss}})$
where
P is an instantaneous power delivered to motor 222, 322 at time t during step 530,
P_avg,ssis the average power delivered to motor 222, 322 during step 510,
n is an angular velocity of basket 130, 320 at time t during step 530, and
n_avg,ssis the first angular velocity.
Thus, the load score of articles within wash chamber 25, 326 of basket 130, 320 can correspond to a sum of the difference between each instantaneous power delivered to motor 222, 322 at step 530 and a product of the average power delivered to motor 222, 322 during step 510 and a weighting or scaling factor, where the weighting factor is a quotient of the angular velocity of basket 130, 320 at time t and the first angular velocity.
The load score of articles within wash chamber 25, 326 of basket 130, 320 can be directly proportional to a mass, m, of articles within wash chamber 25, 326 of basket 130, 320 such that
m∝Load Score
Thus, method 500 can also include correlating the load score of articles within wash chamber 25, 326 of basket 130, 320 to the mass of articles within wash chamber 25, 326 of basket 130, 320. For example, controller 56, 366 can obtain an associated mass of the load score from a lookup table or a function, such as a transfer function, within the memory of controller 56, 366.
It should be understood that method 500 can also include repeating steps 510, 520, 530, 540 and 550 and calculating an average load score for articles within wash chamber 25, 326 of basket 130, 320. Repeating steps 510-550 can improve the accuracy and/or consistency of method 300. However, repeating steps 510, 520, 530, 540 and 550 can increase a duration or time interval of method 500.
Turning now to FIG. 11 , embodiments of the present disclosure may also include methods of operating a laundry appliance, such as the example method 700 illustrated in FIG. 11 . Such methods may be used with any suitable laundry appliance, such as a combination appliance, e.g., combination appliance 10 of FIGS. 1 and 2 , or a dryer appliance, e.g., dryer appliance 400 of FIGS. 5 and 6 .
For example, as mentioned above, the laundry appliance 10 or 400 may include a controller 56 or 490 and the controller 56 or 490 may be operable for, e.g., configured for, performing some or all of the method steps. For example, one or more method steps may be embodied as an algorithm or program stored in a memory of the controller 56 or 490 and executed by the controller 56 or 490 in response to a user input such as a selection of a dry operation or wash and dry operation of the laundry appliance.
As illustrated in FIG. 11 , in some embodiments, the method 700 may include a step 710 of determining a load size of articles to be dried in the laundry appliance. In embodiments where the laundry appliance is a combination appliance such as combination appliance 10 illustrated in FIGS. 1 and 2 , step 710 of determining the load size may include determining the load size while the articles are in a laundry basket of the laundry appliance, such as by performing the method 500 with the combination appliance 10. In embodiments where the laundry appliance is a dryer appliance such as dryer appliance 400 illustrated in FIGS. 5 and 6 , step 710 of determining the load size may include receiving load size information from a washer appliance, such as the washer appliance 300 illustrated in FIGS. 3 and 4 , where the washer appliance may perform the method 500 and then transmit, e.g., wirelessly, the load score or a load size derived from the load score (e.g., from a lookup table or transfer function as mentioned above) to the dryer appliance.
Thus, in various embodiments, the step 710 of determining a load size of articles to be dried in the laundry appliance may include calculating a load score of the articles to be dried based on a power delivered to a motor while the motor is accelerating a basket with the laundry articles in the basket and correlating the load score of the articles to mass of articles, e.g., as described above regarding FIGS. 9 and 10 . For example, the motor may be the motor 222 of the combination laundry appliance 10, in embodiments where the laundry appliance is a combination appliance or may be a motor of a connected washing machine appliance in embodiments where the laundry appliance is a dryer appliance.
Method 700 may also include a step 720 of determining a load type of the articles to be dried in the laundry appliance. For example, method 700 may include determining a plurality of load scores, e.g., either directly determining the plurality of load scores while the articles are in the laundry appliance in combination embodiments or receiving load scores from a connected washing machine appliance in dryer embodiments. The plurality of load scores may include a dry load score, a wet or saturated load score, and a damp load score, or any combination of two of the foregoing load scores. The dry load score may be proportional to the mass of the articles themselves, e.g., without any water or wash liquid. For example, the dry load score may be determined prior to an initial fill of a wash cycle whereby the articles, having been loaded into the washing machine appliance for the wash cycle, are generally dry or relatively dry as compared to later stages of the same wash cycle. The wet load score may be proportional to the mass of the articles plus a full volume of water, such as a rinse volume of the wash cycle. Thus, the wet load score may be obtained after the initial fill of the wash cycle and before a spin cycle or extraction phase of the spin cycle of the wash cycle, such as after a rinse phase of the wash cycle. The damp load score may be proportional to the mass of the articles plus a portion of the volume of water, such as the portion of the volume of water remaining after the extraction phase or spin cycle. For example, the damp load score may be obtained (calculated) after the spin cycle, including the extraction phase, is completed. In particular, the damp load score may be a post-extraction load score calculated after a max extraction phase of a spin cycle of the wash operation or wash cycle is complete.
The load type may be determined based on two or more load scores of the plurality of load scores, such as based on the mathematical difference between a first load score of the plurality of load scores and a second load score of the plurality of load scores. Further, in some embodiments, the load type may be based on a ratio of the mathematical difference between the first score and the second score and one load score of the plurality of load scores, such as the first load score. Such difference between the first load score and the second load score may correspond to a volume of water absorbed, extracted from, or retained by the articles, e.g., the difference between the first load score and the second load score may correspond or be proportional to the absorptivity of the articles. Similarly, the ratio of the difference to a prior load score, such as an initial load score, may also correspond or be proportional to the absorptivity of the articles and may be indicative of the drying rate or moisture extraction rate of the articles. Thus, the load type may be determined or classified based on the absorptivity of the articles. For example, the load type may be classified as towel load, denim load, bedding load, natural fiber load, synthetic load, or mixed load, among other possible load type classifications.
For example, the first load score may be the dry load score and the second load score may be the wet load score, where the mathematical difference between the first load score and the second load score may be the wet load score minus the dry load score and may correspond to the amount of water absorbed by the articles during the wash phase and/or rinse phase of the wash cycle. Additionally, the load type may also be determined based on (e.g., may be a function of) a ratio of the wet load score minus the dry load score to the dry load score. As another example, the first load score may be the dry load score and the second load score may be the damp load score, where the mathematical difference between the first load score and the second load score may be the damp load score minus the dry load score and may correspond to the amount of water remaining in the articles after the spin cycle and/or extraction phase of the spin cycle of the wash cycle. In yet another example, the first load score may be the damp load score and the second load score may be the wet load score, where the mathematical difference between the first load score and the second load score may be the wet load score minus the damp load score and may correspond to the amount of water extracted from the articles during the spin cycle and/or extraction phase of the spin cycle of the wash cycle. In each of the foregoing examples, the amount of water absorbed by, remaining in, or extracted from the load of articles is a function of the absorptivity of the articles and may then be used to determine the load type, such as towels, natural fiber, or synthetic load type, etc., where the various load types are distinguished from each other based on the absorptivity of the articles in the load. Further, the load type may be determined based on the mathematical difference between two load scores as in any of the following examples either alone or as a ratio to a load score, such as a ratio of the mathematical difference to the dry load score.
Method 700 may further include a step 730 of determining a termination criterion for a dry operation of the laundry appliance based on the load size and the load type, e.g., the termination criterion may be a function of the load size and/or load type. For example, the termination criterion may be an atmospheric condition, e.g., relative humidity or temperature, of air circulating in or exhausted from the laundry appliance during a dry cycle or drying operation of the laundry appliance. As another example, the termination criterion that is a function of the load size and/or load type may also or instead be a drying time, or may be a humidity measured by a humidity sensor comprising a pair of sensor rods, e.g., as described above in the context of the dryer appliance 410. In exemplary embodiments where the termination criterion based on the load size and/or load type is a humidity measured with sensor rods, the humidity may be measured with the sensor rods to a certain point, e.g., until the humidity corresponds to about 20% remaining moisture content in the articles in the laundry appliance, and the termination criterion may be a humidity that is interpolated from the sensor rod humidity measurements and that corresponds to a remaining moisture content less than 20%. The method 700 may, in some embodiments, include a step 740 of performing the dry operation in the laundry appliance and the dry operation of step 740 may be terminated when the termination criterion is reached. For example, in various embodiments, the dry operation may be terminated after a calculated time has elapsed, where the calculated time is based on (e.g., a function of) the load size and the load type. In additional exemplary embodiments, the dry operation may be terminated when a target temperature or humidity is reached, where the temperature or humidity may be measured with one or more temperature sensors and/or humidity sensors as described above. In some embodiments, the target temperature or humidity may be directly measured, and in other embodiments, the target temperature or humidity may be interpolated from one or more temperature or humidity measurements, such as humidity measurements taken with sensor rods.
In some embodiments, e.g., where the termination criterion is a temperature or humidity value, the method 700 may also include a step 750 of measuring at least one atmospheric condition, e.g., relative humidity and/or temperature, within the laundry appliance during the dry operation, such as within a recirculation duct or an exhaust duct of the laundry appliance. In various embodiments, the method 700 may then include a step 760 of terminating the dry operation when the at least one atmospheric condition reaches the termination criterion. For example, where the termination criterion is a relative humidity level, the method 700 may include terminating the dry operation at step 760 when (because, and in response to) the measured relative humidity level reaches the termination relative humidity level. As another example, in embodiments where the termination criteria is a temperature, the method 700 may include terminating the dry operation at step 760 when (because, and in response to) the measured temperature reaches the termination temperature level.
The termination criterion will generally correspond to the load size in that larger load sizes will stop at a higher relative humidity and/or temperature, whereas smaller load sizes will stop at a lower relative humidity and/or temperature. The termination criterion will also generally correspond to the load type in that more absorptive load types will stop at a higher relative humidity and/or temperature, whereas less absorptive load types will stop at a lower relative humidity and/or temperature. For example, in embodiments where the termination criterion is a relative humidity level, the termination criterion may be between about 10% relative humidity and about 45% relative humidity, such as between about 20% relative humidity and about 35% relative humidity, such as between about 15% and about 20% relative humidity for a smaller and/or less absorptive load, such as between about 25% relative humidity and about 30% for a medium-sized and/or mixed fabric load, such as between about 35% relative humidity and about 40% relative humidity for a larger and/or more absorptive load.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

What is claimed is:

1. A method of operating a laundry appliance, comprising:

determining a load size of articles to be dried in the laundry appliance;

determining a load type of the articles to be dried in the laundry appliance;

determining a termination criterion for a dry operation of the laundry appliance based on the load size and the load type;

performing the dry operation in the laundry appliance; and

terminating the dry operation when the termination criterion is reached.

2. The method of claim 1, wherein the laundry appliance is a dryer appliance, wherein the step of determining the load size comprises receiving load size information from a washer appliance, and the step of determining the load type comprises receiving load type information from the washer appliance.

3. The method of claim 1, wherein the laundry appliance is a combination appliance, wherein the step of determining the load size comprises determining the load size while the articles are in a laundry basket of the laundry appliance, and the step of determining the load type comprises determining the load type while the articles are in the laundry basket of the laundry appliance.

4. The method of claim 1, wherein the step of determining the load size comprises calculating a load score of the articles to be dried based on a power delivered to a motor while the motor is accelerating a basket with the laundry articles in the basket and correlating the load score of the articles to mass of articles.

5. The method of claim 1, wherein the step of determining the load type comprises calculating a first load score of the articles, calculating a second load score of the articles, and determining the load type based on the mathematical difference between the first load score and the second load score.

6. The method of claim 5, wherein the first load score is a dry load score calculated prior to wetting the articles during a wash operation and the second load score is a saturated load score calculated after wetting the articles during the wash operation and before a spin cycle of the wash operation is complete, whereby the mathematical difference between the first load score and the second load score corresponds to an amount of water absorbed by the articles.

7. The method of claim 5, wherein the first load score is a dry load score calculated prior to wetting the articles during a wash operation and the second load score is a post-extraction load score calculated after a max extraction phase of a spin cycle of the wash operation is complete, whereby the mathematical difference between the first load score and the second load score corresponds to an amount of water retained in the articles.

8. The method of claim 5, wherein the first load score is a saturated load score calculated after wetting the articles during the wash operation and before a spin cycle of the wash operation is complete and the second load score is a post-extraction load score calculated after a max extraction phase of the spin cycle of the wash operation is complete, whereby the mathematical difference between the first load score and the second load score corresponds to an amount of water extracted from the articles.

9. The method of claim 1, wherein the termination criterion is a termination relative humidity level, further comprising measuring relative humidity within the laundry appliance during the dry operation, and wherein the step of terminating the dry operation comprises terminating the dry operation when the measured relative humidity reaches the termination relative humidity level.

10. The method of claim 1, wherein the termination criterion is a termination temperature level, further comprising measuring temperature within the laundry appliance during the dry operation, and wherein the step of terminating the dry operation comprises terminating the dry operation when the measured temperature reaches the termination temperature level.

11. A laundry appliance, comprising:

a cabinet defining an interior volume;

a laundry basket rotatably mounted within the interior volume of the cabinet, the laundry basket defining a chamber for the receipt of articles for treatment;

a heating system in thermal communication with the chamber whereby heated air flows from the heating system to the chamber; and

a controller, the controller configured for:

determining a load size of articles to be dried in the laundry appliance;

determining a load type of the articles to be dried in the laundry appliance;

performing the dry operation in the laundry appliance; and

terminating the dry operation when the termination criterion is reached.

12. The laundry appliance of claim 11, wherein the laundry appliance is a dryer appliance, wherein the controller is configured for determining the load size by receiving load size information from a washer appliance, and the controller is configured for determining the load type by receiving load type information from the washer appliance.

13. The laundry appliance of claim 11, wherein the laundry appliance is a combination appliance, wherein the controller is configured for determining the load size while the articles are in a laundry basket of the laundry appliance, and the controller is configured for determining the load size while the articles are in the laundry basket of the laundry appliance.

14. The laundry appliance of claim 11, wherein determining the load size comprises calculating a load score of the articles to be dried based on a power delivered to a motor while the motor is accelerating a basket with the laundry articles in the basket and correlating the load score of the articles to mass of articles.

15. The laundry appliance of claim 11, wherein determining the load type comprises calculating a first load score of the articles, calculating a second load score of the articles, and determining the load type based on the mathematical difference between the first load score and the second load score.

16. The laundry appliance of claim 15, wherein the first load score is a dry load score calculated prior to wetting the articles during a wash operation and the second load score is a saturated load score calculated after wetting the articles during the wash operation and before a spin cycle of the wash operation is complete, whereby the mathematical difference between the first load score and the second load score corresponds to an amount of water absorbed by the articles.

17. The laundry appliance of claim 15, wherein the first load score is a dry load score calculated prior to wetting the articles during a wash operation and the second load score is a post-extraction load score calculated after a max extraction phase of a spin cycle of the wash operation is complete, whereby the mathematical difference between the first load score and the second load score corresponds to an amount of water retained in the articles.

18. The laundry appliance of claim 15, wherein the first load score is a saturated load score calculated after wetting the articles during the wash operation and before a spin cycle of the wash operation is complete and the second load score is a post-extraction load score calculated after a max extraction phase of the spin cycle of the wash operation is complete, whereby the mathematical difference between the first load score and the second load score corresponds to an amount of water extracted from the articles.

19. The laundry appliance of claim 11, wherein the termination criterion is a termination relative humidity level, further comprising measuring relative humidity within the laundry appliance during the dry operation, and wherein the step of terminating the dry operation comprises terminating the dry operation when the measured relative humidity reaches the termination relative humidity level.

20. The laundry appliance of claim 11, wherein the termination criterion is a termination temperature level, further comprising measuring temperature within the laundry appliance during the dry operation, and wherein the step of terminating the dry operation comprises terminating the dry operation when the measured temperature reaches the termination temperature level.