US20240011210A1

US20240011210A1 - Washing machine appliance and methods for drying a wash chamber

Info

Publication number: US20240011210A1
Application number: US17/857,693
Authority: US
Inventors: JaeHyo Lee; Je Kwon Yoon
Original assignee: Haier US Appliance Solutions Inc
Current assignee: Haier US Appliance Solutions Inc
Priority date: 2022-07-05
Filing date: 2022-07-05
Publication date: 2024-01-11

Abstract

A washing machine appliance may include a cabinet, a tub, a wash basket, a ventilation line, a humidity sensor, and a controller. The ventilation line may define an air path from the tub through the cabinet. The humidity sensor may be mounted along the ventilation line to detect humidity therein. The controller may be in operative communication with the humidity sensor. The controller may be configured to direct a dry cycle that includes detecting a humidity level at the humidity sensor reaching a predetermined level target, measuring an elapsed time period to detecting the humidity level, determining the elapsed time period exceeds a baseline time period, recording an excess instance in response to determining the elapsed time period exceeds the baseline time period, determining a previous excess instance corresponding to a prior dry cycle, and determining a fault condition based on the excess instance and previous excess instance.

Description

FIELD OF THE INVENTION

The present subject matter relates generally to washing machine appliances, and more particularly to systems and methods for drying the wash chamber.

BACKGROUND OF THE INVENTION

Washing machine appliances generally include a wash tub for containing water or wash fluid (e.g., water, detergent, bleach, or other wash additives). A basket is rotatably mounted within the wash tub and defines a wash chamber for receipt of articles for washing. During normal operation of such washing machine appliances, the wash fluid is directed into the wash tub and onto articles within the wash chamber of the basket. The basket or an agitation element can rotate at various speeds to agitate articles within the wash chamber, to wring wash fluid from articles within the wash chamber, etc.
Some existing washing machine appliances, such as horizontal axis washing machines, are provided with one or more ventilation features. Such features may allow washing machine appliance to exchange air between the wash tub and the ambient environment. The exchange of air may be necessary to prevent moisture from accumulating within the tub. For example, if the tub is not ventilated, mold or mildew may form within the washing machine. In turn, undesirable odors may be generated.
Although ventilation features may ensure that moisture does not accumulate within the washing machine appliance while the washing machine appliance is not in use, it may be difficult for a user to know if or when such features are not operating properly. In many cases, a user may not have any warning of poor operation until mold or mildew has already begun to accumulate and produce a noticeable odor.
As a result, it would be desirable to provide a washing machine appliance or methods of operation that address one or more of the above identified issues. In particular, it would be useful to provide an appliance or method capable of detecting or addressing faulty conditions of one or more ventilation features.

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 exemplary aspect of the present disclosure, a washing machine appliance is provided. The washing machine appliance may include a cabinet, a tub, a wash basket, a ventilation line, a humidity sensor, and a controller. The tub may be positioned within the cabinet. The wash basket may be rotatably mounted within the tub. The ventilation line may define an air path from the tub through the cabinet. The humidity sensor may be mounted along the ventilation line to detect humidity therein. The controller may be in operative communication with the humidity sensor. The controller may be configured to direct a dry cycle that includes detecting a humidity level at the humidity sensor reaching a predetermined level target, measuring an elapsed time period to detecting the humidity level, determining the elapsed time period exceeds a baseline time period, recording an excess instance in response to determining the elapsed time period exceeds the baseline time period, determining a previous excess instance corresponding to a prior dry cycle, and determining a fault condition based on the excess instance and previous excess instance.
In another exemplary aspect of the present disclosure, a method of operating a washing machine appliance is provided. The method may include detecting a humidity level at a humidity sensor reaching a predetermined level target and measuring an elapsed time period to detecting the humidity level. The method may also include determining the elapsed time period exceeds a baseline time period and recording an excess instance in response to determining the elapsed time period exceeds the baseline time period. The method may further include determining a previous excess instance corresponding to a prior dry cycle. The method may still further include determining a fault condition based on the excess instance and previous excess instance.
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 washing machine appliance according to exemplary embodiments of the present disclosure.

FIG. 2 provides a cross-sectional side view of the exemplary washing machine appliance of FIG. 1 .

FIG. 3 provides a front view of the exemplary washing machine appliance of FIG. 1 , wherein the door has been removed for clarity.

FIG. 4 provides a magnified, cross-sectional, side view of a portion the exemplary washing machine appliance of FIG. 1 .

FIG. 5 provides a perspective view of a damper assembly according to exemplary embodiments of the present disclosure.

FIG. 6 provides a cross-sectional schematic view of the exemplary damper assembly of FIG. 5 in a closed first position.

FIG. 7 provides a cross-sectional schematic view of the exemplary damper assembly of FIG. 5 in an open second position.

FIG. 8 provides a flow chart of a method of operating a washing machine appliance according to exemplary embodiments of the present disclosure.

FIG. 9 provides a flow chart of a method of operating a washing machine appliance according to exemplary embodiments of the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

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 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, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). In addition, here and throughout the specification and claims, range limitations may be combined or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components or systems. For example, the approximating language may refer to being within a 10 percent margin (i.e., including values within ten percent greater or less than the stated value). In this regard, for example, 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 (e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, such as, clockwise or counterclockwise, with the vertical direction V).
The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, 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 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.
Referring now to the figures, FIG. 1 is a perspective view of an exemplary washing machine appliance 100. FIG. 2 is a side cross-sectional view of washing machine appliance 100. FIG. 3 provides a front view of washing machine appliance 100, wherein a door 134 (FIG. 2 ) has been removed for clarity. As illustrated, washing machine appliance 100 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. Washing machine appliance 100 includes a cabinet 102 that extends between a top 104 and a bottom 106 along the vertical direction V, between a left side 108 and a right side 110 along the lateral direction L, and between a front 112 and a rear 114 along the transverse direction T.
A wash tub 124 is positioned within cabinet 102 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 124 is substantially fixed relative to cabinet 102 such that it does not rotate or translate relative to cabinet 102.
A wash basket 120 is received within wash tub 124 and defines a wash chamber 126 that is configured for receipt of articles for washing. More specifically, wash basket 120 is rotatably mounted within wash tub 124 such that it is rotatable about an axis of rotation A. According to the illustrated embodiments, the axis of rotation A is substantially parallel (e.g., within 30°) relative to the transverse direction T. In this regard, washing machine appliance 100 is generally referred to as a “horizontal axis” or “front load” washing machine appliance 100. However, it is noted that the illustrated embodiments are provided merely as non-limiting examples and the present disclosure may be applicable to any other suitable washing machine appliance configuration (e.g., as top load washing machine appliance, combination washer-dryer appliance, etc.).
Wash basket 120 may define one or more agitator features that extend into wash chamber 126 to assist in agitation and cleaning articles disposed within wash chamber 126 during operation of washing machine appliance 100. For example, as illustrated in FIG. 2 , a plurality of ribs 128 extends from basket 120 into wash chamber 126. In this manner, for example, ribs 128 may lift articles disposed in wash basket 120 during rotation of wash basket 120.
Washing machine appliance 100 includes a motor assembly 122 that is in mechanical communication with wash basket 120 to selectively rotate wash basket 120 (e.g., during an agitation or a rinse cycle of washing machine appliance 100). According to the illustrated embodiments, motor assembly 122 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 120 according to alternative embodiments.
Cabinet 102 also includes a front panel 130 that defines an opening 132, which generally permits user access to wash basket 120 of wash tub 124. More specifically, washing machine appliance 100 includes a door 134 that is selectively positioned over opening 132 and is rotatably mounted to front panel 130 (e.g., about a door axis that is substantially parallel to the vertical direction V). In this manner, door 134 permits selective access to opening 132 by being movable between an open position (see e.g., FIG. 8 ) facilitating access to a wash tub 124 and a closed position (see e.g., FIG. 1 ) prohibiting access to wash tub 124. In exemplary embodiments, a lock assembly 182 is fixed to cabinet 102 to selectively lock or hold a free end of the door 134 to cabinet 102 when door 134 is in the closed position (e.g., during certain operations or wash cycles).
In some embodiments, a central body 136 of door 134 is provide on a perimeter rim 135 that extends about (e.g., radially about) at least a portion of central body 136. In optional embodiments, central body 136 is provided as a window and permits viewing of wash basket 120 when door 134 is in the closed position (e.g., during operation of washing machine appliance 100). Generally, door 134 defines a footprint 170 on a front portion of cabinet 102 (e.g., in a plane defined by the lateral direction L and the transverse direction T). For instance, when door 134 is in the closed position, central body 136 and perimeter rim 135 may extend across footprint 170 and thus cover the area of the front panel 130 within footprint 170 (e.g., when viewed along the transverse direction T directly in front of washing machine appliance 100). As shown, particularly in FIG. 3 , footprint 170 may extend radially outward from opening 132. Thus, footprint 170 may encompass and define a larger width (e.g., diameter) than opening 132. In some such embodiments, central body 136 extends across and, optionally, within opening 132. Perimeter rim 135 may extend radially outward from opening 132 and define the radial extrema of footprint 170.
In certain embodiments, central body 136 is provided as a non-permeable body, which blocks or prevents wash fluid or air from passing therethrough. In alternative embodiments, central body 136 defines one or more air aperture therethrough. Additionally or alternatively, door 134 may also include a handle (not shown) that, for example, a user may pull when opening 132 and closing door 134. Further, although door 134 is illustrated as mounted to front panel 130, it should be appreciated that door 134 may be mounted to another side of cabinet 102 or any other suitable support according to alternative embodiments.
A front gasket or baffle 138 may extend between tub 124 and the front panel 130 about the opening 132 covered by door 134, further sealing tub 124 from cabinet 102. For example, when door 134 is in the closed position, baffle 138 may contact central body 136 in sealing engagement therewith and within footprint 170.
As shown, wash basket 120 defines a plurality of perforations 140 in order to facilitate fluid communication between an interior of basket 120 and wash tub 124. A sump 142 is defined by wash tub 124 at a bottom of wash tub 124 along the vertical direction V. Thus, sump 142 is configured for receipt of, and generally collects, wash fluid during operation of washing machine appliance 100. For example, during operation of washing machine appliance 100, wash fluid may be urged (e.g., by gravity) from basket 120 to sump 142 through plurality of perforations 140. A pump assembly 144 is located beneath wash tub 124 for gravity assisted flow when draining wash tub 124 (e.g., via a drain 146). Pump assembly 144 may also be configured for recirculating wash fluid within wash tub 124.
In some embodiments, washing machine appliance 100 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 wash tub 124. Spout 150 may also be in fluid communication with the sump 142. For example, pump assembly 144 may direct wash fluid disposed in sump 142 to spout 150 in order to circulate wash fluid in wash tub 124.
As illustrated, a detergent drawer 152 may be slidably mounted within front panel 130. Detergent drawer 152 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 126 during certain operations or wash cycle phases of washing machine appliance 100. According to the illustrated embodiment, detergent drawer 152 may also be fluidly coupled to spout 150 to facilitate the complete and accurate dispensing of wash additive.
In optional embodiments, a bulk reservoir 154 is disposed within cabinet 102. Bulk reservoir 154 may be configured for receipt of fluid additive for use during operation of washing machine appliance 100. Moreover, bulk reservoir 154 may be sized such that a volume of fluid additive sufficient for a plurality or multitude of wash cycles of washing machine appliance 100 (e.g., five, ten, twenty, fifty, or any other suitable number of wash cycles) may fill bulk reservoir 154. Thus, for example, a user can fill bulk reservoir 154 with fluid additive and operate washing machine appliance 100 for a plurality of wash cycles without refilling bulk reservoir 154 with fluid additive. A reservoir pump 156 is configured for selective delivery of the fluid additive from bulk reservoir 154 to wash tub 124.
In some embodiments, a control panel 160 including a plurality of input selectors 162 is coupled to front panel 130. Control panel 160 and input selectors 162 may collectively form a user interface input for operator selection of machine cycles and features. For example, in exemplary embodiments, a display 164 indicates selected features, a countdown timer, or other items of interest to machine users.
Operation of washing machine appliance 100 is generally controlled by a controller or processing device 166. In some embodiments, controller 166 is in operative communication with (e.g., electrically or wirelessly connected to) control panel 160 for user manipulation to select washing machine cycles and features. In response to user manipulation of control panel 160, controller 166 operates the various components of washing machine appliance 100 to execute selected machine cycles and features.
Controller 166 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 166 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 160 and other components of washing machine appliance 100, such as motor assembly 122, a fan 198, and a vent damper 210, may be in operative communication with controller 166 via one or more signal lines or shared communication busses. Additionally or alternatively, other features, such as an electronic lock assembly 182 for door 134 may be in operative communication with controller 166 via one or more other signal lines or shared communication busses.
In exemplary embodiments, during operation of washing machine appliance 100, laundry items are loaded into wash basket 120 through opening 132, and a wash cycle is initiated through operator manipulation of input selectors 162. For example, a wash cycle may be initiated such that wash tub 124 is filled with water, detergent, or other fluid additives (e.g., via additive dispenser 150 during a fill phase). One or more valves (not shown) can be controlled by washing machine appliance 100 to provide for filling wash basket 120 to the appropriate level for the amount of articles being washed or rinsed. By way of example, once wash basket 120 is properly filled with fluid, the contents of wash basket 120 can be agitated (e.g., with ribs 128) for an agitation phase of laundry items in wash basket 120. During the agitation phase, the basket 120 may be motivated about the axis of rotation A at a set speed (e.g., first speed or tumble speed). As the basket 120 is rotated, articles within the basket 120 may be lifted and permitted to drop therein.
After the agitation phase of the washing operation or wash cycle is completed, wash tub 124 can be drained (e.g., through a drain phase). Laundry articles can then be rinsed (e.g., through a rinse phase) by again adding fluid to wash tub 124, depending on the particulars of the wash cycle selected by a user. Ribs 128 may again provide agitation within wash basket 120. One or more spin phases may also be used. In particular, a spin phase 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 phase, basket 120 is rotated at relatively high speeds. For instance, basket 120 may be rotated at one set speed (e.g., second speed or pre-plaster speed) before being rotated at another set speed (e.g., third speed or 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 120 increases its rotational velocity such that the plaster speed maintains the articles at a generally fixed position relative to basket 120.
After articles disposed in wash basket 120 are cleaned (or the wash cycle otherwise ends), a user can remove the articles from wash basket 120 (e.g., by opening door 134 and reaching into wash basket 120 through opening 132).
In some embodiments, a rear ventilation line 190 is provided within washing machine appliance 100. In particular, rear ventilation line 190 may be enclosed within cabinet 102. As shown in FIGS. 2 and 4 , exemplary embodiments include rear ventilation line 190 at a position in fluid communication between tub 124 and the surrounding region (e.g., the ambient environment outside of or immediately surrounding cabinet 102, the enclosed volume of cabinet 102 surrounding tub 124, etc.). Generally, it is understood that rear ventilation line 190 may be provided as any suitable pipe or conduit (e.g., having non-permeable wall) for directing air therethrough. When assembled, rear ventilation line 190 defines an air path (e.g., an output air path 192) from tub 124 and within or through cabinet 102 (e.g., to the ambient environment outside of cabinet 102). Specifically, output air path 192 extends from a ventilation inlet 194, through cabinet 102, and to a ventilation outlet 196. In some embodiments, ventilation inlet 194 is defined through a top portion of wash tub 124 and ventilation outlet 196 is defined through an upper portion of cabinet 102. Thus, output air path 192 may extend from the top portion of tub 124 to an upper portion of cabinet 102. Optionally, ventilation inlet 194 may be positioned below ventilation outlet 196 along a vertical direction V. Advantageously, a convective airflow may be naturally motivated from wash tub 124, through output air path 192, and to the ambient environment. Additionally or alternatively, splashing of wash fluid and the collection of moisture within output air path 192 may be prevented. However, any other suitable configuration may be provided to facilitate the flow of air from tub 124 and, for example, to the ambient environment.
Although a convective airflow may be facilitated, some embodiments further include a fan or blower 198 (indicated in phantom lines). Specifically, fan 198 may be provided in fluid communication with rear ventilation line 190 to motivate an active airflow therethrough. For instance, fan 198 may be mounted within rear ventilation line 190 to selectively rotate and draw air from wash tub 124, through ventilation inlet 194, and to ventilation outlet 196 (e.g., to output an airflow from tub 124 to the ambient environment).
In certain embodiments, a humidity sensor 188 is provided in fluid communication with rear ventilation line 190. For instance, humidity sensor 188 may be mounted within rear ventilation line 190 (e.g., at or proximal to outlet 196) to detect humidity of air along air path 192. Thus, humidity sensor 188 may be provided and configured to detect a humidity level or dew point along air path 192. When assembled, humidity sensor 188 may be communicatively coupled with controller 166 (e.g., via a suitable wired or wireless communication link) and may include, for instance, a capacitive hygrometer, resistive hygrometer, thermal hygrometer, or optical hygrometer.
In certain embodiments, a front ventilation line 200, separate and spaced apart from rear ventilation line 190, is provided in fluid communication with wash tub 124. For instance, front ventilation line 200 may be any suitable pipe or conduit in fluid communication (e.g., upstream fluid communication) with wash tub 124 and rear ventilation line 190. As shown, in exemplary embodiments, front ventilation line 200 extends from front panel 130 to wash tub 124. When assembled, front ventilation line 200 defines an air path (e.g., intake air path 208) from front panel 130 to wash tub 124 (e.g., upstream of output air path 192). Specifically, intake air path 208 extends from an intake inlet 202, through cabinet 102, and to an intake outlet 206. In some embodiments, A cabinet aperture 204 may be defined through front panel 130 as intake inlet 202. Thus, intake air path 208 may extend from front panel 130 to, for example, a top portion of tub 124. Optionally, intake inlet 202 may be positioned above intake outlet 206 along a vertical direction V.
Turning especially in FIGS. 2 and 3 , in some embodiments, cabinet aperture 204 is defined within the footprint 170 of door 134. Thus, when door 134 is in the closed position, cabinet aperture 204 may be generally covered and hidden from view. As shown, even though door 134 is in the closed position, a gap 254 may be defined between at least a portion of door 134 and cabinet aperture 204 to permit an ambient airflow 230 from the ambient environment to cabinet aperture 204. In other words, one portion of door 134 (e.g., perimeter rim 135) may be spaced apart from cabinet aperture 204 while another portion of door 134 (e.g., central body 136) blocks opening 132 and contacts baffle 138.
In additional or alternative embodiments, one or more secondary apertures 256 (FIG. 1 —shown in phantom lines) may be defined through door 134 (e.g., through perimeter rim 135 along the transverse direction T) and in alignment with cabinet aperture 204. In such embodiments, air may pass between secondary aperture 256 and cabinet aperture 204 (e.g., from the ambient environment) when door 134 is in the closed position.
Although exemplary embodiments may provide cabinet aperture 204 and intake inlet 202 within the footprint 170 of door 134 above opening 132, it is noted that alternative embodiments may include cabinet aperture 204 and intake inlet 202 at another suitable location.
Notably, in the disclosed embodiments, air (e.g., an ambient airflow 230) may flow between tub 124 and the ambient environment through cabinet aperture 204 even while door 134 remains closed. For instance, air may be motivated through the air paths 192, 208 and tub 124 by convective airflow or by fan 198 in fluid communication with the ventilation lines 190, 200.
Turning especially to FIGS. 2, 4 and 5 , a vent damper 210 may be provided to selectively control an airflow between tub 124 and, for example, the ambient environment. Generally, vent damper 210 is in communication with wash tub 124 (e.g., in fluid communication with the air paths 192, 208). In certain embodiments, vent damper 210 is enclosed, at least in part, within cabinet 102. For instance, vent damper may be positioned along front ventilation line 200. As will be described in detail below, vent damper 210 may be selectively controlled or operated to limit the flow of air through front ventilation line 200 (e.g., and thereby through rear ventilation line 190, output air path 192, or intake air path 208) during certain operations, phases, or cycles. Thus, vent damper 210 may selectively limit airflow between tub 124 and the ambient environment.
When front ventilation line 200 is unobstructed (e.g., when vent damper 210 is in an open second position), air may flow to/from tub 124 between front ventilation line 200 and rear ventilation line 190. In other words, an airflow circuit with the ambient environment may be formed by the lines 190, 200 and tub 124. Moreover, when one line (e.g., front ventilation line 200 or rear ventilation line 190) is obstructed, the other line (e.g., rear ventilation line 190 or front ventilation line 200) may permit pressure within tub 124 to equalize relative to the ambient environment.
Turning especially to FIGS. 6 and 7 , various views are provided of a damper assembly (e.g., vent damper 210) according to exemplary embodiments of the present disclosure. Generally, vent damper 210 may include a rigid, non-permeable housing or chute 212. Chute 212 may define an opening 214 to selectively permit air therethrough and communicate with rear ventilation line 190 (e.g., via front ventilation line 200—FIG. 5 ). Thus, chute 212 may extend about opening 214, and opening 214 may extend through chute 212. In certain embodiments, an interior lip 216 extends radially inward from chute 212 toward opening 214 (e.g., coaxial or concentric with opening 214), thus defining a perimeter (or perimeter portion) of opening 214.
In certain embodiments, restrictor plate 218 is configured to move between a discrete first position and second position. As illustrated in FIG. 6 , the first position generally restricts airflow through opening 214 (e.g., and thereby through front ventilation line 200 or rear ventilation line 190). In the first position, restrictor plate 218 may extend across opening 214. By contrast, and as illustrated in FIG. 7 , the second position may generally permit airflow through opening 214 (e.g., and thereby through front ventilation line 200 or rear ventilation line 190). In the second position, restrictor plate 218 may be moved away from opening 214.
In certain embodiments, a resilient foam layer 220 is provided on restrictor plate 218. For instance, resilient foam layer 220 may be fixed to a surface of restrictor plate 218 between opening 214 and restrictor plate 218 (e.g., relative to or along front ventilation line 200). When restrictor plate 218 is in the first position, resilient foam layer 220 may contact at least a portion of chute 212. For instance, resilient foam layer 220 may be positioned in contact with interior lip 216. Optionally, resilient foam layer 220 may be at least partially compressed against chute 212, sealing front ventilation line 200 to prevent air from passing through opening 214. It is understood that resilient foam layer 220 may be provided as any suitable resilient or elastic foam material that can be compressed before returning to its uncompressed state or shape.
In exemplary embodiments, a motor 222 is mechanically coupled to non-permeable restrictor plate 218. Motor 222 may be attached at any suitable location on or near chute 212 to move restrictor plate 218 relative to opening 214. For instance, motor 222 may be configured to selectively rotate restrictor plate 218 about the pivot access P. Moreover, motor 222 may be provided as any suitable electromechanical device (e.g., gear assembly, solenoid, actuator, etc.) for moving restrictor plate 218 or holding restrictor plate 218 in a directed position. In certain embodiments, motor 222 is in operative communication with (e.g., electrically or wirelessly connected to) controller 166. Controller 166 may be configured to direct motor 222 to move or hold restrictor plate 218 in a selected position (e.g., according to a selected wash cycle or phase). In other words, controller 166 may be configured to move or rotate vent damper 210 between the first position and the second position.
Referring now to FIGS. 8 and 9 , various methods may be provided for use with washing machine appliances in accordance with the present disclosure. In general, the various steps of methods as disclosed herein may, in exemplary embodiments, be performed by the controller 166 (FIG. 1 ), which may receive inputs and transmit outputs from various other components of the appliance 100 (FIG. 1 ). In particular, the present disclosure is further directed to methods, as indicated by reference numbers 800 and 900, for operating a washing machine appliance 100, as described above. Such methods advantageously facilitate detection of a fault condition or poor ventilation, generally.
FIGS. 8 and 9 depict steps performed in a particular order for purpose of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that (except as otherwise indicated) methods 800 and 900 are not mutually exclusive. Moreover, the steps of the methods 800 and 900 can be modified, adapted, rearranged, omitted, interchanged, or expanded in various ways without deviating from the scope of the present disclosure.
Turning especially to FIG. 8 , at 810, the method 800 includes detecting a humidity level at the humidity sensor during a dry cycle. Thus, a signal may be received from the humidity sensor, which generally indicates or corresponds to a humidity value (e.g., level) of humidity as measured within or along the air path of the ventilation line. In particular, based on the received signal, it may be detected that the humidity level (i.e., as measured at the humidity sensor) has failed to reach a predetermined level target. In other words, 810 may include determining the humidity level along the air path of the ventilation line has failed to reach the predetermined level target (e.g., fallen to a measurable humidity value that is less than or equal to the predetermined level target) after the dry cycle has been initiated.
Generally, the dry cycle may be initiated following a wash cycle in which a load of clothes or articles is washed within the wash chamber (e.g., as described above). Optionally, the basket may be held in a stationary (e.g., non-rotating) position following the end of the wash cycle, such as for the duration of the dry cycle. In some embodiments, the dry cycle includes opening the ventilation line or otherwise facilitating an airflow through the ventilation line (e.g., before and during 810). As an example, the dry cycle and method 800 may include moving the vent damper to the open or second position prior to 810, thereby permitting airflow through the ventilation line during 810. As an additional or alternative example, the dry cycle and method 800 may include activating or otherwise directing rotation of the fan during 810, thereby motivating the airflow across the humidity sensor during 810.
At 820, the method 800 includes measuring an elapsed time period to (e.g., up to the moment of) detecting the humidity level. In other words, prior to 810, a timer or timing function may be initiated and then subsequently stopped in response to 810 (e.g., in response to detecting a humidity level that is greater than the predetermined level target). Generally, the start point for measuring the elapsed time period may follow the wash cycle. In some such embodiments, the elapsed time period is measured from a start point of the dry cycle. Thus, the method 800 may include initiating measurement of the elapsed time period in response to determining the start point of the dry cycle and subsequently halting measurement of the elapsed time period in response to detecting the humidity level.
At 830, the method 800 includes determining the elapsed time period measured at 820 exceeds a baseline time period. For instance, as part of 830 it may be required that the elapsed time period exceed the baseline time period by a fixed amount or percentage. In some embodiments, a fixed percentage of the baseline time period may be provided as a percentage greater than or equal to 10% (e.g., 10%, 15%, 20%, 25%, or 30%). Thus, 830 may include or otherwise require determining the elapsed time period exceeds the baseline time period by at least 10%.
Generally, the baseline time period is set or determined prior to the dry cycle or 810. In some embodiments, the baseline time period is calculated from times measured during one or more previous cycles on the washing machine appliance. Specifically, the elapsed time taken to complete one or more prior dry cycles (e.g., reach the predetermined level target during prior dry cycles). As an example, an average cycle time may be calculated based on the elapsed time period from a plurality of prior dry cycles. Thus, the baseline time period may include or be provided as an average cycle time period of a plurality of prior dry cycles. Optionally, the number of prior dry cycles may be a fixed number (e.g., 5 prior dry cycles, 10 prior dry cycles, 15 prior dry cycles, etc.). Thus, the plurality of prior dry cycles comprises a fixed number of prior dry cycles. The baseline time period may be updated on a rolling basis (e.g., with new measured elapsed time periods). Additionally or alternatively, the prior dry cycles used to calculate the baseline time period may all be consecutive dry cycles. In other words, the data for the baseline time period may be drawn from prior dry cycles that occurred sequentially. In turn, the plurality of prior dry cycles may be a rolling plurality of consecutive dry cycles.
At 840, the method 800 includes recording an excess instance in response to determining the elapsed time period exceeds the baseline time period. Thus, the controller may note and preserve a record of 830 (e.g., in response to the same). Such a recording may be preserved for the duration of the corresponding dry cycle or beyond (e.g., for a set amount of days, for a set number of subsequent dry cycles, etc.).
At 850, the method 800 includes determining a previous excess instance corresponding to a prior dry cycle. For instance, a record of the previous excess instance may be stored in the memory of the controller. Thus, the controller may look-up and identify the recorded previous instance. Optionally, the previous excess instance may be required to have occurred in the immediately prior dry cycle. Thus, for the purposes of 850, the prior dry cycle may be is limited to an immediately prior dry cycle such that the dry cycle is consecutive with the prior dry cycle. In turn, after two or more dry cycles that do not include an excess instance, a record of the previous excess instance may be deleted or otherwise moved to a different portion of the memory.
At 860, the method 800 includes determining a fault condition based on the excess instance and previous excess instance. For instance, the sequence of 840 and 850 may indicate a fault condition. In response to the fault condition, a notification signal may be transmitted, for instance, to the control panel of the appliance or a separate remote device (e.g., cell phone, computer, remote server, etc.), as would be understood in light of the present disclosure. Such a notification signal may prompt a visual or audible signal, such as to notify a user or service person that the fault condition has occurred.
Turning especially to FIG. 9 , at 910, the method 900 includes detecting a humidity level at the humidity sensor during a dry cycle. Thus, a signal may be received from the humidity sensor, which generally indicates or corresponds to a humidity value (e.g., level) of humidity as measured within or along the air path of the ventilation line.
Generally, the dry cycle may be initiated following a wash cycle in which a load of clothes or articles is washed within the wash chamber (e.g., as described above). Optionally, the basket may be held in a stationary (e.g., non-rotating) position following the end of the wash cycle, such as for the duration of the dry cycle. In some embodiments, the dry cycle includes opening the ventilation line or otherwise facilitating an airflow through the ventilation line (e.g., before and during 910). As an example, the dry cycle and method 900 may include moving the vent damper to the open or second position prior to 910, thereby permitting airflow through the ventilation line during 910. As an additional or alternative example, the dry cycle and method 900 may include activating or otherwise directing rotation of the fan during 910, thereby motivating the airflow across the humidity sensor during 910.
At 920, the method 900 includes measuring an elapsed time period to (e.g., up to the moment of) detecting the humidity level. In other words, prior to 910, a timer or timing function may be initiated and then subsequently stopped in response to 910 (e.g., in response to detecting a humidity level that is less than or equal to the predetermined level target). Generally, the start point for measuring the elapsed time period may follow the wash cycle. In some such embodiments, the elapsed time period is measured from a start point of the dry cycle. Thus, the method 900 may include initiating measurement of the elapsed time period in response to determining the start point of the dry cycle and subsequently halting or marking measurement of the elapsed time period in response to detecting the humidity level at 910.
At 930, the method 900 includes evaluating the humidity level detected at 910. Specifically, the detected humidity level may be compared to a predetermined humidity target (e.g., which may generally indicate or correspond to the end of a dry cycle). If the detected humidity level is less than or equal to the predetermined humidity target, the method 900 may proceed to 935A. By contrast, if the detected humidity level is greater than the predetermined humidity target, the method 900 may proceed to 935B.
At 935A, a baseline time period may be adjusted (e.g., using the measured elapsed time of 920). Generally, the baseline time period is first set or determined prior to the dry cycle or 910. In some embodiments, the baseline time period is calculated from times measured during one or more previous cycles on the washing machine appliance. Specifically, the elapsed time taken to complete one or more prior dry cycles (e.g., reach the predetermined level target during prior dry cycles). As an example, an average cycle time may be calculated based on the elapsed time period from a plurality of prior dry cycles. Thus, the baseline time period may include or be provided as an average cycle time period of a plurality of prior dry cycles. Optionally, the number of prior dry cycles may be a fixed number (e.g., 5 prior dry cycles, 10 prior dry cycles, 15 prior dry cycles, etc.). Thus, the plurality of prior dry cycles comprises a fixed number of prior dry cycles. The baseline time period may be updated on a rolling basis (e.g., with new measured elapsed time periods). Additionally or alternatively, the prior dry cycles used to calculate the baseline time period may all be consecutive dry cycles. In other words, the data for the baseline time period may be drawn from prior dry cycles that occurred sequentially. In turn, the plurality of prior dry cycles may be a rolling plurality of consecutive dry cycles. At 935A, the measured elapsed time of 920 may be used to update, adjust, recalculate, or otherwise change the previously established baseline time period as it existed prior to 910.
At 935B, the method 900 includes evaluating the elapsed time from 920. In particular, the measured elapsed time may be compared to the baseline time period (e.g., in its form established prior to 910). If the measured elapsed time is less than or equal to the baseline time period, the method 900 may return to 910 (e.g., to repeat the above steps). By contrast, if the measured elapsed time is greater than the baseline time period (e.g., by at least a fixed percentage, such as 10%, 15%, 20%, 25%, or 30%), the method 900 may proceed to 940.
At 940, the method 900 includes recording an excess instance in response to determining the elapsed time period exceeds the baseline time period (e.g., by at least a fixed percentage, such as 10%, 15%, 20%, 25%, or 30%). Thus, the controller may note and preserve a record of 935B (e.g., in response to the same). Such a recording may be preserved for the duration of the corresponding dry cycle or beyond (e.g., for a set amount of days, for a set number of subsequent dry cycles, etc.).
At 950, the method 900 includes directing an excess-time notification. Specifically, an excess-time notification signal may be transmitted, for instance, to the control panel of the appliance or a separate remote device (e.g., cell phone, computer, remote server, etc.), as would be understood in light of the present disclosure. Such a notification signal may prompt a visual or audible signal, such as to notify a user or service person that the dry cycle has continued for an excessive amount of time. Optionally, the control panel may be prompted to display a cancelation input, permitting a user to prematurely end the dry cycle or method 900 (e.g., prior to determination of one or more set end conditions).
At 960, the method 900 includes, determining a previous excess instance corresponding to a prior dry cycle. For instance, a record of the previous excess instance may be stored in the memory of the controller. Thus, the controller may look-up and identify the recorded previous instance. Optionally, the previous excess instance may be required to have occurred in the immediately prior dry cycle. Thus, for the purposes of 960, the prior dry cycle may be is limited to an immediately prior dry cycle such that the dry cycle is consecutive with the prior dry cycle. In turn, after two or more dry cycles that do not include an excess instance, a record of the previous excess instance may be deleted or otherwise moved to a different portion of the memory.
At 970, the method 900 includes determining a fault condition based on the excess instance and previous excess instance. For instance, the sequence of 940 through 960 may indicate a fault condition. In response to the fault condition, a fault-notification signal may be transmitted, for instance, to the control panel of the appliance or a separate remote device (e.g., cell phone, computer, remote server, etc.), as would be understood in light of the present disclosure. Such a fault-notification signal may prompt a visual or audible signal, such as to notify a user or service person that the fault condition has occurred.
At 980, the method 900 includes determining a cycle end point (e.g., following 970). Such a cycle end point may be determined based on or in response to, for instance, determination of one or more set end conditions. As an example, the set end condition(s) may include reaching a maximum overall cycle time of the dry cycle. As an additional or alternative example, the set end condition(s) may include detection of a second or subsequent humidity level (e.g., following the level detected at 910) that is less than or equal to the predetermined humidity target. Thus, following 970, one or more additional humidity levels may be detected and compared to the predetermined humidity target.
Once the set end condition(s) have been met or determined, the dry cycle may be halted or otherwise stopped to end the method 900.
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 washing machine appliance comprising:

a cabinet;

a tub positioned within the cabinet;

a wash basket rotatably mounted within the tub;

a ventilation line defining an air path from the tub through the cabinet;

a humidity sensor mounted along the ventilation line to detect humidity therein; and

a controller in operative communication with the humidity sensor, the controller being configured to direct a dry cycle comprising

detecting a humidity level at the humidity sensor reaching a predetermined level target,

measuring an elapsed time period to detecting the humidity level,

determining the elapsed time period exceeds a baseline time period,

recording an excess instance in response to determining the elapsed time period exceeds the baseline time period,

determining a previous excess instance corresponding to a prior dry cycle, and

determining a fault condition based on the excess instance and previous excess instance.

2. The washing machine appliance of claim 1, further comprising:

a vent damper positioned along ventilation line in fluid communication therewith, the vent damper being selectively movable between a first position restricting airflow through the ventilation line and a second position permitting airflow through the ventilation line,

wherein the dry cycle further comprises moving the vent damper to the second position prior to detecting the humidity level.

3. The washing machine appliance of claim 1, further comprising:

a fan positioned in fluid communication with the ventilation line to motivate an airflow therethrough,

wherein the dry cycle further comprises directing rotation of the fan during detecting the humidity level.

4. The washing machine appliance of claim 1, wherein the elapsed time period is measured from a start point of the dry cycle.

5. The washing machine appliance of claim 1, wherein determining the elapsed time period exceeds the baseline time period comprises determining the elapsed time period exceeds the baseline time period by at least 10%.

6. The washing machine appliance of claim 1, wherein the baseline time period comprises an average cycle time period of a plurality of prior dry cycles.

7. The washing machine appliance of claim 6, wherein the plurality of prior dry cycles comprises a fixed number of prior dry cycles.

8. The washing machine appliance of claim 7, wherein the plurality of prior dry cycles is a rolling plurality of consecutive dry cycles.

9. The washing machine appliance of claim 1, wherein the prior dry cycle is limited to an immediately prior dry cycle such that the dry cycle is consecutive with the prior dry cycle.

10. A method of operating a washing machine appliance, the washing machine appliance comprising a cabinet, a tub positioned within the cabinet, a ventilation line defining an air path from the tub through the cabinet, and a humidity sensor positioned along ventilation line in fluid communication therewith, the method comprising:

detecting a humidity level at the humidity sensor reaching a predetermined level target;

measuring an elapsed time period to detecting the humidity level;

determining the elapsed time period exceeds a baseline time period;

recording an excess instance in response to determining the elapsed time period exceeds the baseline time period;

determining a previous excess instance corresponding to a prior dry cycle; and

11. The method of claim 10, wherein the washing machine appliance further comprises a vent damper positioned along ventilation line in fluid communication therewith, the vent damper being selectively movable between a first position restricting airflow through the ventilation line and a second position permitting airflow through the ventilation line, and

wherein the method further comprises moving the vent damper to the second position prior to detecting the humidity level.

12. The method of claim 10, wherein the washing machine appliance further comprises a fan positioned in fluid communication with the ventilation line to motivate an airflow therethrough, and

wherein the method further comprises directing rotation of the fan during detecting the humidity level.

13. The method of claim 10, wherein the elapsed time period is measured from a start point of the dry cycle.

14. The method of claim 10, wherein determining the elapsed time period exceeds the baseline time period comprises determining the elapsed time period exceeds the baseline time period by at least 10%.

15. The method of claim 10, wherein the baseline time period comprises an average cycle time period of a plurality of prior dry cycles.

16. The method of claim 15, wherein the plurality of prior dry cycles comprises a fixed number of prior dry cycles.

17. The method of claim 16, wherein the plurality of prior dry cycles is a rolling plurality of consecutive dry cycles.

18. The method of claim 10, wherein the prior dry cycle is limited to an immediately prior dry cycle such that the dry cycle is consecutive with the prior dry cycle.