Clothes washer with clothing trap

An automatic clothes washer having a clothes trap for reducing the likelihood that an article of clothing can escape from a wash basket during the spinning of the basket.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to clothes washers for automatically washing one or more clothing articles. More specifically, the invention relates to a clothes washer having a clothing trap to prevent an article of clothing from being expelled over the top of a wash basket during a spin operation.

2. Description of the Related Art

Automatic clothes washers are widely known and commonly used to wash a load of clothes comprising one or more clothing articles in accordance with a programmed wash cycle. Clothes washers of this type typically comprise a perforated basket located within an imperforate tub, with the basket being rotatable relative to the tub. The clothing is placed in the basket where the wash liquid is free to flow between the basket and the tub through the perforations. With this configuration, wash liquid can be extracted from the clothes through centrifugal force by rotating the basket. The centrifugal extraction is generally referred to as a spin step or the spinning of the clothes.

In a vertical axis clothes washers, the basket and tub both have an open top defined by corresponding upper edges. A balancing ring is normally mounted to the upper edge of the basket and is designed to retard off-axis rotation caused by an unbalanced load. A decorative tub shroud for hiding the balancing ring from view and preventing the user from accidentally placing clothes in the tub during loading extends from the upper edge of the tub, over the balancing ring, and terminates in the interior of the basket at a position radially inwardly of the balancing ring.

The off-axis rotation causes the basket to move radially relative to the axis of rotation, which, if great enough, can cause the balancing ring or basket to contact the shroud or the tub. To prevent such contact the basket and tub are sized such that there is a gap between the balancing ring and tub and shroud, which provides the basket with a range of motion about which it can rotate off-axis without contacting either the tub or shroud.

While the gap is beneficial in preventing contact between the basket and the tub or shroud, it is disadvantageous in that it provides an opening though which the clothing can escape the basket. Depending on the size of the clothes load and the spin speed, the centrifugal force can push the clothing to the exterior of the basket. As the clothing piles up against the basket, it also pushes upwardly along the basket side wall. Under the right conditions, an article of clothing can be pushed over the top of the basket and out the gap where it can fall into the tub. Once in the tub, the article of clothing can be drawn into the pump inlet, which is normally fluidly connected to the tub, where it can clog and damage the pump.

It is desirable to have a clothes washer that can accommodate the off-axis rotation of the basket while preventing the escape of an article of clothing through the gap between balancing ring and the guard.

SUMMARY OF THE INVENTION

The invention relates to an automatic clothes washer. The clothes washer comprises a cabinet defining an interior and having a top defining a loading opening providing access to the cabinet interior. Within the cabinet is positioned a a tub comprising a bottom wall and a peripheral wall extending upwardly from the bottom wall, with the peripheral wall terminating in an upper edge to define an open top for the tub. Within the tub is positioned a basket comprising a bottom wall and a peripheral wall extending upwardly from the bottom wall, with the peripheral wall terminating in an upper edge to define an open top for the basket. A balancing ring is mounted to the upper edge of the basket and a shroud overlies the balancing ring and terminates in a peripheral edge that extends radially inwardly of the balancing ring such that the peripheral edge axially overlaps the balancing ring to define a radial gap between the peripheral edge and the balancing ring. A clothes trap is mounted to the balancing ring and has a barrier flange that extends into the radial gap, wherein the barrier flange effectively reduces the radial gap and stops articles of clothing from passing through the radial gap during a spinning operation of the basket.

The barrier flange can partially define a volume below the barrier flange. The volume being used to receive at least a portion of an article of clothing. The barrier flange can also terminate in a terminal edge that is located axially above the peripheral edge of the shroud.

One of the balancing ring and the clothes trap comprises multiple projections and the other of the balancing ring and clothes trap comprises multiple apertures, and the projections are received within the apertures to mount the clothes trap to the balancing ring. A mechanical connection connects the projections to the other of the balancing ring and clothes trap. The mechanical connection is formed by one of heat staking or welding the projections to the other of the balancing ring and clothes trap.

The clothes trap is preferably continuous about the balancing ring. Preferably, the radial gap has a nominal dimension of less than 12.50 mm and the barrier flange extends 7.5-15 mm beyond the balancing ring.

The barrier flange can have different shapes but is preferably substantially straight. The barrier flange also extends substantially perpendicularly to the basket peripheral wall. Preferably, any portion of the barrier flange extending radially interiorly of the balancing ring is substantially perpendicular to the peripheral wall of the basket.

The shroud can be sized such that it hides the balancing ring from view through the loading opening.

DESCRIPTION OF THE INVENTION

Referring toFIG. 1, there is shown a clothes washer10providing an illustrative environment for the invention. As illustrated, the clothes washer10is a vertical axis clothes washer comprising an exterior cabinet12defining an interior14accessible through an opening16in the top of the cabinet12, which is normally closed by a door (not shown) hingedly mounted to the cabinet12. An imperforate tub20and a perforated basket22are located within the interior14of the cabinet12. The tub20and basket22are mounted in the cabinet12in a traditional manner such that the basket22can rotate relative to the tub20.

Each of the tub20and basket22comprise a closed bottom20a,22aand a peripheral wall20b,22b, extending upwardly from the corresponding bottom20a,22aand terminating in an upper edge20c,22c, which defines an open top. The peripheral walls20band22bare preferably cylindrical resulting in the open top having a circular shape.

A wash liquid system (not shown) is commonly used to introduce wash liquid onto clothing placed in the basket16. The wash liquid can comprise water or a mixture of water with wash aid, such as detergent. The wash liquid system normally comprises a wash aid dispenser and a water inlet along with a pump coupled to the tub for draining or recirculating wash liquid from the tub. The type of wash system is not germane to the invention. There are many well known wash systems. One common type of wash system is the immersion type which at least partially fills the basket16and tub14with wash liquid to clean the clothes while they are immersed in the wash liquid. Another common wash system is a reciprocating wash liquid system that reciprocates wash liquid through the clothing. Some systems are capable of both immersion and reciprocation, with the selection of a particular method being dependent on a particular wash cycle.

An agitator24is provided within the basket22and rotates relative to the basket22to aid in cleaning the clothing. The agitator24is illustrated as a the well known combination of a reciprocating skirt25with vanes27and an auger29, which is more commonly used with immersion type wash liquid systems. However, the type of agitator is not germane to the invention. Any suitable type of agitator can be used. For example, an impeller or nutating plate can be used in place of the reciprocating auger. Each of the agitator types can be used with all of the wash liquid systems.

Referring toFIGS. 1 and 2, a shroud30is mounted to and extends from the upper edge20cof the tub20. The shroud30defines an opening31that is aligned with the cabinet opening16. The shroud30extends over and beyond the basket22and terminates radially internally of the basket22at terminal end32. The shroud30performs multiple functions. It prevents wash liquid from running up the walls of the tub20and basket22and splashing out. Any wash liquid running up the walls of the tub20and basket22will ultimately encounter the splash guard, which will redirect the wash liquid back into the tub20and/or basket22. The shroud also acts as a decorative cover and hides the upper ends20c,22cof the tub20and basket22. Another function is to prevent access by the user to the upper ends of the tub20and basket22when the door is opened, which prevents the user from accidentally placing clothing in the tub20when loading clothes in the basket22.

A balancing ring40is mounted to the upper end of the basket22and functions to dampen the off-axis rotation of the basket22, especially during the spinning of the basket22. A clothes trap70is mounted to and extends from the balancing ring40. The terminal end32of the shroud30axially overlaps with the balancing ring40. The extent of the shroud30such that it axially overlaps the balancing ring40aids the shroud30in its intended functions. The axial overlap of the shroud30and balancing ring40also defines a radial gap34between the shroud30and the clothes trap70. As illustrated, the nominal radial gap34is approximately 12.50 mm.

Referring toFIGS. 2-4, the balancing ring40comprises lower and upper channel members42,44arranged in a confronting relationship to a dividing wall46to collectively form lower and upper annular chambers48,50. Multiple, spaced embossments62extend from the upper channel member42. The lower chamber48is partially filled with a first fluid, such as water. The upper chamber50is partially filled with a second fluid, such as a light-weight oil, having a higher viscosity than the first fluid. Weighted balls (not shown) are also placed within the upper chamber50. The first fluid is free to flow within the lower chamber48, except that baffles52are located periodically within the lower chamber48to slow down, but not prevent the free flow of the first fluid. The second fluid and weighted balls are free to flow around the upper chamber50.

With this configuration, the first fluid, second fluid, and weighted balls flow about the corresponding chamber48,50to balance any out-of-balance condition and retard the off-axis rotation. Such a dual chamber balancing ring is shown and described in greater detail in U.S. Pat. No. 6,658,902, which is incorporated by reference. Other types of balancing rings can be used.

Referring toFIGS. 2-5, a clothes trap70is mounted to and extends from the balancing ring40. The trap70preferably comprises an annular base72from which extend a pair of spaced, concentric ribs74,76, which define a channel78therebetween. A series of openings80are located in the channel and extend through the base72. An arcuate flange84extends from the radially exterior of the base72. The arcuate shape is selected to conform with the corresponding shape of the balancing ring40. A barrier flange86extends radially inwardly from the base72. More specifically, the barrier flange86extends from the rib74. The barrier flange86is preferably substantially straight in cross section.

The trap70is mounted to the balancing ring40by placing the trap70on the balancing ring40such that the projections62are received within the openings80. A mechanical connection is then formed between the projections62and the trap70, preferably by heat staking or welding the projections62to the trap70.

When the trap70is mounted to the balancing ring40, for the preferred embodiment, the barrier flange86extends 7.5 to 15 mm beyond the balancing ring40. It should be noted that the radial extent of the barrier flange86is limited in that it should not extend so far as to contact the shroud during off-axis rotation. However, the barrier flange86does need to extend radially a distant sufficient to block any clothing article from sliding up the basket peripheral wall and escaping through the gap34. It is worth noting that the barrier flange86extends a sufficient distance away from the balancing ring40that the barrier flange86defines a partially enclosed volume88(FIG. 2) beneath the barrier flange86, with the barrier flange86forming the axial limit of the volume and the balancing ring40forming the radial limit of the volume. It is further worth noting that the barrier flange86, especially a terminal edge90of the barrier flange86, is axially overlapped with the peripheral edge32of the shroud30, which ensures that an article of clothing must pass over the barrier edge86to escape the basket. This configuration effectively forms a labyrinth-type passage that the article of clothing must pass to escape. In this way, the trap70makes it unlikely that an article of clothing can exit the gap34.

Another advantage of the balancing ring40and trap70configuration that may not be immediately recognizable is that the trap70is not integrally formed with the balancing ring. Most manufactures of automatic clothes washers have multiple models. It is desirable for as many parts as possible to be shared between models. However, not all models may need the clothes trap, whereas most models will need a balancing ring. Even for those models that require a trap, the radial extent of the trap may not be the same. Making the trap70separate from the balancing ring40while providing a simple means of mounting the trap70to the balancing ring, makes it easy for the manufacture to add the trap70to the models as needed without having to keep separate inventories of balancing rings40if the trap were integrally formed with the balancing ring.

FIG. 6illustrates an alternative trap70′ mounted to a single chamber balancing ring40′. The structures of the alternative trap70′ and balancing ring40′ are generally similar to those previously described. Therefore, similar parts will be identified with the same number using the prime suffix. The alternative trap70′ is identical to the trap70in that it has openings that receive projections to mount the trap70′ to the upper channel member42′ of the balancing ring40′. The alternative trap70′ differs in that the base72′ is substantially flat, both on the upper and lower surface and the barrier flange86′ extends perpendicularly relative to the side wall22b′ of the basket.

While the invention has been specifically described in connection with certain embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.