Front-loading washing machine drain system

A drain system for adapting the drain/extraction plumbing of a front-loading washing machine which includes an agitator drum mounted for rotation about a generally horizontal axis, means for driving the drum in rotation about the axis during the various cycles of the machine, and a drain pipe extending downward from the agitator drum and disposed to convey a water/suds mixture vacated from the agitator drum away from the drum. The system includes a conduit into which the water/suds mixture is conveyed from the drain pipe. The conduit is oriented generally horizontally with a first end of the conduit intersecting, and being in fluid communication with, the distal end of the drain pipe. The water/suds mixture, as it is channeled through the conduit, separates into a water component and a suds component floating on the water component. The system includes a water scavenger line and a suds duct, both of which diverge and extend from the second end of the conduit. A baffle is interposed in the system to occlude an upper portion of the water scavenger line so as to permit the water component of the mixture to enter the water scavenger line yet divert the suds component of the mixture into the suds duct.

TECHNICAL FIELD 
The present invention deals broadly with the field of machines for washing 
clothing and other such items. More narrowly, however, the invention deals 
with front-loading washing machines. The specific focus of the invention 
is a drain system for channeling water and suds components of a by-product 
residue of the washing process. 
BACKGROUND OF THE INVENTION 
Washing machines have applications in both commercial and residential 
situations. Large machines are employed in commercial laundry facilities 
for washing, for example, institutional items such as hospital sheets, 
pillow cases, etc. 
Certainly, washing machines have distinct advantages in a residential 
setting. Depending upon the size of a family, a washing machine in the 
dwelling might be used as infrequently as once each week, and as 
frequently as multiple times each day. 
In both residential and commercial settings, a number of types of machines 
are available for purchase. These machines fall primarily into two 
categories. These categories are front-loading machines and top-loading 
machines. 
Front-loading machines include an agitator drum which is disposed for 
rotation about a generally horizontal axis. As the drum rotates, the items 
within the drum will be tossed upward and agitated to facilitate the 
washing process. 
In top-loading machines, an agitator disposed for rotation about a 
generally vertical axis is employed. Agitation is effected by the beating 
of clothes by agitator vanes. 
It is generally conceded that front-loading machines have definite 
advantages over top loaders. This is so for a number of reasons. 
First, front loaders tend to use less soap. This is because of the manner 
in which the water and soap are mixed together. Because of the tumbling 
action induced by a front loader, an aeration effect is created. This 
aeration effect generates more suds with a given quantity of soap then 
does a top-loading machine with the same quantity of soap. As a result, 
most soap and detergent manufacturers recommend that less than half of the 
washing agent amount suggested for top loaders be used with a 
front-loading machine. 
Second, with a front loader, the water tumbling effect results in a 
cleaner, more effective process. As a result, the process is safer to the 
fabrics being washed. The harmful effects of agitator vanes or paddles are 
eliminated. Further, the typical consequent winding of clothing items 
tightly around the agitator member is eliminated with a front-loading 
machine. This result is particularly advantageous in the case of sensitive 
fabric blends such a pure cottons, pure wools, and linen fabrics. The 
chance of fraying is, as a result, minimized. 
Front-loading machines also tend to have a longer useful life. In view of 
the nature of their operation, they are, typically, more solidly 
constructed and, frequently, even reinforced. Because of this more durable 
construction, front loaders can even be used in laundromats where they are 
subjected to particularly adverse handling. 
Because of gravitational forces exerted upon the front loader during the 
drain/extraction cycle (that is, spin cycle), a front-loading machine is, 
typically, securely bolted to a foundational base surface. If such were 
not the case, the machine could lurch and tip over during the cycle. The 
bolting of the machine to the substrate, further, enables the front loader 
to out-perform a typical top loading machine. 
Front-loading washers also tend to be less complex. The agitator drum is 
driven by a duty-rated motor having reverse and high-speed motor windings. 
The motor, in turn, attaches directly to the pulley for driving the drum 
by a standard belt-to-drum assembly. Electrical relay operation of the 
drum rotation is employed. 
Top-loading machines, however, depend upon complex mechanical transmission 
and clutch units. Typically, such units are located inaccessibly 
underneath the agitator. Top-loaders also depend on a motor which shifts 
to different operating modes by a complicated configuration of drives and 
pulleys in order to drive the agitator mechanism. In view of these 
drawbacks, the repair of a problem can cost as much as buying a new 
top-loading machine. When a serious mechanical problem occurs with a 
top-loader, the machine often has to be removed from its location and 
completely disassembled. 
With all of the advantages of a top-loading machine, such machines are not 
completely devoid of problems. Because of the small volume of soap or 
detergent necessary in their operation, owners of front loaders frequently 
use too much cleaning agent. This can result in over-sudsing and possible 
damage to the machine. At a minimum, difficulty in draining can result. 
Drain pumps which are typically interposed in the drain pipe can become 
vapor-locked. When this occurs, the functioning of the machine is 
diminished. 
It is to these problems and positive dictates of the prior art that the 
present invention is directed. It is a drainage system which achieves the 
positive characteristics of a front-loading washing machine while solving 
many of the problems of the prior art. 
SUMMARY OF THE INVENTION 
The present invention is a drain system including plumbing to adapt a 
front-loading washing machine in order to effect efficient draining and 
vacating of a water/suds mixture from an agitator drum of the machine. 
Front-loading washing machines include such an agitator drum which is 
disposed for rotation about a generally horizontally oriented axis. 
Further, such machines include means for driving the drum in the intended 
rotation of the axis during the various wash, rinse, and drain/extraction 
cycles. In the drain system invention, a first conduit is provided to 
vacate the agitator drum of the water/suds mixture. The conduit extends 
downward from the drum and is disposed in a location relative to the drum 
to convey a water/suds mixture away from the drum by means of gravity and 
centrifugal action. A second conduit having first and second ends is also 
included. The second conduit is oriented generally horizontally and is 
positioned such that a first end thereof intersects, and is in fluid 
communication with, a distal end of the first conduit. Consequently, the 
water/suds mixture by-product of washing and rinse cycles is channeled 
into and through the conduit in such a manner so that it is separated into 
a water component and a suds component which floats on the water component 
as the mixture passes through the second conduit. The invention also 
includes a water scavenger line and a suds duct, both of which extend 
from, and diverge with respect to, the second end of the second conduit. 
The water scavenger line is generally aligned with the lower portion of 
the second conduit, and the suds duct is generally aligned with the upper 
portion of the second conduit. Consequently, the water component will tend 
to flow into the water scavenger line and the suds component will tend to 
flow into the suds duct. 
A baffle can be provided proximate the second end of the second conduit to 
facilitate separation of the water and suds components. The baffle is 
positioned to facilitate the water component of the mixture having passed 
through the second conduit to enter the water scavenger line. At the same 
time, however, the baffle functions to divert the suds component having 
passed through the second conduit into the suds duct. 
The invention also envisions an embodiment to be used in adapting an 
existing front-loading washing machine so that it functions as would the 
drainage system previously discussed. A front-loading washing machine, 
typically, includes a drain pipe which functions to accomplish vacation of 
the water/suds by-product from the agitator drum as does the first conduit 
in the drain system described above. That is, it is positioned relative to 
the agitator drum so that the water/suds by-product is vacated from the 
drum through the drain pipe by gravity and centrifugal action. 
In this adaptor embodiment of the invention, a conduit is provided to 
intersect the drain pipe at its end distal from the agitator drum. The 
conduit is oriented generally horizontally and functions to separate the 
suds component from the water component of the by-product mixture in a 
manner wherein the suds component floats to the top of the water component 
as the mixture is channeled through the duct. This embodiment also 
includes a water scavenger line and a suds duct diverging from one another 
at a second end of the generally horizontally oriented mixture channeling 
duct. 
This embodiment can also include a baffle as described above. That is, it 
can include a baffle which occludes an upper portion of the water 
scavenger line so as to permit the water component to pass into the water 
scavenger line yet divert the suds component into the suds duct. 
In certain embodiments, a mechanical pump can be interposed in the water 
scavenger line. The provision of such a pump enables more efficient 
drawing of the by-product mixture through the duct extending from the 
drain pipe to the location at which the water scavenger line and suds duct 
diverge. More efficient separation of the water and suds components and 
drainage of the water component are, thereby, achieved. 
It will be understood that such a pump can be employed in the overall 
drainage system embodiment also. That is, a pump can be included in the 
water scavenger line of an embodiment including a first conduit extending 
downwardly from the agitator drum. More efficient drainage, separation of 
by-products, and passage of the separated components for further 
disposition are, thereby, accomplished. 
The present invention is thus an improved drainage system and drainage 
system adaptor for use in combination with a typical front loading washing 
machine. More specific features and advantages obtained in view of those 
features will become apparent with reference to the DETAILED DESCRIPTION 
OF THE INVENTION, appended claims, and accompanying drawing figures.

DETAILED DESCRIPTION OF THE INVENTION 
Referring now to the drawings, and particularly FIGS. 1 and 2, wherein like 
reference numerals denote like elements throughout the several views, a 
typical front-loading washing machine 10 as known in the prior art is 
illustrated. In addition to the machine 10 of the prior art, however, 
those two figures also illustrate structure in accordance with the present 
invention reconfiguring and/or adapting a known machine. 
FIGS. 1 and 2 show a machine having an enclosure housing 12. The housing 
12, in turn, mounts therewithin a tub structure 14. The tub 14 disposes 
within its generally cylindrical wall an agitator drum 16. The drum 16 is 
disposed for rotation about a generally horizontal axis 18. 
Rotation of the agitator drum 16 is accomplished by means of a drive motor 
20. Rotational motion generated by the drive motor 20 is transmitted to 
the agitator drum 16 by means of a drive belt 22 which extends around a 
drive sprocket 24 carried by the motor shaft 26 and a driven sprocket 28 
carried by a shaft 30 aligned along the axis 18 of rotation of the 
agitator drum 16. Typically, the drive belt 22 has a "V" cross-section. It 
is, thereby, more readily maintained in position with respect to the 
sprockets 24, 28 and precluded from slipping off. 
A typical front-loading washing machine includes a water inlet 32 through 
which water from a source (not shown) is fed into the agitator drum 16 for 
wash and rinse cycles. A machine of the construction illustrated in the 
drawings also includes a soap compartment 34 into which soap or detergent 
is poured. Typically, such a compartment 34 is accessible through a top 
panel 36 of the enclosure housing 12 and is normally closed by a door 38. 
When the operator of a machine wishes to insert soap or detergent into the 
soap compartment 34, the door 38 can be pivoted into an open position and 
closed after the compartment 34 has been filled with the desired amount of 
soap or detergent. 
A soap inlet 40 interconnects the compartment 34 to the agitator drum 16 so 
that, during the wash cycle, soap or detergent in the compartment 34 can 
be fed into the drum 16 to effect cleaning of the clothes or other fabric 
materials in the drum 16. As seen in FIG. 2, the inlet 40 inputs the soap 
or detergent into the drum 16 at a height above the axis 18 of rotation 
above the drum 16. During wash and rinse cycles, the water level within 
the drum 16 is intended to be approximately at the height of the axis 18. 
As a result, soap or detergent dispensed into the drum 16 is done so at a 
height above the water level. This allows for more efficient dispensing of 
the soap or detergent powder. 
It will be understood that in the typical front-loading washing machine a 
sensor can be incorporated for ascertaining when the water level which is 
desired within the drum 16 has been achieved. Since such a sensor does not 
comprise part of the present invention, however, it is not shown in the 
drawing figures. Discussion is given merely for a better understanding of 
overall machine operation. 
An operator of the machine 10 will insert clothes to be laundered through a 
sealed door 42 in the front panel 44 of the enclosure housing 12. After 
the machine 10 is loaded with clothes to be washed, the door 42 is closed 
(thereby effecting a seal along the aperture surface defined in the front 
panel 44), and the door 42 is locked closed by a latch 46. The operator 
then initiates a series of cycles by means of a sequencer (not shown). 
Typically, such cycles include a wash cycle, one or more rinse cycles, and 
a drain/extraction cycle after the wash cycle and each rinse cycle. During 
the wash and rinse cycles, the agitator drum 16 is rotated about its axis 
18 to agitate the clothes so as, during the wash cycle, to effect 
interspersion of the soap or detergent settled into the items to be 
laundered, and, during a rinse cycle, to extract a maximum of the soap or 
detergent in the garments. Typically, agitation during the wash and rinse 
cycles is relatively gentle and in a tumbling fashion. 
Each drain/extraction cycle serves to vacate the agitator drum 16 of wash 
or rinse by-product (that is, a mixture of water and soap suds generated 
by the washing and rinsing processes). During these drain/extraction 
cycles, the agitator drum 16 is rotated at a high speed, and the 
water/suds mixture by-product is expelled centrifugally from the drum 16 
into a first conduit or drain 48. Typically, the drain pipe or conduit 48 
extends downwardly from the agitator drum 16, and the centrifugal vacation 
of the water/suds mixture is augmented by gravity. Because of the high 
speed of rotation of the drum 16 during the drain/extraction cycles, 
centrifugal vacation of the wash and rinse cycle by-products is 
accomplished to a high degree. The structure and operation described to 
this point is typical of front-loading washing machines known in the prior 
art. It has been described herein merely to serve as a background for 
further discussion to the improvement invention in accordance with this 
document. 
FIGS. 1-4 illustrate a second conduit 50 intersecting, at its first end 52, 
a distal end 54 of the drain pipe 48. These figures illustrate this second 
conduit 50 as being disposed generally horizontally. The second conduit 50 
is in fluid communication with the drain pipe 48 so that the water/suds 
by-product mixture of the wash and rinse cycles is channeled into the 
second conduit 50 and passes therethrough. FIGS. 3 and 6 best illustrate 
the structure of the invention proximate the second end 56 of the second 
conduit 50. Those figures illustrate a water scavenger line 58 which is 
intended to transfer a water component 60 of the by-product mixture for 
disposal or recycling, and a suds duct 62 which functions to transfer the 
suds component 64 for disposal. Those figures illustrate the water 
scavenger line 58 as having a smaller diameter than the second conduit 50 
which intersects the drain pipe 48. The water scavenger line 58 is 
generally axially aligned, at least initially, with the lower portion of 
the second conduit 50. It is shown as, thereafter, bending 90.degree. 
through an elbow fitting 66. 
The suds duct 62, however, is shown as being diverted upwardly with respect 
to the water scavenger line 58. The figures illustrate a 90.degree. elbow 
68 being employed to accomplish this diversion. 
As best seen in FIGS. 3 and 6, a baffle 70 is shown as being employed to 
occlude an upper portion of the water scavenger line 58. The baffle 70 is 
showing as having been made to conform substantially to the contours of 
the plumbing at the location at which it is positioned. 
As previously discussed, the high rate of rotation of the agitator drum 16 
during the drain/extractor cycles, centrifugally impels the water/suds 
mixture from the drum 16. A measure of momentum is imparted to the mixture 
as it passes through the drain pipe 48 in consequence. This momentum is 
augmented when, as shown in the drawing figures, the drain pipe 48 extends 
downwardly from the agitator drum 16. 
This momentum continues, although to an attenuated extent, as the mixture 
passes through the length of the second conduit 50. The mixture continues 
to be impelled through the second conduit 50 from the first end 52 to the 
second end 56 thereof. As the mixture passes along this generally 
horizontal conduit 50, however, the suds component 64 will tend to rise 
and float on the surface of the water component 60. This is so since the 
suds component 64 is highly aerated. 
It will be understood that some of amounts of soap or detergent will remain 
entrained in the water component 60. This is so in view of the solubility 
of the soap or detergent. Any such dissolved material, however, does not 
present any problems from a disposal standpoint since it is not aerated 
and will not give rise to vapor lock in any pump 72 that might be 
interposed in the water scavenger line 58. 
As previously discussed, the upper portion of the water scavenger line 58 
is occluded by the baffle 70. This fact, in combination with the fact that 
the water scavenger line 58 is aligned with a lower portion of the second 
conduit 50 results in only water or water having dissolved soap or 
detergent therein entering the water scavenger line 58. 
FIG. 1 illustrates a pump 72 driven by a motor 73 interposed in the water 
scavenger line 58. This pump 72 serves a number of functions. First, it 
facilitates the pumping of the water component 60 to a location for 
discharge and disposal or recycling. FIG. 1 illustrates the water 
component 60 being elevated through a stand pipe 74 so that it can be 
disposed of, for example, in a laundry tub 76. Additionally, however, the 
pump 72 serves to generate vacuum to draw the mixture through the second 
conduit 50 at a higher rate of flow than it would have otherwise. 
As previously discussed, as the mixture passes through the second conduit 
50, the suds component 64 separates from the water component 60 and rises 
to the surface of the water component 60. As the now at least partially 
separated components 60, 64 approach the second end 56 of the second 
conduit 50, the suds component 64 will engage the baffle 70 and be 
diverted upwardly through the suds duct 62 for disposal. The suds can be 
disposed of in the laundry tub 76 also. 
FIGS. 3 and 4, in particular, illustrate a clean-out structure. This 
structure comprises a cap 78 fitted onto the first end 52 of the second 
conduit 50. The cap 78 is removable in order to afford access to the 
interior of the second conduit 50. The cap 78 can be removed by an 
operator of the equipment, and any undesirable sludge or other residue 
accumulating within the second conduit 50 can be removed. 
It will be understood that, in the typical front-loading washing machine, 
not all of the suds generated during a washing or rinsing cycle will be 
impelled into the drain pipe 48. Front loading washing machines, 
typically, include an overflow pipe 80 having an inlet 82 at the agitator 
drum 16. The inlet 82 is, typically, disposed at a height immediately 
above the intended water level in the drum 16. As a result, initial excess 
suds will enter the overflow pipe 80 and be fed by gravity, for example, 
to a drain (not shown). The presence of such an overflow pipe 80, thereby, 
reduces the amount of suds component 64 being passed into the second 
conduit 50 for separation therein. Consequently, the present invention 
will function more efficiently. 
Numerous characteristics and advantages of the invention covered by this 
document have been set forth in the foregoing description. It will be 
understood, however, that this disclosure is, in many respects, only 
illustrative. Changes may be made in details, particularly in matters of 
shape, size, and arrangement of parts without exceeding the scope of the 
invention. The invention's scope is, of course, defined in the language in 
which the appended claims are expressed.