Dryer appliance with an impeller assembly

A dryer appliance includes an impeller assembly. The impeller assembly is rotatable about an axis of rotation in order to urge a flow of air through a drum of the dryer appliance. The impeller assembly includes a base plate, a plurality of blades and a plurality of extensions. The size and position of the plurality of extensions can assist with urging the flow of air through the drum of the dryer appliance.

FIELD OF THE INVENTION

The present subject matter relates generally to impeller assemblies for appliances, e.g., dryer appliances.

BACKGROUND OF THE INVENTION

Dryer appliances generally include a cabinet with a drum rotatably mounted therein. A motor can selectively rotate the drum during operation of the dryer appliance, e.g., to tumble articles located within a chamber defined by the drum. Dryer appliances also generally include a heater assembly that passes heated air through the chamber of the drum in order to dry moisture laden articles disposed within the chamber.

To circulate heated air, certain dryer appliances include an impeller positioned within a housing. During operation of the dryer appliance, the impeller urges a flow of heated air into the chamber of the drum. Such heated air absorbs moisture from articles disposed within the chamber. The impeller also urges moisture laden air out of the chamber through a vent. The vent can be connected to household ductwork that directs the moisture laden air outdoors.

Performance of a dryer appliance can be affected by the flow of heated air. For example, dryer appliance performance can be improved by generating a large volume of heated air. Conversely, dryer appliance performance can be negatively affected if the heating assembly generates a low volume of heated air.

To improve dryer performance, a size of the impeller can be increased. However, space with a dryer appliance is generally limited or constrained. Thus, increasing a size of the impeller can be difficult. To improve dryer performance, certain dryer appliances include a second motor configured to rotate the impeller. However, motors can be expensive, and adding the second motor to the dryer appliance can increase the cost of the dryer appliance.

Accordingly, a dryer appliance with features for improving air flow through the dryer appliance would be useful. In particular, a dryer appliance with features for improving air flow through the dryer appliance without requiring a relatively large impeller or adding a second motor to the dryer appliance would be useful.

BRIEF DESCRIPTION OF THE INVENTION

The present subject matter provides a dryer appliance. The dryer appliance includes an impeller assembly. The impeller assembly is rotatable about an axis of rotation in order to urge a flow of air through a drum of the dryer appliance. The impeller assembly includes a base plate, a plurality of blades and a plurality of extensions. The size and position of the plurality of extensions can assist with urging the flow of air through the drum of the dryer appliance. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In a first exemplary embodiment, a dryer appliance is provided. The dryer appliance includes a cabinet that defines a vent. A drum is rotatably mounted within the cabinet. The drum defines a chamber for receipt of articles for drying. A conduit connects the chamber of the drum and the vent of the cabinet such that the chamber of the drum and the vent of the cabinet are in fluid communication. The dryer appliance also includes a motor and an impeller assembly. The impeller assembly has an axis of rotation about which the impeller assembly is rotatable. The impeller assembly is in mechanical communication with the motor. The impeller assembly is rotatable about the axis of rotation by the motor in order to urge a flow of air from the chamber of the drum to the vent of the cabinet through the conduit. The impeller assembly defines a radial direction, a circumferential direction and an axial direction. The impeller assembly includes a base plate and a plurality of blades mounted to the base plate. Each blade of the plurality of blades extends from the base plate by a height, BH, along the axial direction. The blades of the plurality of blades are spaced apart from each other along the circumferential direction on the base plate. A plurality of extensions is mounted to the base plate. Each extension of the plurality of extensions extends between a leading portion and a trailing portion. The leading portion of each extension of the plurality of extensions is positioned adjacent the axis of rotation. The trailing portion of each extension of the plurality of extensions is positioned at a respective blade of the plurality of blades. Each extension of the plurality of extensions defines a radius, ER, between the leading portion and the trailing portion. The radius ER is less than the height BH.

In a second exemplary embodiment, a dryer appliance is provided. The dryer appliance includes a cabinet that defines a vent. A drum is rotatably mounted within the cabinet. The drum defines a chamber for receipt of articles for drying. A conduit connects the chamber of the drum and the vent of the cabinet such that the chamber of the drum and the vent of the cabinet are in fluid communication. The dryer appliance also includes a motor and an impeller assembly. The impeller assembly has an axis of rotation about which the impeller assembly is rotatable. The impeller assembly is in mechanical communication with the motor. The impeller assembly is rotatable about the axis of rotation by the motor in order to urge a flow of air from the chamber of the drum to the vent of the cabinet through the conduit. The impeller assembly defines a radial direction, a circumferential direction and an axial direction. The impeller assembly includes a base plate and a plurality of blades mounted to the base plate. The blades of the plurality of blades are spaced apart from each other along the circumferential direction on the base plate. A plurality of extensions is mounted to the base plate. Each extension of the plurality of extensions extends between a leading portion and a trailing portion. The leading portion of each extension of the plurality of extensions is positioned adjacent the axis of rotation. The trailing portion of each extension of the plurality of extensions is positioned at a respective blade of the plurality of blades. The leading portion of each extension of the plurality of extensions is spaced apart from the trailing portion of each extension of the plurality of extensions by a length, EL. The trailing portion of each extension of the plurality of extensions is also spaced apart from the axis of rotation along the radial direction by a radial length, RL. A ratio of the length EL to the radial length RL is greater than about two tenths and less than about eight tenths.

In a third exemplary embodiment, a dryer appliance is provided. The dryer appliance includes a cabinet that defines a vent. A drum is rotatably mounted within the cabinet. The drum defines a chamber for receipt of articles for drying. A conduit connects the chamber of the drum and the vent of the cabinet such that the chamber of the drum and the vent of the cabinet are in fluid communication. The dryer appliance also includes a motor and an impeller assembly. The impeller assembly has an axis of rotation about which the impeller assembly is rotatable. The impeller assembly is in mechanical communication with the motor. The impeller assembly is rotatable about the axis of rotation by the motor in order to urge a flow of air from the chamber of the drum to the vent of the cabinet through the conduit. The impeller assembly defines a radial direction, a circumferential direction and an axial direction. The impeller assembly includes a base plate and a plurality of blades mounted to the base plate. Each blade of the plurality of blades extends from the base plate by a height, BH, along the axial direction. The blades of the plurality of blades are spaced apart from each other along the circumferential direction on the base plate. A plurality of extensions is mounted to the base plate. Each extension of the plurality of extensions extends between a leading portion and a trailing portion. The leading portion of each extension of the plurality of extensions is positioned adjacent the axis of rotation. The trailing portion of each extension of the plurality of extensions is positioned at a respective blade of the plurality of blades. The trailing portion of each extension of the plurality of extensions defines a height, EH, along the axial direction. The height EH is less than the height BH.

DETAILED DESCRIPTION

As used herein, the term “article” may refer to but need not be limited to fabrics, textiles, garments (or clothing), and linens. Furthermore, the term “load” or “laundry load” refers to the combination of articles that may be washed together in a washing machine or dried together in a laundry dryer (i.e., a clothes dryer) and may include a mixture of different or similar articles of different or similar types and kinds of fabrics, textiles, garments and linens within a particular laundering process.

FIGS. 1 and 2illustrate a dryer appliance10according to an exemplary embodiment of the present subject matter. While described in the context of a specific embodiment of dryer appliance10, using the teachings disclosed herein it will be understood that dryer appliance10is provided by way of example only. Other dryer appliances having different appearances and different features may also be utilized with the present subject matter as well. For example, dryer appliance10illustrated inFIGS. 1 and 2is a gas dryer appliance with a combustion chamber36. In alternative exemplary embodiments, dryer appliance10may be an electric dryer appliance with electric heating elements replacing combustion chamber36.

Dryer appliance10includes a cabinet12having a front panel14, a rear panel16, a pair of side panels18and20spaced apart from each other by front and rear panels14and16, a bottom panel22, and a top cover24. Within cabinet12is a drum or container26mounted for rotation about a substantially horizontal axis. Drum26is generally cylindrical in shape and defines a chamber27for receipt of articles for drying.

Drum26also defines an opening29for permitting access to the chamber27of drum26. Opening29of drum26, e.g., permits loading and unloading of clothing articles and other fabrics from chamber27of drum26. A door33is rotatably mounted at opening29and selectively hinders access to chamber27of drum26through opening29.

Drum26includes a rear wall25rotatably supported within cabinet12by a suitable fixed bearing. Rear wall25can be fixed or can be rotatable. A motor28rotates the drum26about the horizontal axis through a pulley30and a belt31. Motor28is also in mechanical communication with a fan or air handler42such that motor28rotates an impeller assembly43, e.g., a centrifugal impeller assembly, of air handler42. Air handler42is configured for drawing air through chamber27of drum26, e.g., in order to dry articles located therein as discussed in greater detail below. In alternative exemplary embodiments, dryer appliance10may include an additional motor (not shown) for rotating impeller assembly43of air handler42independently of drum26.

Drum26is configured to receive heated air that has been heated by a heater assembly34, e.g., in order to dry damp articles disposed within chamber27of drum26. Heater assembly34includes a combustion chamber36. As discussed above, during operation of dryer appliance10, motor28rotates drum26and impeller assembly43of air handler42such that air handler42draws air through chamber27of drum26when motor28rotates impeller assembly43. In particular, ambient air, shown with arrow Aa, enters combustion chamber36via an inlet38due to air handler42urging such ambient air Aainto inlet38. Such ambient air Aais heated within combustion chamber36and exits combustion chamber36as heated air, shown with arrow Ah. Air handler42draws such heated air Ahthrough a back duct40to drum26. The heated air Ahenters drum26through a plurality of holes32defined in rear wall25of drum26.

Within chamber27, the heated air Ahcan accumulates moisture, e.g., from damp articles disposed within chamber27. In turn, air handler42draws moisture laden air, shown as arrow Am, through a screen filter44which traps lint particles. Such moisture laden air Amthen enters a front duct46and is passed through air handler42to an exhaust duct48. From exhaust duct48, such moisture laden air Ampasses out of clothes dryer10through a vent49defined by cabinet12.

Front duct46and exhaust duct48form a conduit47that extends between and connects chamber27of drum26and vent49. Conduit47places chamber27of drum26and vent49in fluid communication in order to permit moisture laden air Amto exit dryer appliance10. Air handler42is in fluid communication with conduit47, and impeller assembly43of air handler42is positioned within conduit47.

A cycle selector knob50is mounted on a cabinet backsplash52and is in communication with a controller54. Signals generated in controller54operate motor28and heater assembly34in response to a position of selector knob50. Alternatively, a touch screen type interface may be provided. As used herein, “processing device” or “controller” may refer to one or more microprocessors or semiconductor devices and is not restricted necessarily to a single element. The processing device can be programmed to operate dryer appliance10. The processing device may include, or be associated with, one or memory elements such as e.g., electrically erasable, programmable read only memory (EEPROM).

FIG. 3provides a perspective view of a blade wheel or impeller assembly100according to an exemplary embodiment of the present subject matter mounted within a housing or casing110. Impeller assembly100and casing110may be used with any suitable dryer appliance. As an example, impeller assembly100may be used in dryer appliance10as impeller assembly43(FIG. 2). Impeller assembly100includes features for drawing sufficient heated air into chamber27of drum26, e.g., in order to dry articles therein.

Casing110defines an inlet112, an outlet114and a flow passage116. Flow passage116extends between inlet112of casing110and outlet114of casing110. Thus, flow passage116places inlet112of casing110in fluid communication with outlet114of casing110such that flows of air (shown with arrows F) can enter casing110at inlet112of casing110and flow into flow passage116. Inlet112of casing110may be positioned at or mounted to front duct46of dryer appliance10in order to receive moisture laden air Amfrom chamber27of drum26. Flows of air F can flow through casing110in flow passage116to outlet114of casing110. At outlet114of casing110, flows of air F can exit casing110. Outlet114of casing110may be positioned at or mounted to exhaust duct48of dryer appliance10in order to direct moisture laden air Amout of casing110and/or dryer appliance10.

Impeller assembly100is position within casing110, e.g., within flow passage116. Impeller assembly100has an axis of rotation X about or on which impeller assembly100is rotatable. When impeller assembly100is rotating about the axis of rotation X, impeller assembly100draws or urges flows of air F into casing110, e.g., in the manner described above. Impeller assembly100may be in mechanical communication with motor28of dryer appliance10. Thus, impeller assembly100may be rotatable about the axis of rotation X by motor28in order to urge flows of air F into casing110. In particular, motor28can rotate or spin impeller assembly100on the axis of rotation X in order to draw moisture laden air Amfrom chamber27of drum26and urge moisture laden air Amto vent49of cabinet12in the manner described above. It should be understood that impeller assembly100may be rotatable about the axis of rotation X by any suitable motor. For example, dryer appliance10may include an additional motor (not shown) that can rotate impeller assembly100independently of drum26.

FIG. 4provides a perspective view of impeller assembly100. As may be seen inFIG. 4, impeller assembly100defines a radial direction R, a circumferential direction C and an axial direction A. The axis of rotation X may be substantially parallel to the axial direction A, e.g., such that the axis of rotation X is substantially perpendicular to the radial direction R and circumferential direction C. Impeller assembly100includes a base plate120, an annular front plate130and a plurality of blades150. Base plate120, annular front plate130and blades150define a plurality of passages160for directing flows of air F during rotation of impeller assembly100about the axis of rotation X.

Base plate120has a substantially circular shape, e.g., in a plane that is perpendicular to the axial direction A, such that base plate120is substantially disk-shaped. Base plate120includes a mounting feature124for mounting base plate120to a motor, such as motor28, or a rotational shaft, such as a pulley structure shaft. Mounting feature124is positioned at the axis of rotation X and can be any suitable mechanism for mounting impeller assembly100to the motor. For example, mounting feature124may include threads for securing impeller assembly100to the motor.

Annular front plate130is spaced apart from base plate120, e.g., along the axial direction A. Further, annular front plate130is positioned up stream of base plate120relative to flow of air F (FIG. 3) Annular front plate130is substantially ring-shaped e.g., in a plane that is perpendicular to the axial direction A. Thus, annular front plate130defines an opening132that permits flow of air F therethrough during rotation of impeller assembly100about the axis of rotation X.

Blades150extend between base plate120and annular front plate130, e.g., along the axial direction A. Thus, base plate120and annular front plate130may be coupled together with blades150. Blades150are spaced apart from each other, e.g., along the circumferential direction C. In particular, blades150may be spaced apart from each other such that blades150are uniformly dispersed or distributed along the circumferential direction C. Base plate120, annular front plate130and blades150are sized, shaped and oriented for drawing flows of air F during rotation of impeller assembly100about the axis of rotation X, as discussed in greater detail below.

As may be seen inFIG. 4, impeller assembly100also includes a plurality of extensions170. Extensions170are mounted base plate120, and each extension of extensions170is positioned at or adjacent a respective one of blades150. Extensions170may assist with urging and directing air flow F during rotation of impeller assembly100about the axis of rotation X.

FIG. 5provides a top, plan view of impeller assembly100. As may be seen inFIG. 5, each blade of blades150extends between an inner or leading edge152and an outer or trailing edge154, e.g., along the radial direction R. Further, each blade of blades150defines an arcuate or curved shape, e.g., in a plane that is perpendicular to the axial direction A, between about the leading and trailing edges152and154of each blade. Thus, each blade of blades150includes a concave surface156and a convex surface158positioned on opposite sides of each blade such that the concave and convex surfaces156and158of each blade are spaced apart from each other along the circumferential direction C. As may be seen inFIG. 5, concave surface156of one of blades150and convex surface158of an adjacent one of blades150define one of passages160therebetween. The arcuate or curved shape of blades150can assist with urging flows of air F through passages160during rotation of impeller assembly100about the axis of rotation X.

As may be seen inFIG. 5, each of extensions170extends between a leading portion172and a trailing portion174. Leading portions172of extensions170are positioned adjacent the axis of rotation X. Conversely, each trailing portion174is positioned at a respective blade of blades150. In particular, each trailing portion174may be mounted or secured to the respective one of blades150at the leading edge152of the respective one of blades150. Extensions170may extend linearly between leading portion172and trailing portion174, e.g., in a plane that is perpendicular to the axial direction A. However, in alternative exemplary embodiments, extensions170may be curved between leading portion172and trailing portion174, e.g., in the plane that is perpendicular to the axial direction A. In addition, leading portion172and trailing portion174of each extension170may be spaced apart or offset from each other along at least one of the radial direction R and the circumferential direction C.

FIG. 6provides a partial, perspective view of impeller assembly100. As may be seenFIG. 6, leading portions172of extensions170are positioned at or adjacent base plate120. Thus, a top edge176of extensions170tapers upwardly or increases in height from leading portion172to trailing portion174.

FIG. 7provides a side, elevation view of one of blades150of impeller assembly100. As may be seen inFIG. 7, blade150extends from base plate120and defines a height, BH, e.g., along the axial direction A. Thus, base plate120and annular front plate130may be spaced apart from each other by about the height BH, e.g., along the axial direction A. The height BH may be any suitable height. For example, the height BH may be greater than about one inch and less than about four inches.

Extension170also defines a radius, ER, between leading portion172and trailing portion174. In particular, top edge176of extension170may extend between leading portion172and trailing portion174of extension170and define the radius ER. The radius ER may be any suitable radius. For example, the radius ER may be greater than about half an inch and less than about four inches. In addition, the radius ER may be less than the height BH. In particular, a ratio of the radius ER to the height BH may be greater than about one quarter (0.25) and less than about nine tenths (0.9).

As may be seen inFIG. 7, leading portion172of extension170is spaced apart from trailing portion174of extension170by a length, EL, e.g., along at least one of the radial direction R and the circumferential direction C. Thus, extension170may extend along at least one of the radial direction R and the circumferential direction C by the length EL. The length EL may be any suitable length. For example, the length EL may be greater than about half an inch and less than about four inches.

Trailing portion174of extension170is also spaced apart from the axis of rotation X by a radial length, RL, e.g., along the radial direction R. The radial length RL may be any suitable length. For example, the radial length RL may be greater than about two inches and less than about six inches. In addition, a ratio of the length EL to the radial length RL may be greater than about two tenths (0.2) and less than about eight tenths (0.8).

As may be seen inFIG. 7, trailing portion174of extension170defines a height, EH, e.g., along the axial direction A. The height EH may be any suitable height. For example, the height EH may be greater than about an eighth of an inch and less than about three and one half inches. In addition, the height EH may be less than the height BH. In particular, a ratio of the height EH to the height BH may be greater than about one tenth (0.1) and less than about eight tenths (0.8).

As discussed above, blades150and extensions170are sized, shaped and oriented for drawing flows of air F during rotation of impeller assembly100about the axis of rotation X. In particular, proper selection of the ratio of the radius ER to the height BH, the ratio of the length EL to the radial length RL and/or the ratio of the height EH to the height BH can assist with drawing flows of air F during rotation of impeller assembly100about the axis of rotation X. For example, such sizing, shaping and orientation can assist with providing a relatively high pressure rise in flows of air F and relatively large flow rates for flows of air F.

In the exemplary embodiment shown inFIGS. 6 and 7, top edge176of extension170defines a constant radius between leading portion172and trailing portion174. It should be understood that top edge176of extension170may have any other suitable shape or curvature in alternative exemplary embodiments. For example, top edge176of extension170may define multiple radii. As another example, top edge176of extension170may define a smooth and/or continuous sinuous shape.

FIG. 8provides a side, elevation view of a blade200and extension210according to another exemplary embodiment of the present subject matter. Blade200and extension210may be used in any suitable impeller assembly. For example, blade200and extension210may be used in or with impeller assembly100(FIG. 4), such that blade200is mounted to base plate120of impeller assembly100.

Extension210extends between a leading portion212and a trailing portion214. As may be seen inFIG. 8, extension210also defines a radius, ERR. In particular, a top edge216of extension210may extend between leading portion212and trailing portion214of extension210and define the radius ERR. In addition, top edge216of extension210defines transitions radii at leading portion212and trailing portion214, respectively. Thus, top edge216of extension210defines multiple radii. It should be understood that top edge216of extension210may have any other suitable shape or curvature in alternative exemplary embodiments. For example, top edge216of extension210may define additional radii. As another example, top edge216of extension210may define a smooth and/or continuous sinuous shape.