LAUNDRY APPLIANCE

Abstract: A laundry appliance (10) comprises an outer casing (14) and a container (34) mounted inside the outer casing (14) and spaced from the casing to permit movement of the container (34) in use. The container (34) has a door (42) for closing the opening in the container which moves with the container (34) during use of the applicance. A seal (80) is located between the outer casing (14) and the container (34). The seal (80) extends radially inwardly from the lip (85) of the opening in the outer casing (14) and lies against the front surface of the container (34). The seal has a rigid portion (81) with a channel (83) for receiving the lip (85) of the container and a flexible portion (82).

Description: Laundry Appliance The invention relates to a laundry appliance such as a washing machine, a washer-dryer or a tumble dryer. A washing machine generally consists of an outer casing in which is mounted a watertight interior container, often called a tub. A perforated drum is commonly mounted inside the container in a manner which allows the drum to rotate with respect to the container. During operation, washing liquid is contained within the container and the laundry to be washed is located within the perforated drum. The laundry is agitated, either by slow rotation of the drum or by the operation of an agitator located within the dram. When the laundry has been washed, some washing liquid is drained from the interior container and further washing liquid is extracted from the laundry by fast rotation of the drum within the interior container to spin washing liquid therefrom. Extraction of rinse water is achieved in a similar manner. The imbalance of the drum caused by the inevitably uneven distribution of the laundry causes some vibration of the interior container within the outer casing when the drum is rotated at fast speeds. In order to avoid this vibration being transmitted to the outer casing of the washing machine, the interior container is mounted within the outer casing so as to allow a limited amount of movement between the container and outer casing. It is common, in this respect, to mount the interior container in the outer casing by way of tension springs which dampen the movements of the interior container and urge it to return to its equilibrium position. The fact that the interior container is allowed to move with respect to the outer container causes difficulties with respect to the sealing of the washing machine in the area of the door, particularly in the case of front-loading washing machines. In most cases, the door is mounted on the outer casing and is arranged so as to seal the outer casing when the door is in a closed position. In the case of front-loading washing machines, the door will also normally be dished in shape so as to project inwardly towards the interior container. A large flexible bellows seal is provided between the interior container and either the door or the rim of the opening so as to prevent washing liquid from escaping from the interior container. In the case of top-loading washing machines, the door need not be shaped so as to project towards the interior container, although the flexible seal may extend between the upper end thereof and the outer casing or the door. The flexible seal is normally designed with sufficient flexibility to allow the movement of the interior container to be accommodated without causing excessive stresses or damage to the remainder of the machine. The known arrangements outlined above have a common disadvantage in that the flexible seal on which the sealing of the interior container depends is prone to wear or damage. This is because, by necessity, it surrounds and projects, in an unsupported manner, into the opening through which laundry is passed in order to introduce it to the interior of the drum. It is common to use considerable force to pass the laundry through the available opening and this can distort, dislodge or damage the seal. If fastenings such as zips and/or buttons are present in the laundry, the damage to the seal can be considerable. Another disadvantage of the known front-loading arrangements is that, because the seal must be flexible in order to accommodate the movements of the interior container, there is a possibility of small articles of laundry becoming lodged in a fold or crevice of the seal which can lead to the article not being properly washed or being damaged. It is known for some front-loading washing machines to have a door mounted on the container itself. The door seals the container when it is closed. As with conventional machines, the container is located inside an outer casing in a manner which allows limited movement between the container and the outer casing but the need for a large bellows seal between the container and the outer casing is avoided. An opening in the outer casing is aligned with container door so as to allow access to the drum, and a front panel is hingedly fixed to the outer casing to cover the opening. A form of rubber seal is provided in the space between the container and the outer casing, the seal being positioned some distance radially outwardly from the opening in the casing to provide cushioning between the container and outer casing. In this type of machine there is a risk that objects can fall or become caught between the outer casing and the container. The present invention seeks to provide a laundry appliance which is more convenient to use. Accordingly, the present invention provides a laundry appliance comprising an outer casing, a container mounted inside the outer casing and spaced from the outer casing to permit movement of the container in use, the outer casing and container each having an opening to allow the introduction of laundry into the container, a door for closing the opening in the container which is movable with the container when the appliance is in use and a seal located in the space between the outer casing and the container, the seal extending from the lip of the opening in the outer casing. By providing a seal which extends from the lip of the outer casing, the gap between the outer casing and the container is safely guarded. Thus a user cannot trap their hand and an object cannot fall or become trapped between the outer casing and the container. Preferably the seal extends radially inwardly from the lip of the outer casing. With this orientation, the seal always guards the gap between the container and outer casing, even as the container moves with respect to the outer casing. Preferably the seal lies against the container to further minimise the risk of a user trapping their hand or an object falling between the outer casing and the container. The seal can be resiliently biased so that it lies against the container. Preferably the seal is sufficiently flexible so as to not unduly restrain the container when the container moves with respect to the outer casing. Preferably the seal lies flush with the lip of the opening in the outer casing. Preferably the seal comprises a part for connecting to the lip of the opening in the outer casing. This can take the form of a channel for receiving the lip of the opening in the outer casing. An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, wherein: Figure 1 is a perspective view of a washing machine according to the invention; Figure 2 is a side view of the washing machine of Figure 1 showing, schematically, the interior components of the machine; Figure 3 is a front view of the washing machine of Figure 1 with the outer door open to show the inner container; Figure 4 is a front view of just the seal which fits between the outer casing and container; Figure 5 is a cross-section through the front machine of Figure 3; and Figure 6 shows, in more detail, part of the cross-section of Figure 5; Figure 7 shows the same cross-section as Figure 6 with an alternative embodiment of the seal; and, Figure 8 shows the same cross-section as Figure 6 with a modified seal. Figures 1 and 2 show a laundry appliance in the form of a washing machine 10. The washing machine 10 has an outer casing 12 comprising a front panel 14, side panels 16 and a cover 18. The outer casing 12 can be dimensioned so as to fit within a standard appliance space as is commonly provided in European kitchens and utility rooms. However, the dimensions of the washing machine 10 do not form part of the present invention and can be varied to suit requirements. The front panel 14 includes a control panel 20 in which are housed various control buttons or other means for appropriate operation of the washing machine 10. The front panel 14 also includes a soap tray drawer 22 by means of which access to a soap tray for receiving detergent can be gained. Also positioned in the front panel 14 is a coin trap 24 which can be used to provide access to a cavity for collecting large foreign objects inadvertently introduced to the washing machine 10. It will be appreciated that the design, operation and relative positioning of the control panel 20, the soap tray drawer 22 and the coin trap 24 are immaterial to the present invention and variations to these particular features are intended to be encompassed within the invention. Mounted on the front panel 14 of the outer casing 12 is a first door 26. The door 26 is supported on one side thereof by way of a hinge 28. Located on the door 26 on the side thereof remote from the hinge 28 is a handle 30 which co-operates with a latch 32 (Figure 3) mounted on the front panel 14. An interior container or tub 34 is mounted inside the outer casing 12 by way of tension springs and dampers 36. This method of mounting a tub 34 inside a washing machine 10 is known. A cylindrical drum 38 is mounted inside the tub 34, also in a known manner, with a motor 40 being provided so as to cause the drum 38 to rotate about its own longitudinal axis. Perforations are provided in the drum 38 so as to allow washing liquid and/or rinse water contained within the tub 34 to pass through the perforations and into the interior of the drum 38. A second door 42 is provided on the tub 34 on the face thereof closest to and generally parallel with the front panel 14 of the outer casing 12. The door 42, like the door 26, is supported by and pivotable about a hinge 44 (see Figure 3). A handle 46 is also provided on the door 42 on the side remote from the hinge 44. The handle 46 cooperates with a latch mounted on the tub 34. In order to perform as a washing machine, means (not shown) are provided for introducing water to the tub 34 and also for draining water from the tub 34 and pumping it to a water outlet. These features are well known in the art and, for this reason, are not shown in the Figures nor described any further here. The washing machine 10 also includes control means for causing the washing machine 10 to perform appropriate washing cycles. A typical washing cycle will include the introduction of water and detergent to the interior of the tub 34 to produce a washing liquid, the heating of the washing liquid to a required temperature, the rotation of the drum 38 about its axis within the tub 34 to agitate laundry contained within the drum 38, the draining of the washing liquid from the tub 34, a series of rinse cycles involving the introduction of rinse water to the interior of the tub 34 and its extraction from the tub 34 by draining and slow spinning of the drum 38, and spinning of the laundry by fast rotation of the drum 38 about its axis. Further discussion of the washing cycles will not be given here. The control means 50 provided to operate the washing machine 10 are also operatively connected to the latch 32 and the latch 48 as will be described in more detail below. Figure 3 shows the washing machine 10 in a first configuration in which the outer door 26 is open and the inner door 42 is closed. The outer door 26 comprises a generally circular panel 52 which is supported on one side by the hinge 28. The hinge 28 is located on the front panel 14 adjacent one of the side panels 16. Locating the hinge so close to the side panel 16 allows the circular panel 52 to have as large a diameter as possible. The circular panel 52 supports the handle 30 on the side thereof remote from the hinge 28. The circular panel 52 is made from a transparent material. In the embodiment shown, the material used is polycarbonate although other transparent materials may be used. This allows the door 42 to be visible through the door 26. The position of the door 42 is shown in dotted lines in Figure 3. The door 26 is dimensioned and arranged so as to be able to close an opening 54 in the front panel 14. The circular panel 54 carries a lip 56 which projects through the opening 54 into the interior of the outer casing past the front panel 14 when the door 26 is in the closed position. A seal 58 is located on the rim of the circular panel 52 radially outwardly of the lip 56 so that, when the door 26 is in the closed position, the seal 58 is compressed between the circular panel 52 and the rim of the opening 54 in the front panel 14. Thus, when the door 26 is closed, the outer casing 12 is firmly and sealingly closed in the area of the opening 54. The opening 54 in the front panel 14 is sufficiently large that the inner door 42 can pass therethrough when the door 26 is open. The door 42 is supported on the tub 34 by way of the hinge 44. The hinge 44 is located at a greater distance from the side panel 16 than the hinge 28 when the tub 34 is in its equilibrium position. This ensures that the door 42 is able to pass through the aperture 54 when the door 42 is rotated about the hinge 44. The door 42 comprises an annular rim portion 60 which is supported at one side thereof by the hinge 44. The handle 46 is located on the rim portion 60 on the side thereof remote from the hinge 44. The rim portion 60 surrounds and supports a dish-shaped portion 62 which is manufactured from a transparent material such as glass or Pyrex™. Other transparent materials may also be used. When the door 42 is in the closed position, the dish-shaped portion 62 projects into the interior of the tub 34. The door 42 is located and dimensioned so that it closes an opening 64 located in the portion of the tub 34 adjacent the front panel 14 of the outer casing 12. The opening 64 is circular and has a diameter which is smaller than that of the opening 54. A seal 66 is positioned around the rim of the opening 64 on the outer face of the tub 34 in such a position that, when the door 42 is closed, the rim portion 60 is pressed against the seal 66. In this manner, the tub 34 is sealed in a watertight manner when the door 42 is in the closed position. Each of the handles 30,46 co-operates with the respective latch 32,48 in a known manner. In the closed position, each latch 32,48 is operable so as to hold the respective door 26,42 in a closed position until the respective handle 30,46 is operated. In this way, each door 26,42 is maintained in a position in which the respective seal 58,66 remains under compression and therefore operative so as to form a seal against any leakage of water. The provision of two separate doors, a first door 26 mounted on the outer casing 12 and a second door 42 mounted on the tub 34, means that there is no need for a large flexible seal to be provided between the tub 34 and the door 26 mounted on the outer casing 12. The door 42 which closes the tub 34 is mounted directly thereon and therefore the seal 66 which ensures a watertight closure of the tub 34 is not vulnerable to wear and/or damage as a result of laundry being introduced to the interior of the tub 34 through the opening 64. The seal 66 can be made small and compact with adequate support being provided thereto. Furthermore, the seal 58 provided between the front panel 14 and the door 26 is also fully supported and therefore less vulnerable to damage and wear, although it is recognised that this seal 58 is less critical to the operation of the washing machine 10. When the washing machine 10 is in operation, both doors 26,42 are closed. However, the interior of the tub 34 can still be viewed by the user of the washing machine 10 by virtue of the fact that both doors 26,42 are transparent. The user is therefore able to view the interior of the washing machine 10 so as to be able to judge the stage of the cycle reached by the washing machine 10 at any particular time. Figures 3-6 show a seal 80 which is positioned between the front panel 14 and the tub 34. The seal 80 serves the purpose of guarding the region between the tub 34 and the front panel 14. The tub 34 and front panel 14 must be spaced so as to allow for movement of the tub 34 during use of the machine. The seal 80 prevents a user from trapping their hand between the tub 34 and the front panel 14. Figure 4 shows just the seal itself. The seal 80 comprises a first portion 81 for connecting to the front panel 14 and a second portion 82 which is more flexible. The first portion 81 is the radially outermost portion of the seal and is formed of a material which is sufficiently rigid to grasp the lip 85 of the opening in the front panel 14, such as polypropylene. A circular channel 83 is formed within rigid portion 81 and extends around the entire seal. The second portion 82 of the seal 80 is the radially innermost portion of the seal and is formed of a more flexible material such as a thermoplastic elastomer. The properties of the second material are that it should be (i) sufficiently rigid so as to retain a shape which fits against the tub assembly, (ii) sufficiently robust to endure rubbing contact with the tub assembly, and (iii) sufficiently flexible to flex when the tub assembly moves towards the front panel. If the seal is too rigid, it has been found to unnecessarily restrain the natural movement of the tub assembly. The first and second portions 81, 82 are moulded to one another to form a single finished part. The moulding can be achieved by a twin-shot moulding method, with the flexible portion 82 of the seal being moulded over the more rigid portion 81. The radius of the innermost part of the seal 80 increases in the regions 88, 89 to accommodate the hinge 44 and door catch and handle 46 of the inner door 42. Thus, the operation of the catch and hinge is unaffected by the presence of the seal 80. In the region of these parts, the seal still lies flush with the tub 34. As a less desirable alternative, the seal 80 could simply be cut in the regions 88, 89. Figure 5 is a cross-section along line A-A' of Figure 3, with the inner door 42 removed for clarity. Figure 6 shows the region C of Figure 5 in more detail. As shown in Figures 5 and 6, the rigid portion 81 of the seal 80 fits to the lip 85 of the front panel 14, gripping both sides of the lip 85. The seal 80 extends radially inwardly from the lip of the panel. In cross-section the seal 80 has a concave profile and ends in a rounded lip 92. The rounded lip 92 helps to retain the shape of the seal. The lip 92 of the seal substantially lies flush with the front surface 90 of the tub 34. With this arrangement, the seal 80 always guards the gap between the panel and tub assembly, even when the width of the gap changes as the machine is in use. The movement of the tub 34 is shown by arrowed line 100 in Figure 6 and the corresponding movement of the seal is shown by arrowed line 110. It can be seen that as the tub 34 moves the flexible part 82 of the seal 80 will both flex and slide along face 90 of the tub 34. In order to gain access to the region between the front panel 14 and tub 34 a user would need to prise up the innermost lip 92 of the seal. This would be very difficult in view of the rigidity and resilience of the seal 80. The inner surface 93 of the seal 80, which is exposed to a user, substantially lies flush with the lip 85 of the front panel 14. This flush fitting allows easy cleaning of this part of the machine and also improves the visual appearance of the machine. While the above arrangement, in which the resiliently flexible portion 82 lies against the front face 90 of the tub 34, has been found to work well, it would also be possible to secure the innermost edge of the seal to the tub. Figure 7 shows an alternative embodiment in which the innermost lip 92' of the seal extends axially towards the tub 34 so as to be received and secured in a channel 120 formed on the front face 90 of the tub 34. This type of seal could be installed by firstly pressing lip 92' of the seal 80 into channel 120 on the tub 34 and then fitting lip 85 of the fascia into channel 83 at the other end of the seal 80. Other ways of securing the seal 80 to the tub 34 will be apparent to a skilled reader. Figure 6 shows the manner in which the seal 80 fits to the front panel 14. A circular channel 83 is formed within rigid portion 81 and extends around the entire seal. The channel 83 has a profile which matches that of the lip 85 of the front panel 14. The width of the channel 83 narrows towards the entry point to the channel 83 so that the enlarged lip 85 of the front panel, once pressed into the channel 83, remains firmly held in the channel 83. In an alternative embodiment, the channel for receiving the lip of the front panel 14 need not extend entirely around the circumference of the seal. The seal 80 can be secured to the front panel 14 in ways other than by using the channel 83. Alternative ways of achieving a press-fit fixing could be used, and other types of mechanical fixing are possible. For example, seal 80 could be bonded to the panel 14 in the region of the lip 85. Figure 8 shows a further modification to the seal 80. The radially innermost portion of the seal 80 carries a reinforcing part 130. The reinforcing part 130 prevents the flexible portion 82 of the seal from buckling under extreme movements of the tub 34, lengthens the life of the seal by providing a longer lasting surface in the region where most wear occurs and prevents minimises marking of the tub surface which can occur with a more flexible material. Reinforcing part 130 can be moulded over the flexible portion 82. As has previously been explained, the control means 50 of the washing machine are operatively connected to the latch 32 and to the latch 48. By appropriate programming, the control means 50 can be configured so as to allow each door 26,42 to be opened only at specific stages of the washing cycle being carried out by the washing machine 10. For example, and as is well known, it is undesirable for the door 42 closing the tub 34 to be openable when there is sufficient washing liquid or rinse water in the tub 34 to cause spillage if the door 42 were to be opened. Therefore, sensors are provided which determine the level of any liquid contained within the tub 34 and, when the liquid level is at least as high as the bottom of the opening 64 in the tub 34, the door 42 cannot be opened. Also, the door 26 should not be openable at any time when the tub 34 is likely to be moving with respect to the outer casing 12. This is most likely to occur during portions of the washing cycle when the drum 38 is spinning at high speed within the tub 34. Therefore, the control means 50 are programmed in such a manner as to prevent the latch 32 from releasing the door 26 at any time when the drum 38 is rotating. Since the amount of movement between the tub 34 and the outer casing 12 is increased as the speed of rotation of the drum 38 increases, it is also possible to arrange for the control means 50 to prevent opening of the door 26 under spinning conditions, i.e. when the drum 38 is rotating at speeds of 800rpm or more. It will be appreciated that the invention is not limited to the precise details of the embodiment described above. The doors 26,42 and openings 54,64 can be arranged so as to be any convenient shape. They do not have to be circular. Furthermore, although the doors 26,42 are here shown as being substantially wholly transparent, it is possible for the advantage of the invention to be achieved by providing a transparent portion on each door, with the transparent portions being aligned so as to allow the interior of the tub 34 to be viewed by a user. It is also possible for the material from which the doors 26,42 are made to be coloured or tinted, although it is preferred that the doors 26,42 are colourless.

Claims: Claims: 1. A laundry appliance comprising an outer casing, a container mounted inside the outer casing and spaced from the outer casing to permit movement of the container in use, the outer casing and container each having an opening to allow the introduction of laundry into the container, a door for closing the opening in the container which is movable with the container when the appliance is in use and a seal located in the space between the outer casing and the container, the seal extending from the lip of the opening in the outer casing. 2. An appliance according to claim 1 wherein the seal extends radially inwardly from the lip of the opening in the outer casing. 3. An appliance according to claim 1 or 2 wherein the seal lies against the container. 4. An appliance according to claim 3 wherein the seal is resiliently biased so that it lies against the container. 5. An appliance according to any one of the preceding claims wherein the seal is flexible. 6. An appliance according to claim 5 wherein the seal comprises a first portion which connects to the lip of the outer casing which is formed of a rigid material and a second portion which extends towards the container which is formed of a more flexible material. 7. An appliance according to claim 5 or 6 wherein the portion of the seal nearest to the container is formed of a material which is more rigid than the flexible portion of the seal. 8. An appliance according to any one of the preceding claims wherein the seal lies flush with the lip of the opening in the outer casing. 9. An appliance according to any one of the preceding claims wherein the seal comprises a part for connecting to the lip of the opening in the outer casing. 10. An appliance according to claim 9 wherein the seal has a channel for receiving the lip of the opening in the outer casing. 11. An appliance according to any one of the preceding claims wherein the seal comprises a part for connecting to the container. 12. An appliance according to any one of the preceding claims comprising a further door for closing the opening in the outer casing. 13. An appliance according to any one of the preceding claims in the form of a washing machine. 14. A laundry appliance substantially as described herein with reference to the accompanying drawings.

Inventors: FITTON NICHOLAS GERALD, ROBERTS IAIN, FITTON, NICHOLAS, GERALD, ROBERTS, IAIN
Applicants: DYSON LTD, FITTON NICHOLAS GERALD, ROBERTS IAIN, DYSON LIMITED, FITTON, NICHOLAS, GERALD, ROBERTS, IAIN
Application year: 2001
Main classification: D06F37
IPC codes: D06F25, D06F37, D06F39, D06F58