Abstract:
One exemplary embodiment of the present disclosure is directed to a vertical axis washing machine. The washing machine includes a cabinet having a top portion with a lid and side portions extending downwardly from the top portion. A tub is positioned within the cabinet with a basket rotatably supported within the tub. The washing machine also includes a heater, a water level sensor, and a fan. The water level sensor controls the volume of water that enters the tub such that the fan is not submerged in such volume of water and the heater generates steam from such volume of water. The fan rotates and circulates air inside the tub so that the steam is distributed throughout the tub.

Description:
FIELD OF THE INVENTION 
     The present disclosure relates generally to washing machines, and more particularly to vertical axis washing machines with steam features. 
     BACKGROUND OF THE INVENTION 
     Washing machines typically include a cabinet which receives a stationary tub for containing wash and rinse water. A wash basket is rotatably mounted within the wash tub, and an agitating element is rotatably positioned within the wash basket. A drive assembly and a brake assembly can be positioned with respect to the wash tub and configured to rotate and control the agitation of the wash basket to cleanse the wash load loaded into the wash basket. Upon completion of a wash cycle, a pump assembly can be used to rinse and drain the soiled water to a draining system. 
     Certain horizontal axis washers are equipped with the capability to produce steam inside the cabinet. However, there are currently no vertical axis machines that satisfactorily provide this capability. 
     Thus, a need exists for a top load washing machine that provides steam features to enhance garments. Mechanisms for circulating steam throughout a top load washing machine would be particularly useful. 
     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. 
     One exemplary embodiment of the present disclosure is directed to a vertical axis washing machine. The washing machine includes a cabinet having a top portion with a lid and side portions extending downwardly from the top portion. A tub is positioned within the cabinet with a basket rotatably supported within the tub. The washing machine also includes a heater, a water level sensor, and a fan. The water level sensor controls the volume of water that enters the tub such that the fan is not submerged in such volume of water and the heater generates steam from such volume of water. During generation of steam, the fan rotates and circulates air inside the tub so that the steam is distributed throughout the tub. Spinning of the basket, the impeller or both can constitute the fan as described, although the fan could be separate from the basket or impeller. 
     Another exemplary embodiment is directed to a method for operating a vertical axis washing machine. The washing machine includes a cabinet having a top portion with a lid and side portions extending downwardly from the top portion. A tub is positioned within the cabinet with a basket rotatably supported within the tub. The washing machine also includes a heater and a water level sensor. The method includes adding water to the tub until a predetermined volume of water has been added. The volume of water is only sufficient for generating steam. The water level sensor is utilized to determine when the predetermined volume of water has been added. The method further includes initiating the heater after the predetermined volume of water has been added to generate steam from the predetermined volume of water. 
     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, in which: 
         FIG. 1  is a perspective cutaway view of an exemplary top load washing machine according to an exemplary embodiment of the present disclosure; 
         FIG. 2  is a front schematic view of the washing machine shown in  FIG. 1 ; and 
         FIG. 3  is a schematic block diagram of a control system for the washing machine shown in  FIG. 1  and  FIG. 2  in accordance with certain aspects of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     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 or spirit 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. 
     In general, the present disclosure is directed to a top load washing machine that includes the ability to produce steam. When a predetermined level of water is added to the washer as determined by one or more water level sensor(s), a heater is utilized to produce steam within the washer. As is known to one of ordinary skill in the art, since heat rises such steam would typically concentrate in the upper portion of the washing machine. Importantly, the present disclosure permits distribution of steam throughout the washing machine. Steam can be utilized to remove wrinkles in garments as well as for more efficient cleaning of garments. 
       FIG. 1  is a perspective view partially broken away of an exemplary top load (vertical axis) washing machine  50  including a cabinet  52  having a top portion  54 . A backsplash  56  extends from top portion  54 , and a control panel  58  including a plurality of input selectors  60  is coupled to backsplash  56 . Control panel  58  and input selectors  60  collectively form a user interface input for operator selection of machine cycles and features, and in one embodiment, a display  61  indicates selected features, a countdown timer, and other items of interest to machine users. A lid  62  is mounted to top portion  54  and is rotatable about a hinge (not shown) between an open position (not shown) facilitating access to wash tube  64  located within cabinet  52 , and a closed position (shown in  FIG. 1 ) forming an enclosure over wash tub  64 . 
     Tub  64  includes a bottom wall  66  and a sidewall  68 , and a basket  70  is rotatably mounted within wash tub  64 . The top portion of tub  64  generally defines a tub opening (not shown). A pump assembly  72  is located beneath tub  64  and basket  70  for gravity assisted flow when draining tub  64 . Pump assembly  72  includes a pump  74  and a motor  76 . A pump inlet hose  80  extends from a wash tub outlet  82  in tub bottom wall  66  to a pump inlet  84 , and a pump outlet hose  86  extends from a pump outlet  88  to an appliance washing machine drain outlet  90  and ultimately to a building plumbing system discharge line (not shown) in flow communication with drain outlet  90 . 
       FIG. 2  is a front elevational schematic view of washing machine  50  including wash basket  70  movably disposed and rotatably mounted in wash tub  64  in a spaced apart relationship from tub side wall  68  and tub bottom. A wash load such as garment  75  is disposed within basket  70 . The top portion of tub  64  generally defines a tub opening  73 . Basket  70  includes a plurality of perforations therein to facilitate fluid communication between an interior of basket  70  and wash tub  64 . 
     A hot liquid valve  102  and a cold liquid valve  104  deliver fluid, such as water, to basket  70  and wash tub  64  through a respective hot liquid hose  106  and a cold liquid hose  108 . Liquid valves  102 ,  104  and liquid hoses  106 ,  108  together form a liquid supply connection for washing machine  50  and, when connected to a building plumbing system (not shown), provide a fresh water supply for use in washing machine  50 . Liquid valves  102 ,  104  and liquid hoses  106 ,  108  are connected to a basket inlet tube  110 , and fluid is dispersed from inlet tube  110  through a known nozzle assembly  112  having a number of openings therein to direct washing liquid into basket  70  at a given trajectory and velocity. A known dispenser  153  (shown in  FIG. 3 , not shown in  FIG. 2 ), may also be provided to produce a wash solution by mixing fresh water with a known detergent or other composition for cleansing of articles in basket  70 . 
     In an alternative embodiment, a known spray fill conduit  114  (shown in phantom in  FIG. 2 ) may be employed in lieu of nozzle assembly  112 . Along the length of the spray fill conduit  114  are a plurality of openings arranged in a predetermined pattern to direct incoming streams of water in a downward tangential manner towards articles in basket  70 . The openings in spray fill conduit  114  are located a predetermined distance apart from one another to produce an overlapping coverage of liquid streams into basket  70 . Articles in basket  70  may therefore be uniformly wetted even when basket  70  is maintained in a stationary position. 
     A known agitation element  116 , such as an impeller is disposed in basket  70  to impart an oscillatory motion to garments and liquid in basket  70  while leaving sufficient room to hang a garment as will be described in more detail herein. In addition, in embodiments where the agitation element  116  is an impeller, the impeller can be utilized to circulate steam as will be described in greater detail herein. As illustrated in  FIG. 2 , agitation element  116  is oriented to rotate about a vertical axis  118 . 
     Basket  70  and agitator  116  are driven by motor  120  through a transmission and clutch system  122 . A transmission belt  124  is coupled to respective pulleys of a motor output shaft  126  and a transmission input shaft  128 . The drive system may also be of the direct type where no belt is necessary and the motor is directly inline with the drive shaft. Thus, as motor output shaft  126  is rotated, transmission input shaft  128  is also rotated. Clutch system  122  facilitates driving engagement of basket  70  and agitation element  116  for rotatable movement within wash tub  64 , and clutch system  122  facilitates relative rotation of basket  70  and agitation element  116  for selected portions of wash cycles. Motor  120 , the transmission and clutch system  122  and belt  124  collectively are referred herein as a machine drive system. 
     Washing machine  50  also includes a brake assembly (not shown) selectively applied or released for respectively maintaining basket  70  in a stationary position within tub  64  or for allowing basket  70  to spin within tub  64 . Pump assembly  72  is selectively activated, in the example embodiment, to remove liquid from basket  70  and tub  64  through drain outlet  90  and a drain valve  130  during appropriate points in washing cycles as machine  50  is used. 
     Operation of machine  50  is controlled by a controller  138  which is operatively coupled to the user interface input located on washing machine backsplash  56  (shown in  FIG. 1 ) for user manipulation to select washing machine cycles and features such as wash cycles and steam cycles as will be described in more detail herein. In response to user manipulation of the user interface input, controller  138  operates the various components of machine  50  to execute selected machine cycles and features. 
     Referring to  FIG. 3 , controller  138  can, for example, be a microcomputer  140  coupled to a user interface input  141 . An operator may enter instructions or select desired washing machine cycles and features via user interface input  141 , such as through input selectors  60  (shown in  FIG. 1 ) and a display or indicator  61  coupled to microcomputer  140  displays appropriate messages and/or indicators, such as a timer, and other known items of interest to washing machine users. A memory  142  is also coupled to microcomputer  140  and stores instructions, calibration constants, and other information as required to satisfactorily complete a selected wash cycle. Memory  142  may, for example, be a random access memory (RAM). In alternative embodiments, other forms of memory could be used in conjunction with RAM memory, including but not limited to flash memory (FLASH), programmable read only memory (PROM), and electronically erasable programmable read only memory (EEPROM). 
     Power to controller  138  can be provided by a power supply  146  configured to be coupled to a power line L. Analog to digital and digital to analog converters (not shown) are coupled to controller  138  to implement controller inputs and executable instructions to generate controller output to washing machine components such as those described above in relation to  FIGS. 1 and 2 . More specifically, controller  138  is operatively coupled to water level sensor  202  and heater  204  (as further described herein) in addition to machine drive system  148  (e.g., motor  120 , clutch system  122 , and agitation element  116  shown in  FIG. 2 ), a brake assembly  151  associated with basket  70  (shown in  FIG. 2 ), machine water valves  152  (e.g., valves  102 ,  104  and diverter valve  184  shown in  FIG. 2 ) and machine drain system  154  (e.g., drain pump assembly  72  and/or drain valve  130  shown in  FIG. 2 ) according to known methods. 
     In an illustrative embodiment, laundry items are loaded into basket  70 , and washing operation is initiated through operator manipulation of control input selectors  60  (shown in  FIG. 1 ). Tub  64  is filled with water and mixed with detergent to form a wash fluid, and basket  70  is agitated with agitation element  116  for cleansing of laundry items in basket  70 . That is, agitation element is moved back and forth in an oscillatory back and forth motion. In the illustrated embodiment, agitation element  116  is rotated clockwise a specified amount about the vertical axis of the machine, and then rotated counterclockwise by a specified amount. The clockwise/counterclockwise reciprocating motion is sometimes referred to as a stroke, and the agitation phase of the wash cycle constitutes a number of strokes in sequence. Acceleration and deceleration of agitation element  116  during the strokes imparts mechanical energy to articles in basket  70  for cleansing action. The strokes may be obtained in different embodiments with a reversing motor, a reversible clutch, or other known reciprocating mechanism. 
     After the agitation phase of the wash cycle is completed, tub  64  is drained with pump assembly  72 . Laundry items are then rinsed and portions of the cycle repeated, including the agitation phase, depending on the particulars of the wash cycle selected by a user. 
     In accordance with the present disclosure, the washing machine can also advantageously permit one or more steam cycles and/or fabric enhancing cycles. Heretofore, top load (vertical axis) washing machines have not included steam features. In accordance with the present disclosure, steam features are described in connection with top load washing machines. In this manner, consumers of top load washing machines can enjoy the deep clean benefits afforded by steam. The washing machines described herein can also permit reduction and/or elimination of wrinkles from garments. 
     Referring to  FIG. 2 , sump  200  is in fluid communication with tub  64 . Sump  200  can be of any suitable size and/or shape to permit a volume of water to accumulate for the production of steam as will be described herein. In this manner, water can flow into tub  64  as previously described herein and fill sump  200 . 
     Water level sensor  202  can be positioned in or adjacent to sump  200  and can control the volume of water to ensure that only a predetermined volume of water enters sump  200 . Water level sensor  202  can be any suitable water level sensor as would be known to one of ordinary skill in the art. Water level sensor  202  can be in communication with controller  138  such that water level sensor  202  can cause the flow of water into tub  64  to stop when the volume of water in sump  200  reaches a predetermined sufficient volume. 
     In this regard, sump  200  can include heater  204 . Heater  204  is immersed by the volume of water in sump  200  and once the volume of water reaches a predetermined level, heater  204  can be activated by controller  138  and increase in temperature to boil the water and generate steam. Steam can rise and fill tub  64 . Any suitable heater as would be known to one of ordinary skill in the art can be utilized for such purpose. Heater  204  can be deactivated by controller  138  when water level sensor  202  indicates that some portion or substantially all of the volume of water in sump  200  has been released into the tub  64  as steam. 
     Steam can be circulated throughout tub  64  with fan  206 . Fan  206  can be located in any suitable location within tub  64  so as to enable effective circulation of steam. In an particular embodiment, fan  206  can be represented by spinning the basket and or the impeller to circulate air. In this regard, due to the buoyant nature of steam and the physical configuration of a vertical axis washing machine, steam typically concentrates toward the top portion  208  of tub  64 . Fan  206  can ensure that steam is distributed more evenly throughout the tub  64 . The speed, direction, and duration of operation of fan  206  can be activated by controller  138  as steam is being generated by heater  204 . Fan  206  can also be activated after steam generation is complete. Fan  206  can operate for predetermined intervals of time based on the steam cycle selected by a user. In certain embodiments, agitation  116  can also be utilized as fan  206 . 
     A reservoir (not shown) is located within washing machine  50  and can receive fragrant material added by a user. Fragrant material can include liquid fragrant material or solid fragrant capsules. Reservoir can be in communication with controller  138  and release the fragrant material to be delivered into the volume of water to generate a fragrant steam. For instance, reservoir can be opened based upon a fabric enhancing cycle being selected by a user. Although illustrated within washing machine  50 , reservoir can also be located outside of washing machine in communication with tub  64 . 
     A pumping mechanism (not shown) can be utilized to direct fragrant material into sump  200 . Fragrant material can dissolve or mix with water in sump  200  so that a fragrant steam can be distributed throughout the tub  64 . The fragrant material can take any form including a liquid additive such as detergent or fabric softener, a powered additive or any other scented fluid, gel, tablet, capsule or powder. 
     Referring again to  FIG. 2 , washing machine  50  can also include a removable garment hanger  214 . Removable garment hanger  214  can hang within tub  64 . In this regard, tub  64  can define any suitable feature such as tabs, hooks, fasteners, or the like to mount removable garment hanger  214  within tub  64 . In certain embodiments of the present disclosure, one or more sensors or transducers  156  can detect the presence and/or absence of removable garment hanger  214  and communicate the same to controller  138 . In this manner, when removable garment hanger  214  is positioned within tub  64 , the user interface  141  can optionally only permit access to steam cycle functions of the washing machine  50 . However, it should be appreciated that the steam features described herein can also be used in combination with washing cycles as would be appreciated by one of ordinary skill in the art and the presence of garment hanger  214  within tub  64  does not necessarily require disabling of wash cycle features. 
     For instance, a regular wash load of garments can be loaded into the basket of a top load washing machine. The steam features described herein can be utilized at any suitable time during the regular wash cycle(s). In certain embodiments, the steam features can be activated to add fragrant steam in the tub after an initial wash. Spinning the basket and/or impeller and/or use of a fan can be utilized to distribute the steam throughout the washing machine. Similarly, in certain embodiments, one or more garments can be hung in basket and a steam cycle can be utilized to freshen such garments without the necessity for a full wash cycle. Alternatively, or in conjunction with such freshening, wrinkles can also be reduced or eliminated from the use of a steam cycle without the necessity of a full wash cycle. 
     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.