Patent Publication Number: US-2023151536-A1

Title: Dryer appliance and filter apparatus

Description:
FIELD 
     The present subject matter relates generally to dryer appliances and filters for dryer appliances. 
     BACKGROUND 
     Dryer appliances are generally provided with a filter for collecting lint and other particles from air flowing through the dryer appliances. During a drying cycle, a large volume of lint can collect on the filter. Users of dryer appliances are normally instructed to clean the filter and remove collected lint from the filter between drying cycles. However, it can be difficult and/or inconvenient to frequently remove lint from the filter, and certain consumers forget to regularly clean the filter and/or disregard the cleaning instructions. 
     Lint disposed on the filter can restrict air flow through the dryer appliance and negatively affect performance of the dryer appliance. For example, restricted air flow through a drum of the dryer appliance can raise a temperature of air within the drum and damage clothing articles within the drum. As another example, a thermostat or other temperature regulating device of the dryer appliance may trip due to the increased temperature within the drum causing the drying cycle to be extended. Thus, an efficiency of the dryer appliance may be negatively affected when excessive lint is disposed on the dryer appliance&#39;s filter. 
     Accordingly, a dryer appliance with an improved filter apparatus would be 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. 
     An aspect of the present disclosure is directed to a dryer appliance including a cabinet having a lower panel and a drum rotatably mounted within the cabinet. The drum defines a chamber for receipt of articles for drying. A drawer is removably mounted to the cabinet and includes a front wall, a rear wall, and sidewalls extended between the front wall and the rear wall. The drawer forms a lint collection bin. A filter assembly is removably positionable within the lint collection bin. The filter assembly abuts the lower panel of the cabinet when the drawer is in a closed position. 
     Another aspect of the present disclosure is directed to a dryer appliance including a cabinet having a lower panel, the cabinet housing a drum motor and a heater assembly. The cabinet includes a rail extending along a horizontal direction. A drum is rotatably mounted within the cabinet and forms a chamber for receipt of articles for drying. A drawer is slidable along the rail at the cabinet. The drawer includes a front wall, a rear wall, and sidewalls extended between the front wall and the rear wall. The drawer forms a lint collection bin. A filter assembly is removably positionable within the lint collection bin. The filter assembly abuts the lower panel of the cabinet when the drawer is in a closed position. A control panel is mounted on the cabinet and in communication with a controller configured to operate the drum motor and the heater assembly. 
     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. 
         FIG.  1    is a perspective view of an embodiment of a dryer appliance according to an exemplary embodiment of the present subject matter. 
         FIG.  2    is a partially see-through perspective view of an embodiment of the dryer appliance of  FIG.  1    according to an exemplary embodiment of the present subject matter. 
         FIG.  3    is a partially see-through perspective view of an embodiment of the dryer appliance of  FIGS.  1 - 2    with a drawer removed from the appliance, according to an exemplary embodiment of the present subject matter. 
         FIG.  4    is a side cross-sectional view of an embodiment of the dryer appliance according to an exemplary embodiment of the present subject matter. 
         FIG.  5    is a side cross-sectional view of an embodiment of the dryer appliance according to an exemplary embodiment of the present subject matter. 
         FIG.  6    is a side cross-sectional view of an embodiment of the dryer appliance according to an exemplary embodiment of the present subject matter. 
         FIG.  7    is a schematic, side, cross-sectional view of an embodiment of the dryer appliance according to an exemplary embodiment of the present subject matter. 
     
    
    
     DETAILED DESCRIPTION 
     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. 
     Embodiments of a dryer appliance are provided including a removable, disposable, or replaceable filter assembly positionable within a cabinet. The filter assembly may be formed substantially similarly as filters for heating, ventilation, and air conditioning (HVAC) systems. Embodiments of the appliance may allow for increased time between filter cleanings, changes, or replacements. The increased time may correspond to intervals generally provided by filters for HVAC systems, e.g., up to approximately six months, or up to approximately three months, or up to approximately one month. Particular embodiments of the appliance provided herein may be configured as residential dryer appliances. 
     Embodiments provided herein may decrease risks associated fire or other damage related to clogged or unclean filters. Embodiments provided herein may obviate a need for cleaning and removing lint from a filter per use (e.g., dryer load or cycle operation) by a user, or per day by a user. The appliance with filter assembly provided herein may improve user interaction by increasing the interval between filter cleanings or replacements, allowing for standard replaceable filters (e.g., HVAC filters) in place of custom-sized filters at a dryer appliance, and allowing for improved airflow through the dryer appliance through larger filter areas. 
       FIGS.  1  and  2    provide perspective views of a dryer appliance  10  according to an exemplary embodiment of the present subject matter. While described in the context of a specific embodiment of dryer appliance  10 , using the teachings disclosed herein it will be understood that dryer appliance  10  is 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 appliance  10  illustrated in  FIGS.  1  and  2    is an electric dryer appliance with electric heating element for heating air. In alternative exemplary embodiments, dryer appliance  10  may be a gas dryer appliance with gas burners for heating air. 
     Dryer appliance  10  includes a cabinet  12 . Within cabinet  12  is a drum or container  14  ( FIG.  2   ) mounted for rotation about a substantially horizontal axis. Drum  14  is generally cylindrical in shape and defines a chamber  16  for receipt of articles for drying. Thus, clothing articles and other fabrics may be loaded into chamber  16  of drum  14  and dried therein, as discussed in greater detail below. A door  20  is rotatably mounted to cabinet  12  to permit selective access to chamber  16  of drum  14 . 
     A drawer  44  is removably mounted to cabinet  12  at a bottom portion  46  of cabinet  12 . Drawer  44  is adjustable (e.g., slidable) between a closed position ( FIG.  1   ) and an open position ( FIG.  3   ). In particular embodiments, the drawer  44  is slidable along a rail  45  extending within the cabinet  12  along a horizontal direction H. The drawer  44  includes front and rear walls  144 ,  244  and sidewalls  344 ,  444  extending between the front and rear walls  144 ,  244 , together forming a lint collection bin  38 . The rear wall  244  may form a vent opening  246  through which a flow of air may exhaust from the chamber  16  through the lint collection bin  38  and out of the appliance  10  through the vent opening  246 . Lint collection bin  38  is configured for collecting and storing lint therein via a filter assembly  100 , as discussed in greater detail below. The filter assembly  100  is removably positionable within the lint collection bin  38 . The filter assembly  100  is configured to filter air flowing through dryer appliance  10 , such as discussed further herein. 
     Referring to  FIG.  3   , the filter assembly  100  is positionable between the front and rear walls  144 ,  244  and the sidewalls  344 ,  444 . A track  146  is formed at the sidewalls  344 ,  444  and extending substantially along a vertical direction V. In certain embodiments, the track  146  may extend along a lower wall  544  of the drawer  44 . The track  146  forms a groove or slot through which the filter assembly  100  is selectively affixed within the drawer  44 . 
     Referring to  FIGS.  4 - 6   , the track  146  may extend at an angle relative to the horizontal direction H. In a particular embodiment, the track  146  is extends with an upper portion more proximate to the front wall  144  and a lower portion more proximate to the rear wall  244 . When the filter assembly  100  is positioned in the drawer  44 , an upper portion  102  of the filter assembly  100  is more proximate to the front wall  144  than a lower portion  104  of the filter assembly  100 . In various embodiments, the angle is between approximately 45 degrees and up to approximately 90 degrees. In certain embodiments, the angle is greater than 55 degrees and less than 90 degrees. In still certain embodiments, the angle is greater than 60 degrees, or greater than 65 degrees, or greater than 70 degrees. When the filter assembly  100  is positioned in the drawer  44 , the track  146  allows the filter to be disposed at the corresponding angle. When the drawer  44  with the filter assembly  100  is in the closed position, an upper portion  102  of the filter assembly  100  abuts a lower panel  122  of the cabinet  12 . In a particular embodiments, the filter assembly  100  is in an interference fit or press-fit with a lower panel  122  of the cabinet  12 . The lower panel  122  is extending along the horizontal direction from the front wall  144  to the rear wall  244  when the drawer  44  is in the closed position. Walls of the track  146  at which the filter assembly  100  is positioned provide sealing along a perimeter between the filter assembly  100  and the sidewalls  344 ,  444 . The filter assembly  100  may furthermore be press-fit or interference fit with a lower wall  544  of the drawer  44 . The track  146  and the fits at a lower portion  104  and upper portion  102  of the filter assembly  100  may together promote airflow through the filter and mitigate flow around the filter (e.g., between the filter assembly  100  and one or more sidewalls, lower panel, or lower wall). 
     Referring now to  FIG.  6   , various embodiments of the appliance  10  include a spring  110  extending between the filter assembly  100  and the drawer  44  and configured to force the filter assembly  100  toward the flow of air  101  entering the lint collection bin  38  from the chamber  16 . Certain embodiments of the appliance  10  include the spring  110  extending between the filter assembly  100  and the rear wall  244 . The spring  110  may be configured to push the filter assembly  100  against the flow of air  101  entering the chamber  16  and passing across the filter assembly  100 . The spring  110  may be configured as a compression spring. In other embodiments, such as depicted in  FIG.  7   , the spring  110  may extend between the filter assembly  100  and the front wall  144  be configured to pull the filter assembly  100  against the flow of air  101 . The spring  110  may be configured as an extension spring extending from the front wall  144 . In various embodiments, the spring  110  may promote sealing between the filter assembly  100  and the drawer  44 . The spring  110  may particularly promote sealing between the filter assembly  100  and one or more of the track  146 , the lower panel  122 , or the lower wall  544  of the drawer  44 . 
     A user of dryer appliance  10  may the filter assembly  100  from drawer  44  when drawer  44  is in the open position. With the filter assembly  100  removed from drawer  44 , the user may clean or replace the filter assembly  100  and remove lint from within drawer  44 . The user may adjust drawer  44  to return the filter assembly  100  to a suitable position for collecting lint during operation of dryer appliance  10 . A poka-yoke arrangement between filter assembly  100  and drawer  44  may assist with insuring that filter assembly  100  is properly or suitably positioned within drawer  44  to capture lint during operation of dryer appliance  10 . 
     Various embodiments of the filter assembly  100  include a filter element formed of any suitable filter material, including fiberglass, polyester, or cotton, or combinations thereof, suspended in a frame  106  ( FIG.  3   ). The frame  106  may be formed of a paper-based material, cardboard, wire or wire-mesh material, metal or metallic material, rubber or synthetic rubber, or combinations thereof. The frame  106  may be configured to be deformable, such as to allow the filter assembly  100  to compress or fit against the lower panel  122 , the track  146 , and the lower wall  544  when the drawer  44  is in the closed position, such as to limit or eliminate a flow of air between one or more respective surfaces and the frame  106  and promote airflow through the filter element. 
     Embodiments of the appliance  10  provided herein may allow for air filters generally used for residential or commercial heating, ventilation, or air conditioning (HVAC) systems to be used at the appliance  10 . The drawer  44  may be sized to correspond to one or more standard air filter sizes for HVAC systems. Various embodiments of the track  146  may be formed to accept air filters of various dimensions. For instance, the track  146  and the drawer  44  may be configured to accept a filter assembly between approximately 12 inches to approximately 15 inches along the vertical direction V, and between approximately 17 inches to approximately 24 inches in a lateral direction L. The filter assembly  100  may include any appropriate area insertable within the tracks  146  and abutting at least the lower panel  122 . 
     The track  146  may allow for overlap over a filter element of the filter assembly  100 . For instance, the track  146  may allow for an approximately 13.5 inch vertical direction filter, and walls of the track  146  may allow for filters approximately 1.5 inches greater or lesser in the vertical direction. In another instance, the track  146  may allow for an approximately 22 inch lateral direction filter, and may allow for filters approximately 3 inches greater or less in the lateral direction. In such embodiments, the appliance may be configured to desirably operate with a 13 inch by 21.5 inch filter, a 14 inch by 25 inch filter, a 16 inch by 20 inch filter, a 16 inch by 25 inch filter, or other filter size that may be standard to HVAC systems. It should be appreciated that the appliance  10  may be configured for any appropriate combination of vertical direction and lateral direction, and the appliance  10  may be configured to accept any appropriate or desired filter assembly  100 . 
       FIG.  4    provides a side view of certain components of dryer appliance  10 . Dryer appliance  10  includes drum  14  rotatably mounted within cabinet  12 . A rear wall of drum  14  may be rotatably supported within cabinet  12  by a suitable fixed bearing. A drum motor  18  rotates the drum  14  about a horizontal axis. For example, drum motor  18  may be coupled to drum  14  via a pulley and belt system or drum motor  18  may be directly coupled to drum  14  and directly drive drum  14 . Drum motor  18  may also be in mechanical communication with an air handler  24  such that drum motor  18  rotates an impeller assembly (not shown) of air handler  24 . Air handler  24  is configured for drawing air through chamber  16  of drum  14 , e.g., in order to dry articles located therein as discussed in greater detail below. In alternative exemplary embodiments, dryer appliance  10  may include an additional motor (not shown) for operating air handler  24  independently of drum  14 . 
     Drum  14  is configured to receive heated air that has been heated by a heater assembly  22 , e.g., in order to dry damp articles disposed within chamber  16  of drum  14 . During operation of dryer appliance  10 , drum motor  18  rotates drum  14  and air handler  24  such that air handler  24  draws air through chamber  16  of drum  14 . In particular, ambient air enters heater assembly  22  due to air handler  24  urging such ambient air into heater assembly  22 . Ambient air is heated within heater assembly  22  and exits heater assembly  22  as heated air. Air handler  24  draws such heated air to drum  14 . The heated air enters drum  14 , e.g., through a plurality of holes  114  defined in drum  14 . 
     Within chamber  16 , the heated air accumulates moisture and lint, e.g., from damp articles disposed within chamber  16 . In turn, air handler  24  draws lint and moisture laden air  101  from chamber  16  to a filter assembly  100  which traps lint and removes lint particles from the lint and moisture laden air. The lint may generally be captured at an upstream side of the filter assembly  100 . The upstream side of the filter assembly  100  may generally be distal to a vent opening  246  formed through the rear wall  244  of the drawer  44 . After filter assembly  100 , moisture laden air passes out of clothes dryer  10  through the vent opening  246  through the rear wall  244  of the drawer  44  and through the cabinet  12 . 
     Referring particularly to a schematic side view embodiment of a dryer appliance  10  depicted in  FIG.  7   , the appliance  10  may be configured such as described above with regard to  FIG.  4   . In the embodiment depicted in  FIG.  7   , an impeller assembly  116  is configured to pull the heated air from the chamber  16  and across the filter assembly  100 . Embodiments of the appliance  10  including the filter assembly  100  such as described further herein may allow the impeller assembly  116  to be positioned at or next to the drawer  44 . In a still particular embodiment, the appliance  10  including the filter assembly  100  such as described further herein may allow the impeller assembly  116  to be positioned downstream of the filter assembly  100 , such as proximate to the filtered air that has passed through the filter assembly  100 , or distal to the lint-laden air entering the filter assembly  100 . 
     Turning back to  FIG.  1   , dryer appliance  10  includes a cycle selector knob  56  mounted on a cabinet control panel  58 . Cycle selector knob  56  and other control inputs of cabinet control panel  58  are in communication with a controller. Signals generated in the controller operate a drum motor and heater assembly in response to a position of selector knob  56 . Alternatively, a touch screen type interface may be provided. The controller may include a memory and one or more microprocessors, CPUs or the like, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with operation of dryer appliance  10 . The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, the controller may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software. 
     The controller may be positioned in a variety of locations throughout dryer appliance  10 . For example, the controller may be located at, adjacent to, or integral to cabinet control panel  58  in cabinet  12 . In such an embodiment, input/output (“I/O”) signals may be routed between controller and various operational components of dryer appliance  10 . As an example, the various operational components of dryer appliance  10  may be in communication with controller via one or more signal lines or shared communication buses. 
     Referring back to  FIG.  3   , certain embodiments of the appliance  10  may include a position sensor  160  configured to detect whether the drawer  44  is in an open position ( FIG.  3   ) or a closed position ( FIGS.  4 - 6   ). In a particular embodiment, the position sensor  160  is positioned at the rail  45 . The position sensor  160  may include any appropriate device for determining or measuring proximity or position. The position sensor  160  may form a switch determining whether a threshold hold has been met (e.g., closed or opened). Certain embodiments of the position sensor  160  may form a magneto-resistive device, an inductive device, a capacitive displacement device, a Hall effect device, or other appropriate type of switch or sensor. The position sensor  160  may furthermore form an electronic or mechanical lock configured to secure the drawer  44  to the bottom portion  46  of the cabinet  12 . 
     Certain embodiments of the appliance  10  include the sensor  160  in operative or communicative coupling with the controller or control panel  58 . The control panel  58  may be configured to receive a signal from the sensor  160  indicative of whether the drawer  44  is in an open position or a closed position. In particular embodiments, an open drawer signal from the sensor  160  received by the control panel  58  causes the control panel  58  to generate a fault signal. The fault signal may indicate to a user that the drawer  44  is open. Additionally, or alternatively, the fault signal may inhibit further operation of the appliance  10 , such as inhibiting operation of the heater, fan, and/or drum. In still particular embodiments, a closed drawer signal from the sensor  160  received by the control panel  58  may cause the control panel  58  to allow operation of the heater, fan, and/or drum. Furthermore, the closed drawer signal from the sensor  160  may cause the sensor  160  to lock the drawer  44  to the cabinet  12 . At the end of a cycle, or upon cancelation by a user or opening of the chamber  16 , the control panel  58  may generate a signal allowing the sensor  160  to unlock the drawer  44  from the cabinet  12 . 
     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.