Patent Publication Number: US-2021172111-A1

Title: Clothes drying systems having control based on surrounding temperature detection

Description:
FIELD 
     The present application relates to clothes drying systems and, in particular, clothes drying systems that control operations based on surrounding temperatures. 
     BACKGROUND 
     Combination washing and drying apparatuses include both a washing cycle for washing clothes and a drying cycle for drying clothes. For the drying cycle, the washing and drying apparatuses may be either open-loop (vented) or closed-loop (condensing). In the case of an open-loop washing and drying apparatus, the wet air from a drum where the clothes are dried is directed to the environment. In the case of a closed-loop washing and drying apparatus, the wet air from the drum is directed to a condenser where moisture is removed from the wet air. The drier air is then directed from the condenser back to the drum for the drying operation. 
     Both open and closed-loop drying systems have advantages. For example, open-loop drying systems vent the wet air to the environment and replace the vented air with drier intake air. This venting of the relatively wet air can reduce drying time compared to a closed-loop drying system. Closed-loop drying systems may be used in locations where a vent is not present or would require major infrastructure changes to allow access to an outside space, such as in some apartment buildings. These closed-loop drying systems can have longer drying times than open-loop drying systems. It would be desirable to allow some controlled venting into a room to relatively quickly remove moist air from the system, which can reduce drying time compared to a closed-loop drying system. 
     SUMMARY 
     In an embodiment, a clothes drying system includes an apparatus that comprises a drying air circuit. The system includes a drum in communication with the drying air circuit. A condenser is in communication with the drying air circuit and is located downstream of the drum. The condenser includes a cooled water inlet that directs cooled water into the heated air to remove moisture from the heated air. The condenser includes a condenser water outlet for egress of water from the condenser. The cooled water inlet of the condenser is configured to receive water from a tap water source. A temperature sensor provides a signal indicative of a temperature of an environment outside the apparatus. The temperature sensor may be part of the apparatus or may be removed from the apparatus and communicate wirelessly with the apparatus. A memory and processing circuitry is coupled to the memory. The memory includes logic that, when executed by the processing circuitry, directs at least one of: (i) a vent air control valve to change an amount of heated air flowing from the drum through the vent air control valve and into the environment based on the signal from the temperature sensor, (ii) a fan to change a flow rate of air flowing through the drying air circuit based on the signal from the temperature sensor, and (iii) a heater to change an amount of heat provided to the air flowing through the drying air circuit based on the signal from the temperature sensor. 
     In another embodiment, a method of controlling a clothes drying system comprising an apparatus that comprises a drying air circuit is provided. The method includes directing air through the drying air circuit to a drum. Heated air is directed from the drum to a condenser in communication with the drying air circuit and located downstream of the drum. The condenser includes a cooled water inlet directing cooled water into the heated air thereby removing moisture from the heated air, the cooled water inlet of the condenser configured to receive water from a tap water source. A signal is provided using a temperature sensor indicative of a temperature of an environment outside the apparatus. Based on the signal from the temperature sensor, a controller directs at least one of: (i) a vent air control valve to change an amount of heated air flowing from the drum through the vent air control valve and into the environment based on the signal from the temperature sensor, (ii) a fan to change a flow rate of air flowing through the drying air circuit based on the signal from the temperature sensor, and (iii) a heater to change an amount of heat provided to the air flowing through the drying air circuit based on the signal from the temperature sensor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed the same will be better understood from the following description taken in conjunction with the accompanying drawing in which: 
         FIG. 1  is a schematic view of a washing and drying apparatus including temperature sensor, according to one or more embodiments shown and described herein; 
         FIG. 2  is a schematic view of a washing and drying system including the washing and drying apparatus of  FIG. 1 , according to one or more embodiments shown and described herein; and 
         FIG. 3  is a method of controlling the washing and drying apparatus of  FIG. 1 , according to one or more embodiments shown and described herein. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments described herein may be understood more readily by reference to the following detailed description. It is to be understood that the scope of the claims is not limited to the specific compositions, methods, conditions, devices, or parameters described herein, and that the terminology used herein is not intended to be limiting. Also, as used in the specification, including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. When a range of values is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent basis “about,” it will be understood that the particular values form another embodiment. All ranges are inclusive and combinable. 
     Embodiments described herein are generally directed to a drying apparatuses that include a drying air circuit for use during a drying cycle. The drying apparatuses may also include a wash water circuit for use in a washing cycle. The drying apparatuses include a drum that is in communication with both the drying air circuit and the wash water circuit. A condenser is in communication with the closed drying air circuit and is located downstream of the drum for receiving heated wet air (i.e., high humidity) from the drum during the drying cycle. The condenser has a water inlet that directs water into the heated air for removing moisture from the heated wet air through the process of condensation. 
     The drying apparatuses further include a temperature sensor that provides a signal that is indicative of a temperature of an environment outside the drying apparatuses. The temperature sensor may be part of the apparatus or may be removed from the apparatus and communicate wirelessly with the apparatus. The drying apparatuses include a memory and processing circuitry coupled to the memory. The memory includes logic that, when executed by the processing circuitry, directs at least one of (i) an air control valve (i.e., a vent valve) to change an amount of heated, wet air that exits the drum to travel through the air control valve and into the environment based on the signal from the temperature sensor, (ii) a fan to change a flow rate of air flowing through the drying air circuit based on the signal from the temperature sensor, and (iii) a heater to change an amount of heat provided to the air flowing through the drying air circuit based on the signal from the temperature sensor. 
     Referring to  FIG. 1 , a washing and drying apparatus  10  is illustrated diagrammatically and includes a housing  12 , a tub  14  located in the housing and a drum  16  that is located inside the tub  14 . A motor  19  is located inside the housing  12  and is used to rotate the drum  16 . The washing and drying apparatus  10  includes a closed drying air circuit, generally referenced as element  18 , and a wash water circuit, generally referenced as element  20 . While components of the closed drying air circuit  18  and the wash water circuit  20  are illustrated outside the housing  12 , this is merely for illustration as the closed drying air circuit  18  and wash water circuit  20  are located inside the housing  12 . 
     The closed drying air circuit  18  includes an air circulation duct  22  that is fluidly connected to the drum  16 . The air circulation duct  22  is fluidly connected to the drum  16  for delivering air that is heated by heater  24  to a heated temperature to the drum  16  during a drying cycle. A fan  27  may be provided to encourage air circulation through the air circulation duct  22  to and from the drum  16 . The closed drying air circuit  18  further includes a vent air control valve  28  that is located upstream from a condenser  30  and between the condenser  30  and the drum  16  and an intake air control valve  32  that is located downstream of the condenser  30  and between the condenser  30  and the fan  27 . 
     Once the heated air is cycled through the drum  16 , the heated wet air may be delivered through the circulation duct  22  to an air inlet  34  of the condenser  30 . The condenser  30  includes a condensing apparatus  36  (e.g., a tube, etc.) that is fluidly connected to the circulation duct  22  at both the air inlet  34  and an air outlet  38 . The condenser  30  is configured to remove moisture from the heated wet air and through the process of condensation before the air is reheated by heater  24  and delivered back to the drum  16  with reduced relative humidity after heating back to about the same (e.g., ±5° C.) heated temperature. 
     The vent air control valve  28  allows the heated air to be vented from the circulation duct  22  to the surrounding environment. In some embodiments, a filter  33  may be provided for filtering the air as it is being vented. The vent air control valve  28  may be controllable to allow venting of between zero percent and 100 percent. The percentage or fraction of total air flow being vented at the vent air control valve  28  may be referred to as the “vented fraction.” The vent air control valve  28  is used to change the vented fraction, as will be described in greater detail below. The intake air control valve  32  allows drier outside air to enter the circulation duct  22 . The amount of air entering the circulation duct  22  through the intake air control valve  32  may be controlled to be substantially the same amount of air exiting the circulation duct  22  through the vent air control valve  28  in order to maintain a desired pressure within the circulation duct  22 . 
     A thermoelectric apparatus  40  includes a thermoelectric device  56  that may be provided between the condenser  30  and a tap water source  42 . A “thermoelectric device” refers to a device that uses the Peltier effect to create a heat flux at the junction of two different types of materials. The thermoelectric device is a solid-state active heat pump that transfers heat from one side of the device to the other using electrical energy. The thermoelectric apparatus  40  includes a hot side flow device  44  that includes a hot side water input  46  and a hot side water output  48 . The thermoelectric apparatus  40  further includes a cold side flow device  50  that includes a cold side water input  52  and a cold side water output  54 . The hot side flow device  44  and the cold side flow device  50  each contain a duct that extends between the inputs  46 ,  52  and outputs  48 ,  54  that can be any suitable shape, such as curved, undulating, straight, etc. that allows for heating and cooling of the tap water therethrough. Located between the hot side flow device  44  and the cold side flow device  50  is the thermoelectric device  56 . The thermoelectric device  56  may be connected to the hot side flow device  44  and the cold side flow device  50  using any suitable process, such as a thermal adhesive. The thermoelectric device  56  transfers heat from tap water flow through the cold side flow device  50  to tap water flowing through the hot side flow device  44  thereby cooling the tap water from an initial tap outlet temperature to a cooled water temperature. While a thermoelectric device is described, any other suitable device (e.g., refrigerant-based, water-based, etc.) may be used to cool the incoming tap water or, in some embodiments, a device to cool the incoming tap water may not be used. 
     The cooled water is delivered along line  58  to the condenser  30 . At the condenser, the cooled water  60  is released into the condenser  30  at a rate of between about 1 g/s and about 16 g/s. In one embodiment, the cooled water  60  is released from a cooled water inlet  64  along an inner surface of a wall of the condenser  30 , which cools the wall to a temperature below that of the heated wet air  70  entering the condenser. 
     In some embodiments, the cooled water inlet  64  may include a nozzle  72  having a reduced inner diameter compared to the line  58  to generate a spray of small cooled water droplets. The droplet size may be large enough that the water droplets do not become entrained in the heated wet air  70  and to increase the heat transfer coefficient and/or the heat transfer area of the cooled water droplets. As one example, for an air flow of greater than about 4 m/s through the condensing tube  36 , a droplet size of greater than about 1076 μm from the nozzle  72  may be used. A pump upstream of the nozzle may be used to generate adequate hydraulic pressure necessary for atomization of the water. Water that is removed from the air and also provided to the condenser  30  through the line  58  is directed to a drain, represented by element  74 . A pump  76  may be provided at a condenser water outlet  78  to pump the water from the condenser  30 . 
     The washing and drying apparatus  10  may include a controller  80 . The controller  80  may include processing circuitry and a memory that includes logic in the form of machine-readable instructions that is used to control operation of the one or more valves and pumps during the washing and drying cycles. For example, during a washing cycle, the logic may cause the processing circuitry to direct cooled water from the cold side flow device  50  to the drain  74  using valve  82  (e.g., a 3-way valve) that is communicatively coupled to the controller  80 . The heated water from the hot side flow device  44  may be directed to the tub  14  using valve  84  and pump  86  that are communicatively coupled to the controller  80 . During a drying cycle, the logic may cause the processing circuitry to direct heated water from the hot side flow device  44  to the drain  74  using valve  84 . The cooled water from the cold side flow device  50  may be directed to the condenser  30  using the valve  82 . In some embodiments, the controller  80  may control the fan  27 , the vent air control valve  28  and/or the intake air control valve  32  to maintain a preselected air flow rate through the condenser  30 . 
     A temperature sensor  90  may provide a signal that is indicative of a temperature of an environment outside the washing and drying apparatus  10 . The controller  80  may include the memory that may include logic that, when executed by the processing circuitry, directs at least one of the (i) vent air control valve  28  to change an amount of heated, wet air that exits the drum  16  to travel through the vent air control valve  28  and into the environment based on the signal from the temperature sensor  90 , (ii) fan  27  to change a flow rate of air flowing through the circulation duct  22  based on the signal from the temperature sensor, and (iii) heater  24  to change an amount of heat provided to the air flowing through the circulation duct  22  based on the signal from the temperature sensor. Other sensor types may also be used in conjunction with the temperature sensor  90 , such as a humidity sensor that provides a signal indicative of a humidity level of the environment outside the washing and drying apparatus  10  and/or a proximity sensor that can provide spatial information, such as dimensions of a room in which the washing and drying apparatus  10  is located. 
     The memory may include a default temperature (e.g., between about 20° C. and 25° C.) that is used by the controller  80  to control operation of the washing and drying apparatus  10  based on a difference between the default temperature and a surrounding temperature determined based on the signal from the temperature sensor  90 . Details of the control based on temperature difference will be described in greater detail below. In some embodiments, a user input  94  may be provided that allows a user to input a user selected temperature that is different from (i.e., higher or lower) the default temperature. In this case, the controller  80  may control operation of the washing and drying apparatus  10  based on a difference between the user selected temperature and the surrounding temperature determined based on the signal from the temperature sensor  90 . 
     Referring to  FIG. 2 , an exemplary washing and drying system  100  utilizing the washing and drying apparatus  10  is illustrated schematically. It should be noted that only selected components of the washing and drying system  100  will be described below for clarity and other components, such as various pumps and control valves, may also be utilized. The washing and drying system  100  includes a communication path  102 , the controller  80  including a processor  104 , a memory module  106 , the fan  27 , the heater  24 , the vent air control valve  28 , the intake air control valve  32 , the sensor  90  (temperature, proximity and humidity) and the user input  94 . 
     The processor  104  may include any device capable of executing machine-readable instructions stored on a non-transitory computer-readable medium. The processor  104  may include one or more processors. Accordingly, each processor  104  may include a controller, an integrated circuit, a microchip, a computer, and/or any other computing device. The washing and drying system  100  may further include network interface hardware  108 . The communication path  102  can provide data interconnectivity between the various modules that may send and receive data. The communication path  102  may be wired and/or wireless. 
     The washing and drying system  100  may further include the network interface hardware  108  for communicatively coupling the washing and drying system  100  with a network  110 . The network interface hardware  108  can be communicatively coupled to the communication path  102  and can be any device capable to transmitting and receiving data via the network  113 . The network interface hardware  108  may include antenna, modem, LAN port, Wi-Fi, mobile communications hardware, etc. The network interface hardware  108  may include a Bluetooth® module for sending and receiving Bluetooth communications to and from a mobile device  114 . The network interface hardware  108  can allow to control operation of the washing and drying system  100  and to input the user selected temperature remotely, for example, using a handheld computing device  113 . 
     Referring to  FIG. 3 , a method  120  of controlling the washing and drying system  100  is illustrated. The method includes the temperature sensor  90  sending a signal to the controller  80  that is indicative of temperature of the environment around the washing and drying apparatus  10  at step  122 . At step  124 , the controller  80  checks for a user selected temperature. If a user selected temperature is present, the controller  80  determines if the surrounding temperature is greater than the user selected temperature at step  126 . If the surrounding temperature is greater than the user selected temperature, the controller  80  may reduce one or more of (i) the vented fraction using the vent air control valve  28 , which reduces the amount of wet, heated air vented into the surroundings as step  128 , (ii) the heat from the heater  24 , which reduces the air temperature in the circulation duct  22  at step  130 , and (iii) the air flow rate using the fan  27 , which also reduces the amount of wet, heated air vented at step  132 . Conversely, if the surrounding temperature is less than the user selected temperature, the controller  80  may increase one or more of (i) the vented fraction using the vent air control valve  28 , which increases the amount of wet, heated air vented into the surroundings as step  134 , (ii) the heat from the heater  24 , which increases the air temperature in the circulation duct  22  at step  136 , and (iii) the air flow rate using the fan  27 , which also increases the amount of wet, heated air vented at step  138 . Increasing one or more of the vented fraction, air temperature and air flow rate can reduce drying time of clothes in the drum, taking advantage of the reduced temperature of the surroundings. The amount of change of the vented fraction, air temperature and air flow rate can be determined by an algorithm to reduce the absolute value of the difference between the user selected temperature and the surrounding temperature. 
     Similarly, if a user selected temperature is not present and the default is used, the controller determines if the surrounding temperature is greater than the default temperature at step  140 . If the surrounding temperature is greater than the default temperature, the controller  80  may reduce one or more of (i) the vented fraction using the vent air control valve  28 , which reduces the amount of wet, heated air vented into the surroundings at step  142 , (ii) the heat from the heater  24 , which reduces the air temperature in the circulation duct  22  at step  144 , and (iii) the air flow rate using the fan  27 , which also reduces the amount of wet, heated air vented at step  146 . Conversely, if the surrounding temperature is less than the default temperature, the controller  80  may increase one or more of (i) the vented fraction using the vent air control valve  28 , which increases the amount of wet, heated air vented into the surroundings as step  148 , (ii) the heat from the heater  24 , which increases the air temperature in the circulation duct  22  at step  150 , and (iii) the air flow rate using the fan  27 , which also increases the amount of wet, heated air vented at step  152 . 
     The above-described washing and drying systems and apparatuses provide drying systems that react based on a surrounding temperature outside the apparatuses. If the surrounding temperature is above a set temperature (either default or user selected), the washing and drying apparatuses can reduce the amount of heated, wet air vented into the surrounding environment, reduce the heat provided to the air and/or reduce an air flow rate through the drying circuit. If the surrounding temperature is below the set temperature, the washing and drying apparatuses can increase the amount of heated, wet air vented into the surrounding environment, increase the heat provided to the air and/or increase an air flow rate through the drying circuit, taking advantage of the reduced environmental temperature to decrease drying time. While a temperature sensor is described above, referring again to  FIG. 2 , other inputs may be used to control the vent air control valve, the fan and the heater. For example, another temperature sensor  160  may be located at an air vent of a heating, ventilation and air conditioning (HVAC) system to provide a signal indicative of temperature at the air conditioning vent. Such an arrangement of a temperature sensor  160  at the air conditioning vent can allow the washing and drying system to predict a temperature change in the surroundings and adjust accordingly. As another example, the heating and drying system may receive remotely provided weather information from a server of a weather information source, e.g., through the network interface hardware  108 . This weather information can also be used by the washing and drying system to predict a temperature change in the surroundings and adjust accordingly. As yet another example, a proximity sensor  162  may be used to provide size information (e.g., distance to walls, floors and ceilings of a room in which the washing and drying apparatus is located. 
     An example is below: 
     Clause 1: A clothes drying system comprising an apparatus that comprises a drying air circuit, the system comprising: a drum in communication with the drying air circuit; a condenser in communication with the drying air circuit and located downstream of the drum, the condenser comprising a cooled water inlet that directs cooled water into the heated air to remove moisture from the heated air, the condenser comprising a condenser water outlet for egress of water from the condenser, the cooled water inlet of the condenser configured to receive water from a tap water source; a temperature sensor that provides a signal indicative of a temperature of an environment outside the apparatus; and a memory and processing circuitry coupled to the memory, the memory including logic that, when executed by the processing circuitry, directs at least one of (i) a vent air control valve to change an amount of heated air flowing from the drum through the vent air control valve and into the environment based on the signal from the temperature sensor; (ii) a fan to change a flow rate of air flowing through the drying air circuit based on the signal from the temperature sensor; and (iii) a heater to change an amount of heat provided to the air flowing through the drying air circuit based on the signal from the temperature sensor. 
     Clause 2: The system of clause 1, wherein the memory includes logic that, when executed by the processing circuitry, directs the vent air control valve to increase or decrease an amount of heated air flowing from the drum into the environment based on the signal from the temperature sensor. 
     Clause 3: The system of clause 2, wherein the memory includes logic that, when executed by the processing circuitry, directs the vent air control valve to reduce an amount of heated air flowing from the drum into the environment based on the signal when a detected temperature is above a default temperature and to increase an amount of heated air flowing from the drum into the environment when a detected temperature is below the default temperature. 
     Clause 4: The system of any one of clauses 1-3, wherein the memory includes logic that, when executed by the processing circuitry, directs an intake air control valve to control an amount of air flowing into the drying air circuit from the environment at a location downstream of the condenser to a flow rate that is about equal to a flow rate that the vent control valve vents into the environment. 
     Clause 5: The system of any one of clauses 1-4 further comprising a user input that allows a user to provide a user selected temperature. 
     Clause 6: The system of any one of clauses 1-5, wherein the temperature sensor is located outside of the apparatus. 
     Clause 7: The system of any one of clauses 1-6 further comprising a sensor that provides a signal indicative of a distance of the proximity sensor to one or more walls that at least partially define a boundary of the environment. 
     Clause 8: The system of any one of clauses 1-7, wherein the memory includes logic that, when executed by the processing circuitry, controls a flow rate of air through the condenser using the vent air control valve, an intake air control valve and/or the fan. 
     Clause 9: The system of any one of clauses 1-8 further comprising another temperature sensor at an air vent of an HVAC system that provides a signal indicative of a temperature at the air vent, the memory includes logic that, when executed by the processing circuitry, directs the vent air control valve to control an amount of heated air flowing from the drum into the environment based on the signal from the another temperature sensor. 
     Clause 10: The system of any one of clauses 1-9, the memory includes logic that, when executed by the processing circuitry, directs the vent air control valve to control an amount of heated air flowing from the drum into the environment based on weather information received over a wireless network. 
     Clause 11: A method of controlling a clothes drying system comprising an apparatus that comprises a drying air circuit, the method comprising: directing air through the drying air circuit to a drum; directing heated air from the drum to a condenser in communication with the drying air circuit and located downstream of the drum, the condenser comprising a cooled water inlet directing cooled water into the heated air thereby removing moisture from the heated air, the cooled water inlet of the condenser configured to receive water from a tap water source; providing a signal using a temperature sensor indicative of a temperature of an environment outside the apparatus; and based on the signal from the temperature sensor, a controller directing at least one of: (i) a vent air control valve to change an amount of heated air flowing from the drum through the vent air control valve and into the environment based on the signal from the temperature sensor; (ii) a fan to change a flow rate of air flowing through the drying air circuit based on the signal from the temperature sensor; and (iii) a heater to change an amount of heat provided to the air flowing through the drying air circuit based on the signal from the temperature sensor. 
     Clause 12: The method of clause 11 comprising directing the air control valve using the controller to increase or decrease an amount of heated air flowing from the drum into the environment based on the signal from the temperature sensor. 
     Clause 13: The method of clause 12 comprising directing the vent air control valve using the controller to reduce an amount of heated air flowing from the drum into the environment based on the signal when a detected temperature is above a default temperature and to increase an amount of heated air flowing from the drum into the environment when a detected temperature is below the default temperature. 
     Clause 14: The method of any one of clauses 11-13 further comprising changing the default temperature to a user selected temperature that is different from the default temperature. 
     Clause 15: The method of any one of clauses 11-14, wherein the method further comprises directing an intake air control valve to control an amount of air flowing into the drying air circuit from the environment at a location downstream of the condenser to a flow rate that is about equal to a flow rate that the vent air control valve vents air into the environment. 
     Clause 16: The method of any one of clauses 11-15, wherein the temperature sensor is located outside of the apparatus. 
     Clause 17: The method of any one of clauses 11-16 further comprising providing a signal indicative of a distance of a proximity sensor to a wall that at least partially defines a boundary of the environment using a sensor. 
     Clause 18: The method of any one of clauses 11-17 further comprising heating air in the drying circuit using the heater downstream of the condenser. 
     Clause 19: The method of any one of clauses 11-18 further comprising providing a signal indicative of a temperature at an air vent of a HVAC system using another temperature sensor at the air vent, and the controller directing the vent air control valve to control an amount of heated air flowing from the drum into the environment using the processing circuitry based on the signal from the another temperature sensor. 
     Clause 20: The method of any one of clauses 11-19 further comprising directing the vent air control valve to control an amount of heated air flowing from the drum into the environment using the processing circuitry based on weather information. 
     The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”