Patent Publication Number: US-2023143674-A1

Title: Dryer appliance with adaptive cycle parameters

Description:
FIELD OF THE INVENTION 
     The present subject matter relates generally to dryer appliances, and more particularly to dryer appliances configured for detecting user dissatisfaction with drying performance thereof and adapting cycle parameters in response to the detected dissatisfaction. 
     BACKGROUND OF THE INVENTION 
     A conventional appliance for drying articles such as a clothes dryer (or laundry dryer) for drying clothing articles typically includes a cabinet having a rotating drum for tumbling clothes and laundry articles therein. One or more heating elements, for example electric heating elements, heat air prior to the air entering the drum, and the warm air is circulated through the drum as the clothes are tumbled to remove moisture from laundry articles in the drum. 
     In some instances, a dryer appliance may over dry a load of articles therein. Over drying, such as continued heating of articles beyond the point at which the articles are dry, may result in damage, e.g., shrinkage, to some articles. Under drying may result in articles which retain a higher moisture content than desired after the dryer operation is completed. 
     Typical dryer appliances may use sensors to determine when a load of articles is done. Such sensor-based operations, however, are set up based on assumed conditions or average conditions and may not provide satisfactory drying performance across all installation conditions or all use cases. Variations in, for example, vent installation conditions or user preferences may result in instances of over drying or under drying in some dryer appliances when standardized sensor operations are performed. 
     Accordingly, a dryer appliance having features for adapting operations thereof to provide satisfactory drying performance across a wider range of conditions would be advantageous. 
     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. 
     In an exemplary aspect of the present disclosure, a method of operating a dryer appliance is provided. The dryer appliance includes a cabinet with a drum rotatably mounted within the cabinet. The drum defines a chamber for the receipt of articles for drying. The dryer appliance also includes a heating system fluidly coupled to the drum whereby heated air flows from the heating system to the chamber of the drum for drying of articles within the chamber. The method includes performing a first sensor cycle of the dryer appliance. The first sensor cycle includes rotating the drum of the dryer appliance and activating the heating system of the dryer appliance according to a first set of cycle parameters. The method also includes detecting one or more user interactions with the dryer appliance and inferring from the one or more detected user interactions that the dry performance of the first sensor cycle was unsatisfactory. The method further includes defining a second set of cycle parameters in response to the one or more detected user interactions. The method also includes performing a second sensor dry cycle of the dryer appliance according to the second set of cycle parameters after the first sensor dry cycle. 
     In another exemplary aspect of the present disclosure, a dryer appliance is provided. The dryer appliance includes a cabinet with a drum rotatably mounted within the cabinet. The drum defines a chamber for the receipt of articles for drying. The dryer appliance also includes a heating system fluidly coupled to the drum whereby heated air flows from the heating system to the chamber of the drum for drying of articles within the chamber. The dryer appliance further includes a controller. The controller is configured for performing a first sensor cycle of the dryer appliance. The first sensor cycle includes rotating the drum of the dryer appliance and activating the heating system of the dryer appliance according to a first set of cycle parameters. The controller is also configured for detecting one or more user interactions with the dryer appliance and inferring from the one or more detected user interactions that the dry performance of the first sensor cycle was unsatisfactory. The controller is further configured for defining a second set of cycle parameters in response to the one or more detected user interactions. The controller is also configured for performing a second sensor dry cycle of the dryer appliance according to the second set of cycle parameters after the first sensor dry cycle. 
     These and other features, aspects, and advantages of the present disclosure 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 disclosure and, together with the description, serve to explain the principles of the disclosure. 
    
    
     
       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    provides a perspective view of a dryer appliance in accordance with exemplary embodiments of the present disclosure. 
         FIG.  2    provides a perspective view of the example dryer appliance of  FIG.  1    with portions of a cabinet of the dryer appliance removed to reveal certain components of the dryer appliance. 
         FIG.  3    provides a flow chart of an exemplary method of operating a dryer appliance according to one or more embodiments of the present disclosure. 
     
    
    
     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. 
     As used herein, terms of approximation, such as “generally,” or “about” include values within ten percent greater or less than the stated value. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction. For example, “generally vertical” includes directions within ten degrees of vertical in any direction, e.g., clockwise or counter-clockwise. 
     Turning now to the figures,  FIG.  1    provides a perspective view of dryer appliance  10  according to one or more exemplary embodiments of the present disclosure.  FIG.  2    provides another perspective view of dryer appliance  10  with a portion of a cabinet or housing  12  of dryer appliance  10  removed in order to show certain components of dryer appliance  10 . Dryer appliance  10  generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is defined. 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. 
     Cabinet  12  includes a front panel  14 , a rear panel  16 , a pair of side panels  18  and  20  spaced apart from each other by front and rear panels  14  and  16 , a bottom panel  22 , and a top cover  24 . Within cabinet  12 , an interior volume  29  is defined. A drum or container  26  is mounted for rotation about a substantially horizontal axis within the interior volume  29 . Drum  26  defines a chamber  25  for receipt of articles of clothing for tumbling and/or drying. Drum  26  extends between a front portion  37  and a back portion  38 . Drum  26  also includes a back or rear wall  34 , e.g., at back portion  38  of drum  26 . A supply duct  41  may be mounted to rear wall  34  and receives heated air that has been heated by a heating assembly or system  40 . 
     As used herein, the terms “clothing” or “articles” includes but need not be limited to fabrics, textiles, garments, linens, papers, or other items from which the extraction of moisture is desirable. Furthermore, the term “load” or “laundry load” refers to the combination of clothing that may be washed together in a washing machine or dried together in a dryer appliance  10  (e.g., clothes dryer) and may include a mixture of different or similar articles of clothing of different or similar types and kinds of fabrics, textiles, garments and linens within a particular laundering process. 
     A motor  31  is provided in some embodiments to rotate drum  26  about the horizontal axis, e.g., via a pulley and a belt (not pictured). Drum  26  is generally cylindrical in shape, having an outer cylindrical wall  28  and a front flange or wall  30  that defines an opening  32  of drum  26 , e.g., at front portion  37  of drum  26 , for loading and unloading of articles into and out of chamber  25  of drum  26 . A plurality of lifters or baffles  27  are provided within chamber  25  of drum  26  to lift articles therein and then allow such articles to tumble back to a bottom of drum  26  as drum  26  rotates. Baffles  27  may be mounted to drum  26  such that baffles  27  rotate with drum  26  during operation of dryer appliance  10 . 
     Drum  26  includes a rear wall  34  rotatably supported within main housing  12  by a suitable fixed bearing. Rear wall  34  can be fixed or can be rotatable. Rear wall  34  may include, for instance, a plurality of holes that receive hot air that has been heated by a heating assembly or system  40 , as will be described further below. Motor  31  is also in mechanical communication with an air handler  48  such that motor  31  rotates a fan  49 , e.g., a centrifugal fan, of air handler  48 . Air handler  48  is configured for drawing air through chamber  25  of drum  26 , e.g., in order to dry articles located therein. In alternative example embodiments, dryer appliance  10  may include an additional motor (not shown) for rotating fan  49  of air handler  48  independently of drum  26 . 
     Drum  26  is configured to receive heated air that has been heated by a heating assembly  40 , e.g., via holes in the rear wall  34  as mentioned above, in order to dry damp articles disposed within chamber  25  of drum  26 . For example, heating assembly  40  may include a heating element (not shown), such as a gas burner, an electrical resistance heating element, or heat pump, for heating air. In particular embodiments, the heating assembly  40  may be or include an electric heater comprising a plurality of electric resistance heating elements with a plurality of relays for selectively providing or obstructing electrical power to the heating elements, such as two relays which permit operation of the heating assembly  40  at various power levels, such as 50% power when only one of two relays is closed. As discussed above, during operation of dryer appliance  10 , motor  31  rotates drum  26  and fan  49  of air handler  48  such that air handler  48  draws air through chamber  25  of drum  26  when motor  31  rotates fan  49 . In particular, ambient air enters heating assembly  40  via an inlet  51  due to air handler  48  urging such ambient air into inlet  51 . Such ambient air is heated within heating assembly  40  and exits heating assembly  40  as heated air. Air handler  48  draws such heated air through supply duct  41  to drum  26 . The heated air enters drum  26  through a plurality of outlets of supply duct  41  positioned at rear wall  34  of drum  26 . 
     Within chamber  25 , the heated air may accumulate moisture, e.g., from damp clothing disposed within chamber  25 . In turn, air handler  48  draws moisture-saturated air through a screen filter (not shown) which traps lint particles. Such moisture-statured air then enters an exit duct  46  and is passed through air handler  48  to an exhaust duct  52 . From exhaust duct  52 , such moisture-statured air passes out of dryer appliance  10  through a vent  53  defined by cabinet  12 . After the clothing articles have been dried, they are removed from the drum  26  via opening  32 . A door  33  ( FIG.  1   ) provides for closing or accessing drum  26  through opening  32 . The door  33  may be movable between an open position and a closed position, the open position for access to the chamber  25  defined in the drum  26 , and the closed position for sealingly enclosing the chamber  25  defined in the drum  26 . 
     In some embodiments, one or more selector inputs  70 , such as knobs, buttons, touchscreen interfaces, etc., may be provided or mounted on a cabinet  12  (e.g., on a backsplash  71  of the cabinet  12 ) and are in operable communication (e.g., electrically coupled or coupled through a wireless network band) with a processing device or controller  100 . A display  56  may also be provided on the backsplash  71  and may also be in operable communication with the controller  100 . Controller  100  may also be provided in operable communication with motor  31 , air handler  48 , and/or heating assembly  40 . In turn, signals generated in controller  100  direct operation of motor  31 , air handler  48 , and/or heating assembly  40  in response to the position of inputs  70 . In the example illustrated in  FIG.  2   , the inputs  70  are provided as knobs. In other embodiments, inputs  70  may also or instead include buttons, switches, touchpads and/or a touch screen type interface. 
     Controller  100  is a “processing device” or “controller” and may be embodied as described herein. As used herein, “processing device” or “controller” may refer to one or more microprocessors, microcontrollers, application-specific integrated circuits (ASICS), or semiconductor devices and is not restricted necessarily to a single element. The controller  100  may be programmed to operate dryer appliance  10  by executing instructions stored in memory (e.g., non-transitory media). The controller  100  may include, or be associated with, one or more memory elements such as RAM, ROM, or electrically erasable, programmable read only memory (EEPROM). For example, the instructions may be software or any set of instructions that when executed by the processing device, cause the processing device to perform operations. Controller  100  may include one or more processor(s) and associated memory device(s) configured to perform a variety of computer-implemented functions and/or instructions (e.g. performing the methods, steps, calculations and the like and storing relevant data as disclosed herein). It should be noted that controllers as disclosed herein are capable of and may be operable to perform any methods and associated method steps as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in the memory and executed by the controller. 
     In some exemplary embodiments, the dryer appliance  10  may include one or more temperature sensors, such as inlet temperature sensor  43  and/or outlet temperature sensor  47 . The temperature sensor(s) may be in operative communication with the controller  100 . For example, in various embodiments, the controller  100  may be operable to detect, measure, and/or monitor one or more temperatures within the dryer appliance  10 . Such temperatures which may be detected, measured, and/or monitored include, for example, an inlet temperature measured with the inlet temperature sensor  43  and/or an outlet temperature measured with the outlet temperature sensor  47 . The temperature sensors  43  and  47  may be, in some embodiments, thermistors. 
       FIG.  3    provides a flow chart of an exemplary method  400  of operating a dryer appliance according to one or more additional embodiments of the present disclosure. Method  400  may include performing a first sensor cycle of the dryer appliance, as indicated at  410  in  FIG.  3   . The first sensor cycle includes rotating a drum of the dryer appliance and activating a heating system of the dryer appliance according to a first set of cycle parameters. The first set of cycle parameters may be, e.g., a default set of cycle parameters programmed into the dryer appliance, such as into a memory of a controller of the dryer appliance. The default set of cycle parameters may be preprogrammed prior to installation of the dryer appliance, such as in a factory, and/or prior to any operations or cycles being performed by the dryer appliance. 
     In some embodiments, method  400  may further include a step  420  of detecting one or more user interactions with the dryer appliance. The user interactions may be detected during or shortly after the first sensor cycle. User interactions detected “shortly after” the first sensor cycle may be detected within about fifteen minutes or less after the termination of the first sensor cycle, such as within about ten minutes or less after the termination of the first sensor cycle, such as within about five minutes or less after the termination of the first sensor cycle, such as within about one minute or less after the termination of the first sensor cycle. User interactions detected “shortly after” the first sensor cycle may also include user interactions that are detected in the absence of a door opening after the termination of the first sensor cycle, or where a door opening after the termination of the first sensor cycle is detected, followed by a door closing within about two minutes or less after the door opening, such as about one minute or less after the door opening, such as within about thirty seconds after the door opening. 
     Method  400  may also, in some exemplary embodiments, include a step  430  of inferring from the one or more detected user interactions that the dry performance of the first sensor cycle was unsatisfactory. For example, based on the particular user interaction that is detected, a possible over dry or a possible under dry may be detected. Accordingly, method  400  may further include a step  440  of defining a second set of cycle parameters in response to the one or more detected user interactions. For example, if the detected user interaction indicates a possible under dry, the second set of cycle parameters may include settings to increase drying, such as increased heat level and/or increased drying time, etc., whereas if the detected user interaction indicates a possible over dry the second set of cycle parameters may include settings to decrease drying, such as decreased heat level and/or decreased drying time, etc. 
     After defining the second set of cycle parameters, method  400  may then include a step  450  of performing a second sensor dry cycle of the dryer appliance according to the second set of cycle parameters after the first sensor dry cycle. 
     In some embodiments, the one or more detected user interactions may include a timer cycle selection input after the first sensor cycle. In particular, the timer cycle selection input may indicate that the same load of articles is being dried again (thus indicating a possible under dry). For example, when the timer cycle selection input is received within a first time threshold of the termination of the first sensor cycle, this may indicate that the load of articles from the first sensor dry cycle has not been removed from the dryer appliance. The first time threshold may be about fifteen minutes or less, such as about ten minutes or less, such as about five minutes or less, such as about two minutes or less, such as about one minute. Also by way of example, when the timer cycle selection input includes a selected cycle duration of less than a second time threshold, this may indicate that only partial drying is desired, e.g., to complete drying of the load of articles from the first sensor dry cycle which are already at least partially dry from the first sensor dry cycle, as opposed to drying a different load of articles which are starting out at a moisture content that is closer to saturation than the moisture content of the load of articles from the first sensor dry cycle. The second time threshold may be about thirty minutes or less, such as about twenty minutes or less, such as about fifteen minutes or less, such as about ten minutes or less, such as about five minutes. 
     As mentioned above, the detected user interaction may be detected shortly after the termination of the first sensor dry cycle, such as when the door of the dryer appliance has not been opened after the termination of the first sensor dry cycle. For example, in some embodiments, the one or more detected user interactions may include initiating a cycle of the dryer appliance, such as a timed dry cycle, a sensor dry cycle, or other drying cycle, after the first sensor cycle without opening a door of the dryer appliance after the first sensor cycle. 
     In some embodiments, the one or more detected user interactions may include repeating the first sensor cycle after a termination of the first sensor cycle. For example, the first sensor cycle, e.g., a sensor dry cycle with the same selected cycle parameters and options, may be repeated shortly after the termination of the first sensor cycle, where “shortly after” may include within a time limit and/or based on detected door positions, as described above. 
     In some embodiments, the one or more detected user interactions may include selecting the same cycle for a similar load of articles as the first sensor cycle, and selecting a different dryness setting, e.g., a higher dryness setting or a lower dryness setting, than a dryness setting of the first sensor cycle. For example, in contrast to repeating the first sensor dry cycle with all the same selections as described above, every selection of the subsequent cycle may be the same except a dryness setting, and the different dryness setting may be higher (suggesting a possible under dry) or lower (suggesting a possible over dry) than the dryness setting of the first sensor dry cycle. As another example, a temperature setting selection may be the only changed setting, or the dryness and temperature settings may both be changed, where both are changed in the same direction, e.g., either both increased or both decreased. The similar load of articles may be detected in various ways. For example, in some embodiments, the dryer appliance may be in communication with a washing machine appliance, and, in such embodiments, the similar load of articles may be based on a load type of the load of articles detected by the washing machine appliance and transmitted to the dryer appliance from the washer appliance being the same or similar for the subsequent load of articles as for the load of articles from the first sensor dry cycle. As another example, in some embodiments, the similar load of articles may be detected based on a user habit, such as a load of darks being dried every Thursday, wherein a subsequent Thursday includes the cycle with the different, e.g., higher or lower, dryness setting and/or temperature setting. 
     In some embodiments, the one or more detected user interactions may include opening a door of the dryer appliance prior to completion of the first sensor cycle and without running another cycle of the dryer appliance within a time threshold after opening the door. Detecting a premature door opening, e.g., before the completion of the first sensor cycle, may indicate a possible over dry, but may also indicate a user is checking on the load of articles, or adding/removing one or two articles from the load, or other scenarios. When the premature door opening is coupled with an absence of restarting the first sensor cycle or initiating another cycle thereafter, the possible over dry is more likely. 
     In some embodiments, the one or more detected user interactions may include a non-heated cycle selection received immediately after a termination of the first sensor cycle. Such non-heated cycle, e.g., an air fluff cycle, may be initiated to cool down an overdried load of articles. Thus, detecting a non-heated cycle selection received immediately after a termination of the first sensor cycle (where “immediately after” refers to without any other intervening user interactions such as opening and closing a door or initiating another cycle after the termination of the first sensor cycle and before the non-heated cycle selection) may indicate a possible over dry. 
     In some embodiments, the one or more detected user interactions may include a time setting selection received during the first sensor dry cycle, such as an attempt by a user to add or remove time from the sensor dry cycle. In particular, sensor dry cycles do not refer to time setting selections, where such time setting selections are instead used for timed dry cycles, yet a user may attempt to adjust the sensor cycle by adding to or reducing the time of the cycle using the time setting selections. Such attempts may be detected user interactions and may indicate user dissatisfaction, such as a possible under dry or over dry. For example, a detected attempt to add time to the sensor cycle may indicate a possible under dry and a detected attempt to reduce the time of the sensor cycle may indicate a possible over dry. 
     As mentioned above, the dryer appliance may be connected to, e.g., in communication with, a washing machine appliance. In addition to receiving load type data, as described above, the dryer appliance may also or instead receive data about the washing machine appliance status, which may be indicative of the load of articles from the first sensor cycle remaining in the dryer appliance after the first sensor cycle is complete. For example, when the dryer appliance detects user interactions such as running multiple dry cycles and does not receive data from the connected washing machine appliance which indicates that a new load has been added to the dryer appliance, a possible under dry may be inferred from such detected user interactions. Exemplary washing machine data may include the lid of the washing machine appliance not being opened between the multiple dry cycles, no cycle being run on the connected washing machine appliance during the multiple dry cycles, etc. 
     The dryer appliance may also or instead receive selection information from the washing machine appliance, such as when a similar or same load is washed in the washing machine appliance with different wash cycle options, that indicate potential dissatisfaction with the dry performance. The similar or same load may be detected using load identifiers such as a load size or load type or another load identification. Washing machine appliance setting selections which may be received by the dryer appliance and which may indicate a potential under dry include an increased spin speed, or an additional spin cycle, e.g., the user may be attempting to extract more moisture from the articles prior to placing them in the dryer appliance, possibly as a result of an under dry in the dryer appliance. Another example washing machine appliance setting selection which may be received by the dryer appliance and which may indicate a potential under dry may include selecting a lower water volume, such as not selecting a deep fill when the deep fill was previously selected for the same or similar load, which may indicate, e.g., that the user is attempting to reduce the moisture content added to the articles during the wash cycle in order to achieve greater drying in the dryer appliance. 
     In some embodiments, a machine learning classification model may be used to detect unsatisfactory dry performance, as well as categorizing the unsatisfactory dry performance as under dry or over dry. For example, a probabilistic model, e.g., a Bayesian inference model, may be implemented to, over time, predict dissatisfaction and take the appropriate action, e.g., modify cycle parameters, such as defining a new, e.g., second, set of cycle parameters, when a certain level of probability and/or confidence is reached. 
     The second set of cycle parameters which are defined in response to the one or more detected user interactions may include cycle time, such as greater cycle time (in case of a possible under dry) or lesser cycle time (in case of a possible over dry), e.g., ten percent greater or lesser cycle time for instance of a detected possible unsatisfactory dry cycle. The second set of cycle parameters may also or instead include a changed heat level, such as higher heat in the case of a detected possible under dry or lower heat in the case of a detected possible over dry. The higher or lower heat may be provided by altering a duty cycle of the heater or heating system, such as turning the heating system on for longer or shorter times, and/or by altering a heating level, such as an electrical power level, e.g., voltage, of the heating system when activated during the second or other subsequent dry cycle. 
     In some embodiments, the second set of cycle parameters may be defined in response to multiple detected possible unsatisfactory dry cycles. For example, the detected user interactions may be weighted, such as according to how likely a particular interaction or event is an indicator of dissatisfaction and/or varying adjustment in response to some events as opposed to others, such as a larger change, e.g., increase or decrease, in the cycle time based on the weight assigned to the detected user interaction. 
     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.