Patent Publication Number: US-2019194850-A1

Title: Combination washer/dryer apparatus

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional of U.S. Non-Provisional patent application Ser. No. 15/060,897 filed Mar. 4, 2016; which claims priority of Provisional Patent Application 62/129,137 filed Mar. 6, 2015, which is hereby incorporated herein by reference. 
    
    
     BACKGROUND 
     Laundry generally has been cleaned with the application of three forms of cleaning action: chemical action, such as with detergents and other cleaning chemicals; mechanical action, such as by agitation, tumbling, rubbing the clothes by hand; and heat, typically applied by heated water. Typically drying is accomplished by circulating heated air around tumbling clothes in a drum. 
     Some global home laundry markets are “laundry pair” markets where much of the sales are of a matched washer and dryer set (the United States is such a “laundry pair” market). In Europe and in Asia, the separate sale of dryers is a fraction of the number of washers. This is because of the limited space in the home, limited drain and vent infrastructure, higher energy costs, and the inefficiency of small drum or condensing dryers which take hours to dry clothes. Combination washer/dryers are sold worldwide in small volumes because drying efficiency is poor resulting in limited capacity and long drying times. 
     Most washer machines sold are either top loader machines or front loader machines. A top loader washer machine design is shown in U.S. Pat. No. 5,829,277 of Wunderlich. The basic modern day top loading automatic washer consists of an outer drum, an inner basket with agitator, a drive motor, a suspension system, controls, a hot and a cold water fill, a drain pump and a lid. Many consumers consider the top loader to be more convenient than the front loader for loading and unloading. Typically, the outer and inner tubs (drums) are set on a vertical axis. Moreover, a type of combination top loader combination washer/dryer machine is shown in U.S. Pat. No. 5,457,969 of Roaf. 
     In a modern front load (horizontal) washer, the same sorts of elements are found as in the top load washer, but typically turned sideways on a horizontal axis. A type of front loader washer machine is shown in U.S. Pat. No. 4,819,459 of Keith. 
     Most washer/dryer combination machines sold are front loading and consist of an outer drum, an inner basket, drive motor, a suspension system, controls, a hot and cold water fill, a drain pump a heater and a blower and a door. Typically the outer and the inner tubs (drums) are set on a horizontal axis. Not necessarily, but frequently, these include a condenser to collect and expel condensate to assist in moisture removal from the clothes. A type of combined washer dryer machine is shown in U.S. Patent Application Publication Number US 2006/0086001 to Jeong et al. 
     SUMMARY OF THE INVENTION 
     In a first example form, the present invention relates to a combination washer/dryer apparatus in which the washer and the dryer occupy (and share) a single housing. This saves space, material, and cost. 
     Preferably, the combination apparatus comprises a combination clothes washer/dryer apparatus for receiving, washing, rinsing, and drying clothes or other washable items. Preferably, the apparatus includes a housing for resting atop a generally horizontal surface (like the floor), with the housing being generally box-like and having a bottom portion. A first drum is pivotally mounted within the housing, and the first drum is pivotable about a pivot axis that is oriented generally between about 10 degrees and 50 degrees up from the bottom portion of the housing. 
     Preferably, the pivot axis is generally between about 10 degrees and 40 degrees up from the bottom portion of the housing. More preferably, the pivot axis is generally between about 10 degrees and 35 degrees up from the bottom portion of the housing. Most preferably, the pivot axis is generally between about 15 degrees and 20 degrees up from the bottom portion of the housing. 
     Optionally, the apparatus is configured and constructed such that the pivot axis is held at a fixed orientation within the housing. Alternatively, the apparatus is configured and constructed such that the first drum is movably mounted within the housing in such a way that the orientation of the pivot axis relative to the housing can be changed. 
     Preferably, the housing has a movable door for permitting a user to add or remove items to be washed and/or dried, and the movable door is oriented at an angle of between about 40 degrees and 80 degrees up from the bottom portion of the housing. 
     Preferably, the first drum comprises an inner drum and an outer drum is provided for rotatably encasing the inner drum. Optionally, only a single drum can be provided. 
     Optionally, the first drum is mounted for oscillation in both the clockwise and counter-clockwise directions and/or the first drum is mounted for rotation. 
     Optionally, the combination washer/dryer utilizes a shared single drum which is tilted at an angle relative to the horizontal, preferably of between about 10 and 35 degrees and most preferably between about 15 and 20 degrees. This tilt of the drum aids in both the washing cycle and the drying cycle by providing a tumbling agitation action. It can also wash and rinse using less water and avoid having the level of water in the drum during the wash cycles overlie the bottom of the front door to the washer/dryer apparatus, thereby minimizing the likelihood of leakage through the front door. 
     Preferably, the machine is low-speed (low-RPM) and thus minimizes the centrifugal or centripetal force and is relatively vibration free. This facilitates utilization of “uni-body” construction. Elements of the machine may be incorporated into a low-cost molded component. For example, the chassis, ducting, blower mounts, etc., typically found in a washer or dryer can be a part of the molded components. This substantially reduces material, labor and assembly costs and time. This “uni-body” construction generally cannot be utilized by known front and top load machines because of the extensive use of suspension systems and counter-balancing components needed to accommodate the high spin rates required by those machines. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         FIG. 1  is a schematic sectional view of a combination washer/dryer apparatus according to an example embodiment of the present invention, and showing a door attached to an opening thereof and being in the closed position. 
         FIG. 2  is a schematic sectional view of a combination washer/dryer apparatus according to another example embodiment of the present invention. 
         FIG. 3  is a schematic sectional view of a combination washer/dryer apparatus according to another example embodiment of the present invention. 
         FIG. 4  is a perspective view of an inner drum according to another example embodiment of the present invention. 
         FIG. 5  is a schematic sectional view of a combination washer/dryer apparatus according to another example embodiment of the present invention. 
         FIG. 6  is a schematic sectional view of a combination washer/dryer apparatus according to another example embodiment of the present invention. 
         FIG. 7  is a schematic sectional view of the combination washer/dryer apparatus of  FIG. 6 , shown with the drum moved to a new orientation. 
         FIG. 8  is a perspective view of a combination washer/dryer according to another example embodiment of the present invention. 
     
    
    
     DESCRIPTION OF EXAMPLE EMBODIMENTS 
     Referring now to the drawing figures, in which like numerals refer to like elements throughout the several views,  FIGS. 1-8  show particular aspects of a combination washer/dryer according to example embodiments of the present invention. In a first example form, the present invention relates to a combination washer/dryer apparatus  10  in which the washer and the dryer occupy (and share) a single housing (typically, a metal cabinet)  12 . This saves space, material, and money. Preferably, the housing  12  is box-like, with front and rear sides, left and right sides, and a top and bottom  14 . The bottom  14  is adapted for supporting the apparatus upon a support surface, such as a floor, a cabinet, or other generally flat, horizontal surface. Typically, the sides and top and bottom are flat panels. 
     In the particular illustrative example shown in  FIG. 1 , the front and rear panels are folded into two facets. For example, the upper facet  13   a  of the rear panel is substantially vertical (perpendicular to the bottom), while the lower rear facet  13   b  is obliquely canted. Similarly, the lower facet  13   c  of the front panel is substantially vertical (perpendicular to the bottom), while the upper front facet or door  22  is obliquely canted. Other housing shapes can be employed, as desired, for example, with one or more curved surfaces or other surface features, or for example, comprise one or more legs extending therefrom for providing support to the first drum. Moreover, as is common in this field, the bottom  14  of the housing  12  can be provided with leveling feet  17  (see  FIG. 2 ). According to one example form, about two or more feet  17  can be mounted to the bottom portion  14  of the housing  12  to account for an unlevel support surface. According to one example form, about four or more feet are mounted to the bottom portion  14  of the housing  12 . As shown in  FIG. 2 , the lower rear facet  13   b  of the rear panel can be substantially vertically aligned with the upper rear facet  13   a  to form a generally flat panel. 
     Preferably, the combination apparatus comprises a combination clothes washer/dryer apparatus  10  for receiving, washing, and drying clothes or other washable items. Preferably, the housing  12  is well suited for resting atop a generally horizontal surface (like the floor). A drum  20  is pivotally mounted within the housing, and the drum is pivotable about a pivot axis  21  that is oriented at an angle α relative to the bottom portion  14 . The angle α is generally between about 10 degrees and 50 degrees as measured up from the bottom portion  14  of the housing to the pivot axis  21 . A motor  32  is mounted within the housing  12  and a belt wraps around the drum  20  and mounts to a shaft of the motor  32 . Rotation of the motor shaft causes rotation of the drum  20  about the pivot axis  21 . 
     According to example forms, the drum  20  is generally pivotally mounted to a rear plate  24 , for example, wherein a universal joint is provided such that the drum  20  is capable of rotation relative to the rear plate  24  about the pivot axis  21 . The joint generally provides for a water-tight seal such that water within the drum is incapable of leaking between the plate  24  and the drum  20 . According to some example forms, a drum support member  36  can be provided for supporting the open end of the drum. In example forms, the drum support member  36  comprises a rotatable member  37 , which provides a continuously smooth support as the drum rotates about the pivot axis  21 . 
     In example forms, the drum is generally pivotally mounted to the plate  24 , and the plate  24  is generally mounted to a support  30  which is generally fixedly mounted to portions of the housing  12 . Optionally, the plate  24  may be mounted to portions of the housing or other portions of the apparatus  10  as desired. In example forms, controls can be incorporated with the machine to provide for controlling the rotational movement of the drum, or for example, the input of water and/or air therein to take the article(s) being cleaned therein through the entirety of the cycle(s). In example forms, the drum can rotate in either direction (e.g., clockwise or counter-clockwise) at different intervals depending on the cycle (i.e. wash, rinse or dry). According to one example form, during the wash and rinse cycles, the drum will rotate about 3 times in one direction and then about 3 times in the reverse direction for a predetermined number of sequences, for example, about 8 or more, for example about 10 according to one example embodiment. According to one example form, during the drying cycle, the drum will rotate for a greater number of times before reversing, for example about 12 or more revolutions, for example about 15 revolutions according to one example form. This will continue until the clothes are dry, typically determined by a moisture sensing device common in the industry. 
     The rear plate  24  generally comprises at least one opening extending therethrough for inputting or outputting air and/or water to or from the drum  20 . For example, according to one example form, the rear plate  24  comprises a water input valve  44  (and conduit  45  extending therefrom) for providing the input of hot/cold water into the drum. An upper portion of the plate  24  comprises a heating element  40  and conduit  42  extending therebetween for providing warm/hot air within the drum  20 . In example forms, an air blower is generally configured for moving air across the heating element  40  such that the air is warmed prior to entering the drum. For example, air is move across the heating element  40  whereby warm/hot air moves through the conduit  42 , through the plate  24  and within the drum  20 . A drain  46  (and conduit  50  extending therefrom) is provided near a lower portion of the plate  24  for receiving water to be drained out of the drum. According to some example forms, a vacuum may be employed to facilitate removal of the water from the drum  20 . Generally, the drain  46  is positioned on the plate such that at least a majority of the water within the drum freely enters the drain  46 . For example, as shown in  FIG. 5 , a lower drain port  232  formed through the stationary rear plate  230  is generally positioned such that substantially all of the water W within the drum can freely drain out through the lower drain port. Optionally, other ports  234 ,  236  may be provided at the rear plate  230  for inputting/outputting water/air to or from the drum  220 . 
     An exhaust conduit  52  is provided near an open end of the drum  20 , for example, which is generally coupled to a ring member  54  of the drum  20 . According to example forms, a ring or collar  54  is generally mounted to an upper portion of the drum  20  and provides an opening extending within the drum such that the conduit  52  couples to the opening for receiving air exhausted from the drum. In some example forms, the drum  20  is capable of rotation while the collar  54  generally remains stationary. Optionally, a lint filter or other filter may be provided. 
     Preferably, the pivot axis angle α is generally between about 10 degrees and 40 degrees. More preferably, the pivot axis angle α is generally between about 10 degrees and 35 degrees. Most preferably, the pivot axis angle α is generally between about 15 degrees and 20 degrees. This tilt of the drum aids in both the washing cycle and the drying cycle by providing a tumbling agitation action. It can also reduce the water requirements in wash and rinse cycle and avoid having the level of water in the drum during the wash cycles overlie the bottom of the front door to the washer/dryer apparatus, thereby minimizing the likelihood of leakage through the front door. Moreover, the tilt or angle of the pivot axis can be chosen to be lower for greater tumbling effect or can be chosen to be higher for greater protection against water leakage. Taking such considerations to a logical extreme, if the pivot axis angle were increased all the way to 90 degrees (so that the pivot axis is vertical), maximum protection against water leakage through the door is achieved, but at the expense of eliminating tumbling action (which works with gravity). At the other extreme, if the pivot axis angle were decreased to zero (a horizontal pivot axis), tumbling action is maximized, but protection against leakage through the door is at a minimum. 
     Optionally, the apparatus  10  is configured and constructed such that the pivot axis  21  is held at a fixed orientation within the housing. Thus, in such an embodiment, the drum is stationary (other than rotation/pivoting motion). For example, as depicted in  FIGS. 1-3 and 5 , the pivot axis  21  is generally held at a fixed orientation within the housing. Alternatively, the apparatus  10  can be configured and constructed such that the drum  20  is movably mounted within the housing  12  in such a way that the orientation of the pivot axis  21  relative to the housing  12  can be changed. This can be accomplished in a number of ways. For example, an upper end of the drums can be supported by a pivot bearing and the lower end can be raised and lowered with a jack screw to vary the pivot axis angle (orientation). Also, the lower ends of the drums can be pivotally mounted and the upper ends raised and lowered to change the angle, such as with a cable, a rack and pinion gear arrangement, a jack screw, etc. As shown in  FIGS. 6-7 , a center axial drum  320  is mounted to a drum carrier  330  (e.g., with bearings, seals, etc.), which in turn is mounted to a pivot arm  332 . The pivot arm  332  pivots about a pivot  334 . The orientation of the pivot arm  332  relative to the housing can be varied, thereby varying the pivot axis orientation, for example between a first angle α 1  and a second angle α 2 . According to one example form, a retractable jack  350  is provided for supporting the end portion of the drum  320  while also causing pivotal movement of the drum  320  about pivot  334  by employing a motor and belt similar to the embodiment of  FIG. 1 . If substantial angular adjustment is to be provided, it may be necessary to include a flexible or sliding joint between the housing and the upper ends of the drums, for as the pivot axis angle is varied, the ends of the drums will go through an arcuate movement within the housing, and the flexible or sliding joint can accommodate for the such. 
     According to some example embodiments, the pivot axis of the drum is generally oriented at the first angle α 1  when the apparatus  300  is washing and rinsing the clothes, and the drum  320  is generally oriented at the second angle α 2  when the apparatus  300  is drying the clothes. According to one example form, the first angle α 1  is generally oriented between about 35 and 60 degrees when washing and/or rinsing the clothes, and the second angle α 2  is generally oriented between about 10 and 30 degrees when drying the clothes. Thus, rotation of the drum  320  at a first angle α 1  when washing prevents any water near the lid and reduces the overall water consumption, and rotation of the drum  320  at the second angle α 2  provides for maximizing the tumbling action when drying. According to some example forms, the angle α relative to the bottom portion  14  or horizontal surface is can be adjusted while the drum  320  remains in rotation. For example, when the clothes or garments therein are ready to be dried, the angle α can be varied between an angle generally less than α 1  to an angle that is generally greater or equal to α 1 . In example forms, varying the angle of the pivot axis of the drum  320  relative to horizontal while the drum is in rotation is generally preferred. Optionally, the drum may cease all rotation so that the retractable jack can be provided for changing the angle α, and then maintain an angle throughout the entirety of the wash or dry cycle. Accordingly, according to some example forms of the invention, the angle of the pivot axis of the drum relative to the bottom can be varied while there is at least some rotation of the drum. 
     Preferably, the housing has a movable door  22 ,  122 ,  222  for permitting a user to add or remove items to be washed and/or dried, and the movable door  22 ,  122 ,  222  is oriented at an angle β of between about 40 degrees and 80 degrees as measured up from the bottom portion of the housing  12  (see  FIGS. 1-3 and 5 ). According to example forms, the movable door  22 ,  122 ,  222  can generally be configured for movement in a plurality of different directions relative to the housing or drum. For example, as shown in  FIGS. 1-3 , the door  22 ,  122  is generally configured for traversing up and down between a closed position and an open position. Optionally, the door  22 ,  122  may be configured for horizontal movement in a side-to-side motion, or for example, be hinged or otherwise movably connected to the housing and/or drum. Optionally, the door is mounted to a portion of the drum. The door can be movably fixed to the drum, and may be mounted thereto such that the door generally remains stationary while the drum is capable of rotation relative to the door. In example forms, the door can be slightly lifted or slid upward, thereby providing access within the drum. This allows for a minimum intrusion into the space where the machine is located. According to some example forms, the door includes a vacuum bag that deploys into the inner drum, as will be described below. 
       FIG. 3  shows a washing/drying apparatus comprising an outer drum  120  and an inner drum  121 , for example, wherein the outer drum  120  rotatably encases the inner drum  121 . In example forms, the inner drum  121  rotatably mounts about a pivot axis  21  that is oriented at an angle α, which is generally between about 10 and 40 degrees relative to a generally horizontal axis, or for example, relative to a bottom portion  114  of the housing  112 . Generally, the outer drum  120  substantially encases the inner drum  121  but preferably allows for rotation thereof relative thereto in both the clockwise and counter-clockwise directions. As shown in  FIG. 4 , the lower portion of the inner drum can be perforated. The perforations allow air and water to flow in and out of the inner drum. The actual amount of perforations are dictated by performance results from further testing. 
     In example forms, the inner drum  121  is connected to a conduit shaft (pipe shaft) that allows warm air to enter the inner drum  121 . The shaft is connected to a drive belt, gear, pulley or other suitable drive mechanism connected to a drive motor that will turn the inner drum. The conduit shaft is ultimately in communication with a heating conduit  142 . The heating conduit preferably comprises a heating element  140  positioned therein or at least along a portion thereof such that a blower  136  provides an airflow across the heating element  140  and and supplies heated air through the conduits to within the inner drum  121 . According to some example forms, the drive motor  132  preferably provides input to the blower  136 , for example so that the drive of the motor also drives the blower. Optionally, the drive motor  132  is generally separate from the drive of the blower  136 . Preferably, according to some example embodiments, the outer drum  120  comprises a water and detergent input  160 , a drain coupling  146  (and conduit extending therefrom), and an air exhaust conduit  152 . 
     After the drum has been loaded with clothes or other objects to be washed, and an appropriate amount of water and detergent is in the drum, the drum will oscillate, for example, in a similar manner as the inner drum of current front load machines. While the drum is oscillating/rotating, air is being blown through the pipe shaft creating a jacuzzi-like turbulence, hastening the wash cycle. When the wash cycle is complete, water is drained or evacuated by activating a drain pump or vacuum pump (via the drain  146 ), simultaneously closing the blast gate (or other suitable valve) and a bag or bladder or bellow will deploy from the top of the tank or door, using fluid (air/water) or other mechanical means pressing against the clothes and squeezing the water from the clothes. The vacuum or drain pump will pull the washing wastewater into the drain  146 , and ultimately into a receiving tank until the water is further drained from the machine  100 . According to some example forms, when the liquid has exited the drum, the drain pump will be activated and the water is exited to the drain in the home. 
     Upon draining the liquid, the bag is recalled into the top/lid and the machine is ready for the rinse cycle. The drum rotates/oscillates for a shorter time together with the blower action, for example, as the same as the wash cycle, to rinse the clothes. Again, the bag deploys, pressing against the clothes, thereby allowing the water being removed therefrom. Optionally, the rinsing and water removal process may be repeated again to ensure most (if not all) of the cleaning agent is removed from the clothes. 
     When the rinse cycle(s) are completed and the bag has deployed for the last time pressing against the clothes to remove as much water as possible, the bag is recalled and the blower  136  and heating element  140  are activated, and the drum rotates/oscillates, causing the clothes to tumble within the inner drum. 
     According to one example form, the machine is low-speed (low-RPM), and thus relatively vibration free. This facilitates utilization of “uni-body” construction. Elements of the machine may be incorporated into a low-cost molded component. For example, the chassis, ducting, blower mounts, etc. typically found in a washer or dryer can be a part of the molded components. This substantially reduces material, labor and assembly costs and time. This “uni-body” construction generally cannot be utilized by the front and top load machines because of the extensive use of suspension systems and counter balancing components needed to accommodate the high spin rates required by those machines. 
     According to another example form, the present invention comprises a combination washer-and-dryer apparatus comprising a unibody housing having at least one drum for receiving, washing, and drying clothes or other washable items, wherein the at least one drum is generally rotatably mounted about an axis that is generally offset at an angle relative to a generally vertical axis, wherein the axis of the at least one rotatable drum is generally offset between about 65-80 degrees relative to the vertical axis. Optionally, a door is provided for opening and closing access to the at least one drum, and for proper retention of contents therein substantially within the at least one drum, which may be relieved by one or more conduits or pipes for the addition and/or removal of air and/or water and/or vapor to/from the drum, and which is generally provided for washing and drying patterned textiles, clothes, or other garments or at least washable items. 
       FIG. 8  shows a washer/dryer apparatus  400  according to another example embodiment of the present invention. As depicted, the washer/dryer apparatus  400  generally comprises the elements as described above, for example, a drum rotatably mounted to a rear, fixedly-mounted plate, a drive motor and belt for providing rotation to the drum relative to the plate, and a housing or frame  412 . According to some example forms, the apparatus  400  generally comprises a substantially horizontally oriented washer/dryer apparatus  400  (typically perceived as a front loading machine), and wherein a portion of the frame  412  thereof is generally pivotally mounted to a support or base member  416  that is generally provided for placement against a floor or support surface. Thus, according to example forms, the apparatus  400  is generally pivotable relative to the base member  416  such that the drum can generally be positioned at an angle α relative to a horizontal portion of the base member. For example, the angle α can preferably be oriented between about 0 degrees for orienting the drum in a generally horizontal manner to about 90 degrees for orienting the drum in a generally vertical manner. In example forms, the base member  416  generally comprises one or more stability feed for resting atop a support surface. Optionally, one or more wheels can be incorporated therein for accommodating movement of the base member  416  atop the support surface. 
     It is to be understood that this invention is not limited to the specific devices, methods, conditions, or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only. Thus, the terminology is intended to be broadly construed and is not intended to be limiting of the claimed invention. For example, as used in the specification including the appended claims, the singular forms “a,” “an,” and “one” include the plural, the term “or” means “and/or,” and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. In addition, any methods described herein are not intended to be limited to the sequence of steps described but can be carried out in other sequences, unless expressly stated otherwise herein. 
     While the invention has been shown and described in exemplary forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein without departing from the spirit and scope of the invention as defined by the following claims.