Patent Publication Number: US-9404211-B2

Title: Sequenced water delivery in an additive dispenser

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. patent application Ser. No. 11/939,103, filed Nov. 13, 2007, and titled “Sequenced Water Delivery in an Additive Storage Chamber,” the disclosure of which is herein incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     Automated washing machines (such as laundry washing machines) often include mechanisms for dispensing additives into a washing chamber (e.g., a drum of a laundry washing machine). Some dispensers contain receptacles or chambers for different additives, which can include detergents, whiteners, fabric softeners, scents, rinse aids, etc. Typically, a user fills a dispenser chamber with one or more additives. During a wash cycle, water is then automatically introduced into the dispenser chamber and mixes with the additive. The water/additive mixture then flows into a separate washing chamber. Filling a first dispenser chamber with water or other liquid may, in some instances, cause unintentional water flow into a second dispenser chamber. This gives rise to the undesirable situation of a user encountering liquid in a chamber of the dispenser the next time a user uses the washing machine and needs to add more detergent or other additives. 
     BRIEF SUMMARY OF SELECTED INVENTIVE ASPECTS 
     Aspects of the invention provide a system and method for evacuating one or more additive chambers in a washing device so as avoid the above situation. A washing device such as a laundry washing machine may include multiple cycles involving multiple additives. Each additive may be stored in a separate chamber or compartment in an additive dispenser drawer. Water may be injected into each additive chamber, as needed, to mix with the additive and to cause delivery of same into a wash basin or tub. To avoid an unintentional collection of water in one chamber that may result when filling a second additive chamber, water may be injected into first additive chamber to flush out any residual water or additive residue (e.g., via a siphoning effect). The water may be flowed into the first additive chamber after the second additive chamber has dispensed its contents. For example, a detergent contained in a detergent chamber may be dispensed during a main wash cycle. Subsequently, a fabric softener additive may be dispensed from a softener dispenser during a rinse cycle. After the fabric softener additive has been dispensed, a second flow of water may be directed to the detergent chamber to flush out any water or residue therein. The second flow of water may be used to fill the detergent chamber to a level where siphoning takes hold in order to flush the chamber. 
     This summary is provided to introduce a selection of concepts of the inventive subject matter that are further described below in the detailed description. This summary is not intended to identify essential features or advantages of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Additional features and advantages of various embodiments are further described below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Aspects of the invention are illustrated by way of example and not by limitation in the accompanying figures in which like reference numerals indicate similar elements and in which: 
         FIG. 1  is a partially schematic front perspective view of a washing machine according to some embodiments. 
         FIG. 2  is a perspective view showing an additive dispenser from the washing machine of  FIG. 1 . 
         FIG. 3  is a top view of a drawer from the dispenser of  FIG. 2 . 
         FIG. 4  is a cross-sectional view taken from the location indicated in  FIG. 3 . 
         FIG. 5  illustrates a water inlet configuration according to one or more aspects described herein. 
         FIG. 6  is a flowchart illustrating a sequenced water delivery process for dispensing multiple additives and evacuating liquid collected in one chamber during a water flow into another chamber. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     Although various embodiments are described herein using a front-loading clothes washing (or laundry) machine as an example, the invention is not limited to front loading washers. In other embodiments, additive dispensers similar to those described herein are incorporated into top loading washing machines. The invention is not limited to laundry equipment. Additive dispensers similar to those described herein can also be used in automated dishwashing equipment, as well as in other devices. Indeed, dispensers such as those described herein can be used in devices that perform no washing function. 
       FIG. 1  is a partially schematic front perspective view of a clothes washing machine  1  according to at least some embodiments. The housing  2  of washing machine  1  is shown with uneven broken lines, and numerous details of washing machine  1  have been omitted so as not to obscure this description with unnecessary details. As seen in  FIG. 1 , washing machine  1  is of the front-loading type. Clothes or other items to be laundered are placed into a drum  3 . Drum  3  is then rotated during various portions of a wash cycle by a motor (not shown). In the embodiment of  FIG. 1 , hot and cold water inputs are fed to a dispenser  5 . The outfall from dispenser  5  then flows into drum  3 . Within or associated with dispenser  5 , one or more electrically-controlled valves and/or flow channels are used to direct water into drum  3 . During some parts of the cycle, water bypasses various additive chambers within dispenser  5 , and the outfall from dispenser  5  is water alone. During other parts of a wash cycle, and as described in more detail below, water flows through one or more chambers within dispenser  5  and mixes with additives in those chambers. As a result of said mixing, the outfall from dispenser  5  is a combination of water and one or more of the additives. The outfall may be facilitated by one or more hoses, valves and/or nozzles connecting dispenser  5  and drum  3 . During (or at the conclusion of) each wash cycle, water is drained from drum  3  via a drain line (not shown). 
     In use, after placing a load of laundry in the wash basin or tub of drum  3 , a user may fill dispenser  5  with a suitable type and quantity of laundry detergent, pre-wash, bleach, fabric softener and the like. The structure and operation of dispenser  5  is discussed in further detail below. A wash process may then be initiated by an operator, e.g., through interaction with a control panel (not shown). The process typically begins with a wash basin fill cycle, wherein water enters the wash basin via an inlet hose, valve and/or nozzle (not shown). In one scenario, water is initially delivered into one or more compartments of dispenser  5  (e.g., via an inlet hose) before reaching the wash basin. This allows the water to mix with the appropriate wash additive (e.g., detergent or pre-wash in the beginning stages of a wash cycle) prior to delivery into the wash basin. 
     Water or a mixture of water and one or more additive from dispenser  5  may then fill the wash basin of drum  3  to a predetermined level, which may be varied, e.g., according to a user setting and/or depending upon the size of the wash load. Once the appropriate/set level is reached, the water supply valve is closed and the washer enters a wash cycle comprising a number of sequential stages. For example, the wash cycle may include intermittent rotation of drum  5  (and a wash basin therein) in various directions (e.g., clockwise and counter-clockwise). The speed, duration and direction of rotation may be pre-defined based upon a desired wash type (e.g., delicate, normal, etc.). 
     Upon completion of the wash cycle, a static drain of the wash liquid from the wash basin is carried out via a drain pipe. Once the free wash liquid (liquid not absorbed into the wash load) pooled within the wash basin is drained, a spin cycle is initiated wherein the wash basin is rotated at a high rate of speed. This rotation of drum  3  and the wash basin forces wash liquid absorbed into the wash load out of the load, and out of the wash basin through, e.g., one or more apertures formed in the walls of the wash basin. The wash load may then be subjected to another rinse cycle, in which the water supply valve is again opened to allow fresh water to enter the wash basin. The wash basin is again rotated to generate a vigorous rinse action and the static and spin drain cycles outlined above are repeated. In one or more configurations, the rinse cycle may include the delivery of fabric softener or other post-wash additives into the wash basin. In such configurations, the fabric softener or other additives may be rinsed out of the wash load according to the rinse and spin cycles described herein. 
       FIG. 2  illustrates dispenser  5  in further detail. Dispenser  5  includes a drawer  10  and drawer compartment  12 . Drawer  10  is attached to a front panel  13  and includes a removable cover  15 . Drawer compartment  12  includes a bottom  17 , sides  18  and  19 , and a rear  20 . Side  19  is partially removed in  FIG. 2  so as to show additional internal details. Drawer  10  and cover  15  slide into a cavity  22  formed by sides  18  and  19 , bottom  17 , and rear  20 . With the exception of a drain region  23 , the inner surfaces of sides  18  and  19 , bottom  17  and rear  20  are fluid tight. When water is introduced into drawer  10  (as described below), water and/or additive flows from the rear of drawer  10 . Because bottom  17  slopes downward, water and/or additive from drawer  10  flows into drain region  23 . Drain region  23  is connected to an outfall tube  25  that carries water and/or additive to drum  3  (see  FIG. 1 ). 
     Three separate chambers are formed in drawer  10 . One of the chambers may hold and dispense powdered detergent, and the other two chambers may hold and dispense liquid additives (e.g., fabric softener and bleach). Openings corresponding to each of the three chambers in drawer  10  are formed in cover  15 . Specifically, a first opening  27  is positioned over the chamber used to hold and dispense powdered detergent. Liquid detergent may also be dispensed through the use of an insertable cup and cover assembly. A second opening  28  is positioned over the chamber used to hold and dispense fabric softener, and a third opening  29  is positioned over the chamber used to hold and dispense liquid bleach. 
     When drawer  10  and cover  15  are fully inserted into drawer compartment  12  (as shown in  FIG. 1 ), a water flow control assembly  31  selectively introduces water into one or more of openings  27 ,  28  and  29 . Water flow control assembly  31  is also configurable (e.g., during a rinse cycle) to bypass drawer  10  by directing water between the left side of drawer  10  (i.e., the side not visible in  FIG. 2  and that is opposite to right side  32 ) and the inner surface of side  18  of drawer compartment  12 . In some embodiments, water flow control assembly  31  includes a water conveying tray with groups of holes that are positioned over openings  27 ,  28  and  29  when drawer  10  and cover  15  are inserted into drawer compartment  12 , as well as a group of holes located over the region between the left side of drawer  10  and the inner surface of compartment side  18 . A plurality of channels are also formed in the water conveying tray so as to direct water over an appropriate group (or groups) of holes for dispensing a selected additive during a particular wash cycle. Solenoid valves are coupled to the hot and cold water inputs, and are selectively operated (either individually or in various combinations) so as to direct water through the appropriate channel(s). Such water flow control assemblies are known in the art. One example of a tray-type water flow control assembly having a plurality of channels and hole groupings is described in U.S. Pat. No. 6,227,012 (titled “Device for Housing Detergents and/or Other Washing Agents Which Can Be Used in a Washing Machine, Preferably in a Machine for Washing Laundry”). In other embodiments, different water control mechanisms can be used. For example, a separate tubing output could be placed in each of the locations within drawer compartment  12  that corresponds to one of openings  27 ,  28  and  29  and to the drawer bypass location, with a separate solenoid valve placed in a fluid flow path between each tubing output and the hot and/or cold water inputs.  FIG. 3  illustrates a top view of drawer  10 . 
       FIG. 4  is a cross-sectional view taken from the location shown in  FIG. 3 , and shows drawer  10  with cover  15  in place. A cap  66  is attached to the underside of cover  15  and is positioned over siphon post  43 . A cap  67  (also attached to the underside of cover  15 ) is positioned over siphon post  41 . Chambers  38  and  39  are used to hold and dispense liquid additives. In the embodiment shown, chamber  38  is used to hold and dispense relatively viscous fluid additives (e.g., fabric softener). Chamber  39  is used to hold and dispense less viscous additives (e.g., liquid bleach). In operation, a user pours liquid additives into chambers  38  and  39  through openings  28  and  29  when drawer  10  and attached cover  15  are pulled outwardly to extend from drawer compartment  12 . By way of example, broken lines  69  and  70  indicate the fill levels of fabric softener (chamber  38 ) and bleach (chamber  39 ) added by a user. Actual indicia indicating a desirable fill level may be provided, but are not required. Rather, the additive fill level(s) may be any marked or unmarked fill level below the top of the siphon post, so as to avoid commencement of siphoning action prior to the desired dispensing time. 
     After drawer  10  and attached cover  15  are pushed back into drawer compartment  12 , and during appropriate times in the wash cycle, water is introduced into chamber  38  (through opening  28 ) and into chamber  39  (through opening  29 ). By way of further example, broken line  71  indicates a level of water and fabric softener mixture after water is added to chamber  38 . Similarly, broken line  72  indicates a level of water and bleach mixture after water is added to chamber  39 . As water is added to chamber  38  and the liquid level rises above the top of siphon post  43  (and thus above the inlet  58  of bore  57 ), a siphoning effect occurs within a siphon chamber  75  formed between the inner wall of cap  66  and the outer wall of siphon post  43 . This siphon effect then draws liquid from chamber  38  and releases that liquid through outlet  59  of bore  57  into cavity  64 , with said liquid then flowing from drawer  10  into drawer compartment  12  along bottom  63 . Liquid is drawn from chamber  39  in a similar fashion through a siphon chamber  77  formed by cap  67  and siphon post  41 . 
       FIG. 5  illustrates a water inlet configuration including a water conveying tray, for directing water into an appropriate chamber of the dispenser drawer  10  ( FIG. 2 ). For example, water inlet configuration  501  may be implemented as part of water flow control assembly  31  of  FIGS. 2-4 . Tray  500  includes multiple water dispensing paths  505 ,  506  and  507  that lead to different additive chambers. In particular, water dispensing path  505  directs water into a detergent chamber such as chamber  35  of  FIG. 3 , path  506  directs water into a bleach chamber, e.g., chamber  39  of  FIG. 3 , and dispensing path  507  directs water into a fabric softener chamber such as chamber  38  of  FIG. 3 . Additionally, dispensing path  508  is used to direct water to a water bypass that allows water to flow directly into a wash tub (e.g., tub  3  of  FIG. 1 ) without mixing with an additive. Water is able to flow into each of the various chambers through groupings of holes in the water flow control assembly above each chamber (as discussed previously). 
     Water flow may be directed down an appropriate path by selectively activating one of more of inlet nozzles  580  and  581  connected to the water flow control assembly. Nozzles  580  and  581  may include conduits, such as conduits  515  and  516 , that direct the delivered water in a certain direction (e.g., directions indicated by the illustrated arrows). In order for the assembly to deliver water in direction  517  and down channel  507 , the streams from nozzles  580  and  581  may be collided to produce a single stream running in direction  517 . Such a known arrangement advantageously permits elimination of a third water control valve and nozzle. In some instances, however, unintentional flow of water may result. For example, unintended flows may result from fluctuations in water pressure flowing from one or more of the inlet nozzles. In such instances, the water flowing down one or more unintended paths will collect in one or more corresponding chambers. Since the unintentional flow of water down the one or more unintended paths is typically relatively small, the level of water collected in the corresponding chamber(s) often does not reach a siphon activation level (i.e., the siphon post head). An undesirable result is that a user will often find residual liquid present in a chamber after the wash cycle is complete and/or the next time the user loads wash additives. 
     To compensate for the unintended collection of water in a chamber, a sequential water delivery process, as illustrated by the flowchart of  FIG. 6 , may be used. In step  600 , a first additive chamber may be filled with water down a first inlet path to cause dispensation of a liquid/additive mixture from the chamber. For example, during a rinse cycle, water may be dispensed into a fabric softener chamber to dilute and add fabric softener to the wash. In step  605 , water may be dispensed into one or more other chambers (e.g., a detergent chamber or a bleach chamber) to cause dispensing therefrom. The amount of water delivered into the one or more other chambers may be defined based on an amount of water needed to initiate a siphoning effect in the one or more other chambers. In one or more configurations, a percentage of the water originally intended for a different wash cycle may be reserved for use in evacuating the one or more other chambers. For example, a wash system may reserve 10% of the amount of water originally designated for a fabric softener chamber or cycle, and use that water later for evacuating one or more other chambers with unintended collections of water or other residue. This water allocation scheme allows for the use of the features described herein while using the same overall amount of water in the wash cycle or phase. Alternatively, water used for flushing one or more chambers may be independent of the amounts of water used for other cycles or phases of the wash process. 
     In step  610 , the first chamber may be evacuated by flowing water into the first chamber to cause any water or additive residue collected therein to be flushed away. The evacuation may result from siphoning taking effect and/or other evacuation mechanisms. Liquid may collect in first chamber due to the filling and dispensing of the one or more other chambers. Once evacuated, the wash cycle may continue or resume in step  615 . 
     Further, in one or more configurations, a wash system may include one or more sensor components for detecting when water or residue is unintentionally present in one or more of the chambers at any given time, in which case, the described process for flushing such a chamber may be carried out conditionally, dependent upon a sensor output. 
     As mentioned, in addition to removing the unintended collection of water, the evacuation process discussed in  FIG. 6  also aids in drawing out additive residue that may remain in the various chambers. For example, a powder detergent in the detergent chamber might not have been fully flushed out during the main wash cycle. Accordingly, some of the powder detergent may have been left as a residue on the bottom of the detergent chamber. Flushing or evacuating the detergent chamber a second time helps to eliminate such residue and keep the detergent chamber tidy. Such flushing away of additive residue may also enhance the operation of the siphon draw assemblies, by preventing restriction or clogging thereof by additive residue. 
     The invention has been described in terms of particular exemplary embodiments. Numerous other embodiments, modifications and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure.