Patent ID: 12234595

The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.

DETAILED DESCRIPTION

The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a tub assembly for a combination washing and drying appliance that incorporates a rotating drum having a back wall that separates the processing space from a blower housing that is contained in the space between the tub and the rotating drum. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented inFIG.1. Unless stated otherwise, the term “front” shall refer to the surface of the element closer to an intended viewer, and the term “rear” shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

The terms “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

Referring toFIGS.1-13, reference numeral10generally designates a tub assembly having a tub12, a drum14, and a blower assembly16that is disposed between the drum14and the tub12. The tub assembly10is typically incorporated as part of a combination washing and drying appliance18. This appliance18includes an airflow path20that is disposed within the tub assembly10. The airflow path20is entirely disposed within the tub12for moving process air22within an interstitial space24defined between the tub12and the drum14. The airflow path20also extends through a processing space26defined within the drum14.

According to various aspects of the device, the appliance18includes the tub12that is disposed within an outer cabinet28. The drum14is rotationally operable within the tub12and operates about a rotational axis30. The airflow path20is defined within the interstitial space24that is located between the drum14and the tub12. At least a portion of this interstitial space24defines a blower enclosure32that houses the blower assembly16. A blower fan34of the blower assembly16operates to direct the process air22through the airflow path20. The blower fan34is disposed within the blower enclosure32that is defined by a back wall36, which is attached to the drum14, and a blower housing38, which is attached to the tub12. Engagement of the back wall36of the drum14with the blower housing38of the tub12defines a slidable engagement40that allows the drum14, along with the back wall36, to rotate relative to the tub12and the blower housing38. Engagement of the back wall36of the drum14with the blower housing38defines the slidable engagement40that is selectively sealed during operation of the blower fan34about the rotational axis30to prevent aspiration of ambient air42into the airflow path20. Additionally, this selectively sealed engagement can also prevent the process air22from leaving the airflow path20into areas that are outside of the airflow path20defined between the tub12and the drum14. The blower fan34typically operates about the same rotational axis30as that of the drum14. Additionally, the back wall36is fixedly attached to the drum14and the blower housing38is fixedly attached to the tub12.

Referring again toFIGS.2-13, the slidable engagement40that is formed between the drum14and the tub12can be in the form of a labyrinth seal50that is formed at an interface between the back wall36of the drum14and the blower housing38. This labyrinth seal50provides for the slidable engagement40between the back wall36of the drum14and the blower housing38of the tub12. Again, the slidable engagement40of the labyrinth seal50allows the drum14to operate within the tub12. This labyrinth seal50can include various labyrinth-type engagements that can include an annular protrusion52of the back wall36of the drum14that extends toward the blower housing38. The blower housing38can include an annular channel54that receives the annular protrusion52. Through this engagement between the annular protrusion52and the annular channel54, the labyrinth seal50allows for the rotational operation of the drum14relative to the tub12.

Additionally, during operation of the blower fan34, the blower fan34defines a high-pressure area60within the blower enclosure32. This high-pressure area60is typically disposed near the slidable engagement40between the back wall36and the blower housing38. Accordingly, this labyrinth seal50is acted upon by the increased air pressure62within the high-pressure area60. This increased air pressure62serves to increase the seal strength of the labyrinth seal50such that ambient air42is less capable or incapable of infiltrating into the airflow path20via the labyrinth seal50. Stated another way, during operation of the blower fan34, the increased air pressure62within the high-pressure area60prevents aspiration of ambient air42into the airflow path20via the interface defined by the labyrinth seal50. Also, the slidable and sealed engagement of the labyrinth seal50during operation of the blower fan34prevents expiration of the process air22from the airflow path20, through the labyrinth seal50and to areas external of the airflow path20.

Referring again toFIGS.1-11, a portion of the airflow path20extends through the interstitial space24defined between the tub12and the drum14. During operation of the blower fan34, the process air22is drawn from the processing space26of the drum14and into the blower enclosure32through an aperture70defined within the back wall36of the drum14. One or more filtration members72can be positioned proximate the aperture70of the back wall36to provide a filtering functionality as the process air22moves through the aperture70defined within the back wall36. These filtration members72can include perforated panels, mesh screens, and other similar filtration mechanism that can be used to separate particulate matter from the process air22(or other fluid) moving through the airflow path20. In particular the filtration member72filters the particulate matter as the process air22moves from the processing space26and into the blower enclosure32. In certain aspects of the device, the filtration member72can be incorporated into a contoured wall66that is positioned forward of the back wall36. This contoured wall66can include ridges80and valleys82as well as a series of perforated sections74that define the filtration member72. The contoured wall66can be attached to the back wall36and can rotate with the drum14and the back wall36. The contoured wall66, in certain aspects of the device, can also be selectively operable to rotate independently with respect to the back wall36or in unison with the back wall36.

In certain aspects of the device the back wall36of the drum14defines a portion of the processing space26. In such an aspect, the filtration member72can be attached to the back wall36. Typically, the filtration member72is attached to the back wall36as the contoured wall66described herein. As described herein, this contoured wall66can include the various ridges80and valleys82. These ridges80and valleys82are typically positioned adjacent to the back wall36for providing an agitating or tumbling effect on articles being processed in the drum14. In addition, the contoured wall66can include the filtration member72in the form of a plurality of perforated sections74that allow process air22to move therethrough, while capturing particulate material within the filtration member72. The contoured wall66and the perforated sections74of the filtration member72allow the process air22to move through the aperture70defined within the back wall36and into the blower enclosure32. In this aspect of the device, the contoured wall can define the processing space26. In each of these aspects of the device, the back wall36defines the blower enclosure32that houses the blower fan34. It is also contemplated that the back wall36, in certain aspects of the device, can include the ridges80and valleys82that define the processing space26.

Referring again toFIGS.1-7, the airflow path20continues through the blower enclosure32that is defined between the back wall36of the drum14and the blower housing38of the tub12. Typically, this blower housing38can take the form of a cochlear housing that can be used to direct the process air22from the blower fan34to downstream portions of the airflow path20. These downstream portions of the airflow path20are typically positioned within a lower section90of the tub12and beneath the drum14. The process air22then moves upward to be reintroduced into the processing space26of the rotating drum14.

According to various aspects of the device, certain heat exchange mechanisms100can be disposed within the airflow path20for heating and/or cooling the process air22as it moves through the airflow path20. In certain aspects of the device, these heat exchange mechanisms100can include heating elements, heat pump systems, air-to-air heat exchangers, condensers, combinations thereof, and other similar heat exchange mechanisms100.

Referring again toFIGS.2-11, within the airflow path20defined within a lower section90of the tub12, the heat exchange mechanism100can include a cooler such as an evaporator or an air-to-air heat exchanger that decreases the temperature of the process air22and, in turn, separates condensate110from the process air22. This condensate110can be collected within the lower section90of the tub12, such as within a sump112. This sump112can be attached to an outlet114that directs this condensate110to a drain116that is extends from the lower section90of the tub12. The drain116typically includes a pump that can direct the condensate110and/or wash fluid to be expelled from the appliance18or recirculated through a fluid delivery system. The outlet114is typically defined within an outer wall118of the tub12within the lower section90. This sump112having the outlet114collects the condensate110and directs the condensate110to the drain116for moving the captured condensate110to an external area or to a collection within the appliance18.

Referring again toFIGS.1-4, the tub assembly10can include a first motor130that rotationally operates the blower fan34and a second motor132that rotationally operates the drum14. The first and second motors130,132can be in the form of belt-drive motors, direct drive motors, combinations thereof, and other similar driving mechanisms. The first motor130is coupled to the tub12via an inner drive shaft134, typically a solid shaft that extends from the rear wall182of the tub12and to the drum14. The second motor132is coupled with the blower fan34via a hollow drive tube136that surrounds a portion of the inner drive shaft134. Various bearings138can be positioned between the inner drive shaft134and the hollow drive tube136. Additionally, certain external bearings138can be positioned between the hollow drive tube136and the tub12. Portions of the tub12can include a bearing housing that is attached or incorporated within the tub12.

Referring again toFIGS.1-13, an air handling system150for the combination washing and drying appliance18includes the tub12that is disposed within the cabinet28. The drum14includes the back wall36. The drum14is rotationally operable within the tub12about the rotational axis30. The airflow path20is entirely contained within the tub12and is defined by the interstitial space24between the drum14and the tub12, as well as the processing space26contained within the drum14. The blower fan34delivers the process air22through the airflow path20. As described herein, the blower fan34is disposed between the back wall36of the drum14and the blower housing38of the tub12. The back wall36rotates with the drum14and is slidably engaged within the blower housing38that is attached to the tub12. This slidable engagement40between the back wall36of the drum14and the blower housing38of the tub12defines a labyrinth seal50. Through this engagement, the blower fan34rotationally operates within the blower space or blower enclosure32defined between the back wall36and the blower housing38and contemporaneously allows the back wall36of the drum14to rotate relative to the blower housing38of the tub12.

As described herein, the labyrinth seal50is disposed proximate the high-pressure area60of the blower enclosure32. This high-pressure area60is generated during operation of the blower fan34. During operation of the blower fan34, the blower housing38and the back wall36are biased against one another within the labyrinth seal50. This biasing force160is a result of the increased air pressure62that is generated within the high-pressure area60of the blower housing38. This increased air pressure62increases the seal integrity of the labyrinth seal50. This increased seal integrity prevents aspiration of ambient air42into the airflow path20. In certain aspects of the device, the increased air pressure62can also prevent expiration of process air22away from the airflow path20.

According to various aspects of the device, during operation of the blower fan34, the increased air pressure62increases the seal integrity of the labyrinth seal50that is defined between the back wall36of the drum14and the blower housing38of the tub12. This labyrinth seal50includes certain sliding interface engagements such as lubricants, bearings138, and other similar materials and mechanisms that allow slidable operation of the back wall36of the drum14relative to the blower housing38of the tub12during operation of the blower.

During operation of the blower, a drying-function of the combination washing and drying appliance18is typically being performed. During this drying-function, the drying undergoes a tumble-type operation that includes a relatively slow rotation of the drum14within the tub12. Because the blower fan34is operating during the drying function, the labyrinth seal50has a greater seal integrity as a result of the increased air pressure62. Accordingly, because of the slower operation of the drum14in the tumble operation, the increased seal integrity, and potentially greater friction, does not interfere with the slower rotation of the drum14.

During washing-type functions of the combination washing and drying appliance18, a rinse and spin cycle can be utilized for extracting wash fluid from articles being processed and from the processing space26, generally. During this extraction function, the drum14will rotate at a high rate of speed relative to the blower housing38and the tub12. During this rinse and spin function, the blower fan34will typically be idle such that the air pressure62around the labyrinth seal50will not be increased and the high-pressure area60is not formed. Accordingly, the labyrinth seal50includes a typical seal integrity that allows for less friction at the labyrinth seal50. In turn, the drum14and the back wall36of the drum14are able to rotationally operate at a high rate of speed relative to the blower housing38and the tub12without generating unnecessary amounts of heat from friction or other surface-to-surface contact.

As described herein, the tub12includes a drain116having an outlet114that is defined within an outer wall118of the tub12. This outlet114is positioned within the airflow path20. Accordingly, wash fluid that may accumulate within the processing space26, the blower housing38, or other portion of the airflow path20can be conveniently directed to the lower section90of the tub12to be directed into the drain116for recycling or removal from the appliance18.

Referring again toFIGS.1-13, the labyrinth seal50defined herein can include various structures that engage with one another to form the labyrinth seal50. These structures that form the labyrinth seal50are annular in nature, such that they extend around and concentric with the rotational axis30of the blower fan34and the drum14. In this manner, the labyrinth seal50extends continuously around this rotational axis30and forms the sealing engagement within the labyrinth seal50, as described herein.

Referring again toFIGS.1-13, the combination washing and drying appliance18includes the tub12that is disposed within the outer cabinet28. The drum14includes the back wall36. The drum14and the back wall36are attached to one another and are rotationally operable within the tub12about the rotational axis30. The airflow path20for the combination washing and drying appliance18is entirely contained within the tub12and is positioned within the interstitial space24defined between the drum14and the tub12. The drain116is disposed within the lower section90of the tub12and the outlet114for the drain116is disposed within the airflow path20and is defined by an outer wall118of the tub12. The blower fan34delivers process air22through the airflow path20that is contained within the tub12. The blower fan34is disposed between the back wall36of the drum14and the blower housing38of the tub12. The back wall36rotates with the drum14and is slidably engaged with the blower housing38to define a labyrinth seal50. The blower fan34rotationally operates within the blower enclosure32defined between the back wall36of the drum14and the blower housing38of the tub12. This blower enclosure32can also be referred to as a blower space or the cochlear space170that is defined by the blower housing38. Moisture, typically in the form of condensate110, is collected within the airflow path20is directed to the outlet114of the drain116for recycling within a fluid delivery system of the appliance18or for removal or other expulsion from the appliance18.

Referring toFIGS.11-13, the blower housing38can contain the blower fan34within the cochlear space170. In such an aspect of the device, the blower housing38can include an enclosure panel180having a rear wall182and a sidewall184. The sidewall184of the enclosure panel180is configured to attach to an interface panel186. The interface panel186can include the annular channel54that forms a portion of the labyrinth seal50. In this manner, the enclosure panel180and the interface panel186form the cochlear space170within which the blower fan34operates. The back wall36of the drum14, as described herein, slidably engages the interface panel186of the blower housing38.

According to various aspects of the device, use of the labyrinth seal50defined between the back wall36of the drum14and the blower housing38of the tub12forms a sealing engagement that provides for use of the airflow path20that is entirely contained within the tub12. During certain aspects of the laundry cycle, such as a rinse cycle, spin cycle and other washing-type laundry functions (shown inFIG.7), the labyrinth seal50may allow for movement and fluid and air between the blower enclosure32and the processing space26via the sliding engagement. During drying-functions of a laundry cycle or sections of a laundry cycle where the blower fan34is in operation (shown inFIG.6), the increased air pressure62within the blower housing38creates a greater seal integrity at the labyrinth seal50and seals the airflow path20in the area of the blower enclosure32. This sealed and sliding engagement prevents movement of process air22through the labyrinth seal50and to areas outside of the airflow path20. Accordingly, process air22moving from the processing space26and to the blower enclosure32is directed through, and not around, the aperture70defined within the back wall36of the drum14and through the filtering mechanisms contained within the back wall36. Moreover, ambient air42can be prevented from infiltrating into the airflow space through this labyrinth seal50. This sealing engagement is generated while also allowing rotational operation of the drum14relative to the tub12.

Because the labyrinth seal50is a dynamic seal that changes depending upon whether the blower fan34is being operated or not, certain functions of the drying appliance18are more readily operated depending upon the status of the blower fan34. As described herein, during a rinse and spin function, and other washing-type functions, the blower fan34is idle and does not rotate. This normalizes the seal integrity at the labyrinth seal50and allows for a more convenient high-speed rotation of the drum14relative to the tub12. When the blower fan34operates, such as during a drying function, the increased air pressure62generated by operation of the blower fan34creates the high-pressure area60that increases the seal integrity of the labyrinth seal50and prevents movement of process air22or ambient air42through this labyrinth seal50. As described herein, because the drum14rotates at a slower rate of speed during the drying function, the heightened integrity of the labyrinth seal50provides for the slow rotation, or (tumble) of the drum14during performance of a drying function.

By using this configuration of the back wall36of the drum14and the blower housing38, as well as the labyrinth seal50formed therebetween, a single space can be used for the airflow path20as well as a space for collecting condensate110and wash fluid used during operation of the appliance18. Accordingly, greater efficiencies in the use of space are achieved that can provide for larger sizes of tubs12and rotating drums14, as well as more components being disposed within a similar-sized outer cabinet28.

The invention disclosed herein is further summarized in the following paragraphs and is further characterized by combinations of any and all of the various aspects described therein.

According to one aspect of the present disclosure, a combination washing and drying appliance includes a tub that is disposed within a cabinet. A drum is rotationally operable within the tub about a rotational axis. An airflow path is defined within an interstitial space between the drum and the tub. A blower fan operates to direct process air through the airflow path. The blower fan is disposed within a blower enclosure that is defined by a back wall of the drum and a blower housing that is attached to the tub. Engagement of the back wall of the drum and the blower housing of the tub defines a slidable engagement that is selectively sealed during operation of the blower fan to prevent the process air from leaving the airflow path and to further prevent aspiration of ambient air to the airflow path.

According to another aspect, the back wall rotates with the drum and the blower housing is rotationally fixed with respect to the tub.

According to another aspect, the slidable engagement is a labyrinth seal that is formed at an interface between the back wall of the drum and the blower housing.

According to another aspect, the blower fan and the drum rotationally operate about the rotational axis.

According to another aspect, a first motor rotationally operates the blower fan and a second motor rotationally operates the drum.

According to another aspect, the first motor is coupled to the blower fan via an inner drive shaft.

According to another aspect, the second motor is coupled with the drum via a hollow drive tube that surrounds a portion of the inner drive shaft.

According to another aspect, operation of the blower fan defines a high-pressure area that is disposed near the slidable engagement between the back wall and the blower housing.

According to another aspect, the high-pressure area defines the slidable engagement and a sealed engagement of the labyrinth seal that prevents aspiration of the ambient air into the airflow path.

According to another aspect, the slidable and sealed engagements of the labyrinth seal also prevents expiration of the process air away from the airflow path.

According to another aspect, the airflow path is entirely contained within the tub.

According to another aspect, the blower housing includes a cochlear space that directs the process air from the drum and through a portion of the airflow path that extends below the drum.

According to another aspect of the present disclosure, a combination washing and drying appliance includes a tub that is disposed within a cabinet. A drum has a back wall and is rotationally operable within the tub about a rotational axis. An airflow path is defined within an interstitial space between the drum and the tub. A drain is disposed within a lower section of the tub. An outlet for the drain is disposed within the airflow path. A blower fan delivers process air through the airflow path that is contained within the tub. The blower fan is disposed between the back wall of the drum and a blower housing of the tub. The back wall rotates with the drum and is slidably engaged with the blower housing to define a labyrinth seal. The blower fan rotationally operates within a blower enclosure that is defined between the back wall and the blower housing. Moisture collected in the airflow path is directed to the outlet of the drain.

According to another aspect, the labyrinth seal is disposed proximate a high-pressure area of the blower enclosure, and the high-pressure area is generated during operation of the blower fan.

According to another aspect, operation of the blower fan, the blower housing and the back wall are biased against one another within the labyrinth seal as a result of an increased air pressure within the high-pressure area.

According to another aspect, the increased air pressure increases a seal integrity of the labyrinth seal to prevent aspiration of ambient air into the airflow path.

According to another aspect, the increased air pressure further increases the seal integrity of the labyrinth seal to prevent expiration of the process air from the airflow path.

According to yet another aspect of the present disclosure, an air handling system for a laundry appliance includes a tub that is disposed within a cabinet. A drum has a back wall and is rotationally operable within the tub about a rotational axis. An airflow path is defined within an interstitial space between the drum and the tub. A blower fan delivers process air through the airflow path that is contained within the tub. The blower fan is disposed between the back wall of the drum and a blower housing of the tub. The back wall rotates with the drum and is slidably engaged with the blower housing to define a labyrinth seal. The blower fan rotationally operates within a blower enclosure that is defined between the back wall and the blower housing.

According to another aspect, the labyrinth seal is disposed proximate a high-pressure area of the blower enclosure. The high-pressure area is generated during operation of the blower fan, and, during operation of the blower fan, the blower housing and the back wall are biased against one another within the labyrinth seal as a result of an increased air pressure within the high-pressure area.

According to another aspect, the increased air pressure increases a seal integrity of the labyrinth seal to prevent aspiration of ambient air into the airflow path. The increased air pressure further increases the seal integrity of the labyrinth seal to prevent expiration of the process air from the airflow path.

It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.