LAUNDRY APPLIANCE HAVING AN ENCLOSED SUPPLEMENTAL HEAT EXCHANGE SPACE THAT SURROUNDS A ROTATING DRUM

Abstract

A laundry appliance includes a tub that is positioned within a cabinet. A drum includes an imperforate outer wall that is rotationally positioned within the tub. A blower delivers process air through an airflow path that includes a processing space defined within the drum. A heat exchange system conditions the process air that is delivered at least into the processing space as heated process air for drying articles contained within the processing space. The imperforate outer wall of the drum and the tub define supplemental heat exchange space that delivers supplemental heat through the imperforate outer wall and into the processing space. The supplemental heat exchange space is in thermal communication with the heat exchange system.

Description

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to laundry appliances, and more specifically, laundry appliances that include a rotating drum that operates within an outer tub, and where an imperforate wall of the drum and the tub define an enclosed supplemental heat exchange space that provides supplemental heat to the processing space within the drum, without adding moisture to the processing space.

SUMMARY OF THE DISCLOSURE

According to one aspect of the present disclosure, a laundry appliance includes a tub that is positioned within a cabinet. A drum includes an imperforate outer wall that is positioned within the tub. A blower delivers process air through an airflow path that includes a processing space defined within the drum. A heat exchange system conditions the process air that is delivered at least into the processing space as heated process air for drying articles contained within the processing space. The imperforate outer wall and the tub define supplemental heat exchange space that delivers supplemental heat through the imperforate outer wall and into the processing space. The supplemental heat exchange space is in thermal communication with the heat exchange system.

According to another aspect of the present disclosure, a laundry appliance includes a tub that is positioned within a cabinet. A drum includes an imperforate outer wall that is positioned within the tub and a perforated inner wall that rotationally operates within the tub. A blower delivers process air through an airflow path that includes a processing space defined within the drum. A heat exchange system conditions the process air that is delivered into the processing space as heated process air for drying articles contained within the processing space. The imperforate outer wall and the tub define a supplemental heat exchange space that delivers supplemental heat through the imperforate outer wall and into the processing space. A portion of the heat exchange system extends into the supplemental heat exchange space for heating the supplemental heat exchange space and producing the supplemental heat that is conducted through the imperforate outer wall and into the supplemental heat exchange space.

According to yet another aspect of the present disclosure, a laundry appliance includes a tub that is positioned within a cabinet. A drum includes an imperforate outer wall that is positioned within the tub. A drum includes a perforated wall that is positioned within the imperforate outer wall. A blower delivers process air through an airflow path that includes a processing space defined within the drum. A heat exchange system conditions the process air that is delivered at least into the processing space as heated process air for drying articles contained within the processing space. The imperforate outer wall and the tub define supplemental heat exchange space that delivers supplemental heat through the imperforate outer wall and into the processing space. A supplemental airflow path extends through the supplemental heat exchange space. The airflow path and the supplemental airflow path are each in thermal communication with the heat exchange system.

These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of a laundry appliance that incorporates an aspect of the supplemental heat exchange space and shown with a door panel in an open position for accessing a processing space within the drum;

FIG. 2 is a schematic cross-sectional view of the drum positioned within a tub and showing an aspect of the supplemental heat exchange space defined therebetween;

FIG. 3 is a schematic cross-sectional view of an aspect of the supplemental heat exchange space that utilizes steam for generating heat of condensation that is directed into the processing space within the drum;

FIG. 4 is a schematic view of an aspect of the laundry appliance and showing a heat exchange system that is in thermal communication with the supplemental heat exchange space surrounding the drum;

FIG. 5 is a schematic view of a laundry appliance that incorporates a supplemental airflow path that is directed into the supplemental heat exchange space surrounding the rotating drum;

FIG. 6 is as schematic diagram of a laundry appliance that incorporates a dedicated supplemental airflow path that is in communication with the supplemental heat exchange space surrounding the drum;

FIG. 7 is a schematic diagram of a laundry appliance that incorporates a multi-stage compressor for delivering heat exchange functions to a primary heat exchanger and to the supplemental heat exchange space surrounding the drum;

FIG. 8 is a schematic diagram illustrating an aspect of the multi-stage compressor that incorporates an intercooler for maximizing the heat exchange capability of the multi-stage compressor; and

FIG. 9 is a schematic diagram illustrating an exemplary diagram showing operation of the intercooler for maximizing the heat exchange capability of the compressor.

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 laundry appliance that incorporates an imperforate wall of a drum and an outer tub that form a supplemental heat exchange space therebetween for providing supplemental heat into a processing space within the drum during a drying function of a combination washing and drying appliance. 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 in FIG. 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 now to FIGS. 1 and 2, reference numeral 10 generally refers to a laundry appliance having a processing space 12 defined within a rotating drum 14 that rotates within an outer cabinet 16. The laundry appliance 10 is typically in the form of an appliance 10 that incorporates a drying function, such as a dedicated laundry dryer. According to the various aspects of the device, the laundry appliance 10 includes a tub 18 that is positioned within the cabinet 16. An imperforate outer wall 20 is positioned within the tub 18 and can be incorporated into the drum 14 or can be a separate member that is positioned between the tub 18 and the drum 14. The drum 14 is rotationally positioned within the tub 18. A blower 22 delivers process air 24 through an airflow path 26 that includes the processing space 12 defined within the drum 14. A heat exchange system 28 operates to condition the process air 24 that is delivered at least into the processing space 12. This process air 24 is typically in the form of heated process air 30 that is used for removing moisture from articles 44, dehumidifying articles 44, or otherwise drying articles 44 being treated within the processing space 12 of the drum 14. The imperforate outer wall 20, which takes the form of the cylindrical member, includes an outer surface 32 that opposes an inner surface 34 of the tub 18. The inner surface 34 of the tub 18 and the outer surface 32 of the imperforate outer wall 20 define a supplemental heat exchange space 36. This supplemental heat exchange space 36 is separated from the processing space 12 such that moisture and liquid are not able to pass between the processing space 12 and the supplemental heat exchange space 36 through the imperforate outer wall 20. The supplemental heat exchange space 36 delivers supplemental heat 38 through the imperforate outer wall 20 and into the processing space 12. The supplemental heat exchange space 36 is in thermal communication with the heat exchange system 28. This communication with a heat exchange system 28 can either be through one or more refrigerant lines 40 (shown in FIGS. 4 and 7) or through a flow of supplemental process air 42 (shown in FIGS. 5 and 6) that is moved though the supplemental heat exchange space 36.

According to various aspects of the device, the imperforate outer wall 20 can be stationary relative to the tub 18. In such an aspect of the device, the drum 14 includes a perforated inner wall 46 that rotationally operates within the tub 18 and the imperforate outer wall 20. The perforated inner wall 46 allows process air 24 and moisture to pass therethrough during operation of the appliance 10, such as a combination washing and drying appliance.

It is also contemplated that the imperforate outer wall 20 can be incorporated as part of the drum 14. In such an aspect of the device, the drum can include both the imperforate outer wall 20 as well as the perforated inner wall 46 that rotationally operate within the tub 18 to produce the friction-induced airflow 114 within the supplemental heat exchange space 36, as is described more fully herein. This configuration of the imperforate outer wall 20 and the perforated inner wall 46 can be used within a combination washing and drying appliance. Again this type of appliance 10 requires that fluid and other moisture be directed through the perforated inner wall 46 for disposal or recirculation.

It is also contemplated, in certain appliances that can only perform a drying function, that the imperforate outer wall 46 defines the processing space 12 and the heat exchange space 36. In such an aspect of the device, the drum 14 may not include the perforated inner wall 46. Rather, the imperforate outer wall 20 defines the drum 14 that rotationally operates within the tub 18. In this configuration, rotation of the imperforate outer wall 20 rearranges the articles 44 within the processing space and also produces the friction-induced airflow 114 within the supplemental heat exchange space 36.

In certain aspects of the device, where the imperforate outer wall 20 rotates with respect to the tub 18, the outer surface 32 of the imperforate outer wall 20 can include airflow devices such as fan blades, air foils or other features that can increase the movement of air within the supplemental heat exchange space 36. These air handling features can be used to supplement or enhance the friction-induced airflow 114 generated within the supplemental heat exchange space 36. As described more fully herein, this friction-induced airflow 114 can be used to circulate air within the supplemental heat exchange space 36 as well as through a secondary airflow path 160.

Referring again to FIGS. 1 and 2, it is contemplated that moisture, such as condensate 50, can accumulate within the supplemental heat exchange space 36 during operation of the laundry appliance 10. This condensate 50 can collect within a sump 52 positioned at a lower portion 120 of the tub 18 for directing the condensate 50 toward an outlet. A sump pump 54 can operate to deliver the accumulated condensate 50 from the supplemental heat exchange space 36 and to a separate location, via the outlet. The separate location can be in the form of a drain or a recirculation path for reuse of the condensate 50 within the laundry appliance 10.

Referring now to FIGS. 1, 2 and 4, the heat exchange system 28 for the laundry appliance 10 includes a heat exchange media 60 that is delivered through a heat exchange path 62 that recirculates from a compressor 64 and through a condenser 66 that rejects heat 68 into the airflow path 26 and the process air 24 and an evaporator 70 that absorbs heat 68 from the airflow path 26 and the process air 24. An expansion valve 76, such as a capillary tube is positioned along the heat exchange path 62 between the condenser 66 and the evaporator 70.

As described herein, the condenser 66 of the heat exchange system 28 can include a supplemental section 72 that is in thermal communication with the supplemental heat exchange space 36. Additionally, the drum 14 includes a perforated rear wall 74 that allows for the movement of heated process air 30 through the airflow path 26 and into the processing space 12 of the drum 14. This process air 24 serves to dry articles 44 contained within the processing space 12. The supplemental heat 38 provided to the supplemental heat exchange space 36 is conducted through the imperforate outer wall 20 and provides additional amounts of heat 68 for increasing the temperature of the processing space 12 and the articles 44 being processed therein. This additional heat 68 aids in evaporation of moisture and increases the thermal capacity of the heat exchange system 28 for drying articles 44 within the drum 14 without increasing the amount or flow of the process 24 that is directed into the processing space 12 within the drum 14.

Referring again to FIGS. 1, 2 and 4, certain amounts of lint and other particulate 80 can be accumulated within this process air 24 as it moves through the rear wall 74 of the drum 14 and through the processing space 12 and the articles 44 being treated therein. This process air 24 then leaves the processing space 12 through a downstream portion of the airflow path 26 to be moved through a filtering assembly 82 that includes at least one particulate filter 84. After the process air 24 moves through the particulate filter 84, it is typically directed through the airflow path 26 to be recirculated through the heat exchange system 28, the processing space 12 and the filtering assembly 82.

Referring now to FIGS. 1-3 and 5, supplemental heat 38 can be provided into the processing space 12 from the supplemental heat exchange space 36 using heat 68 released from the process of condensing moisture from steam 88, which can include hot humid air, evaporated moisture, a mist as well as other varying degrees of vaporized liquid, typically water. Using a source of fluid contained within a laundry appliance 10, typically in the form of captured condensate 50 from the heat exchange system 28, steam 88 can be delivered into the supplemental heat exchange space 36 via one or more dedicated steam conduits 90. This steam 88 within the supplemental heat exchange space 36 typically has a higher temperature than the outer surface 32 of the drum 14 as well as the processing space 12 contained within the drum 14. This temperature difference between the steam 88 and the outer surface 32 of the drum 14 causes the steam 88 to decrease in temperature and condense to form condensate 50 on the outer surface 32 of the drum 14. This process of condensation releases a certain amount of heat 68. This heat 68 of condensation is then directed, via conduction, through the imperforate outer wall 20 and into the processing space 12. As described herein, the imperforate outer wall 20 of the drum 14 prevents the formed condensate 50 from passing from the supplemental heat exchange space 36 and into the processing space 12 of the drum 14. The heat 68 transferred through the imperforate outer wall 20 is provided as supplemental heat 38 to the sensible heat 68 that is transferred into the processing space 12 via the process air 24.

According to various aspects of the device, as exemplified in FIGS. 1-3, the use of the imperforate outer wall 20 of the drum 14 and the tub 18 forms a double-walled construction. In certain aspects of the device, a pressure within this supplemental heat exchange space 36 can be reduced by expressing a portion of the gas 46, typically air, from the supplemental heat exchange space 36 using a vacuum pump 48. By reducing the air pressure within the supplemental heat exchange space 36, the condensing temperature for separating condensate 50 from the steam 88 is also lowered. Accordingly, the supplemental heat 38 generated from the process of condensation of the steam 88 is able to deliver greater amounts of supplemental heat 38 into the processing space 12. The amount of gas 46 removed from the supplemental heat exchange space 36 can be changed depending on the amount of supplemental heat 38 desired to be delivered into the processing space 12. This supplemental heat 38, as described herein, can be used for heating the articles 44 within the drum 14 to increase the process of evaporation or to maintain a particular temperature difference between the articles 44 and the process air 24 moving through the processing space 12. According to various aspects of the device, as exemplified in FIGS. 1-4, the fluid used to form the steam 88 that is directed into the supplemental heat exchange space 36 can be contained within a liquid reservoir 100 that is positioned adjacent to the tub 18. This fluid can be heated to form the steam 88 that is then delivered into the supplemental heat exchange space 36. This reservoir 100 can be in the form of a separate container or can be in the form of the sump 52 that is positioned within the lower portion 120 of the tub 18. In each of these configurations, the imperforate outer wall 20 of the drum 14 and the tub 18 form the enclosed supplemental heat exchange space 36 that utilizes the heat 68 of condensation as a heat exchange media 60 for delivering supplemental heat 38 into the processing space 12 for drying articles 44 contained within the drum 14.

Referring again to FIGS. 1-4, the steam 88 that is delivered into the supplemental heat exchange space 36 is generally directed towards lower portions 120 of the imperforate outer wall 20 of the drum 14. Because this is where the articles 44 being processed are generally located, the heat 68 produced from the effect of condensation of the steam 88 can be delivered through the imperforate outer wall 20 and directly into the articles 44 being processed therein. By adding this supplemental heat 38 into the drum 14, the process of evaporation can be increased and the temperature difference needed for effectively drying articles 44 using a heat exchange system 28 is maintained at an efficient level.

In conventional heat pump dryers, at certain points within the drying process, the temperature of the processing space and the temperature of the process air moving through the processing space may be relatively similar such that there is very little temperature difference between the two. This results in a lower efficiency of the drying appliance having a heat pump system. In addition, the temperature of the process air in heat pump dryers is generally lower, thereby requiring a higher volume of air to be moved through the processing space to evaporate the moisture within the articles being processed. Also, where a large amount of articles are processed within the conventional appliance, the movement of the process air is limited. These factors combine to further limit the effectiveness of conventional heat pump dryers.

Also, in conventional combination washing and drying appliances, the size of the drum typically is based upon the amount of drying that can be efficiently performed with respect to a particular amount of articles. However, as described herein, users often overfill the drum with articles. This results in a discordance with respect to the efficient use of the processing space during each of the washing and drying cycles. In other words, in conventional combination washing and drying appliances, the washing phase can efficiently process a large amount of articles, but the same amount of articles cannot be efficiently processed during the subsequent drying cycle.

Using the delivery of steam 88 into the supplemental heat exchange space 36, supplemental heat 38 delivered from the effective condensation increases the temperature within the imperforate outer wall 20 and within the drum 14 so that a sufficient temperature difference is maintained between the temperature inside the drum 14 and the temperature of the process air 24 moving through the processing space 12. The supplemental heat 38 that is conducted through the imperforate outer wall 20 and into the processing space 12 alleviates many of the limitations of conventional heat pump appliances, regardless of the amount of articles 44 being processed.

Referring now to FIGS. 1, 2 and 4, the heat exchange system 28 for the appliance 10 includes a condenser 66 that rejects heat 68 for increasing the temperature of certain media within the laundry appliance 10. A portion of this condenser 66 can include a supplemental condenser 110 that extends toward, and typically into, the supplemental heat exchange space 36 to provide supplemental heat 38 into the supplemental heat exchange space 36 and, in turn the processing space 12.

In certain aspects of the device, the condenser 66 for the heat exchange system 28 can include a primary condenser 112 that is in communication with the airflow path 26. The supplemental condenser 110 delivers the supplemental heat 38 into the supplemental heat exchange space 36. In certain aspects of the device, the imperforate outer wall 20 can rotate within the tub 18 produces a friction-induced airflow 114 within the supplemental heat exchange space 36 that distributes and delivers the supplemental heat 38 throughout the supplemental heat exchange space 36. By delivering this supplemental heat 38 throughout the supplemental heat exchange space 36, the imperforate outer wall 20 of the drum 14 is also increased in temperature and heat 68 is conducted through this imperforate outer wall 20 and into the processing space 12.

In certain aspects of the device, as described herein, the supplemental condenser 110 can be positioned near a lower portion 120 of the tub 18. In this configuration, the supplemental heat 38 produced from the supplemental condenser 110 can be directed into the lower portion 120 of the processing space 12 where articles 44 are typically located during operation of the laundry appliance 10. In this manner, the supplemental heat 38 can be used to increase the temperature of moisture within the articles 44 to increase the rate of evaporation.

According to various aspects of the device, the supplemental condenser 110 can be located within the supplemental heat exchange space 36. In this manner, the refrigerant line 40 of the supplemental condenser 110 can be attached to the inner surface 34 of the tub 18, or can be positioned within an enlarged section 130 of the tub 18 to accommodate the space needed for the supplemental condenser 110. As described herein, the location of the condenser 66 is typically within the lower portion 120 of the tub 18 to provide heat 68 through the imperforate outer wall 20 and into areas where the articles 44 are typically located.

For directing the supplemental heat 38 into the supplemental heat exchange space 36, the refrigerant line 40 can be incorporated within the structure of the tub 18, or can be attached to the inside surface of the tub 18. In certain aspects of the device, the supplemental condenser 110 can be suspended within the supplemental heat exchange space 36 defined between the imperforate outer wall 20 and the inner surface 34 of the tub 18.

According to the various aspects of the device, the supplemental condenser 110 can be in the form of a section of the primary condenser 112 that extends into the supplemental heat exchange space 36. Through this configuration, heat exchange media 60 moving through the condenser 66 can move through the primary condenser 112 and continue through the same heat exchange path 62 proximate the supplemental heat exchange space 36 to reject further amounts of heat 68 in the form of the supplemental heat 38 that is directed into the processing space 12 of the drum 14. Typically, the supplemental condenser 110 will be a separate condenser 66 that includes a dedicated heat exchange media 60 that is moved through the refrigerant line 40 and into the supplemental heat exchange space 36.

Through this configuration of the supplemental condenser 110, the supplemental heat 38 increases the temperature of the imperforate outer wall 20. Using this configuration, as well as other configurations described herein, supplemental heat 38 delivered into the supplemental exchange space and into the processing space 12 increases the temperature of the drum 14 to increase the rate of evaporation of moisture, without the need for increasing the airflow through the processing space 12. As articles 44 move into the lower portion 120 of the drum 14 that is positioned adjacent to the supplemental condenser 110, the supplemental heat 38 is delivered through the imperforate outer wall 20 and into the articles 44 being processed. Through this configuration, increased evaporation of moisture within the articles 44 occurs to increase the efficiency of drying capability for the appliance 10.

In certain aspects of the device, where the condenser 66 for the heat exchange system 28 includes a single condenser 66 that is in thermal communication within each of the airflow path 26 and the supplemental heat exchange space 36, effluent from the heat pump condenser 66 can be delivered through narrow gauge tubes that form the refrigerant line 40, through the tub 18 and into the supplemental heat exchange space 36. In such an aspect of the device, a single compressor 64 can be used to provide refrigerant to each of the primary condenser 112 and the supplemental condenser 110. In certain aspects of the device, separate compressors 64 or two-stage compressors 64 can be utilized for delivering refrigerant to each of the primary condenser 112 and the supplemental condenser 110, as will be described more fully herein.

Referring again to FIG. 4, the supplemental condenser can be used as a desuperheater 116. In such an aspect of the device, the heat exchange media 60 is compressed and heated within the compressor 64. The heat exchange media 60 is then directed to the supplemental condenser 110, which operates as the desuperheater 116, to release a portion of the heat 68 from the charged heat exchange media 60 in the form of supplemental heat 38 that is delivered into the supplemental heat exchange space 36, as described herein. The partially spent heat exchange media 60 is then directed through the refrigerant line 40 and to the primary condenser 112 where additional heat 68 is released by the primary condenser 112 and into the process air 24 within the airflow path 26. It is contemplated that certain valves can be used within the refrigerant line to direct the heat exchange media 60 to the supplemental condenser 110 (or desuperheater 116) before being directed to the primary condenser 112. Such a valving system can be used to regulate when, and how much, supplemental heat 38 is provided to the supplemental heat exchange space 36. It should be understood that the desuperheater 116 or the dedicated expansion device configurations described herein can also be utilized within other aspects of the device, such as the aspect reflected in FIG. 7.

In certain aspects of the device, it should be understood that a dedicated expansion device can be used in combination with the supplemental condenser 110, rather than, or in addition to, the desuperheater 116 described herein. The placement of such a dedicated expansion device in relation to the supplemental condenser 110 can vary depending on the design and the thermal exchange requirements of the appliance 10.

Referring now to FIGS. 1, 2 and 5, the airflow path 26 can include a primary airflow path 140 that delivers the process air 24 through the processing space 12 within the drum 14. The airflow path 26 can also include a supplemental airflow path 142 that delivers a portion of heated process air 30 into the supplemental heat exchange space 36. In such an aspect of the device, the supplemental airflow path 142 can branch off from the primary airflow path 140 by use of a baffle 144, diverter, or other airflow-regulating mechanisms. Once diverted, a section of the heated process air 30 is delivered through the supplemental airflow path 142 and into the supplemental heat exchange space 36. As this heated air moves into and through the supplemental heat exchange space 36, the imperforate outer wall 20 can be heated, such that the supplemental heat 38 can be delivered through the imperforate outer wall 20 and into the articles 44 being processed.

According to various aspects of the device, the supplemental airflow path 142 can move only or primarily through the lower portion 120 of the supplemental heat exchange space 36 such that the supplemental heat 38 is delivered through the imperforate outer wall 20 and directly into the location of the drum 14 where the articles 44 are most likely to be located during operation of the appliance 10. The supplemental airflow path 142 uses this redirected process air 24 from the primary airflow path 140 to direct the heated process air 30 into the supplemental heat exchange space 36. This redirected process air 24, after moving through the supplemental heat exchange space 36, is delivered back into the primary airflow path 140 at a position downstream of the air filter assembly for the airflow path 26. Because the supplemental airflow path 142 is branched off from the primary airflow path 140, the blower 22 operates to move the process air 24 and the supplemental process air 42. Additionally, because the supplemental process air 42 is moved around the imperforate outer wall 20 and within the supplemental heat exchange space 36, this air does not typically collect particulate 80 from the clothing, but is maintained as a separate airflow around the imperforate outer wall 20. Accordingly, no filtration of this air is needed and the supplemental airflow path 142 can bypass the filter assembly of the appliance 10.

As described herein, during operation of the appliance 10, rotation of the imperforate outer wall 20 within the tub 18 produces friction-induced airflow 114 that circulates or recirculates secondary process air 162 within the supplemental heat exchange space 36. It is also contemplated that in order to focus the heat 68 to the lower portions 120 of the processing space 12, the imperforate outer wall 20, and/or the drum 14, may move slowly or may be stationary during operation of the supplemental airflow path 142 through the supplemental heat exchange space 36.

Referring now to FIGS. 1, 2 and 6, it is contemplated that the appliance 10 can include a secondary airflow path 160 that recirculates the secondary process air 162 between the heat exchange system 28 and the supplemental heat exchange space 36. In such an aspect of the device, the secondary airflow path 160 is typically separated from the airflow path 26 such that little to no interchange between these two heat exchange media 60 occurs. As described herein, the blower 22 is used for recirculating process air 24 through the airflow path 26. It is contemplated that rotation of the imperforate outer wall 20 within the tub 18 produces the friction-induced airflow 114 within the supplemental heat exchange space 36. This friction-induced airflow 114 can be used to move the secondary process air 162 and recirculate the secondary process air 162 through the secondary airflow path 160.

As described herein, this secondary process air 162 is moved between the heat exchange system 28 and the supplemental heat exchange space 36 surrounding the imperforate outer wall 20. It is contemplated that certain baffles 144 or louvers 170 can be utilized for activating and deactivating the secondary airflow path 160 during operation of the appliance 10. Where supplemental heat 38 is needed, these louvers 170 can open as the imperforate outer wall 20 rotates about a rotational axis to produce the friction-induced airflow 114. Where the supplemental heat 38 is not needed during operation of the appliance 10, these louvers 170 can close such that the friction-induced airflow 114 is contained entirely or substantially within the heat exchange space 36. As described herein, because the supplemental airflow path 142 does not move through the processing space 12, there is little chance for the secondary process air 162 to pick up lint and other particulate 80. Accordingly, while a filtration mechanism may be included within the secondary airflow path 160, any collected particulate 80 may be cleaned during a routine maintenance checkup of the appliance 10 by a technician.

Referring now to FIGS. 1, 2 and 7-9, the compressor 64 of the heat exchange system 28 for the appliance 10 can include a compressor 64 that includes one of multiple stages or multiple pistons that operate to deliver refrigerant to the primary condenser 112 in thermal communication with the airflow path 26 as well as the supplemental condenser 110 that is in thermal communication with the supplemental heat exchange space 36. In the case of a multi-stage compressor 180, such a compressor 64 is typically used within an intercooler 182 to provide greater efficiency than a single stage compressor 64, as seen in conventional heat pump systems. The use of a multi-stage compressor 180 with an intercooler 182 typically provides volumetric efficiency and reduced the amount of work needed to be performed by the compressor 64 to achieve a certain thermal capacity for operating the condenser 66 and the evaporator 70. This is because more heat exchange media 60 can be compressed in the smaller piston volumes between each of the compression stages of the compressor 64. Because the work being done by the multi-stage compressor 180 is an integral of the product of pressure and volume that is swept by the piston, less work is performed.

As exemplified in FIGS. 8 and 9, the shaded portion of the schematic of FIG. 9 shows the amount of work saved using the multi-stage compressor 180 in conjunction with the intercooler 182. The multi-stage compressor 180 typically keeps the temperature lower in the high-temperature reservoir 100 of the refrigerant circuit. This results in better Carnot efficiency of a heat pump. At the same, this configuration of a multi-stage compressor 180 delivers more compressed heat exchange media 60 that has more thermal capacity in the compressed gas provided by the multi-stage compressor 180. This compressed energy, in the form of charged heat exchange media 60 is then used in the expansion process. More heat 68 can be pumped from the same low-reservoir temperature to provide better efficiency in the heat pumping system. Typically, the multi-stage compressor 180 includes a first stage of compression 190 and a second stage of compression 192, where the intercooler 182 extracts at least a portion of the thermal energy between operation of the first and second stages of compression 190, 192 of the multi-stage compressor 180.

In certain aspects of the device, a single double-acting piston can also be used. Using a single double-acting piston, the compressor 64 can include one cylinder, one piston, one piston seal, and one crank, which is typically offset, that performs two compression stages within the cylinder. The valves, such as first and second valves, can be positioned at both ends of the cylinder, with one end needing an oscillation seal on the piston rod that must pass through that end.

It is also contemplated that a compressor 64 having a wobble plate that operates multiple piston pumps can be used in conjunction with the heat exchange system 28 for the appliance 10. The wobble plate within the compressor 64 can be used to operate a number of pistons as these pistons translate across the wobble plate. These multiple pistons can be used with multiple intercoolers 182 to maintain the efficiency of the heat exchange system 28 for the appliance 10. Varying the angle of the wobble plate within the compressor 64 can also serve to vary the load without the added cost of a variable speed motor. A simple near actuator can be used to vary the offset of the wobble plate to increase or decrease the load of the various pistons that are acted upon by the wobble plate.

According to various aspects of the device, a variable-speed compressor 64 can also be used where additional thermal capacity is required for operating the primary condenser 112 and the supplemental condenser 110 that is contained within the supplemental heat exchange space 36.

Referring now to FIGS. 1-9, the laundry appliance 10 includes the tub 18 that is positioned from the cabinet 16. The drum 14 includes an imperforate outer wall 20 that is rotationally positioned in the tub 18. The drum 14, in certain aspects of the device, can also include a perforated inner wall 46. The blower 22 delivers the process air 24 through the airflow path 26 that includes the processing space 12 defined within the drum 14. The heat exchange system 28 conditions that process air 24 that is delivered into the processing space 12 as heated process air 30 for drying the articles 44 contained within the processing space 12. The imperforate outer wall 20 of the drum 14 and the tub 18 define a supplemental heat exchange space 36 that delivers supplemental heat 38 through the imperforate outer wall 20. This supplemental heat 38 is delivered through the imperforate outer wall 20 and into the processing space 12. A portion of the heat exchange system 28 for the appliance 10 can be positioned to extend into the supplemental heat exchange space 36 which is in thermal communication with the heat exchange system 28. It is contemplated that the supplemental heat exchange space 36 is enclosed such that pressure variations can be achieved within this supplemental heat exchange space 36 for altering the evaporating and condensing points of moisture within this supplemental heat exchange space 36.

Referring again to FIGS. 1-9, the heat exchange system 28 conditions the process air 24 that is delivered at least into the processing space 12 as heated process air 30 for drying articles 44 contained within the processing space 12. The imperforate outer wall 20 and the tub 18 define the supplemental heat exchange space 36. The supplemental airflow path 142 extends through the supplemental heat exchange space 36. The airflow path 26 and the supplemental airflow path 142 are each in thermal communication with the thermal heat exchange system 28. Using the supplemental airflow path 142, supplemental heat 38 is delivered into the supplemental heat exchange space 36, through the imperforate outer wall 20, and into the processing space 12, as described herein.

According to the various aspects of the device, use of the supplemental heat exchange space 36 serves to increase the temperature of the imperforate outer wall 20. This, in turn, provides supplemental heat 38 into the articles 44 being processed. This increase in the temperature within the processing space 12 causes a temperature differential between the articles 44 being processed and the temperature of the process air 24 being moved into the processing space 12. This temperature differential serves to increase the efficiency of the heat exchange system 28 for drying the articles 44 being processed. The increased supplemental heat 38 also increases the effective evaporation of moisture contained within the processing space 12. Using these systems, various dryer settings can be implemented without increasing the volume of air being moved through the processing space 12 of the laundry appliance 10 and without significantly modifying the output of the heat exchange system 28 of the appliance 10. Using the various systems described herein, use of the laundry appliance 10 can be made more efficient, such that the time necessary for drying articles 44 contained within the drum 14 can be diminished.

Use of the supplemental heat exchange space 36 for delivering supplemental heat 38 into the processing space 12 also increases the efficiency of combination washing and drying appliances 10. It is common that users of these appliances place a large amount of articles 44 within the processing space 12 to be processed in a washing stage of a laundry cycle. This large amount of articles 44 can result in an overfilled condition with respect to the articles during the subsequent drying phase of the laundry cycle. As described herein, this overfilled condition can result in a diminished ability of the process air 24 to move through the articles 44 in the processing space 12. This, in turn, results in a diminished drying performance with respect to the movement of process air 24. The addition of the supplemental heat 38 through the supplemental heat exchange space 36 provides increased heat 68 that promoted evaporation of moisture within the processing space without increasing the speed or volume of air that is delivered to the processing space 12. In addition, the various aspects of the device disclosed herein provide for greater efficiency in both the washing and drying cycles of combination washing and drying appliances.

Additionally, use of the supplemental heat exchange space 36 and the provision of supplemental heat 38 into the processing space 12 increases the efficiency of the drying phase of a laundry cycle. Accordingly, the aspects of the device described herein provide for an efficient washing phase and drying phase in the combination washing and drying appliance 10 within the single drum 14 and without increasing the speed or volume of process air 24 that is delivered into the processing space 12. Accordingly, an increased amount of articles 44 within the processing space 12 can be efficiently processed through the washing and drying phases of the laundry cycle.

According to another aspect of the present disclosure, a laundry appliance includes a tub that is positioned within a cabinet. A drum includes an imperforate outer wall that is positioned within the tub. A blower delivers process air through an airflow path that includes a processing space defined within the drum. A heat exchange system conditions the process air that is delivered at least into the processing space as heated process air for drying articles contained within the processing space. The imperforate outer wall and the tub define supplemental heat exchange space that delivers supplemental heat through the imperforate outer wall and into the processing space. The supplemental heat exchange space is in thermal communication with the heat exchange system.

According to another aspect, the heat exchange system includes heat exchange media that is delivered through a heat exchange path that recirculates from a compressor and through a condenser that rejects heat and an evaporator that absorbs heat.

According to yet another aspect, the drum includes the imperforate outer wall and a perforated inner wall that rotationally operates within the tub.

According to another aspect of the present disclosure, steam from the heat exchange system is delivered into the supplemental heat exchange space to form condensate at least on an outer surface of the imperforate outer wall. Condensation of the steam directs heat of condensation from the supplemental heat exchange space, through the imperforate outer wall and into the processing space.

According to another aspect, the tub includes a drain that collects the condensate from the steam. A sump pump delivers the condensate to a separate location outside of the tub.

According to yet another aspect, the heat exchange system includes a condenser having a primary condenser that is in communication with the airflow path, and a supplemental condenser that delivers the supplemental heat into the supplemental heat exchange space. Rotation of the drum produces a friction induced airflow within the supplemental heat exchange space that delivers the supplemental heat throughout the supplemental heat exchange space.

According to another aspect of the present disclosure, the supplemental condenser is located within the supplemental heat exchange space.

According to another aspect, the airflow path includes a primary airflow path that delivers the process air through the processing space. The airflow path includes a supplemental airflow path that delivers a portion of the heated process air into the supplemental heat exchange space.

According to yet another aspect, the supplemental airflow path includes a baffle that directs a portion of the heated process air, as redirected process air into the supplemental airflow path. The redirected process air is delivered back into the airflow path down stream of an air filter assembly of the airflow path.

According to another aspect of the present disclosure, a secondary airflow path that recirculates secondary process air between the heat exchange system and the supplemental heat exchange space, wherein the secondary airflow path is separated from the airflow path.

According to another aspect, rotation of the drum within the tub produces friction-induced airflow that recirculates the secondary process air between the heat exchange system and the supplemental heat exchange space.

According to yet another aspect, the compressor includes a multi-stage compressor having a first stage of compression and a second stage of compression. An intercooler is disposed between the first and second stages of compression.

According to another aspect of the present disclosure, the multi-stage compressor includes a single piston that operates within a single cylinder and first and second valves positioned at opposing ends of the cylinder and an oscillation seal disposed between the first and second valves.

According to another aspect, a laundry appliance includes a tub that is positioned within a cabinet. A drum includes an imperforate outer wall that is positioned within the tub and a perforated inner wall that rotationally operates within the tub. A blower delivers process air through an airflow path that includes a processing space defined within the drum. A heat exchange system conditions the process air that is delivered into the processing space as heated process air for drying articles contained within the processing space. The imperforate outer wall and the tub define a supplemental heat exchange space that delivers supplemental heat through the imperforate outer wall and into the processing space. A portion of the heat exchange system extends into the supplemental heat exchange space for heating the supplemental heat exchange space and producing the supplemental heat that is conducted through the imperforate outer wall and into the supplemental heat exchange space.

According to yet another aspect, the supplemental heat exchange space is enclosed, and gas and the supplemental heat are circulated within the supplemental heat exchange space through a friction induced airflow produced by rotation of the imperforate outer wall and the perforated inner wall of the drum within the tub.

According to another aspect of the present disclosure, the portion of the heat exchange system within the supplemental heat exchange space is attached to an inner surface of the tub. According to another aspect, the portion of the heat exchange system within the supplemental heat exchange space is a supplemental heat exchange path that is separate from the heat exchange path in communication with the airflow path.

According to yet another aspect, a laundry appliance includes a tub that is positioned within a cabinet. A drum includes an imperforate outer wall that is positioned within the tub. A drum includes a perforated wall that is positioned within the imperforate outer wall. A blower delivers process air through an airflow path that includes a processing space defined within the drum. A heat exchange system conditions the process air that is delivered at least into the processing space as heated process air for drying articles contained within the processing space. The imperforate outer wall and the tub define supplemental heat exchange space that delivers supplemental heat through the imperforate outer wall and into the processing space. A supplemental airflow path extends through the supplemental heat exchange space. The airflow path and the supplemental airflow path are each in thermal communication with the heat exchange system.

According to another aspect of the present disclosure, the supplemental airflow path is separated from the blower and wherein rotation of the imperforate outer wall and the perforated wall of the drum within the tub generates a friction induced airflow that directs supplemental process air through the supplemental airflow path.

According to another aspect, the blower directs a portion of the process air through the supplemental airflow path. The supplemental airflow path is diverted away from the airflow path at a baffle that is upstream of the processing space. The supplemental airflow path is diverted back into the airflow path downstream of a particulate filter of 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.

Claims

1. A laundry appliance comprising:

a tub that is positioned within a cabinet;

a drum having an imperforate outer wall that is positioned within the tub;

a blower that delivers process air through an airflow path that includes a processing space defined within the drum; and

a heat exchange system that conditions the process air that is delivered at least into the processing space as heated process air for drying articles contained within the processing space, wherein the imperforate outer wall and the tub define supplemental heat exchange space that delivers supplemental heat through the imperforate outer wall and into the processing space, and wherein the supplemental heat exchange space is in thermal communication with the heat exchange system.

2. The laundry appliance of claim 1, wherein the heat exchange system includes heat exchange media that is delivered through a heat exchange path that recirculates from a compressor and through a condenser that rejects heat and an evaporator that absorbs heat.

3. The laundry appliance of claim 1, wherein the drum includes the imperforate outer wall and a perforated inner wall that rotationally operates within the tub.

4. The laundry appliance of claim 1, wherein steam from the heat exchange system is delivered into the supplemental heat exchange space to form condensate at least on an outer surface of the imperforate outer wall, wherein condensation of the steam directs heat of condensation from the supplemental heat exchange space, through the imperforate outer wall and into the processing space.

5. The laundry appliance of claim 4, wherein the tub includes a drain that collects the condensate from the steam, and wherein a sump pump delivers the condensate to a separate location outside of the tub.

6. The laundry appliance of claim 1, wherein the heat exchange system includes a condenser having a primary condenser that is in communication with the airflow path, and a supplemental condenser that delivers the supplemental heat into the supplemental heat exchange space, wherein rotation of the drum produces a friction induced airflow within the supplemental heat exchange space that delivers the supplemental heat throughout the supplemental heat exchange space.

7. The laundry appliance of claim 6, wherein the supplemental condenser is located within the supplemental heat exchange space.

8. The laundry appliance of claim 1, wherein the airflow path includes a primary airflow path that delivers the process air through the processing space, and wherein the airflow path includes a supplemental airflow path that delivers a portion of the heated process air into the supplemental heat exchange space.

9. The laundry appliance of claim 8, wherein the supplemental airflow path includes a baffle that directs a portion of the heated process air, as redirected process air into the supplemental airflow path, and wherein the redirected process air is delivered back into the airflow path down stream of an air filter assembly of the airflow path.

10. The laundry appliance of claim 1, further comprising:

a secondary airflow path that recirculates secondary process air between the heat exchange system and the supplemental heat exchange space, wherein the secondary airflow path is separated from the airflow path.

11. The laundry appliance of claim 10, wherein rotation of the drum within the tub produces friction-induced airflow that recirculates the secondary process air between the heat exchange system and the supplemental heat exchange space.

12. The laundry appliance of claim 2, wherein the compressor includes a multi-stage compressor having a first stage of compression and a second stage of compression, wherein an intercooler is disposed between the first and second stages of compression.

13. The laundry appliance of claim 1, wherein the multi-stage compressor includes a single piston that operates within a single cylinder and first and second valves positioned at opposing ends of the cylinder and an oscillation seal disposed between the first and second valves.

14. A laundry appliance comprising:

a tub that is positioned within a cabinet;

a drum having an imperforate outer wall that is positioned within the tub and a perforated inner wall that rotationally operates within the tub;

a blower that delivers process air through an airflow path that includes a processing space defined within the drum; and

a heat exchange system that conditions the process air that is delivered into the processing space as heated process air for drying articles contained within the processing space, wherein the imperforate outer wall and the tub define a supplemental heat exchange space that delivers supplemental heat through the imperforate outer wall and into the processing space, and wherein a portion of the heat exchange system extends into the supplemental heat exchange space for heating the supplemental heat exchange space and producing the supplemental heat that is conducted through the imperforate outer wall and into the supplemental heat exchange space.

15. The laundry appliance of claim 14, wherein the supplemental heat exchange space is enclosed, and wherein gas and the supplemental heat are circulated within the supplemental heat exchange space through a friction induced airflow produced by rotation of the imperforate outer wall and the perforated inner wall of the drum within the tub.

16. The laundry appliance of claim 14, wherein the portion of the heat exchange system within the supplemental heat exchange space is attached to an inner surface of the tub.

17. The laundry appliance of claim 14, wherein the portion of the heat exchange system within the supplemental heat exchange space is a supplemental heat exchange path that is separate from the heat exchange path in communication with the airflow path.

18. A laundry appliance comprising:

a tub that is positioned within a cabinet;

an imperforate outer wall that is positioned within the tub;

a drum having a perforated inner wall that is positioned within the imperforate outer wall;

a blower that delivers process air through an airflow path that includes a processing space defined within the drum;

a heat exchange system that conditions the process air that is delivered at least into the processing space as heated process air for drying articles contained within the processing space, wherein the imperforate outer wall and the tub define supplemental heat exchange space that delivers supplemental heat through the imperforate outer wall and into the processing space; and

a supplemental airflow path that extends through the supplemental heat exchange space, wherein the airflow path and the supplemental airflow path are each in thermal communication with the heat exchange system.

19. The laundry appliance of claim 18, wherein the supplemental airflow path is separated from the blower and wherein rotation of the imperforate outer wall and the perforated inner wall of the drum within the tub generates a friction induced airflow that directs supplemental process air through the supplemental airflow path.

20. The laundry appliance of claim 18, wherein the blower directs a portion of the process air through the supplemental airflow path, wherein the supplemental airflow path is diverted away from the airflow path at a baffle that is upstream of the processing space, and wherein the supplemental airflow path is diverted back into the airflow path downstream of a particulate filter of the airflow path.