HEATER POCKET FOR A HOUSEHOLD APPLIANCE

Abstract

A household appliance includes a tub having a rotating drum therein, the drum having an axis of rotation. The tub includes a heater pocket integrally formed in a lower portion of the tub, and forming a cavity in fluid communication with the drum. A cross-section of the heater pocket, which is taken in a direction substantially perpendicular to the axis of rotation of the rotating drum, includes a first sidewall, a second sidewall opposed to the first sidewall, and a bottom wall connecting a lower side of the first sidewall to a lower side of the second sidewall, wherein each of the first sidewall and the second sidewall intersects the bottom wall at an angle other than 90°.

Description

FIELD OF THE INVENTION

The present invention is directed toward a household appliance, and more specifically, toward a household appliance having a heater pocket.

BACKGROUND OF THE INVENTION

A household appliance, such as a front-loading clothes washer includes a housing having a door providing access to a washing unit in the interior of the appliance housing. The washing unit includes a tub having a cylindrical washing drum rotatably mounted inside the tub. In operation, clothes or laundry are inserted into the washer through the door and placed in the rotating washing drum inside the tub. The household appliance wets the laundry to be washed with washing liquid and mechanically moves the laundry to release contaminants from the laundry. A drive system rotates the washing drum inside the tub about an axis of the drum.

A heating element commonly is provided for heating the washing liquid in the tub of the washer. The heating element may be disposed in a heater pocket or cavity formed in the tub of the washer. In operation, the washing liquid flows into the heater pocket and over the heating element, such that heat is transferred from the heating element to the washing liquid, thereby raising the temperature of the washing liquid. The heated washing liquid then flows out of the heater pocket and into the washing drum for washing the laundry.

A partial cross-sectional view of a conventional washer is illustrated in FIG. 8. The washer has drum 1215 rotatably mounted in a tub 1210. The tub 1210 includes a heater pocket 1300. The heater pocket 1300 has a first sidewall 1302, a second sidewall 1304 that is opposed to the first sidewall 1302, and a third wall or bottom wall 1306 connecting the first sidewall 1302 to the second sidewall 1304, thereby forming a generally rectangular, box-shaped cavity. The first sidewall 1302 is substantially parallel to the second sidewall 1304. The first and second sidewalls 1302, 1304 are substantially perpendicular to the bottom wall 1306. In this manner, the heater pocket 1300 is capable of receiving a predetermined volume of washing liquid therein.

A plate 1502 is disposed on the bottom wall 1306 of the heater pocket 1300. A heating element clip 402 is coupled to the plate 1502. A heating element having heater coils 404 and a base 406 is inserted into and sealingly engaged with an opening at a far end of the heater pocket 1300, as viewed in FIG. 8. The heater coils 404 engage and are retained by the heating element clip 402. The heating element can be, for example, a 1300 Watt heating element.

During a washing cycle of the washer, the rotation of the drum 1215 induces a flow of the washing liquid from the drum 1215 into the heater pocket 1300 to be heated by the heater coils 404 and then out of the heater pocket 1300 and back into the drum 1215.

The heater pocket 1300 is in fluid communication with a drain assembly (not shown) at a near end of the heater pocket 1300 as viewed in FIG. 8, which can include a discharge pump and corrugated tubing for discharging the washing liquid from the tub 1210. During a draining cycle of the washer, the drain is opened and the washing liquid flows from the drum 1215 into the heater pocket 1300, and then from the heater pocket 1300 into the corrugated tubing of the drain assembly. A discharge pump can be provided for drawing the washing liquid from the heater pocket 1300 and the tub 1210 into the drain assembly.

SUMMARY OF THE INVENTION

The present invention recognizes that the flow patterns of the washing liquid into, within, and out of the heater pocket can affect the heat distribution from the heater coils to the washing liquid, and thus the efficiency of the washer. The present invention further recognizes that the deposition and accumulation of debris below, on, or around the heater coils can affect the heat distribution from the heater coils to the washing liquid, thereby reducing the efficiency of the washer. The deposition and accumulation of debris below, on, or around the heater coils also can result in early failure of the heating element, thereby affecting the durability and reliability of the washer.

As explained above with reference to FIG. 8, in many conventional washers, the heater pocket 1300 has a generally rectangular, box-shaped design in which the first sidewall 1302 is substantially parallel to the second sidewall 1304, and the first and second sidewalls 1302, 1304 are substantially perpendicular to the bottom wall 1306. The conventional heater pocket may result in irregular flow patterns below and around the heating element, thereby reducing or limiting the heat distribution from the heater coils to the washing liquid.

For example, the sharp edges of the heater pocket 1300 where the sidewalls 1302, 1304 meet the tub 1210, as well as the vertical sidewalls 1302, 1304 of the heater pocket 1300 themselves, can induce irregular and heavily disturbed flow of the washing liquid under and around the heater coils 404. Also, the conventional heater pocket may reduce or limit the drainage efficiency to the discharge pump. The dynamics of the drum motion (i.e., rotation or oscillation) also can induce irregular flow patterns of the washing liquid below and around the heating element. The washing liquid can flow in a plurality of directions and at various velocities. Thus, with the conventional heater pocket 1300, there may be, for example, areas having irregular flow, areas in which the flow velocity is reduced, and/or stagnant areas (i.e., areas of minimal or no flow) below or around the heater coils 404. As a result, the efficiency of the heat distribution from the heater coils 404 to the washing liquid can be reduced. Also, the time to heat the washing liquid in the tub can be increased.

The present invention recognizes that these areas having irregular flow, areas in which the flow velocity is reduced, and/or stagnant areas below or around the heater coils 404 can result in a large amount of debris, such as fluffs (e.g., lint or paper particles) and lime, collecting and accumulating under, on, or around the heater coils 404, since the flow may not be sufficient to sweep or clean this debris off of the heater coils 404 or out from under the heater coils 404. This debris can collect or accumulate under, on, or around the heater coils 404, and eventually, can turn into a paste-like material or coating on the heater coils 404 that may function like a layer of insulation on the heater coils 404. This debris also can collect or accumulate on the heater coil retainer clip.

In this manner, some of the most affected areas of the heater coils 404 may eventually lose some or all of their ability to transfer heat to the washing liquid. As a result, the time to heat the washing liquid in the tub can be increased. As more and more debris accumulates on the heater coils 404, the time to heat the washing liquid can become longer.

Moreover, the insulating effect of the accumulated debris may cause overheating of the heating element, thereby resulting in early failure of the heating element and reducing the reliability of the washer.

As explained above, during a draining cycle of the washer, the washing liquid flows from the drum 1215 into the heater pocket 1300, and then exits the heater pocket 1300 through a drain via the discharge pump and corrugated tubing. The configuration of the conventional heater pocket 1300, and particularly the first and second sidewalls 1302, 1304 of the heater pocket 1300 being substantially perpendicular to the bottom wall 1306, can result in poor drainage from the tub 1210 to the discharge pump, for example, because the washing liquid may not flow smoothly into the heater pocket 1300 and/or may not flow smoothly within/from the heater pocket 1300 toward the drain.

These problems and others are addressed by the present invention, a first exemplary embodiment of which comprises a household appliance including a housing having a door formed in a front panel thereof for accessing an interior of the housing, and a tub disposed inside the housing, the tub having a rotating drum therein for receiving laundry through the door, the drum having an axis of rotation, wherein the tub includes a heater pocket integrally formed in a lower portion of the tub, the heater pocket forming a cavity in fluid communication with the drum, the heater pocket for at least partially surrounding a heating element for heating a washing liquid in the tub, wherein a cross-section of the heater pocket, which is taken in a direction substantially perpendicular to the axis of rotation of the rotating drum, includes a first sidewall; a second sidewall opposed to the first sidewall; and a bottom wall connecting a lower side of the first sidewall to a lower side of the second sidewall, wherein each of the first sidewall and the second sidewall intersects the bottom wall at an angle other than 90°.

Another exemplary embodiment of the invention comprises a front-loading washer including a housing having a door formed in a front panel thereof for accessing an interior of the housing, and a tub disposed inside the housing, the tub having a rotating drum therein for receiving laundry through the door, the drum having an axis of rotation. The tub includes a heater pocket integrally formed in a lower portion of the tub, the heater pocket forming a cavity in fluid communication with the drum, the heater pocket for at least partially surrounding a heating element for heating a washing liquid in the tub, wherein walls of the heater pocket guides the washing liquid one of below and around the heating element at a substantially constant velocity and with a substantially uniform flow pattern.

Another exemplary embodiment of the invention comprises a front-loading washer including a housing having a door formed in a front panel thereof for accessing an interior of the housing; and a tub disposed inside the housing, the tub having a rotating drum therein for receiving laundry through the door, the drum having an axis of rotation, wherein the tub includes a heater pocket integrally formed in a lower portion of the tub, the heater pocket forming a cavity in fluid communication with the drum, the heater pocket for at least partially surrounding a heating element for heating a washing liquid in the tub, wherein the heater pocket includes means for guiding the washing liquid one of below and around the heater coil at a substantially constant velocity and with a substantially uniform flow pattern.

In this manner, the exemplary embodiments can provide a heater pocket that promotes substantially uniform flow and velocity of the washing liquid in the heater pocket, including below and around the heater coil and out of the heater pocket during a heating cycle. The exemplary embodiments can increase the heat distribution from the heater coils to the washing liquid. Also, the exemplary embodiments can reduce the time to heat the washing liquid in the tub. Furthermore, the exemplary embodiments can increase the drainage efficiency to the discharge pump and reduce the resistance of the flow of the washing liquid into the drain.

The exemplary embodiments can promote uniform flow of the washing liquid into the drain assembly during draining of the washing liquid, for example, during a spinning cycle. In this manner, the disclosed exemplary embodiments can reduce or eliminate stagnant areas, low flow areas, or irregular flow areas that may result in large amounts of debris collecting under, on, or around the heater coils. The exemplary embodiments can prevent or reduce the collection or accumulation of debris, such as fluffs (e.g., lint or paper particles) and lime deposits or formations under, on, or around the heater coils.

Moreover, the exemplary embodiments can promote substantially uniform velocity of the washing liquid below and around the heater coils. In an exemplary embodiment, one or more interior surfaces of the first or second sidewalls or the bottom wall of the heater pocket can include an optional diverter for diverting the washing fluid or the washing fluid flow. The diverter can generate a vortex or other flow pattern that improves the cleaning out of accumulated debris under or on the heater coils. In this manner, the exemplary embodiments can induce sufficient velocity of the washing liquid to provide a sweeping or cleaning affect on the heater coils, thereby removing some or all of the collected debris from the heater coils. The exemplary embodiments may extend the operating life of the heater coils and increase the heat distribution from the heater coils to the washing liquid, thereby increasing the efficiency of the washer.

Other features and advantages of the present invention will become apparent to those skilled in the art upon review of the following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects and features of embodiments of the present invention will be better understood after a reading of the following detailed description, together with the attached drawings, wherein:

FIG. 1 is a front elevation view of a washer;

FIG. 2 is a side elevation view of a washing unit according to an exemplary embodiment of the invention;

FIG. 3 is a rear elevation view of the washing unit of FIG. 2;

FIG. 4 is a partial cross-sectional view of a heater pocket according to FIG. 2 taken along the line IV-IV;

FIG. 5 is another partial cross-sectional view of a heater pocket of FIG. 2 taken along the line IV-IV according to an exemplary embodiment of the invention;

FIG. 6 is another partial cross-sectional view of a heater pocket of FIG. 2 taken along the line IV-IV according to an exemplary embodiment of the invention;

FIG. 7 is a partial cross-sectional view of a heater pocket of FIG. 2 taken along the line IV-IV according to another exemplary embodiment of the invention; and

FIG. 8 is a partial cross-sectional view of a conventional heater pocket.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS OF THE INVENTION

The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Referring now to the drawings, FIGS. 1-7 illustrate exemplary embodiments of a household appliance having a heater pocket according to exemplary embodiments of the present invention.

FIG. 1 illustrates a household appliance 100, such as a front-loading clothes washer, having a housing 110 and a door 112 to provide access to the interior of the appliance housing 110. The household appliance 100 wets the laundry to be washed with washing liquid and mechanically moves the laundry to release contaminants from the laundry.

With reference to FIGS. 2-4, the housing 110 encloses a washing unit, which includes a tub 210 having a rotating washing drum 215 that rotates or oscillates about an axis to move the clothes or laundry in the tub 210. The interior of the tub 210 is accessible through the opening 212, which corresponds to the door 112 of the housing 110, as illustrated in FIG. 1. In operation, a drive system rotates or oscillates the rotating washing drum 215 within the tub 210. The drive system can include, for example, a motor 214, a pulley 216, and a drive belt 218.

As shown in FIGS. 2 and 3, the tub 210 can include a heater pocket 300 having a heating element 400 disposed therein. The washing unit also can include a drain assembly 220 coupled to or formed in the tub 210. The drain assembly 220 can be in fluid communication with the heater pocket 300. The drain assembly 220 can include, for example, a discharge pump and corrugated tube for discharging the washing liquid from the tub 210.

With reference to FIG. 4, the heater pocket 300 can include a first sidewall 302, a second sidewall 304, and a bottom wall 306. A plate 502 can be coupled to or integrally formed with the bottom wall 306 of the heater pocket 300. A heater coil retainer clip 402 can be coupled to the plate 502. During assembly of the household appliance, a heating element 400 having heater coils 404 and a base 406 can be inserted into and sealingly engaged with an opening at the far end of the heater pocket 300, as viewed in FIG. 4. The heater coils 404 engage and are retained by the heating element retainer clip 402. The heating element 400 can be, for example, a 300 Watt heating element.

In an exemplary embodiment, the interior surface of the first sidewall 302 and the interior surface of the second sidewall 304 can have a draft angle to assist with removal of the heater pocket from a mold during a manufacturing process. For example, the interior surface of the first sidewall 302 and the interior surface of the second sidewall 304 can be closer to each other at the far end of the heater pocket where the base 406 of the heating element 400 engages the heater pocket, as viewed in FIG. 4, than at the near end of the heater pocket having the drain assembly (not shown) as viewed in FIG. 4.

In an exemplary embodiment, the interior surface of the bottom wall 306 can be sloped in a direction toward the drain assembly 220 to promote the flow of the washing liquid L toward and into the drain assembly 220, as shown in FIG. 2. The drain assembly 220 (not shown in FIG. 4) is located at the near end of the heater pocket 300 as viewed in FIG. 4 (i.e., at an opposite end from the base 406 of the heating element 400). An opening into the drain assembly from the heater pocket can include a mesh screen, for example a metal screen, that prevents or reduces the flow of debris from the heater pocket 300 into the drain assembly.

The exemplary embodiments of FIGS. 4-6 illustrate a cross-section of the heater pocket taken in a direction substantially perpendicular to the axis of rotation of the drum 215. In the exemplary embodiments, the cross-section of the bottom wall 306 can be substantially parallel to the heater coils 404 of the heating element 400.

In cross-section of the heater pocket 300, the first sidewall 302 and the second sidewall 304 of the heater pocket 300 are not perpendicular to the bottom wall 306. That is, the first sidewall 302 and the second sidewall 304 of the heater pocket 300 can be inclined at an angle other than 90° with respect to the bottom wall 306. For example, when viewed in cross-section, the first sidewall 302 can be inclined by a first angle θ1 and the second sidewall 304 can be inclined at a second angle θ2 with respect to the bottom wall 306. By providing the cross-sections of the first sidewall 302 and second sidewall 304 at angles other than 90° with respect to the bottom wall 306, the exemplary embodiments can eliminate or reduce a number of features, such as sharp corners, that may be prone to collecting or accumulating debris, such as fluffs (e.g., lint or paper particles) and deposits or formation of lime.

During operation, the rotation of the drum 215 induces flow of the washing liquid into the heater pocket 300 in a first direction. The drum 215 can include paddle-shaped elements thereon for lifting or pushing the washing liquid L as the drum 215 rotates, thereby inducing flow of the washing liquid L into the heater pocket in a first direction and then out of the other side of the heater pocket. The rotation of the drum 215 also may result in a backflow of a portion of the washing liquid into the heater pocket 300 in a second direction as a result of some of the washing liquid that is dragged or lifted out of the heater pocket by the rotating drum subsequently flowing back into the heater pocket.

During a heating cycle, the washing liquid flows from the drum 215 into the heater pocket 300, wherein the heater coils transfer heat to the washing liquid. The heated washing liquid then flows out of the heater pocket 300 and back into the drum 215. Similarly, during a rinsing cycle, the washing liquid flows from the drum 215 into the heater pocket 300 and then out of the heater pocket 300 and back into the drum 215. During the heating and/or rinsing cycles, the drum 215 may rotate in a first direction (e.g., a clockwise direction) for a period of time, and then rotate in a second direction (e.g., a counter-clockwise direction) for a period of time.

During a draining cycle of the washer, for example a spinning cycle, the washing liquid flows into the heater pocket 300 from the drum 215, and then is permitted to flow into, or be drawn into, the drain assembly 220. As explained above, a discharge pump can be provided for drawing the washing liquid from the heater pocket 300 and the tub 210 into the drain assembly 220. During the draining cycle, the drum 215 may rotate in a single direction such that the washing liquid flows into the heater pocket 300 in a single direction, for example, a clockwise direction in FIGS. 4-7.

In an exemplary embodiment, the configuration of the first sidewall 302, second sidewall 304, and bottom wall 306 can facilitate substantially uniform flow and velocity of the washing liquid below and around the heater coils 404, thereby reducing or eliminating stagnant areas, low flow areas, or irregular flow areas in which large amounts of debris can collect and accumulate under, on, or around the heater coils 404. As a result, the exemplary embodiments can improve water flow and heat distribution from the heater coils 404 to the washing liquid, thereby increasing the efficiency of the washer. Also, the exemplary embodiments can reduce the time to heat the washing liquid L in the tub 210.

The first sidewall 302, second sidewall 304, and bottom wall 306 also can be configured in a manner to promote the flow of the washing liquid into the drain assembly 220. As a result, the exemplary embodiments can increase the drainage efficiency of the washer.

With reference again to the cross-section of the exemplary heater pocket illustrated in FIGS. 5 and 6, the first sidewall 302 intersects the bottom wall 306 at a first angle θ1, and the second sidewall 304 intersects the bottom wall 306 at a second angle θ2. The first angle θ1 and second angle θ2 can be selected to promote uniform flow of washing liquid L (illustrated using dashed lines in FIG. 5) into the heater pocket 300, below and around the heater coil 404, and out of the heater pocket 300, for example during a heating cycle, as well as to promote the flow of water into the heater pocket 300 and into the drain assembly 220, for example during a spinning cycle.

In the exemplary heater pocket illustrated in FIGS. 4-6, first angle θ1 can be selected to be lower than the second angle θ2 to increase the velocity of the washing liquid flowing into the heater pocket 300. The first angle θ1 can be selected such that the first sidewall 302 does not restrict the flow of washing liquid into the heater pocket 300 for heating by the heating element 400. The second angle θ2 can be selected to be higher than the first angle θ1 to increase the velocity of the washing liquid flowing into the drain assembly 220, for example, during a spinning cycle of the washer. The second angle θ2 can promote flow of the washing fluid into the drain assembly 220 from the heater pocket 300 in a clockwise direction.

In an exemplary embodiment, a ratio of the second angle θ2 to the first angle θ1 can be selected to be a 2 to 1 ratio (e.g., 60° to 30° as illustrated in FIG. 6), thereby promoting a higher velocity of washing fluid flowing into the heater pocket 300 during heating, and improving flow of the washing fluid toward the drain during a draining or spinning cycle of the washer. One of ordinary skill will recognize that other ratios of the second angle θ2 to the first angle θ1 are possible within the spirit and scope of the invention and are contemplated by the present invention.

With reference to FIG. 6, the first angle θ1 and the second angle θ2 can be selected such that their sum is equal to 90°. In this manner, the exemplary embodiments can provide a heater pocket 300 that does not increase the volume requirement of the washing liquid in the washer as compared to the conventional heater pocket, such that the water consumption of the exemplary washer is consistent with the water consumption requirements of conventional washers.

As explained above, in the exemplary heater pocket illustrated in FIG. 6, the first angle θ1 can be 30° and the second angle θ2 can be 60°, thereby providing a 2 to 1 ratio. In other exemplary embodiments, the first angle θ1 and second angle θ2 can include other angles having a sum of 90°. For example, as illustrated in FIG. 7, the first angle θ1 can be selected to be equal to the second angle θ2, for example a 45° angle, such that the first angle θ1 and second angle θ2 have a sum of 90°.

In still other exemplary embodiments, the first angle θ1 and the second angle θ2 of the first and second sidewalls 302, 304 with respect to the bottom wall 306 may not sum to 90°. In these cases, the water consumption of the exemplary washer may be different (e.g., increased or reduced) compared to the water consumption requirements of conventional washers.

In another exemplary embodiment, the heater pocket 300 can be configured to cause the washing liquid L flowing in the heater pocket 300 to swirl or rotate within the heater pocket 300, thereby forcing the washing liquid into the space below the heater coils 404 and improving the cleaning out of accumulated debris from under, on, or around the heater coils 404. For example, as illustrated in FIG. 4, one or more interior surfaces of the sidewalls (e.g., 302, 304) or bottom wall 306 of the heater pocket 300 can include an optional diverter 500 for diverting the washing fluid or the washing fluid flow. The diverter 500 can generate a vortex or another flow pattern that improves the cleaning out of accumulated debris from under, on, or around the heater coils 404. The diverter 500 can include, for example, one or more of a fin, a dimple, a raised feature extending from a surface of the sidewalls 302, 304, and/or bottom wall 306, or a depressed feature extending into a surface of one or more of the sidewalls 302, 304, and/or bottom wall 306.

For example, the diverter 500 can be square-shaped, oval-shaped, circular-shaped, or another shape. In this manner, the exemplary embodiments can cause the washing liquid L flowing in the heater pocket 300 to have a flow pattern within the heater pocket 300 that prevents or reduces the accumulation or collection of debris on, around, or below the heater coils 404, thereby increasing or maintaining the heat distribution from the heater coils 404 to the washing liquid L, extending the operating life of the heater coils 404, and increasing the overall efficiency of the washer.

To summarize, according to a disclosed exemplary embodiment, a household appliance is provided. The exemplary household appliance includes a housing 110 having a door 112 formed in a front panel thereof for accessing an interior of the housing 110, and a tub 210 disposed inside the housing 110, the tub 210 having a rotating drum 215 therein for receiving laundry through the door 112, the drum 215 having an axis of rotation, wherein the tub 215 includes a heater pocket 300 integrally formed in a lower portion of the tub 215, the heater pocket 300 forming a cavity in fluid communication with the drum 215, the heater pocket 300 for at least partially surrounding a heating element 400 for heating a washing liquid L in the tub 215, wherein a cross-section of the heater pocket 300, which is taken in a direction substantially perpendicular to the axis of rotation of the rotating drum, includes a first sidewall 302, a second sidewall 304 opposed to the first sidewall 302, and a bottom wall 306 connecting a lower side of the first sidewall 302 to a lower side of the second sidewall 304, wherein each of the first sidewall 302 and the second sidewall 304 intersects the bottom wall 306 at an angle other than 90°.

Another exemplary embodiment of the invention comprises a front-loading washer including a housing 110 having a door 112 formed in a front panel thereof for accessing an interior of the housing 110, and a tub 210 disposed inside the housing 110, the tub 210 having a rotating drum 215 therein for receiving laundry through the door 112, the drum 215 having an axis of rotation, wherein the tub 215 includes a heater pocket 300 integrally formed in a lower portion of the tub 215, the heater pocket 300 forming a cavity in fluid communication with the drum 215, the heater pocket 300 for at least partially surrounding a heating element 400 for heating a washing liquid L in the tub 215, wherein walls 302, 304, and/or 306 of the heater pocket 300 guide the washing liquid L one of below and around the heating element 400 at a substantially constant velocity and with a substantially uniform flow pattern.

Another exemplary embodiment of the invention comprises a front-loading washer including a housing 110 having a door 112 formed in a front panel thereof for accessing an interior of the housing 110, and a tub 210 disposed inside the housing 110, the tub 210 having a rotating drum 215 therein for receiving laundry through the door 112, the drum 215 having an axis of rotation, wherein the tub 215 includes a heater pocket 300 integrally formed in a lower portion of the tub 215, the heater pocket 300 forming a cavity in fluid communication with the drum 215, the heater pocket 300 for at least partially surrounding a heating element 400 for heating a washing liquid L in the tub 215, wherein the heater pocket 300 includes means for guiding (e.g., 302, 304, 306, 550, θ1, θ2, and combinations thereof) the washing liquid L one of below and around the heating element 400 at a substantially constant velocity and with a substantially uniform flow pattern.

As explained above, these features are important for providing a household appliance having a heater pocket that can promote uniform flow of the washing liquid below, on, or around the heater coils 404, thereby reducing or eliminating stagnant areas, low flow areas, or irregular flow areas where large amounts of debris can collect on the heater coils 404. In this manner, the exemplary embodiments can prevent or reduce the collection or accumulation of debris, such as fluffs (e.g., lint or paper particles) and lime, below, on, or around the heater coils 404.

The exemplary embodiments provide important advantages in that, when the flow of the washing liquid is induced by the rotation of the drum 215, the resulting flow may slow down in the area of the heating element 404, since the heater pocket 300 may act like a diffuser. The flow of the washing liquid may substantially follow the shape of the tub 210, thereby providing sufficient washout below, on, or around the heating element 404 and/or the heater coil retainer clip 402. The exemplary embodiments also can facilitate uniform distribution of flow within the heater pocket 300 in the main flow direction, with only minor secondary flow components in other directions. A uniform flow pattern can be provided below and around the heater coils 404.

The exemplary embodiments also can provide substantially uniform velocities of high magnitude below and around the heater coils 404. In this manner, the exemplary embodiments can increase the sweeping or cleaning affect of the washing liquid on the heater coils 404, thereby removing some or all of the accumulated debris from the heater coils 404 and/or the heater coil retainer clip 402. The exemplary embodiments may extend the operating life of the heater coils 404 and increase the heat distribution from the heater coils 404 to the washing liquid, thereby increasing the efficiency of the washer.

The present invention has been described herein in terms of several preferred embodiments. However, modifications and additions to these embodiments will become apparent to those of ordinary skill in the art upon a reading of the foregoing description. It is intended that all such modifications and additions comprise a part of the present invention to the extent that they fall within the scope of the several claims appended hereto.

Like numbers refer to like elements throughout. In the figures, the thickness of certain lines, layers, components, elements or features may be exaggerated for clarity.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.”

It will be understood that when an element is referred to as being “on”, “attached” to, “connected” to, “coupled” with, “contacting”, etc., another element, it can be directly on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper”, “lateral”, “left”, “right” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the descriptors of relative spatial relationships used herein interpreted accordingly.

Claims

1. A household appliance comprising:

a housing having a door formed in a front panel thereof for accessing an interior of the housing; and

a tub disposed inside the housing, the tub having a rotating drum therein for receiving laundry through the door, the drum having an axis of rotation,

wherein the tub includes: a heater pocket integrally formed in a lower portion of the tub, the heater pocket forming a cavity in fluid communication with the drum, the heater pocket for at least partially surrounding a heating element for heating a washing liquid in the tub, wherein a cross-section of the heater pocket, which is taken in a direction substantially perpendicular to the axis of rotation of the rotating drum, includes: a first sidewall; a second sidewall opposed to the first sidewall; and a bottom wall connecting a lower side of the first sidewall to a lower side of the second sidewall, wherein each of the first sidewall and the second sidewall intersects the bottom wall at an angle other than 90°.

2. The household appliance of claim 1, wherein the first sidewall is perpendicular to the second sidewall.

3. The household appliance of claim 1, wherein the first sidewall is angled by a first angle θ1 with respect to the bottom wall, and

wherein the second sidewall is angled by a second angle θ2 with respect to the bottom wall.

4. The household appliance of claim 3, wherein a sum of the first angle θ1 and the second angle θ2 is 90°.

5. The household appliance of claim 3, wherein the first angle θ1 is less than the second angle θ2.

6. The household appliance of claim 3, wherein a ratio of the second angle θ2 to the first angle θ1 is a 2 to 1 ratio.

7. The household appliance of claim 3, wherein the first angle θ1 is equal to the second angle θ2.

8. The household appliance of claim 1, comprising a heating element having a heater coil disposed in the heater pocket.

9. The household appliance of claim 8, wherein the bottom wall is substantially parallel to the heater coil of the heating element.

10. The household appliance of claim 8, wherein at least one of the first sidewall and the second sidewall guides the washing liquid one of below and around the heater coil.

11. The household appliance of claim 8, wherein at least one of the first sidewall and the second sidewall guides the washing liquid such that the washing liquid rotates below the heater coil.

12. The household appliance of claim 8, wherein an interior surface of at least one of the first sidewall and the second sidewall guides the washing liquid one of below and around the heater coil at a substantially constant velocity and with a substantially uniform flow pattern.

13. The household appliance of claim 1, wherein the heater pocket includes:

a drain for draining the washing liquid from the tub,

wherein an interior surface of the bottom wall of the heater pocket is angled with respect to the axis of rotation of the drum toward the drain.

14. The household appliance of claim 1, wherein the household appliance is a front-loading washer.

15. A front-loading washer comprising:

a housing having a door formed in a front panel thereof for accessing an interior of the housing; and

a tub disposed inside the housing, the tub having a rotating drum therein for receiving laundry through the door, the drum having an axis of rotation,

wherein the tub includes: a heater pocket integrally formed in a lower portion of the tub, the heater pocket forming a cavity in fluid communication with the drum, the heater pocket for at least partially surrounding a heating element for heating a washing liquid in the tub, wherein walls of the heater pocket guide the washing liquid one of below and around the heating element at a substantially constant velocity and with a substantially uniform flow pattern.

16. The front-loading washer of claim 15, wherein a cross-section of the heater pocket, which is taken in a direction substantially perpendicular to the axis of rotation of the rotating drum, includes:

a first sidewall;

a second sidewall opposed to the first sidewall; and

a bottom wall connecting a lower side of the first sidewall to a lower side of the second sidewall.

17. The front-loading washer of claim 16, wherein each of the first sidewall and the second sidewall intersects the bottom wall at an angle other than 90°.

18. The front-loading washer of claim 16, wherein the first sidewall is perpendicular to the second sidewall.

19. The front-loading washer of claim 16, wherein the first sidewall is angled by a first angle θ1 with respect to the bottom wall,

wherein the second sidewall is angled by a second angle θ2 with respect to the bottom wall, and

wherein a sum of the first angle θ1 and the second angle θ2 is 90°.

20. The front-loading washer of claim 16, wherein the first sidewall is angled by a first angle θ1 with respect to the bottom wall,

wherein the second sidewall is angled by a second angle θ2 with respect to the bottom wall, and

wherein the first angle θ1 is less than the second angle θ2.

21. The front-loading washer of claim 16, wherein the first sidewall is angled by a first angle θ1 with respect to the bottom wall,

wherein the second sidewall is angled by a second angle θ2 with respect to the bottom wall, and

wherein a ratio of the second angle θ2 to the first angle θ1 is a 2 to 1 ratio.

22. The front-loading washer of claim 16, wherein the first sidewall is angled by a first angle θ1 with respect to the bottom wall,

wherein the second sidewall is angled by a second angle θ2 with respect to the bottom wall, and

wherein the first angle θ1 is equal to the second angle θ2.

23. A front-loading washer comprising:

a housing having a door formed in a front panel thereof for accessing an interior of the housing; and

a tub disposed inside the housing, the tub having a rotating drum therein for receiving laundry through the door, the drum having an axis of rotation,

wherein the tub includes a heater pocket integrally formed in a lower portion of the tub, the heater pocket forming a cavity in fluid communication with the drum, the heater pocket for at least partially surrounding a heating element for heating a washing liquid in the tub,

wherein the heater pocket includes means for guiding the washing liquid one of below and around the heating element at a substantially constant velocity and with a substantially uniform flow pattern.

24. The household appliance of claim 1, wherein an interior surface of one of the first sidewall, the second sidewall, and the bottom wall includes a diverter.