AMBIENT AIR DEHUMIDIFICATION SYSTEM FOR A CONDENSER OR HEAT PUMP LAUNDRY APPLIANCE

Abstract

A laundry appliance includes a drum that is rotatably mounted within a cabinet and defines a chamber for receiving articles of clothing. Primary and ambient air duct systems provide fluid communication between a conditioning system and at least one of the chamber of the drum and an ambient environment, respectively. A blower fan urges air through the conditioning system and a damper system is operably coupled to the ambient air duct system for selectively regulating a flow of ambient air. A controller is configured to receive a command to initiate a dehumidification cycle, operate the conditioning system and the blower, and regulate the damper system to permit the flow of ambient air to pass through conditioning system and through the ambient air duct system, thereby dehumidifying the ambient environment.

Description

FIELD OF THE INVENTION

The present subject matter relates generally to dryer appliances, or more specifically, to systems and methods operating a heat pump or condenser dryer appliance to dehumidify an environment.

BACKGROUND OF THE INVENTION

Dryer appliances generally include a cabinet with a drum rotatably mounted therein. During operation, a motor rotates the drum, e.g., to tumble articles located within a chamber defined by the drum. Dryer appliances also generally include a system for passing dry, heated air through the chamber in order to dry moisture-laden articles positioned therein. Typically, an air handler or blower is used to urge the flow of heated air through the chamber to dry the clothes.

Certain conventional dryer appliances are open loop airflow appliances that are fluidly coupled to an exhaust duct where the heated air is exhausted from the dryer appliance. By contrast, closed loop airflow dryer appliances are types of dryer appliances that circulate a flow of air rather than discharge the heated air through an exhaust duct. These closed loop airflow dryer appliances typically include condenser dryers, heat pump dryers, and spray tower dryer appliances. Such dryer appliances include a closed loop airflow circuit along which process air is moved. The process air is conditioned by a conditioning system, e.g., to remove moisture from the process air after the air has absorbed water from articles and also heats the air to increase the moisture capacity of the air.

Notably, these dryer appliances are often installed in locations where excess moisture and humidity may be a problem, such as in small laundry rooms, basements, etc. While the conditioning system is used during operating cycles to remove humidity from the flow of process air and remove moisture from clothes, the conditioning system is not operational outside of the operating cycle. As a result these dryer appliances do nothing to help reduce humidity within the location surrounding the appliance, resulting in environments with excessive humidity and in appliances that must typically work harder to remove moisture from the clothes.

Accordingly, a dryer appliance with features for regulating ambient humidity would be desirable. More specifically, a heat pump or condenser dryer appliance with automated methods for regulating humidity within a space would be particularly beneficial.

BRIEF DESCRIPTION OF THE INVENTION

Advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In one exemplary embodiment, a laundry appliance is provided including a cabinet, a drum rotatably mounted within the cabinet, the drum defining a chamber for receipt of articles for drying, a conditioning system configured to heat and remove moisture from air flowing therethrough, a primary duct system for providing fluid communication between the chamber and the conditioning system, wherein the primary duct system, the conditioning system, and the drum define a process air flowpath, an ambient air duct system for providing fluid communication between an ambient environment and the conditioning system, wherein the ambient air duct system and the conditioning system at least partially define an ambient air flowpath, a blower fan operable to move at least one of a flow of process air through the process air flowpath or a flow of ambient air through the ambient air flowpath, a damper system operably coupled to the ambient air duct system for selectively regulating the flow of ambient air, and a controller operably coupled to the conditioning system, the blower fan, and the damper system. The controller is configured to receive a command to initiate a dehumidification cycle and regulate the damper system to permit the flow of ambient air to pass through the conditioning system and through the ambient air duct system.

In another exemplary embodiment, a method of operating a laundry appliance is provided. The laundry appliance includes a drum rotatably mounted within a cabinet, the drum defining a chamber for receipt of articles for drying, a conditioning system configured to heat and remove moisture from air flowing therethrough, a primary duct system providing fluid communication between the chamber and the conditioning system, an ambient air duct system providing fluid communication between an ambient environment and the conditioning system, a blower fan operable to move at least one of a flow of process air or a flow of ambient air, and a damper system operably coupled to the ambient air duct system for selectively regulating the flow of ambient air. The method includes receiving a command to initiate a dehumidification cycle and regulating the damper system to permit the flow of ambient air to pass through the conditioning system and through the ambient air duct system.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a perspective view of a dryer appliance in accordance with exemplary embodiments of the present disclosure.

FIG. 2 provides a perspective view of the example dryer appliance of FIG. 1 with portions of a cabinet of the dryer appliance removed to reveal certain components of the dryer appliance.

FIG. 3 provides a schematic diagram of an exemplary heat pump dryer appliance and a conditioning system thereof along with an ambient air duct system in a drying position in accordance with exemplary embodiments of the present disclosure.

FIG. 4 provides a schematic diagram of an exemplary heat pump dryer appliance and a conditioning system thereof along with the ambient air duct system in a dehumidification position in accordance with exemplary embodiments of the present disclosure.

FIG. 5 provides a schematic diagram of an exemplary heat pump dryer appliance and a conditioning system thereof along with an ambient air duct system in accordance with an alternative exemplary embodiment of the present disclosure.

FIG. 6 illustrates a method for operating a heat pump dryer appliance in accordance with one embodiment of the present disclosure.

FIG. 7 illustrates a method for operating a heat pump dryer appliance in accordance with another embodiment of the present disclosure.

Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). In addition, here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. The terms “upstream” and “downstream” refer to the relative flow direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the flow direction from which the fluid flows, and “downstream” refers to the flow direction to which the fluid flows.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

Referring now to the figures, an exemplary laundry appliance that may be used to implement aspects of the present subject matter will be described. Specifically, FIGS. 1 and 2 provide perspective views of a dryer appliance 10 according to exemplary embodiments of the present disclosure. Particularly, FIG. 1 provides a perspective view of dryer appliance 10 and FIG. 2 provides another perspective view of dryer appliance 10 with a portion of a housing or cabinet 12 of dryer appliance 10 removed in order to show certain components of dryer appliance 10. As depicted, dryer appliance 10 defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular such that an orthogonal coordinate system is defined. While described in the context of a specific embodiment of dryer appliance 10, using the teachings disclosed herein it will be understood that dryer appliance 10 is provided by way of example only. Other dryer appliances having different appearances and different features may also be utilized with the present subject matter as well. For instance, in some embodiments, dryer appliance 10 can be a combination washing machine/dryer appliance, a condenser dryer, or any other suitable laundry appliance.

Cabinet 12 includes a front panel 14, a rear panel 16, a pair of side panels 18 and 20 spaced apart from each other by front and rear panels 14 and 16 along the lateral direction L, a bottom panel 22, and a top cover 24. Cabinet 12 defines an interior volume 29. A drum or container 26 is mounted for rotation about a substantially horizontal axis within the interior volume 29 of cabinet 12. Drum 26 defines a chamber 25 for receipt of articles for tumbling and/or drying. Drum 26 extends between a front portion 37 and a back portion 38, e.g., along the transverse direction T. Drum 26 also includes a back or rear wall 34, e.g., at back portion 38 of drum 26. A supply duct 41 may be mounted to rear wall 34. Supply duct 41 receives heated air that has been heated by a conditioning system 40 and provides the heated air to drum 26 via one or more holes defined by rear wall 34.

As used herein, the terms “clothing” or “articles” includes but need not be limited to fabrics, textiles, garments, linens, papers, or other items from which the extraction of moisture is desirable. Furthermore, the term “load” or “laundry load” refers to the combination of clothing that may be washed together in a washing machine or dried together in a dryer appliance 10 (e.g., clothes dryer) and may include a mixture of different or similar articles of clothing of different or similar types and kinds of fabrics, textiles, garments and linens within a particular laundering process.

In some embodiments, a motor 31 is provided to rotate drum 26 about the horizontal axis, e.g., via a pulley and a belt (not pictured). Drum 26 is generally cylindrical in shape. Drum 26 has an outer cylindrical wall 28 and a front flange or wall 30 that defines an opening 32 of drum 26, e.g., at front portion 37 of drum 26, for loading and unloading of articles into and out of chamber 25 of drum 26. Drum 26 includes a plurality of lifters or baffles 27 that extend into chamber 25 to lift articles therein and then allow such articles to tumble back to a bottom of drum 26 as drum 26 rotates. Baffles 27 may be mounted to drum 26 such that baffles 27 rotate with drum 26 during operation of dryer appliance 10.

Rear wall 34 of drum 26 is rotatably supported within cabinet 12 by a suitable bearing. Rear wall 34 can be fixed or can be rotatable. Rear wall 34 may include, for instance, a plurality of holes that receive hot air that has been heated by a conditioning system 40, e.g., a heat pump or refrigerant-based conditioning system as will be described further below. Moisture laden, heated air is drawn from drum 26 by an air handler, such as a blower fan 48, which generates a negative air pressure within drum 26.

As shown, dryer appliance 10 may further include one or more lint filters 46 (FIG. 2) to collect lint during drying operations. The moisture laden heated air passes through a duct 44 enclosing screen filter 46, which traps lint particles. More specifically, filter 46 may be placed into a process airflow path 58 of air flow through appliance 10 and include a screen, mesh, other material to capture lint in the air flow. The location of lint filters in appliance 10 as shown in FIG. 2 is provided by way of example only, and other locations may be used as well. As shown, lint filter 46 is readily accessible by a user of the appliance. As such, lint filter 46 should be manually cleaned by removal of the filter, pulling or wiping away accumulated lint, and then replacing the filter 46 for subsequent drying cycles.

As the air passes from blower fan 48, it enters a duct 50 and then is passed into conditioning system 40. In some embodiments, the conditioning system 40 may be or include an electric heating element, e.g., a resistive heating element, or a gas-powered heating element, e.g., a gas burner. According to the illustrated exemplary embodiment, dryer appliance 10 is a heat pump dryer appliance and thus conditioning system 40 may be or include a heat pump including a sealed refrigerant circuit, as described in more detail below with reference to FIG. 3. Heated air (with a lower moisture content than was received from drum 26), exits conditioning system 40 and returns to drum 26 by duct 41. After the clothing articles have been dried, they are removed from the drum 26 via opening 32.

A door 33 provides for closing or accessing drum 26 through opening 32. According to exemplary embodiments, a window (not shown) in door 33 permits viewing of chamber 25 when door 33 is in the closed position, e.g., during operation of dryer appliance 10. Door 33 also includes a handle that, e.g., a user may pull when opening and closing door 33. Further, although door 33 is illustrated as mounted to front panel 14, it should be appreciated that door 33 may be mounted to another side of cabinet 12 or any other suitable support according to alternative embodiments. Dryer appliance 10 may further include a latch assembly 36 (see FIG. 1) that is mounted to cabinet 12 and/or door 33 for selectively locking door 33 in the closed position. Latch assembly 36 may be desirable, for example, to ensure only secured access to chamber 25 or to otherwise ensure and verify that door 33 is closed during certain operating cycles or events.

According to exemplary embodiments, dryer appliance 10 may facilitate a steam dry process. In this regard, dryer appliance 10 may offer a steam drying cycle, during which steam is injected into chamber 25, e.g., to function similar to a traditional garment steamer to help remove wrinkles, static, etc. Accordingly, as shown for example in FIG. 3, dryer appliance 10 may include a misting nozzle 62 that is in fluid communication with a water supply 64 in order to direct mist into chamber 25. Dryer appliance 10 may further include a water supply valve or control valve 66 for selecting discharging the flow of mist into chamber 25. It should be appreciated that control valve 66 may be positioned at any other suitable location within cabinet 12.

In some embodiments, one or more selector inputs 70, such as knobs, buttons, touchscreen interfaces, etc., may be provided or mounted on a cabinet 12 (e.g., on a user interface panel 71) and are communicatively coupled with (e.g., electrically coupled or coupled through a wireless network band) a processing device or controller 56. Controller 56 may also be communicatively coupled with various operational components of dryer appliance 10, such as motor 31, blower 48, and/or components of conditioning system 40. In turn, signals generated in controller 56 direct operation of motor 31, blower 48, or conditioning system 40 in response user inputs to selector inputs 70. As used herein, “processing device” or “controller” may refer to one or more microprocessors, microcontroller, ASICS, or semiconductor devices and is not restricted necessarily to a single element. The controller 56 may be programmed to operate dryer appliance 10 by executing instructions stored in memory (e.g., non-transitory media). The controller 56 may include, or be associated with, one or more memory elements such as RAM, ROM, or electrically erasable, programmable read only memory (EEPROM). For example, the instructions may be software or any set of instructions that when executed by the processing device, cause the processing device to perform operations. It should be noted that controller 56 as disclosed herein is capable of and may be operable to perform any methods or associated method steps as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in the memory and executed by the controller 56.

FIG. 3 provides a schematic view of dryer appliance 10 and depicts conditioning system 40 in more detail. For this embodiment, dryer appliance 10 is a heat pump dryer appliance and thus conditioning system 40 includes a sealed system 80. Sealed system 80 includes various operational components, which can be encased or located within a machinery compartment of dryer appliance 10. Generally, the operational components are operable to execute a vapor compression cycle for heating process air passing through conditioning system 40. The operational components of sealed system 80 include an evaporator 82, a compressor 84, a condenser 86, and one or more expansion devices 88 connected in series along a refrigerant circuit or line 90. Refrigerant line 90 is charged with a working fluid, which in this example is a refrigerant. Sealed system 80 depicted in FIG. 3 is provided by way of example only. Thus, it is within the scope of the present subject matter for other configurations of the sealed system to be used as well. As will be understood by those skilled in the art, sealed system 80 may include additional components, e.g., at least one additional evaporator, compressor, expansion device, and/or condenser. As an example, sealed system 80 may include two (2) evaporators.

In performing a drying and/or tumbling cycle, one or more laundry articles LA may be placed within the chamber 25 of drum 26. Hot dry air HDA is supplied to chamber 25 via duct 41. The hot dry air HDA enters chamber 25 of drum 26 via a drum inlet 52 defined by drum 26, e.g., the plurality of holes defined in rear wall 34 of drum 26 as shown in FIG. 2. The hot dry air HDA provided to chamber 25 causes moisture within laundry articles LA to evaporate. Accordingly, the air within chamber 25 increases in water content and exits chamber 25 as warm moisture laden air MLA. The warm moisture laden air MLA exits chamber 25 through a drum outlet 54 defined by drum 26 and flows into duct 44.

After exiting chamber 25 of drum 26, the warm moisture laden air MLA flows downstream to conditioning system 40. Blower fan 48 moves the warm moisture laden air MLA, as well as the air more generally, through a process air flowpath 58 defined by drum 26, conditioning system 40, and the primary duct system 60. Thus, generally, blower fan 48 is operable to move air through or along the process air flowpath 58. Primary duct system 60 includes all ducts that provide fluid communication (e.g., airflow communication) between drum outlet 54 and conditioning system 40 and between conditioning system 40 and drum inlet 52. Although blower fan 48 is shown positioned between drum 26 and conditioning system 40 along duct 44, it will be appreciated that blower fan 48 can be positioned in other suitable positions or locations along primary duct system 60.

As further depicted in FIG. 3, the warm moisture laden air MLA flows into or across evaporator 82 of the conditioning system 40. As the moisture-laden air MLA passes across evaporator 82, the temperature of the air is reduced through heat exchange with refrigerant that is vaporized within, for example, coils or tubing of evaporator 82. This vaporization process absorbs both the sensible and the latent heat from the moisture-laden air MLA—thereby reducing its temperature. As a result, moisture in the air is condensed and such condensate water may be drained from conditioning system 40, e.g., using a drain line 92, which is also depicted in FIG. 2.

For this embodiment, a condenser tank or a condensate collection tank 94 is in fluid communication with conditioning system 40, e.g., via drain line 92. Collection tank 94 is operable to receive condensate water from the process air flowing through conditioning system 40, and more particularly, condensate water from evaporator 82. A sensor 96 operable to detect when water within collection tank 94 has reached a predetermined level. Sensor 96 can be any suitable type of sensor, such as a float switch as shown in FIG. 3. Sensor 96 can be communicatively coupled with controller 56, e.g., via a suitable wired or wireless communication link, and maybe used to determine when condensate collection tank 94 needs to be drained.

A drain pump 98 is in fluid communication with collection tank 94. Drain pump 98 is operable to remove a volume of water from collection tank 94 and, for example, discharge the collected condensate to an external drain (e.g., to an external drain used by an associated washing machine appliance within the same environment). In some embodiments, drain pump 98 can remove a known or predetermined volume of water from collection tank 94. Drain pump 98 can remove the condensate water from collection tank 94 and can move or drain the condensate water downstream, e.g., to a gray water collection system. Particularly, in some embodiments, controller 56 is configured to receive, from sensor 96, an input indicating that water within the collection tank has reached the predetermined level. In response to the input indicating that water within collection tank 94 has reached the predetermined level, controller 56 can cause drain pump 98 to remove the predetermined volume of water from collection tank 94.

Air passing over evaporator 82 becomes cooler than when it exited drum 26 at drum outlet 54. As shown in FIG. 3, cool air CA (cool relative to hot dry air HDA and moisture laden air MLA) flowing downstream of evaporator 82 is subsequently caused to flow across condenser 86, e.g., across coils or tubing thereof, which condenses refrigerant therein. The refrigerant enters condenser 86 in a gaseous state at a relatively high temperature compared to the cool air CA from evaporator 82. As a result, heat energy is transferred to the cool air CA at the condenser 86, thereby elevating its temperature and providing warm dry air HDA for resupply to drum 26 of dryer appliance 10. The warm dry air HDA passes over and around laundry articles LA within the chamber 25 of the drum 26, such that warm moisture laden air MLA is generated, as mentioned above. Because the air is recycled through drum 26 and conditioning system 40, dryer appliance 10 can have a much greater efficiency than traditional clothes dryers can where all of the warm, moisture-laden air MLA is exhausted to the environment.

With respect to sealed system 80, compressor 84 pressurizes refrigerant (i.e., increases the pressure of the refrigerant) passing therethrough and generally motivates refrigerant through the sealed refrigerant circuit or refrigerant line 90 of conditioning system 40. Compressor 84 may be communicatively coupled with controller 56 (communication lines not shown in FIG. 3). Refrigerant is supplied from the evaporator 82 to compressor 84 in a low pressure gas phase. The pressurization of the refrigerant within compressor 84 increases the temperature of the refrigerant. The compressed refrigerant is fed from compressor 84 to condenser 86 through refrigerant line 90. As the relatively cool air CA from evaporator 82 flows across condenser 86, the refrigerant is cooled and its temperature is lowered as heat is transferred to the air for supply to chamber 25 of drum 26.

Upon exiting condenser 86, the refrigerant is fed through refrigerant line 90 to expansion device 88. Although only one expansion device 88 is shown, such is by way of example only. It is understood that multiple such devices may be used. In the illustrated example, expansion device 88 is an electronic expansion valve, although a thermal expansion valve or any other suitable expansion device can be used. In additional embodiments, any other suitable expansion device, such as a capillary tube, may be used as well. Expansion device 88 lowers the pressure of the refrigerant and controls the amount of refrigerant that is allowed to enter the evaporator 82. Importantly, the flow of liquid refrigerant into evaporator 82 is limited by expansion device 88 in order to keep the pressure low and allow expansion of the refrigerant back into the gas phase in evaporator 82. The evaporation of the refrigerant in evaporator 82 converts the refrigerant from its liquid-dominated phase to a gas phase while cooling and drying the moisture laden air MLA received from chamber 25 of drum 26. The process is repeated as air is circulated along process air flowpath 58 while the refrigerant is cycled through sealed system 80, as described above.

Although dryer appliance 10 is depicted and described herein as a heat pump dryer appliance, the inventive aspects of the present disclosure can apply to other types of closed loop airflow circuit dryer appliances. For instance, in other embodiments, dryer appliance 10 can be a condenser dryer that utilizes an air-to-air heat exchanger instead of evaporator 82 and/or an electric heater may be provided instead of condenser 86. Thus, in such embodiments, the working fluid that interacts thermally with the process air may be air. In yet other embodiments, dryer appliance 10 can be a spray tower dryer appliance that utilizes a water-to-air heat exchanger instead of utilizing a sealed refrigerant. Thus, in such embodiments, the working fluid that interacts thermally with the process air may be water. Further, in some embodiments, dryer appliance 10 can be a combination washer/dryer appliance having a closed loop airflow circuit along which process air may flow for drying operations.

Referring again to FIG. 1, a schematic diagram of an external communication system 100 will be described according to an exemplary embodiment of the present subject matter. In general, external communication system 100 is configured for permitting interaction, data transfer, and other communications with dryer appliance 10. For example, this communication may be used to provide and receive operating parameters, user instructions or notifications, performance characteristics, user preferences, or any other suitable information for improved performance of dryer appliance 10.

External communication system 100 permits controller 56 of dryer appliance 10 to communicate with external devices either directly or through a network 102. For example, a consumer may use a consumer device 104 to communicate directly with dryer appliance 10. For example, consumer devices 104 may be in direct or indirect communication with dryer appliance 10, e.g., directly through a local area network (LAN), Wi-Fi, Bluetooth, Zigbee, etc. or indirectly through network 102. In general, consumer device 104 may be any suitable device for providing and/or receiving communications or commands from a user. In this regard, consumer device 104 may include, for example, a personal phone, a tablet, a laptop computer, or another mobile device.

In addition, a remote server 106 may be in communication with dryer appliance 10 and/or consumer device 104 through network 102. In this regard, for example, remote server 106 may be a cloud-based server 106, and is thus located at a distant location, such as in a separate state, country, etc. In general, communication between the remote server 106 and the client devices may be carried via a network interface using any type of wireless connection, using a variety of communication protocols (e.g. TCP/IP, HTTP, SMTP, FTP), encodings or formats (e.g. HTML, XML), and/or protection schemes (e.g. VPN, secure HTTP, SSL).

In general, network 102 can be any type of communication network. For example, network 102 can include one or more of a wireless network, a wired network, a personal area network, a local area network, a wide area network, the internet, a cellular network, etc. According to an exemplary embodiment, consumer device 104 may communicate with a remote server 106 over network 102, such as the internet, to provide user inputs, receive user notifications or instructions, etc. In addition, consumer device 104 and remote server 106 may communicate with dryer appliance 10 to communicate similar information.

External communication system 100 is described herein according to an exemplary embodiment of the present subject matter. However, it should be appreciated that the exemplary functions and configurations of external communication system 100 provided herein are used only as examples to facilitate description of aspects of the present subject matter. System configurations may vary, other communication devices may be used to communicate directly or indirectly with one or more laundry appliances, other communication protocols and steps may be implemented, etc. These variations and modifications are contemplated as within the scope of the present subject matter.

As explained above, dryer appliance 10 generally includes a primary duct system 60 that defines a process airflow path 58 that is generally configured for circulating a flow of process air (e.g., as identified generally in FIGS. 3 through 5 by reference numeral 120). This flow of process air 120 is generally circulated through chamber 25 during a drying process while the clothes are tumbled by drum 26 to remove moisture from the clothes. However, according to exemplary embodiments of the present subject matter, dryer appliance 10 may include additional airflow paths that are intended to facilitate dehumidification of an external environment (e.g., such as an ambient environment 122) that surrounds dryer appliance 10. For example, ambient environment 122 maybe the laundry room, basement, or other location where dryer appliance 10 is housed or located. As explained above, these laundry locations may typically experience issues related to high levels of humidity and moisture. As a result, aspects of the present subject matter are directed to systems and methods for using a dryer appliance, such as dryer appliance 10, to remove humidity and moisture from the ambient environment 122, e.g., without necessitating the purchase and installation of an additional dehumidification device.

According to the illustrated embodiment, dryer appliance 10 may include an ambient air duct system 128 that is generally configured for providing fluid communication between ambient environment 122 and conditioning system 40. In this regard, for example, ambient air duct system 128 may at least partially define and ambient airflow path 130. Specifically, according to the illustrated embodiment, ambient air duct system 128 may include an intake duct 132 and a discharge duct 134 that are generally configured for receiving and discharging a flow of ambient air (e.g., as identified generally in FIGS. 3 through 5 by reference numeral 136). More specifically, as illustrated, intake duct 132 may be fluidly coupled to an intake vent 138 for receiving the flow of ambient air 136 from ambient environment 122 and discharge duct 134 may be fluidly coupled to a discharge vent 140 for discharging the flow of ambient air 136 back into ambient environment 122, e.g., after it has been dehumidified.

It should be appreciated that the positions, sizes, locations, and configurations of the various ducts and vents of ambient air duct system 128 may vary while remaining within scope the present subject matter. For example, according to exemplary embodiments and as best illustrated in FIG. 2, intake vent 138 may be defined in top cover 24 of cabinet 12. In addition, referring briefly to FIG. 1, discharge vent 140 may be defined in door 33 of dryer appliance 10. In addition, intake duct 132 may extend from intake vent 138 and be fluidly coupled to primary duct system 60. For example, intake duct 132 may fluidly couple intake vent 138 to an intake junction 142 defined on a duct 44 primary duct system 60. Similarly, discharge duct 134 may extend from discharge vent 140 and be fluidly coupled to primary duct system 60. For example, discharge duct 134 may fluidly couple discharge vent 140 to a discharge junction 144 defined on supply duct 41 of primary duct system 60.

According to the illustrated embodiment, intake junction 142 is defined upstream of blower fan 48 and downstream of drum outlet 54. In addition, discharge junction 144 may be positioned downstream of sealed system 80 and upstream of drum inlet 52. In this manner, ambient air duct system 128 may be used to draw the flow of ambient air 136 through sealed system 80 while avoiding chamber 25. According to still other embodiments, intake vent 138 and intake duct 132 may be positioned and routed at any other suitable location within and throughout cabinet 12. For example, according to alternative embodiments, ambient air duct system 128 may be entirely distinct from primary duct system 60. In this regard, these duct systems 60, 128 may be fluidly decoupled, e.g., except for where they pass over the coils of evaporator 82 of sealed system 80. Other configurations of duct systems and sealed system configurations are possible and within the scope of the present subject matter.

Referring still generally to FIGS. 3 through 5, dryer appliance 10 may further include a damper system 150 that is operably coupled to ambient air duct system 128 for selectively regulating the flow of ambient air 136. For example, according to the illustrated embodiment, damper system 150 may include an inlet damper 152 that is operably coupled to at least one of intake vent 138, intake duct 132, and/or intake junction 142 for selectively regulating the flow of ambient air 136 through intake duct 132. Similarly, damper system 150 may include an outlet damper 154 that is operably coupled to discharge junction 144, discharge duct 134, and/or discharge vent 140 for selectively regulating the flow of ambient air 136 through discharge duct 134. As used herein, the term “damper” may refer to any device or system intended to regulate a flow of air within a duct. For example, these dampers may include pivoting flaps, butterfly valves, louvers, or any other suitable flow regulating device.

In general, controller 56 of dryer appliance 10 may be operably coupled with damper system 150, e.g., to regulate the position of inlet damper 152 and/or outlet damper 154. For example, referring now specifically to FIG. 3, inlet damper 152 and outlet damper 154 are both the illustrated in the closed position (e.g., corresponding to a drying cycle) such that ambient air 136 does not flow through ambient air duct system 128. Notably, damper system 150 may be in this configuration when a dehumidification process is not desired, when a standard drying process is being performed (e.g., such that the flow of process air 120 is being circulated), when there is a system fault, etc. By contrast, as illustrated for example in FIG. 4, inlet damper 152 and outlet damper 154 are both illustrated in the open position such that the flow of ambient air 136 is drawn in from the ambient environment 122, dehumidified by conditioning system 40, and discharged back into ambient environment 122. In this manner, the ambient environment 122 may be dehumidified without necessitating the purchase and installation of an additional, dedicated dehumidifying unit.

Notably, the configuration of damper system 150 as shown in FIGS. 3 and 4 still permits the flow of process air 120 from passing through chamber 25 while a dehumidification process is being performed. However, according to alternative embodiments, damper system 150 may have an alternative configuration that isolates the process airflow path 58 from the ambient airflow path 130 as the dryer appliance 10 alternates between a standard drying cycle and a dehumidification cycle. In this regard, as best illustrated in FIG. 5, inlet damper 152 and outlet damper 154 may each be positioned such that they are pivotable between an open position where the process airflow path 58 is blocked and a closed position where the ambient airflow path 130 is blocked. For example, when damper system 150 as shown in FIG. 5 is in the open position, inlet damper 152 blocks drum outlet 54 and opens intake junction 142. It should be appreciated that other damper configurations are possible and within the scope of the present subject matter.

Notably, it may be desirable to filter the flow of ambient air 136 prior to passing through conditioning system 40. In this regard, air from ambient environment 122 may include unknown debris, dust, and other undesirable particulates. As such, dryer appliance 10 may further include an air filter 160 that is positioned within ambient air duct system 128 for filtering the flow of ambient air 136. Specifically, as shown for example in FIGS. 3 through 5, air filter 160 is positioned within intake duct 132 for filtering the flow of ambient air 136 before it passes into evaporator 82 of sealed system 80. In this manner, clogging of evaporator coils or other fouling of components of conditioning system 40 may be prevented. It should be appreciated that any suitable number, type, and configuration of air filter 160 may be used while remaining within the scope of the present subject matter. For example, air filter 160 may include one or more pleated air filters, mesh filter, High Efficiency Particulate Air (HEPA) filters, or any other suitable air filtration device or system.

According to exemplary embodiments of the present subject matter, dryer appliance 10 may be used to reduce the humidity within ambient environment 122. As such, it may be desirable to periodically or continuously measured the humidity within ambient environment 122 and or within the ambient airflow path 130. As such, dryer appliance 10 may include a humidity sensor 162 that is generally positioned and configured for measuring a humidity of ambient environment 122, e.g., to provide useful information as to when a dehumidification cycle may be needed. According to the illustrated embodiment, humidity sensor 162 is positioned within intake duct 132, e.g., upstream of air filter 160.

As used herein, the terms “humidity sensor” or the equivalent may be intended to refer to any suitable type of humidity measuring system or device positioned at any suitable location for measuring the desired humidity. Thus, for example, “humidity sensor” may refer to any suitable type of humidity sensor, such as capacitive digital sensors, resistive sensors, and thermal conductivity humidity sensors. In addition, humidity sensor 162 may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and/or indicative of the humidity being measured. Although exemplary positioning of humidity sensors is described herein, it should be appreciated that dryer appliance 10 may include any other suitable number, type, and position of humidity sensors according to alternative embodiments.

Now that the construction of dryer appliance 10 and the configuration of controller 56 according to exemplary embodiments have been presented, exemplary methods of operating a dryer appliance will be described. Although the discussion below refers to exemplary methods of operating dryer appliance 10, one skilled in the art will appreciate that the exemplary methods are applicable to the operation of a variety of other dryer appliances or laundry appliances. In exemplary embodiments, the various method steps as disclosed herein may be performed by controller 56 or a separate, dedicated controller.

Referring now to FIG. 6, method 200 is generally directed to an on-demand dehumidification cycle. In this regard, the dehumidification cycle may begin in response to user interaction with dryer appliance 10, e.g., via a user command from a remote device, such as remote device 104, via one or more input selectors 70 from user interface panel 71, or in any other suitable manner. In addition, method 200 is generally directed to the performance of a dehumidification cycle when a standard drying cycle of dryer appliance 10 is not currently being performed (though method 200 may account for this particular circumstance as described below).

As shown, method 200 includes, at step 202, receiving a command to start or initiate a dehumidification cycle. For example, this start command may be received from any suitable source and in any suitable manner. According to exemplary embodiments, a user may enter the command using a user interface panel, such as user interface panel 71 of dryer appliance 10. In this regard, for example, one of input selectors 70 may be a button, a switch, a rotary dial, a capacitive touch button, a touchscreen, or another mechanical or tactile input that a user may select to initiate the dehumidification cycle. According to still other embodiments, a user may initiate the dehumidification cycle remotely, e.g., using a consumer device 104 such as a cell phone. In this regard, a user may enter a mobile software application on their phone and may enter a command to enter the dehumidification cycle. According to still other embodiments, the command to start a dehumidification cycle may be based on a measured humidity versus a target humidity, as described in more detail below. Other manners of receiving the dehumidification cycle command are possible and within the scope of the present subject matter.

Notably method 200 illustrates a method that is initiated by a command, e.g., from a user, to initiate a dehumidification process. However, it should be appreciated that method 200 may also be initiated automatically, e.g., based on measured system parameters, to compensate situations where the measured humidity is outside the desired range. For example, method 200 may be modified to operate in a situation where an automatic humidity control mode is turned on. More specifically, method 200 may be directed to an automatic operating method where humidity sensor 162 is constantly measuring the humidity and dryer appliance 10 is automatically performing a dehumidification cycle when the measured humidity exceeds a target humidity (e.g., unless a drying cycle is commenced). In this regard, method 200 may include determining (e.g., prior to step 204) whether a drying cycle is being performed. If a regular drying cycle is being performed, damper system 150 may remain closed and the regular drying cycle may be completed. However, if the regular drying operation is not being performed and a command to initiate a dehumidification cycle is received or if the measured humidity is above a target humidity, method may proceed as discussed herein.

Method 200 may further include, at step 204, determining whether the user has set a target humidity. In this regard, for example, a user may program or control the setpoint humidity to which dryer appliance 10 may limit the ambient humidity. If the user has previously set or programmed a target humidity, step 206 may include using the requested target humidity. By contrast, step 208 may include using a default humidity value in the event the user has not programmed the desired target humidity. In this regard, the default target humidity may be a predetermined humidity threshold that is programmed by the manufacturer or determined in any other suitable manner. Now that the desired humidity level has been determined, damper system 150 and conditioning system 40 may be used to regulate the humidity of the flow of ambient air 136 to the target humidity level. In this regard, step 210 may include regulating damper system 150 to permit the flow of ambient air 136 to pass through the conditioning system 40 and through the ambient air duct system 128. For example, continuing the example from above, inlet damper 152 and outlet damper 154 may be moved to the open position at step 210.

Step 212 may include operating a circulation fan, air blower, etc. for urging the flow of ambient air through the ambient air duct system 128. In this regard, continuing the example from above, blower fan 48 may be activated after the dampers are in their open position to urge the flow of ambient air 136 through ambient air duct system 128. Notably, the flow of ambient air 136 may first pass through air filter 160 to remove impurities prior to passing through conditioning system 40. Step 214 may include measuring the humidity of the flow of ambient air and comparing it to the target humidity (e.g., as determined at steps 206 and 208). In this regard, if the currently measured humidity is greater than the target humidity (e.g., such that the humidity needs to be reduced or a dehumidification cycle needs to be implemented), step 216 may include activating sealed system 80 to start the dehumidification process.

Step 218 may include determining whether a command has been received to stop the dehumidification cycle. For example, this request to stop the dehumidification cycle may be received when a new drying cycle is initiated, when a user is comfortable with the humidity level in ambient environment 122, or for various other reasons. In such events, step 220 may include turning off conditioning system 40, blower fan 48, closing damper system 150 (if the application calls for such action), etc. If no stop command has been received at step 218, method 200 may proceed again to step 214 where the measured humidity is compared to the target humidity. If the measured humidity is still elevated, the dehumidification cycle may proceed as described above. By contrast, once the measured current humidity falls below the target humidity, step 222 may include ceasing the performance of method 200, e.g., by doing nothing until a further command is received or the ambient humidity again exceeds the target humidity.

Referring now briefly to FIG. 7, the dehumidification system described herein may also be used to detect faults or the occurrence of specific conditions during the operation of a dryer appliance. In this regard, method 300 may generally be directed to such a fault detection method. Specifically, as shown, step 302 may include starting a dehumidification cycle. Similar to step 202 described above, is command to initiate a dehumidification cycle may be received from any suitable source and in any suitable manner. Step 304 includes determining that the conditioning system has been operating to reduce the ambient humidity for longer than a predetermined amount of time. If this predetermined amount of time has not passed, step 306 may include doing nothing and waiting for the predetermined amount of time to pass. By contrast, once the predetermined amount of time has passed, step 308 includes determining whether the ambient humidity has dropped by a predetermined amount within the predetermined amount of time.

In this regard, method 300 is generally configured for ensuring that the humidity is dropping at the expected rate while the dehumidification process is running. If the dehumidification process is not dropping the humidity at that desired rate, this may indicate a fault with the dryer appliance and/or the dehumidification system. For example, if the humidity has dropped by the predetermined amount or percentage of relative humidity, step 310 may include determining that there is no fault condition. By contrast, if the humidity has not dropped by more than a predetermined percentage, step 312 may include determining that there is a potential system fault and notifying a user of dryer appliance. In this regard, for example, step 312 may include stopping the dehumidification cycle and/or alerting the consumer via user interface panel 71, remote device 104, or in any other suitable manner. Notably, this fault detection process may be used to determine when conditioning system 40 is not operating properly, such as in the event of a refrigerant leak or any other condition that prevents a proper dehumidification process. Alternatively, this fault may mean there is a leak or improper installation in the room where dryer appliance 100 is used. For example, elevated humidity levels and an inability of a dehumidification process to lower the humidity may indicate that there is an open window. According to other embodiments, this fault detection process may indicate that the humidity sensor is malfunctioning, needs to be cleaned, or needs to otherwise be repaired or replaced.

FIGS. 6 through 7 depict steps performed in a particular order for purposes of illustration and discussion. Those of ordinary skill in the art, using the disclosures provided herein, will understand that the steps of any of the methods discussed herein can be adapted, rearranged, expanded, omitted, or modified in various ways without deviating from the scope of the present disclosure. Moreover, although aspects of methods 200, 300, and 400 are explained using dryer appliance 10 as an example, it should be appreciated that these methods may be applied to the operation of any suitable dryer appliance or laundry appliance.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A laundry appliance comprising:

a cabinet;

a drum rotatably mounted within the cabinet, the drum defining a chamber for receipt of articles for drying;

a conditioning system configured to heat and remove moisture from air flowing therethrough;

a primary duct system for providing fluid communication between the chamber and the conditioning system, wherein the primary duct system, the conditioning system, and the drum define a process air flowpath;

an ambient air duct system for providing fluid communication between an ambient environment and the conditioning system, wherein the ambient air duct system and the conditioning system at least partially define an ambient air flowpath;

a blower fan operable to move at least one of a flow of process air through the process air flowpath or a flow of ambient air through the ambient air flowpath;

a damper system operably coupled to the ambient air duct system for selectively regulating the flow of ambient air; and

a controller operably coupled to the conditioning system, the blower fan, and the damper system, the controller being configured to: receive a command to initiate a dehumidification cycle; and regulate the damper system to permit the flow of ambient air to pass through the conditioning system and through the ambient air duct system.

2. The laundry appliance of claim 1, wherein the ambient air duct system comprises:

an intake vent for receiving the flow of ambient air from the ambient environment; and

a discharge vent for discharging the flow of ambient air to the ambient environment.

3. The laundry appliance of claim 2, further comprising:

a door pivotally mounted to the cabinet for providing selective access to the chamber, wherein the discharge vent is defined in the door.

4. The laundry appliance of claim 2, wherein the damper system comprises:

an inlet damper operably coupled to the intake vent for selectively regulating the flow of ambient air through the intake vent; and

an outlet damper operably coupled to the discharge vent for selectively regulating the flow of ambient air through the discharge vent.

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

an air filter positioned within the ambient air duct system for filtering the flow of ambient air.

6. The laundry appliance of claim 5, wherein the air filter is a High Efficiency Particulate Air (HEPA) filter.

7. The laundry appliance of claim 5, wherein the air filter is positioned proximate an intake vent upstream of an evaporator of the conditioning system.

8. The laundry appliance of claim 1, further comprising a humidity sensor, wherein the controller is further configured to:

measure an ambient humidity using the humidity sensor; and

initiate the dehumidification cycle when the ambient humidity exceeds a predetermined humidity threshold.

9. The laundry appliance of claim 8, wherein the humidity sensor is positioned proximate an intake vent upstream of an evaporator of the conditioning system.

10. The laundry appliance of claim 8, wherein the controller is further configured to:

determine that the conditioning system has been operating to reduce the ambient humidity for longer than a predetermined amount of time;

determine that the ambient humidity has not dropped by a predetermined amount within the predetermined amount of time; and

notify a user of a fault in the conditioning system or the humidity sensor.

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

a condensate collection tank for collecting condensed water from the conditioning system; and

a drain pump in fluid communication with condensate collection tank for selectively discharging the condensed water to an external drain.

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

a user interface panel positioned on the cabinet for facilitating user interaction with the laundry appliance, wherein the command to initiate the dehumidification cycle is received from a user through the user interface panel.

13. The laundry appliance of claim 1, wherein the controller is in operative communication with a remote device through an external network, and wherein the command to initiate the dehumidification cycle is provided through the remote device.

14. The laundry appliance of claim 1, wherein the laundry appliance is a heat pump dryer appliance or a combination washer and heat pump dryer appliance.

15. A method of operating a laundry appliance, the laundry appliance comprising a drum rotatably mounted within a cabinet, the drum defining a chamber for receipt of articles for drying, a conditioning system configured to heat and remove moisture from air flowing therethrough, a primary duct system providing fluid communication between the chamber and the conditioning system, an ambient air duct system providing fluid communication between an ambient environment and the conditioning system, a blower fan operable to move at least one of a flow of process air or a flow of ambient air, and a damper system operably coupled to the ambient air duct system for selectively regulating the flow of ambient air, the method comprising:

receiving a command to initiate a dehumidification cycle; and

regulating the damper system to permit the flow of ambient air to pass through the conditioning system and through the ambient air duct system.

16. The method of claim 15, wherein the ambient air duct system comprises:

an intake vent for receiving the flow of ambient air from the ambient environment; and

a discharge vent for discharging the flow of ambient air to the ambient environment.

17. The method of claim 16, wherein the damper system comprises:

an inlet damper operably coupled to the intake vent for selectively regulating the flow of ambient air through the intake vent; and

an outlet damper operably coupled to the discharge vent for selectively regulating the flow of ambient air through the discharge vent.

18. The method of claim 15, wherein the laundry appliance further comprises:

an air filter positioned within the ambient air duct system for filtering the flow of ambient air.

19. The method of claim 15, wherein the laundry appliance further comprises a humidity sensor, the method further comprising:

measuring an ambient humidity using the humidity sensor; and

initiating the dehumidification cycle when the ambient humidity exceeds a predetermined humidity threshold.

20. The method of claim 19, further comprising:

determining that the conditioning system has been operating to reduce the ambient humidity for longer than a predetermined amount of time;

determining that the ambient humidity has not dropped by a predetermined amount within the predetermined amount of time; and

notifying s user of a fault in the conditioning system or the humidity sensor.