LAUNDRY APPLIANCE HAVING A THERMAL STORAGE MECHANISM FOR CAPTURING EXCESS HEAT FROM ONE OR MORE HEAT SOURCES

Abstract

A laundry appliance includes a blower that directs process air through an airflow path. A rotating drum holds articles to be processed. A heat pump system has a condenser and an evaporator. The evaporator dehumidifies the process air that is delivered from the drum and the condenser heats the process air that is delivered from the evaporator. A phase change material retains heat from the condenser that is directed away from the process air, and the captured heat of the phase change material is utilized during a subsequent laundry cycle.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 63/312,127, filed on Feb. 21, 2022, entitled LAUNDRY APPLIANCE HAVING A THERMAL STORAGE MECHANISM FOR CAPTURING EXCESS HEAT FROM ONE OR MORE HEAT SOURCES, the entire disclosure of which is hereby incorporated herein by reference.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to appliances, and more specifically, to laundry appliances that utilize a thermal storage mechanism, such as a phase change material, for capturing and retaining excess thermal energy for later use.

SUMMARY OF THE DISCLOSURE

According to an aspect of the present disclosure, a laundry appliance includes a blower that directs process air through an airflow path. A rotating drum holds articles to be processed. A heat pump system has a condenser and an evaporator. The evaporator dehumidifies the process air that is delivered from the drum and the condenser heats the process air that is delivered from the evaporator. A phase change material retains heat from the condenser that is directed away from the process air to define captured heat, and the captured heat of the phase change material is utilized during a subsequent laundry cycle.

According to another aspect of the present disclosure, a laundry appliance includes a blower that directs process air through an airflow path. A rotating drum holds articles to be processed. A heat exchange system has a heating assembly. A heating assembly generates heat that is delivered into the process air from a processing space defined within the rotating drum. A phase change material retains heat from the heating assembly that is directed away from the process air to define captured heat, and the captured heat of the phase change material is utilized during a subsequent laundry cycle.

According to yet another aspect of the present disclosure, a method for operating a laundry appliance includes the steps of activating a blower that delivers process air through an airflow path, activating at least one heater that is in thermal communication with the airflow path wherein heat from the at least one heater is delivered into the airflow path, capturing excess thermal energy from the at least one heater within a phase change material to define captured heat, storing the captured heat for a period of time, activating a subsequent laundry cycle (e.g. a drying cycle), and delivering process air into thermal communication with the phase change material to transfer the captured heat from the phase change material to the process air for increasing a temperature of the process air.

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

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a schematic diagram illustrating an aspect of a laundry appliance that incorporates a phase change material within an airflow path;

FIG. 2 is a schematic diagram illustrating an appliance that incorporates an aspect of the thermal storage mechanism that is in thermal communication with a plurality of branches of an airflow path for the appliance;

FIG. 3 is a linear flow diagram illustrating a method for heating process air for drying articles within a laundry appliance; and

FIG. 4 is a schematic diagram illustrating an aspect of a laundry appliance that incorporates a phase change material within a secondary condenser.

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

DETAILED DESCRIPTION

The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to apparatus components related to a thermal storage mechanism that captures thermal energy produced by one or more heat sources, where heat that is not directed into process air for an airflow path is captured within the thermal storage mechanism for subsequent use within the same laundry cycle or a separate laundry cycle. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

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

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

Referring to FIGS. 1, 2 and 4, reference numeral 10 generally refers to a laundry appliance, typically a dryer, a laundry appliance having a drying capability, or other heating, cooling or dehumidifying appliance. Included within the laundry appliance 10 is a heating assembly that includes one or more heaters 12 that are used to heat process air 14 that is delivered by a blower 16 through an airflow path 18 for drying articles 20 within a processing space 22. The thermal storage mechanism 24 typically includes a phase change material 26 that can receive thermal energy 28, or heat, from one of the heaters 12 and store that thermal energy 28 for an extended period of time.

This stored thermal energy 28 can be used later within the same laundry cycle or within a subsequent laundry cycle. According to various aspects of the device, the laundry appliance 10 includes the blower 16 that directs the process air 14 through the airflow path 18. A rotating drum 40 defines the processing space 22 and holds articles 20 to be processed. An outer cabinet 100 surrounds the drum 40. Typically, processing articles 20 includes drying articles 20 that have been washed or otherwise treated within the same appliance 10 or a separate washing appliance 10. A heater 12 is positioned in thermal communication with the airflow path 18. This heater 12 provides thermal energy 28 to the process air 14 and elevates the temperature of the process air 14 for use in drying the articles 20 within the processing space 22.

In at least one aspect of the device, the primary heater 12 is in the form of a condenser of a heat exchange system, such as a heat pump system. Typically, a heat pump system includes a condenser and an evaporator, where the evaporator absorbs thermal energy 28 to cool and dehumidify the process air 14 that is delivered from the drum 40. After this dehumidification occurs, the process air 14 is delivered by or through the condenser. The condenser rejects thermal energy 28 and delivers this rejected thermal energy 28 to the process air 14 for delivery back to the processing space 22. The thermal storage mechanism 24 includes the phase change material 26. This phase change material 26 retains thermal energy 28 from the condenser that has not been directed into the process air 14. Stated another way, the thermal energy 28 captured by the phase change material 26 is in the form of heat that would dissipate, be lost, wasted, or would otherwise not be used within a drying operation of the appliance 10. The captured heat 30 stored within the phase change material 26 is kept for an extended period of time. The stored thermal energy 28 can then be utilized during a subsequent laundry cycle or a subsequent portion of the same laundry cycle.

According to various aspects of the device, the primary heater 12 for the appliance 10 can include the condenser for a heat pump system, a condenser for a condensing dryer, a resistive heating element, a gas-powered heating element, combinations thereof, and other similar heating elements that are used within laundry appliances 10. Where the primary heater 12 is in the form of the condenser for a heat pump system, or a condensing dryer, it is common that a secondary heater 50 is incorporated within the laundry appliance 10 for providing additional thermal energy 28 to the process air 14 moved through the airflow path 18. This secondary heater 50 is in communication with the airflow path 18 as well as the phase change material 26. In this manner, the secondary heater 50 can provide heat directly to the process air 14 for elevating the temperature of the process air 14 to be used within a current laundry cycle. Additionally, excess thermal energy 28 generated by the secondary heater 50 can be captured within the phase change material 26 for later use. It is contemplated that the secondary heater 50 can be in the form of an electrically resistive heating element or a gas-powered heater. Additionally, the secondary heater 50 can be positioned adjacent to the primary heater 12 or can be positioned downstream from the primary heater 12. In either instance, the secondary heater 50 and the primary heater 12 are typically positioned adjacent to the phase change material 26. In this manner, the phase change material 26 can obtain thermal energy 28 from the primary heater 12 and the secondary heater 50 to prevent a loss of thermal energy 28 from the appliance 10.

According to various aspects of the device, as exemplified in FIGS. 1 and 2, the airflow path 18 can include a single air duct 60 that moves through the appliance 10 between the processing space 22 within the drum 40 and the thermal storage mechanism 24. As discussed herein, the thermal storage mechanism 24 can include any one or more of the heaters described herein and a cooling mechanism. This cooling mechanism can be in the form of an evaporator, air-to-air heat exchanger, or other similar mechanism for extracting thermal energy 28 from the process air 14. Where the airflow path 18 includes a single air duct 60, the various heaters and the phase change material 26 are each positioned in communication with the airflow path 18. Additionally, the phase change material 26 is placed in thermal communication with each of the heaters, the primary heater 12 and the secondary heater 50, for capturing thermal energy 28 that is not directly used for elevating the temperature of the process air 14.

Use of the captured heat 30 within the phase change material 26 typically occurs where additional thermal energy 28 is needed for accomplishing a particular laundry function. Such a laundry function can include a quick-dry cycle 70. In a quick-dry cycle 70, the process air 14 is heated to a higher temperature that is typically not achievable using the primary heater 12 and the secondary heater 50. Using this higher temperature, greater amounts of moisture from within the processing space 22 can be captured by the process air 14 moving through the drum 40. In turn, the higher temperature of the process air 14 typically results in a lower time needed for drying the articles 20 within the drum 40. To achieve this elevated temperature, the phase change material 26, having captured thermal energy 28 from a previous laundry cycle or previous portion of the current laundry cycle releases this captured heat 30 into the process air 14. This release of captured heat 30 can be combined with the heat generated from the heating assembly for providing a combined heat that achieves the desired temperature of the process air 14 to perform the quick-dry cycle 70.

The phase change material 26 can also use the captured heat 30 for use during a start-up function. The additional heat may be needed in an appliance 10 having a heat pump system. Certain heat pump systems require a certain amount of time for the condenser to achieve a desired thermal output. As the condenser achieves the desired thermal output, captured heat 30 from the phase change material 26 can be utilized for adding heat and increasing the temperature of the process air 14 at the beginning of a particular laundry cycle. Typically, captured heat 30 within the phase change material 26 will be used within laundry cycles that require a higher than normal temperature of the process air 14.

Referring now to FIG. 2, the airflow path 18 can include separate branches that move through the thermal storage mechanism 24 for the appliance 10. A primary branch 80 can move past the primary heater 12 as well as a secondary heater 50. This primary branch 80 of the airflow path 18 is typically used in each of the laundry cycles performed by the appliance 10. The phase change material 26 can also be positioned adjacent to the primary branch 80 of the airflow path 18 for receiving excess thermal energy 28 from the various heat sources of the appliance 10. The airflow path 18 can also include a secondary branch 82 that is positioned adjacent to the phase change material 26. The secondary branch 82 can be utilized during the quick-dry cycle 70 for delivering process air 14 past or through the phase change material 26. During this operation, captured heat 30 within the phase change material 26 is delivered into an accessory flow 84 of process air 14 to be combined with a primary flow 86 of process air 14 that moves through the primary branch 80 of the airflow path 18.

The combination of the primary flow 86 of process air 14 that is heated by the primary heater 12 and, in certain instances, a secondary heater 50, is combined with the secondary flow of process air 14 that is heated by receiving thermal energy 28 from the phase change material 26. This combination of the primary flow 86 of process air 14 and the accessory flow 84 of process air 14 results in the higher temperature of the process air 14 that can be delivered to the processing space 22 within the drum 40 during the quick-dry cycle 70 and other high-heat demand situations. Various baffles, air handlers, and other air directing devices can be utilized for providing the accessory flow 84 of process air 14 through the secondary branch 82 of the airflow path 18 and through the phase change material 26.

In such an aspect of the device, as exemplified in FIG. 2, where only the primary branch 80 of the airflow path 18 is utilized, the primary heater 12 and the secondary heater 50 each operate to heat the process air 14. As discussed herein, excess thermal energy 28 produced by the primary heater 12 and the secondary heater 50 is captured by the phase change material 26. Storage of this captured heat 30 within the phase change material 26 can be utilized for heating the accessory flow 84 of process air 14 within the secondary branch 82 of the airflow path 18. It is also contemplated that the phase change material 26 can be utilized for heating the primary flow 86 of process air 14 through the primary branch 80. In each of the instances described herein, the thermal energy 28 stored by the phase change material 26 is utilized for increasing the temperature of the process air 14. Use of the phase change material 26 can result in the appliance 10 being fitted with heating elements of slightly diminished size due to the more efficient use and storage of thermal energy 28 produced by each of the primary heater 12, the secondary heater 50, and other heating mechanisms that are incorporated into the appliance 10. Additionally, by capturing excess thermal energy 28, the phase change material 26 can be used for decreasing the time needed for drying articles 20 within the drum 40.

According to various aspects of the device, the phase change material 26 can be located within the thermal storage mechanism 24 for the appliance 10. This thermal storage mechanism 24 can be positioned within the cabinet 100 and near the various heaters for heating the process air 14. It is also contemplated that the thermal storage mechanism 24 can be a separate module 102 that is positioned adjacent to and exterior to the cabinet 100 for the appliance 10. In such an aspect of the device, the airflow path 18 can be configured to move from within the cabinet 100, through a wall of the cabinet 100 and to an area outside of the cabinet 100 and through the module 102 containing the thermal storage mechanism 24, and then back through the wall and into the cabinet 100 for delivery to the processing space 22 within the drum 40. Where the thermal storage mechanism 24 is an external module, this external module can be in the form of a factory-installed module or an aftermarket module that can be installed after purchase.

According to various aspects of the device, the thermal storage mechanism 24 can be used in combination with a single drying appliance 10, as well as within multiple appliances 10. In such an aspect of the device, the thermal storage mechanism 24 can be attached to one or more heaters of a washer and dryer pair where excess thermal energy 28 produced by these appliances 10 can be gathered within the phase change material 26 of the thermal storage mechanism 24 as captured heat 30. In such an aspect, captured heat 30 within the phase change material 26 can be utilized for heating fluid materials (liquid and/or gas) within either of the washer or the dryer. Additionally, where the appliance 10 is a combination washing and drying appliance 10, the phase change material 26 can be utilized for storing captured heat 30 from the various heaters within the appliance 10. As described herein, the captured heat 30 retained by the phase change material 26 can be utilized for washing and drying phases of a particular laundry cycle.

In various aspects of the device, as exemplified in FIG. 4, an appliance 10 that incorporates the heat exchange system, such as a heat pump system or a condensing system, can include a cooler, such as an evaporator 108, for extracting heat from the process air 14. This extraction of heat is utilized for dehumidifying the process air 14 after it leaves the processing space 22. By extracting heat from the process air 14, moisture is also condensed from the process air 14. The now cooled and dehumidified air can then be returned to the condenser, being the primary heater 12 for the system, or other heating mechanism, as described herein. The process air 14 is reheated using the primary heater 12 and is returned to the drum 40. To provide increased heating, the appliance 10 can include a secondary heater 50 that is positioned downstream of the primary heater 12.

Referring again to FIG. 4, to assist in the rejection of thermal energy 28 from the primary heater 12 and the transfer of thermal energy 28 into the process air 14 by the primary heater 12, certain appliances 10 can include a secondary condenser 110 that rejects additional amount of thermal energy 28 that cannot be delivered into the process air 14. Thermal energy 28, typically from a refrigerant or other heat exchange media, is delivered through each of the primary heater 12 and the secondary condenser 110 to reject a sufficient amount of thermal energy 28. This use of the primary heater 12 and the secondary condenser 110 accounts for a proper balance of the system to provide for a consistent exchange of thermal energy 28 between the process air 14 and the evaporator 108 and the primary heater 12 and the secondary condenser 110.

Referring again to FIG. 4, a portion of the phase change material 26 can be positioned around the secondary condenser 110 for receiving this additionally extracted thermal energy 28. This extracted thermal energy 28 can be utilized, as described herein, for other portions of the laundry cycle or subsequent laundry cycles. In certain aspects of the device, the secondary condenser 110 can be used to reject or expel additional amounts of thermal energy 28. This rejection of thermal energy 28 is useful for preventing overheating of the systems within the appliance 10. It is contemplated that this rejected thermal energy 28 can be captured within a portion of the phase change material 26 that is positioned adjacent to the secondary condenser 110. In this aspect of the device, the phase change material 26 receives the rejected thermal energy 28 from the secondary condenser 110 for later use. During a later laundry cycle, the captured heat 30 within the phase change material 26 can be transferred back into the refrigerant moving through a refrigerant loop that includes the secondary condenser 110. In this manner, the phase change material 26 transfers the thermal energy 28 back into the refrigerant and the now charged refrigerant is delivered to the primary condenser or primary heater 12 to be delivered into the process air 14 moving through the airflow path 18. In certain aspects of the device, it is contemplated that the thermal energy 28 that is received and stored within the phase change material 26 as captured heat 30 can be delivered, via an alternative path, back into the process air 14 moving through the airflow path 18.

According to the various aspects of the device, as exemplified in FIGS. 1-4, the phase change material 26 receives thermal energy 28, typically excess thermal energy 28, from the primary heater 12 and the secondary heater 50 to define captured heat 30. This captured heat 30 can be stored and utilized later in the laundry cycle or within the subsequent laundry cycle. A controller 112 for the appliance 10 can be placed in communication with the evaporator 108, the primary heater 12, the secondary condenser 110, the secondary heater 50 and the blower 16, along with other components of the appliance 10. In this manner, the controller 112 can operate these components to allow for the efficient exchange of thermal energy 28 for operating the appliance 10.

The phase change material 26 can be in the form of any one of various materials. Such materials can include, but are not limited to, glycol, paraffin wax, a refrigerant, water, air, combinations thereof, and other similar materials that can be used to absorb and store thermal energy 28 for a period of time.

Having described various aspects of the device, a method 400 is disclosed for operating a laundry appliance 10 utilizing a thermal storage mechanism 24. According to the method 400, step 402 includes activating a laundry cycle. Step 404 includes activating one or more heaters within the appliance 10 for heating process air 14. Step 406 includes capturing excess thermal energy 28 within a phase change material 26 to define captured heat 30. Step 408 includes storing the captured heat 30 for a period of time. Step 410 includes activating a quick-dry cycle 70. Step 412 includes directing process air 14 in thermal communication with the phase change material 26 to receive the captured heat 30 and increase the temperature of the process air 14. As described herein, the captured heat 30 can be delivered from the phase change material 26 and to the process air 14 either directly through thermal communication, or indirectly through the use of a refrigerant within a refrigerant loop. As described herein, the quick-dry cycle 70 utilizes the one or more heaters to directly heat the process air 14 that is delivered to the processing space 22 of the appliance 10. The captured heat 30 within the phase change material 26 is also directed into the process air 14 for elevating the temperature of the process air 14.

In certain aspects of the device, the phase change material 26 may be located upstream of the primary heater 12 and/or the secondary heater 50 to provide a greater temperature difference between the temperature of the process air 14 and the temperature of the phase change material 26 having the captured heat 30. Where there is a greater difference between the temperature of the process air 14 and the phase change material 26, a greater exchange of thermal energy 28 can occur. This initial elevation of the temperature of the process air 14 can be followed by the process air 14 moving past the primary heater 12 and/or the secondary heater 50 for providing a greater increase in temperature of the process air 14 as it moves toward the processing space 22.

In certain aspects of the device, it is also contemplated that the phase change material 26 can be located downstream of the various heaters and also adjacent to the various heaters.

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

According to an aspect of the present disclosure, a laundry appliance includes a blower that directs process air through an airflow path. A rotating drum holds articles to be processed. A heat pump system has a condenser and an evaporator. The evaporator dehumidifies the process air that is delivered from the drum and the condenser heats the process air that is delivered from the evaporator. A phase change material retains heat from the condenser that is directed away from the process air to define captured heat, and the captured heat of the phase change material is utilized during a subsequent laundry cycle.

According to another aspect, the airflow path includes a single duct that extends between a processing space within the rotating drum and the heat pump system.

According to another aspect, the laundry appliance further includes a secondary heater that is positioned adjacent to the phase change material. The secondary heater is in thermal communication with the phase change material and the airflow path.

According to another aspect, the captured heat is utilizing during one of a quick-start function of the subsequent laundry cycle and a quick-dry function of the subsequent laundry cycle.

According to another aspect, the airflow path proximate the phase change material includes a primary branch and a secondary branch. The secondary branch is utilized for delivering the captured heat from the phase change material to the airflow path via the secondary branch.

According to another aspect, the primary branch is continuously used during operation of the blower.

According to another aspect, the phase change material includes at least one of glycol, paraffin wax, and a refrigerant.

According to another aspect, the laundry appliance further includes a secondary condenser. The phase change material is positioned adjacent to the secondary condenser for receiving heat from the secondary condenser to define the captured heat. The captured heat is delivered to the airflow path during the subsequent laundry cycle.

According to another aspect, the secondary condenser is in thermal communication with the airflow path via a refrigerant.

According to another aspect, operation of the condenser and the secondary heater are operated using a controller.

According to another aspect, the phase change material is positioned upstream of the condenser.

According to another aspect, the phase change material is disposed within a module that is positioned exterior to a structural cabinet that surrounds the rotating drum.

According to another aspect, the airflow path extends through a wall of the structural cabinet to move through the module having the phase change material, and the module includes the secondary heater.

According to another aspect, the phase change material is also in thermal communication with a separate laundry appliance that includes a washing function.

According to another aspect of the present disclosure, a laundry appliance includes a blower that directs process air through an airflow path. A rotating drum holds articles to be processed. A heat exchange system has a heating assembly. A heating assembly generates heat that is delivered into the process air from a processing space defined within the rotating drum. A phase change material retains heat from the heating assembly that is directed away from the process air to define captured heat, and the captured heat of the phase change material is utilized during a subsequent laundry cycle.

According to another aspect, during the subsequent laundry cycle, the captured heat from the phase change material and heat from the heating assembly cooperate to deliver a combined heat to the process air.

According to another aspect, the heating assembly includes an electrically resistive heating element.

According to another aspect, the heating assembly includes a condenser.

According to another aspect, the heating assembly includes a primary heater in communication with the airflow path that delivers the process air, and the heating assembly also includes a secondary heater that is in communication with the airflow path and the phase change material.

According to yet another aspect of the present disclosure, a method for operating a laundry appliance includes the steps of activating a blower that delivers process air through an airflow path, activating at least one heater that is in thermal communication with the airflow path wherein heat from the at least one heater is delivered into the airflow path, capturing excess thermal energy from the at least one heater within a phase change material to define captured heat, storing the captured heat for a period of time, activating a subsequent laundry cycle (e.g. a drying cycle), and delivering process air into thermal communication with the phase change material to transfer the captured heat from the phase change material to the process air for increasing a temperature of the process air.

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

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

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

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

Claims

1. A laundry appliance comprising:

a blower that directs process air through an airflow path;

a rotating drum that holds articles to be processed;

a heat pump system having a condenser and an evaporator, wherein the evaporator dehumidifies the process air delivered from the drum and wherein the condenser heats the process air delivered from the evaporator; and

a phase change material that retains heat from the condenser that is directed away from the process air to define captured heat, and wherein the captured heat of the phase change material is utilized during a subsequent laundry cycle.

2. The laundry appliance of claim 1, wherein the airflow path includes a single duct that extends between a processing space within the rotating drum and the heat pump system.

3. The laundry appliance of claim 1, further comprising a secondary heater that is positioned adjacent to the phase change material, wherein the secondary heater is in thermal communication with the phase change material and the airflow path.

4. The laundry appliance of claim 1, wherein the captured heat is utilized during one of a quick-start function of the subsequent laundry cycle and a quick-dry function of the subsequent laundry cycle.

5. The laundry appliance of claim 1, wherein the airflow path proximate the phase change material includes a primary branch and a secondary branch, wherein the secondary branch is utilized for delivering the captured heat from the phase change material to the airflow path via the secondary branch.

6. The laundry appliance of claim 5, wherein the primary branch is continuously used during operation of the blower.

7. The laundry appliance of claim 1, wherein the phase change material includes at least one of glycol, paraffin wax, and a refrigerant.

8. The laundry appliance of claim 1, further comprising a secondary condenser, wherein the phase change material is positioned adjacent to the secondary condenser for receiving heat from the secondary condenser to define the captured heat, and wherein the captured heat is delivered to the airflow path during the subsequent laundry cycle.

9. The laundry appliance of claim 8, wherein the secondary condenser is in thermal communication with the airflow path via a refrigerant.

10. The laundry appliance of claim 3, wherein operation of the condenser and the secondary heater are operated using a controller.

11. The laundry appliance of claim 3, wherein the phase change material is positioned upstream of the condenser.

12. The laundry appliance of claim 11, wherein the phase change material is disposed within a module that is positioned exterior to a structural cabinet that surrounds the rotating drum.

13. The laundry appliance of claim 12, wherein the airflow path extends through a wall of the structural cabinet to move through the module having the phase change material, wherein the module includes the secondary heater.

14. The laundry appliance of claim 1, wherein the phase change material is also in thermal communication with a separate laundry appliance that includes a washing function.

15. A laundry appliance comprising:

a blower that directs process air through an airflow path;

a rotating drum that holds articles to be processed;

a heat exchange system having a heating assembly, wherein the heating assembly generates heat that is delivered into the process air delivered from a processing space defined within the rotating drum; and

a phase change material that retains heat from the heating assembly that is directed away from the process air to define captured heat, and wherein the captured heat of the phase change material is utilized during a subsequent laundry cycle.

16. The laundry appliance of claim 15, wherein during the subsequent laundry cycle, the captured heat from the phase change material and heat from the heating assembly cooperate to deliver a combined heat to the process air.

17. The laundry appliance of claim 15, wherein the heating assembly includes an electrically resistive heating element.

18. The laundry appliance of claim 15, wherein the heating assembly includes a condenser.

19. The laundry appliance of claim 15, wherein the heating assembly includes a primary heater in communication with the airflow path that delivers the process air, and wherein the heating assembly also includes a secondary heater that is in communication with the airflow path and the phase change material.

20. A method for operating a laundry appliance, the method comprising steps of:

activating a blower that delivers process air through an airflow path;

activating at least one heater that is in thermal communication with the airflow path wherein heat from the at least one heater is delivered into the airflow path;

capturing excess thermal energy from the at least one heater within a phase change material to define captured heat;

storing the captured heat for a period of time;

activating a subsequent laundry cycle; and

delivering process air into thermal communication with the phase change material to transfer the captured heat from the phase change material to the process air for increasing a temperature of the process air.