LAUNDRY TREATING APPLIANCE WITH HEATING ASSEMBLY

Abstract

A laundry treating appliance includes a treating chamber and a drying circuit fluidly coupled to the treating chamber and supplying process air. A heating assembly for the laundry treating appliance is in thermal interaction with the supplied process air. The heating assembly includes a housing defining an air inlet and an air outlet, an air flow path extending through the housing from the air inlet to the air outlet, and a heat exchange plate disposed within the housing. A first heating element is positioned within the housing and spaced from a first side of the heat exchange plate. A set of fins can also extend from at least the first side of the heat exchange plate.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Patent Application No. 63/351,655, filed Jun. 13, 2022, which is incorporated by reference herein in its entirety.

BACKGROUND

Laundry treating appliances, such as washing machines, combination washer/dryers, refreshers, and non-aqueous systems, can have a configuration based on a treating chamber in which laundry items are placed for treating. The laundry treating appliance can have a controller that implements a number of user-selectable, pre-programmed cycles of operation having one or more operating parameters. Hot water, cold water, or a mixture thereof, along with various treating chemistries, can be supplied to the treating chamber in accordance with the cycle of operation. In addition, hot air, cold air, or a mixture thereof can be supplied to the treating chamber in accordance with the cycle of operation and via an air flow assembly.

BRIEF SUMMARY

In one aspect, the disclosure relates to a laundry treating appliance. The laundry treating appliance includes a chassis defining an interior, a treating chamber located within the interior, a drying circuit within the interior and comprising an air recirculation conduit fluidly coupled to the treating chamber, a blower supplying process air to the air recirculation conduit, and a heating assembly in thermal interaction with the process air supplied to the treating chamber. The heating assembly includes a housing extending along an axial direction and defining an air inlet and an air outlet, with the air outlet configured to fluidly couple to an air recirculation conduit in the laundry treating appliance, an air flow path extending through the housing from the air inlet to the air outlet, a heat exchange plate disposed within the housing and having a first side radially opposite a second side, with each of the first and second sides thermally coupled to the air flow path, a first heating element positioned within the housing and spaced from the first side of the plate, and a set of fins extending from at least the first side of the plate, with a fin in the set of fins comprising a distal end radially spaced between the first heating element and the first side of the plate.

In another aspect, the disclosure relates to a heating assembly for heating process air in a laundry treating appliance. The heating assembly includes a housing extending along an axial direction and defining an air inlet and an air outlet, with the air outlet configured to fluidly couple to an air recirculation conduit in the laundry treating appliance, an air flow path extending through the housing from the air inlet to the air outlet, a heat exchange plate disposed within the housing and having a first side radially spaced from a second side, with each of the first and second sides thermally coupled to the air flow path, a first heating element positioned within the housing and spaced from the first side of the plate, and a set of fins extending from at least the first side of the plate, with each fin in the set of fins comprising a distal end radially spaced from the heating element.

In another aspect, the disclosure relates to a heating assembly for heating process air in a laundry treating appliance. The heating assembly includes a housing extending along an axial direction and defining an interior surface, an air inlet, and an air outlet, with the interior surface defining a cross-sectional area, and with the air outlet configured to fluidly couple to an air recirculation conduit in the laundry treating appliance, an air flow path extending through the housing from the air inlet to the air outlet, a heat exchange plate disposed within the housing, a first heating element positioned within the housing, with the first heating element spaced from the heat exchange plate to define a first spacing distance, wherein at least one of the first spacing distance or the cross-sectional area increases along the axial direction from the air inlet toward the air outlet.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 illustrates a schematic cross-sectional view of a laundry treating appliance in accordance with various aspects described herein.

FIG. 2 illustrates a schematic of a control system of the laundry treating appliance of FIG. 1.

FIG. 3 is a perspective view of a heating assembly that can be utilized in the laundry treating appliance of FIG. 1 in accordance with various aspects described herein.

FIG. 4 is a perspective view of the heating assembly of FIG. 3 with a housing removed.

FIG. 5 is a perspective view of a heat exchange plate in the heating assembly of FIG. 3.

FIG. 6 is a perspective view of a portion of the heat exchange plate of FIG. 5 illustrating a set of fins.

FIG. 7 is a perspective view of another heating assembly that can be utilized in the laundry treating assembly of FIG. 1 in accordance with various aspects described herein.

FIG. 8 illustrates some exemplary plots of air temperatures for a conventional heater and for the heating assembly of FIG. 3.

FIG. 9 illustrates some exemplary plots of housing temperatures for a conventional heater and for the heating assembly of FIG. 3.

DETAILED DESCRIPTION

Aspects of the disclosure generally relate to a heating assembly for a laundry treating appliance, such as a laundry dryer in one example. Traditional heating assemblies can include a heating element coupled to a smooth steel plate and surrounded by a steel housing duct. Air flowing through the duct and over the steel plate can be warmed for use in a laundry treating cycle. Heat transfer from the smooth steel plate to the flowing air can be inefficient or lossy. In addition, heat can be lost from the steel housing to the surroundings. The present disclosure relates to an improved heating assembly with more efficient heat transfer compared to traditional heating assemblies.

The described aspects of the present disclosure have applicability in a variety of household appliances including, but not limited to, laundry treating appliances, dishwashers, or the like. Some non-limiting examples of laundry treating appliances include laundry washing appliances, laundry drying appliances, combination laundry washer/dryers, refreshing/revitalizing machines, extractors, non-aqueous washing apparatuses, or the like.

Washing machines are typically categorized as either a vertical axis washing machine or a horizontal axis washing machine. The terms “vertical axis” and “horizontal axis” are often used as shorthand terms for the manner in which the appliance imparts mechanical energy to the load of laundry, even when the relevant rotational axis is not absolutely vertical or horizontal. As used herein, the “vertical axis” washing machine refers to a washing machine having a rotatable drum, perforate or imperforate, that holds fabric items and a clothes mover, such as an agitator, impeller, nutator, and the like within the drum. The clothes mover moves within the drum to impart mechanical energy directly to the clothes or indirectly through wash liquid in the drum. The clothes mover can typically be moved in a reciprocating rotational movement. In some vertical axis washing machines, the drum rotates about a vertical axis generally perpendicular to a surface that supports the washing machine. However, the rotational axis need not be vertical. The drum can rotate about an axis inclined relative to the vertical axis.

As used herein, the “horizontal axis” washing machine refers to a washing machine having a rotatable drum, perforated or imperforate, that holds laundry items and washes the laundry items. In some horizontal axis washing machines, the drum rotates about a horizontal axis generally parallel to a surface that supports the washing machine. However, the rotational axis need not be horizontal. The drum can rotate about an axis inclined or declined relative to the horizontal axis. In horizontal axis washing machines, the clothes are lifted by the rotating drum and then fall in response to gravity to form a tumbling action. Mechanical energy is imparted to the clothes by the tumbling action formed by the repeated lifting and dropping of the clothes. Vertical axis and horizontal axis machines are best differentiated by the manner in which they impart mechanical energy to the fabric articles.

Regardless of the axis of rotation, a washing machine can be top-loading or front-loading. In a top-loading washing machine, laundry items are placed into the drum through an access opening in the top of a cabinet, while in a front-loading washing machine laundry items are placed into the drum through an access opening in the front of a cabinet. If a washing machine is a top-loading horizontal axis washing machine or a front-loading vertical axis washing machine, an additional access opening is located on the drum.

All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the disclosure. Connection references (e.g., attached, coupled, connected, or joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. Furthermore, as used herein, the term “set” or a “set” of elements can be any number of elements, including only one. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary.

FIG. 1 is a schematic cross-sectional view of an exemplary laundry treating appliance 1. In the illustrated example, the exemplary laundry treating appliance 1 is shown as a horizontal axis, front-load combination washing and drying machine 10 though this need not be the case. The laundry treating appliance 1 can be any appliance which performs an automatic cycle of operation to clean, dry, or otherwise treat items placed therein. In some non-limiting examples, the laundry treating appliance 1 can include a horizontal-axis or vertical-axis clothes washer, a combination washing machine and dryer, a tumbling or stationary refreshing/revitalizing machine, an extractor, a non-aqueous washing apparatus, a revitalizing machine, or the like.

The combination washing and drying machine 10 can include a structural support system including a cabinet or chassis 12. The chassis 12 can include a housing defining an interior 13. The chassis 12 can enclose components typically found in a conventional washing machine, such as motors, pumps, fluid lines, controls, sensors, transducers, and the like. Such components will not be described further herein except as necessary for a complete understanding of the present disclosure.

The chassis 12 can define a housing within which a laundry holding system resides. Such a laundry holding system can include a tub 14 dynamically suspended within the structural support system of the chassis 12 by a suitable suspension system 28 and a drum 16 provided within the tub 14. The tub 14 can define at least a portion of a treating chamber 18. For example, the treating chamber 18 can be located within the drum 16. The treating chamber 18 can have an access opening 19. The drum 16 can be configured to receive a laundry load through the access opening 19 with articles for treatment, including, but not limited to, a hat, a scarf, a glove, a sweater, a blouse, a shirt, a pair of shorts, a dress, a sock, and a pair of pants, a shoe, an undergarment, and a jacket. The drum 16 can include a plurality of perforations 20 such that liquid can flow between the tub 14 and the drum 16 through the perforations 20. It is also within the scope of the present disclosure for the laundry holding system to include only one receptacle with the receptacle defining the laundry treating chamber for receiving the load to be treated. At least one lifter 22 can extend from a wall of the drum 16 to lift the laundry load received in the treating chamber 18 while the drum 16 rotates.

The laundry holding system can further include a closure 24 which can be movably mounted to the chassis 12 to selectively close both the tub 14 and the drum 16. In the example shown, the closure 24 is in the form of a door positioned on the front of the chassis 12. In some examples, the closure 24 can include a lid, panel, viewing window, or the like. A bellows 26 can couple an open face of the tub 14 with the chassis 12, with the closure 24 sealing against the bellows 26 when the closure 24 is in the closed position.

The combination washing and drying machine 10 can further include a washing circuit 30 having at least one wash circuit component 32 located within the chassis 12. The at least one wash circuit component 32 can include a liquid supply system for supplying water to the combination washing and drying machine 10 for use in treating laundry during a cycle of operation. The liquid supply system can include a source of water, such as a household water supply 40, which can include separate valves 42 and 44 for controlling the flow of hot and cold water, respectively. Water can be supplied through an inlet conduit 46 directly to the tub 14 or the drum 16 by controlling first and second diverter mechanisms 48 and 50, respectively. The diverter mechanisms 48, 50 can be a diverter valve having two outlets such that the diverter mechanisms 48, 50 can selectively direct a flow of liquid to one or both of two flow paths. Water from the household water supply 40 can flow through the inlet conduit 46 to the first diverter mechanism 48 which can direct the flow of liquid to a supply conduit 52. The second diverter mechanism 50 on the supply conduit 52 can direct the flow of liquid to a tub outlet conduit 54 which can be provided with a spray nozzle 56 configured to spray the flow of liquid 58 into the tub 14. In this manner, water from the household water supply 40 can be supplied directly to the tub 14. While the valves 42, 44 and the inlet conduit 46 are illustrated exteriorly of the chassis 12, it will be understood that these components can be internal to the chassis 12.

The combination washing and drying machine 10 can also be provided with a dispensing system for dispensing treating chemistry to the treating chamber 18 for use in treating the load of laundry according to a cycle of operation. The dispensing system can include a treating chemistry dispenser 62 which can be a single dose dispenser, a bulk dispenser, or an integrated single dose and bulk dispenser and is fluidly coupled to the treating chamber 18. The treating chemistry dispenser 62 can be configured to dispense a treating chemistry directly to the tub 14 or mixed with water from the liquid supply system through a dispensing outlet conduit 64. The dispensing outlet conduit 64 can include a dispensing nozzle 66 configured to dispense the treating chemistry into the tub 14 in a desired pattern and under a desired amount of pressure. For example, the dispensing nozzle 66 can be configured to dispense a flow or stream of treating chemistry into the tub 14 by gravity, i.e. a non-pressurized stream. Water can be supplied to the treating chemistry dispenser 62 from the supply conduit 52 by directing the diverter mechanism 50 to direct the flow of water to a dispensing supply conduit 68.

The treating chemistry dispenser 62 can include multiple chambers or reservoirs for receiving doses of different treating chemistries. The treating chemistry dispenser 62 can be implemented as a dispensing drawer that is slidably received within the chassis 12, or within a separate dispenser housing which can be provided in the chassis 12. The treating chemistry dispenser 62 can be moveable between a fill position, where the treating chemistry dispenser 62 is exterior to the chassis 12 and can be filled with treating chemistry, and a dispense position, where the treating chemistry dispenser 62 are interior of the chassis 12.

Non-limiting examples of treating chemistries that can be dispensed by the dispensing system during a cycle of operation include one or more of the following: water, enzymes, fragrances, stiffness/sizing agents, wrinkle releasers/reducers, softeners, antistatic or electrostatic agents, stain repellants, water repellants, energy reduction/extraction aids, antibacterial agents, medicinal agents, vitamins, moisturizers, shrinkage inhibitors, and color fidelity agents, and combinations thereof.

The combination washing and drying machine 10 can also include a recirculation and drain system for recirculating liquid within the laundry holding system and draining liquid from the combination washing and drying machine 10. Liquid supplied to the tub 14 through tub outlet conduit 54 and/or the dispensing supply conduit 68 typically enters a space between the tub 14 and the drum 16 and can flow by gravity to a sump 70 formed in part by a lower portion of the tub 14. The sump 70 can also be formed by a sump conduit 72 that can fluidly couple the lower portion of the tub 14 to a pump 74. The pump 74 can direct liquid to a drain conduit 76, which can drain the liquid from the combination washing and drying machine 10, or to a recirculation conduit 78, which can terminate at a recirculation inlet 80. The recirculation inlet 80 can direct the liquid from the recirculation conduit 78 into the drum 16. The recirculation inlet 80 can introduce the liquid into the drum 16 in any suitable manner, such as by spraying, dripping, or providing a steady flow of liquid. In this manner, liquid provided to the tub 14, with or without treating chemistry can be recirculated into the treating chamber 18 for treating the load of laundry within.

The liquid supply and/or recirculation and drain system can be provided with a heating system which can include one or more devices for heating laundry and/or liquid supplied to the tub 14, such as a steam generator 82, an inline heater 83 and/or a sump heater 84. Liquid from the household water supply 40 can be provided to the steam generator 82 through the inlet conduit 46 by controlling the first diverter mechanism 48 to direct the flow of liquid to a steam supply conduit 86. Steam generated by the steam generator 82 can be supplied to the tub 14 through a steam outlet conduit 87. The steam generator 82 can be any suitable type of steam generator such as a flow through steam generator or a tank-type steam generator. Alternatively, the sump heater 84 can be used to generate steam in place of or in addition to the steam generator 82. In addition or alternatively to generating steam, the steam generator 82 and/or sump heater 84 can be used to heat the laundry and/or liquid within the tub 14 as part of a cycle of operation.

It is noted that the illustrated suspension system, liquid supply system, recirculation and drain system, and dispensing system are shown for exemplary purposes only and are not limited to the systems shown in the drawings and described above. For example, the liquid supply, dispensing, and recirculation and pump systems can differ from the configuration shown in FIG. 1, such as by inclusion of other valves, conduits, treating chemistry dispensers, sensors, such as water level sensors and temperature sensors, and the like, to control the flow of liquid through the combination washing and drying machine 10 and for the introduction of more than one type of treating chemistry. For example, the liquid supply system can include a single valve for controlling the flow of water from the household water source. In another example, the recirculation and pump system can include two separate pumps for recirculation and draining, instead of the single pump as previously described.

The combination washing and drying machine 10 can also include a drive system for rotating the drum 16 within the tub 14. The drive system can include a motor 88, which can be directly coupled with the drum 16 through a drive shaft 90 to rotate the drum 16 about a rotational axis during a cycle of operation. The motor 88 can be a brushless permanent magnet (BPM) motor having a stator 92 and a rotor 94. Alternately, the motor 88 can be coupled to the drum 16 through a belt and a drive shaft to rotate the drum 16, as is known in the art. Other motors, such as an induction motor or a permanent split capacitor (PSC) motor, can also be used. The motor 88 can rotate the drum 16 at various speeds in either rotational direction.

The motor 88 can rotate the drum 16 at various speeds in opposite rotational directions. In particular, the motor 88 can rotate the drum 16 at tumbling speeds wherein the fabric items in the drum 16 rotate with the drum 16 from a lowest location of the drum 16 towards a highest location of the drum 16, but fall back to the lowest location of the drum 16 before reaching the highest location of the drum 16. The rotation of the fabric items with the drum 16 can be facilitated by the at least one lifter 22. Typically, the force applied to the fabric items at the tumbling speeds is less than about 1 G. Alternatively, the motor 88 can rotate the drum 16 at spin speeds wherein the fabric items rotate with the drum 16 without falling. The spin speeds can also be referred to as satellizing speeds or sticking speeds. Typically, the force applied to the fabric items at the spin speeds is greater than or about equal to 1 G. As used herein, “tumbling” of the drum 16 refers to rotating the drum at a tumble speed, “spinning” the drum 16 refers to rotating the drum 16 at a spin speed, and “rotating” of the drum 16 refers to rotating the drum 16 at any speed.

The combination washing and drying machine 10 can also include a drying circuit 96. The drying circuit 96 can include a closed-loop or an open-loop circuit. The drying circuit 96 can have at least one drying circuit component 97 located within the chassis 12. The at least one drying circuit component 97 can include an air recirculation conduit that is fluidly coupled to and recirculates air 104 through the treating chamber 18. The air recirculation conduit can include a blower 98 and a heating element 102. In some examples, a condenser 100 can also be provided. In such a case, the condenser 100 can be provided with a condenser drain conduit (not shown in FIG. 1) that fluidly couples the condenser 100 with the pump 74 and the drain conduit 76. Condensed liquid collected within the condenser 100 can flow through the condenser drain conduit to the pump 74, where it can be provided to the recirculation and drain system. While the drying circuit 96 is shown adjacent an upper portion of the tub 14, it will be understood that the disclosure is not so limited and the drying circuit 96 can be provided at any suitable location within the chassis 12. In some examples, the drying circuit 96 can provide drying air 104 into the treating chamber 18 via the perforations 20 for drying the laundry items. In some examples, an open loop circuit can be implemented where air is heated by the heating element 102, passed through the drum 16, and exhausted out of the combination washing and drying machine 10.

The combination washing and drying machine 10 can also include a control system for controlling the operation of the combination washing and drying machine 10 to implement one or more cycles of operation. The control system can include a controller 106 located within the chassis 12 and a user interface 108 that is operably coupled with the controller 106. The user interface 108 can include one or more knobs, dials, switches, displays, touch screens and the like for communicating with the user, such as to receive input and provide output. The user can enter different types of information including, without limitation, cycle selection and cycle parameters, such as cycle options.

The controller 106 can include the machine controller and any additional controllers provided for controlling any of the components of the washing machine 10. For example, the controller 106 can include the machine controller and a motor controller. Many known types of controllers can be used for the controller 106. It is contemplated that the controller is a microprocessor-based controller that implements control software and sends/receives one or more electrical signals to/from each of the various working components to effect the control software. As an example, proportional control (P), proportional integral control (PI), and proportional derivative control (PD), or a combination thereof, a proportional integral derivative control (PID control), can be used to control the various components.

As illustrated in FIG. 2, the controller 106 can be provided with a memory 110 and a central processing unit (CPU) 112. The memory 110 can be used for storing the control software that is executed by the CPU 112 in completing a cycle of operation using the combination washing and drying machine 10 and any additional software. Examples, without limitation, of cycles of operation include: wash, heavy duty wash, delicate wash, quick wash, pre-wash, refresh, rinse only, and timed wash. The memory 110 can also be used to store information, such as a database or table, and to store data received from one or more components of the combination washing and drying machine 10 that can be communicably coupled with the controller 106. The database or table can be used to store the various operating parameters for the one or more cycles of operation, including factory default values for the operating parameters and any adjustments to them by the control system or by user input.

The controller 106 can be operably coupled with one or more components of the combination washing and drying machine 10 for communicating with and controlling the operation of the component to complete a cycle of operation. For example, the controller 106 can be operably coupled with the motor 88, the pump 74, the treating chemistry dispenser 62, the steam generator 82, the sump heater 84, and the drying circuit 96 to control the operation of these and other components to implement one or more of the cycles of operation.

The controller 106 can also be coupled with one or more sensors 114 provided in one or more of the systems of the washing machine 10 to receive input from the sensors, which are known in the art and illustrated in FIG. 1 in a lower portion of the treating chamber 18 for exemplary purposes only. Non-limiting examples of sensors 114 that can be communicably coupled with the controller 106 include: a treating chamber temperature sensor, a moisture sensor, a weight sensor, a chemical sensor, a position sensor and a motor torque sensor, which can be used to determine a variety of system and laundry characteristics, such as laundry load inertia or mass.

Referring now to FIG. 3, a heating assembly 120 is illustrated that can be utilized as the heating element 102 for the laundry treating appliance 1, such as in the combination washing and drying machine 10. The heating assembly 120 can include a housing 122 with an interior surface 123, an air inlet 124, and an air outlet 126 as shown. The air inlet 124 can be fluidly coupled to at least one source of air including, but not limited to, ambient air external to the laundry treating appliance 1, or air from within the treating chamber 18 (FIG. 1). The air outlet 126 can be fluidly coupled to the treating chamber 18 (FIG. 1).

For reference purposes, a coordinate system is provided in FIG. 3 and applied to the heating assembly 120. The housing 122 extends along an axial direction A as shown. A radial direction R is defined orthogonally from the axial direction A as shown. The air inlet 124 can be spaced from the air outlet 126 along the axial direction A.

An air flow path 125 is provided through the housing 122 between the air inlet 124 and the air outlet 126. In the illustrated example, a cool airflow 128 is shown entering the housing 122 at the air inlet 124. A heated airflow 130 is shown exiting the housing 122 at the air outlet 126. It should be understood that “cool airflow” as used herein can be defined relative to the heated airflow 130. In some examples, the cool airflow 128 can include warm air from the treating chamber 18 (FIG. 1) provided to the heating assembly 120 for additional heating. In some examples, the cool airflow 128 can include room-temperature air or ambient air provided to the heating assembly 120. Regardless of the temperature of the cool airflow 128, the heated airflow 130 can have a higher temperature relative to the cool airflow 128.

A heat exchange plate 140 (also referred to herein as “plate 140”) can be centrally located within the housing 122. The plate 140 can include a first side 141 radially spaced from a second side 142. In some examples, the first side 141 can define a top side and the second side 142 can define a bottom side of the plate 140. The plate 140 can also include sidewalls 144 as shown.

A portion 143 of the plate 140 can extend outside of the housing 122. In the example shown, the portion 143 extends outside of the housing 122 at the inlet 124. It is also contemplated that the housing 122 can support or carry the plate 140. In the example shown, the housing 122 includes side rails or supports 146 configured to engage the sidewalls 144 of the plate 140. In this manner, the plate 140 can be slidably inserted into the housing 122 and supported therein.

It is contemplated that the plate 140 can have a higher emissivity than the housing 122. In one non-limiting example, the plate 140 can include steel with an emissivity of 0.2, and the housing 122 can include aluminum with an emissivity of 0.05. Such an arrangement can at least provide for reduced thermal losses from the housing 122 to the surrounding environment.

Referring to FIG. 4, the heating assembly 120 can include a first coil 131 spaced from a second coil 132. The heating assembly 120 can include any number of coils, including only one, or three or more. Individual windings of the first and second coils 131, 132 are omitted for visual clarity.

The heating assembly 120 can also include any suitable component for generating heat including, but not limited to, a heating coil, heating ribbon, heating rod, heating plate, or the like, or combinations thereof. Any number of heating elements can be provided. The plate 140 can be positioned between the first coil 131 and the second coil 132. Some exemplary coil windings 135 are illustrated on the first coil 131.

In addition, spacers 150 can be provided for separation between the first coil 131, plate 140, and second coil 132. The spacers 150 can include any suitable material including ceramic, aluminum, steel, a composite material, or the like, or combinations thereof. In addition, the spacers 150 can include a radially-extending body with any suitable geometric profile, shape, or form, including straight, rounded, curved, or the like, or combinations thereof.

In the non-limiting example shown, each spacer 150 includes a first end 151 and a second end 152, with the first end 151 coupled to the first coil 131 and the second end 152 coupled to the second coil 132. The plate 140 also includes apertures 148 through which the spacers 150 can extend. In another example, each spacer 150 can be coupled between one of the first or second coils 131, 132 and the plate 140. In such a case, the first and second coils 131, 132 can be independently coupled to the plate 140 by separate spacers 150.

A first spacing distance 161 can be defined radially between the first coil 131 and the plate 140. A second spacing distance 162 can be defined radially between the second coil 132 and the plate 140. In the illustrated example, the first spacing distance 161 and the second spacing distance 162 are uniform over the entire plate 140, and the first spacing distance 161 is the same as the second spacing distance 162, though this need not be the case. The first spacing distance 161 or second spacing distance 162 can vary over different portions of the plate 140. In some non-limiting examples: the first spacing distance 161 can be constant between the air inlet 124 and the air outlet 126; the first spacing distance 161 can be variable between the air inlet 124 and the air outlet 126; the second spacing distance 162 can be constant between the air inlet 124 and the air outlet 126; the second spacing distance 162 can be variable between the air inlet 124 and the air outlet 126; the first spacing distance 161 can be the same as the second spacing distance 162; or the first spacing distance 161 can differ from the second spacing distance 162.

The first coil 131 and second coil 132 can be arranged over the plate 140 having any suitable geometric profile or orientation. In the example shown, the first coil 131 and second coil 132 have the same geometric profile, though this need not be the case. In some examples, the first coil 131 or second coil 132 can include linear rows, a serpentine profile, a circular profile, a spiral profile, a symmetric profile, or an asymmetric or irregular profile.

It is contemplated that the apertures 148 can be configured to form a twist-lock arrangement with the spacers 150 (FIG. 4). The spacers 150 can include protruding legs 155 configured to extend laterally beyond the aperture 148. The protruding legs 155 can rest on or otherwise engage the plate 140 for supporting the first coil 131 or second coil 132, or reducing relative movement between the first coil 131, second coil 132, and plate 140, or combinations thereof. The spacer 150 can be inserted through the aperture 148 and rotated such that the protruding legs 155 can secure the spacer 150 to the plate 140.

FIG. 5 illustrates the plate 140, with the spacers 150 and coils 131, 132 removed for clarity. A set of fins 170 can also be provided with the plate 140. In the non-limiting example shown, the set of fins 170 can include pin fins extending at least radially from the plate 140 for increased convective heat transfer. The set of fins 170 can include the same or different material compared to the plate 140. In one example, the set of fins 170 can be made from steel. The set of fins 170 can also include fins having any suitable geometric profile or form, including strips, pins, squared portions, rounded portions, asymmetric or irregular portions, or the like, or combinations thereof.

The set of fins 170 can extend radially from the plate 140. In the example shown, the set of fins 170 extend from each of the first side 141 and the second side 142 of the plate 140 though this need not be the case. Some exemplary fins in the set of fins 170 extending from the second side 142 are shown in dashed line. The set of fins 170 can also extend at least from the first side 141, including from the first side 141 only, the second side 142 only, or from the sidewalls 144, or combinations thereof.

FIG. 6 illustrates a portion of the heating assembly 120 in further detail. Each fin in the set of fins 170 can have a body 172 with a distal end 173 as shown. The body 172 can define a fin width 174. The distal end 173 can define a fin height 175. In the example shown, the distal ends 173 can also define a top radius 176 though this need not be the case. The fin height 175 can be in a range between 2-10 mm, including between 4-6 mm, or including 5 mm, in some non-limiting examples. The fin width 174 can be in a range between 2-10 mm, including between 4-7 mm, or including 6 mm, in some non-limiting examples. The top radius 176 can be in a range between 1-4 mm, including between 1-3 mm, or including 2 mm, in some non-limiting examples.

The set of fins 170 can also have staggered positions over the plate 140. For example, a first fin 170A extending from the first side 141 of the plate 140 can be offset from a second fin 170B extending from the second side 142 of the plate 140.

In addition, in the example shown, the apertures 148 can include a first width 148A and a second width 148B smaller than the first width 148A. The first width 148A can be sized for insertion of the spacer 150 and protruding legs 155 (FIG. 4). The second width 148B can be angularly offset from the first width 148A. Rotation of the inserted spacer 150 from the first width 148A to the second width 148B can provide for a locking or secure engagement between the spacer 150 and plate 140, whereby the protruding legs 155 (FIG. 4) can be prevented from moving through the aperture 148.

Referring generally to FIGS. 1-6, during operation, the cool airflow 128 can enter the housing 122 through the air inlet 124. A controller, such as the controller 106 (FIG. 2), can energize the first coil 131 and second 132 to generate heat within the housing 122. The generated heat can transfer to the plate 140 and set of fins 170. As the cool airflow 128 moves over the plate 140 and fins 170, convective heat transfer can occur to increase the airflow temperature and form the heated airflow at the air outlet 126.

Turning to FIG. 7, another heating assembly 220 is illustrated that can be utilized in the laundry treating appliance 1. The heating assembly 220 is similar to the heating assembly 120. Therefore, like parts of the heating assembly 220 will be identified with like numerals increased by 100, with it being understood that the description of the like parts of the heating assembly 120 applies to the heating assembly 220, except where noted.

The heating assembly 220 includes a housing 222, a heating element 202, and a heat exchange plate 240 (also referred to herein as “plate 240”). In the illustrated example, the housing 222 is shown in dashed line. The housing can include an interior surface 223, an air inlet 224, and an air outlet 226. The heating element 202 can include a first coil 231 and a second coil 232. Spacers 250 can be provided for separation between the first coil 231, plate 240, and second coil 232. A set of fins 270 can be provided along the plate 240.

A first spacing distance 261 can be defined between the first coil 231 and the plate 240. A second spacing distance 262 can be defined between the second coil 232 and the plate 240. One difference compared to the heating assembly 120 is that the spacers 250 can have a variable height, thereby forming a variable spacing distance. In the example shown, the first spacing distance 261 and second spacing distance 262 increase in a direction between the air inlet 224 and air outlet 226 though this need not be the case. In another non-limiting example, the first spacing distance 261 can increase and the second spacing distance 262 can decrease between the air inlet 224 and air outlet 226. In still another non-limiting example, each of the first spacing distance 262 and second spacing distance 262 can decrease and increase between the air inlet 224 and air outlet 226, forming a wide and narrow space between the respective first and second coils 231, 232 and plate 240. In this manner, the first spacing distance 261 and second spacing distance 262 can vary in any suitable manner within the housing 222.

A first coil distance 231D can be defined between the first coil 231 and the interior surface 223 of the housing 222. A second coil distance 232D can be defined between the second coil 232 and the interior surface 223. In some non-limiting examples: the first coil distance 231D can be constant between the air inlet 224 and the air outlet 226; the first coil distance 231D can be non-constant or variable between the air inlet 224 and the air outlet 226; the second coil distance 232D can be constant between the air inlet 224 and the air outlet 226; the second coil distance 232D can be non-constant or variable between the air inlet 224 and the air outlet 226; the first coil distance 231D can be the same as the second coil distance 232D; or the first coil distance 231D can differ from the second coil distance 232D.

One difference compared to the heating assembly 120 is that the housing 222 can have an asymmetric geometric profile. In the example shown, the housing 222 include a wedge-shaped side profile. It is also contemplated that the housing 222 can include a wedge-shaped top profile in some examples.

A cross-sectional area 225 can be defined by the interior surface 223 of the housing 222 (shown in a side view). The cross-sectional area 225 can be non-constant or vary in a direction from the air inlet 224 to the air outlet 226. In one non-limiting example, the cross-sectional area 225 can increase or decrease in a direction from the air inlet 224 to the air outlet 226. In another non-limiting examples, the cross-sectional area 225 can include multiple wide and narrow portions between the air inlet 224 and the air outlet 226. It is further contemplated that the cross-sectional area 225 can also increase or decrease based on a size or arrangement of the first coil 231, second coil 232, spacers 250, or fins 270. For example, the first coil 231 or second coil 232 can be arranged to constrict flow in one portion of the housing 222, thereby altering the cross-sectional area 225 within the housing 222. In this manner, air flowing through the housing 222 can speed up or slow down based on variances in the cross-sectional area 225, providing for additional turbulences or flow variances and improved heat transfer from the plate 240.

Another difference compared to the heating assembly 120 is that either or both of the first or second coils 231, 232 can have a non-constant or variable coil width. An exemplary first coil winding 235A and second coil winding 235B are illustrated in the first coil 231. The first coil winding 235A defines a first coil width 236A, and the second coil winding 235B defines a coil width 236B. In an example where the first and second coils 231, 232 include wrapped wire coils with circular windings, the first and second coil widths 236A, 236B can represent a diameter of the circular first and second coil windings 235A, 235B, respectively. In the example shown, the first coil width 236A is smaller than the second coil width 236B. It is contemplated that the coil windings can have variable widths, including decreasing or increasing widths, within either or both of the first or second coils 231, 232 in a direction between the air inlet 224 and the air outlet 226. In one non-limiting example, the coil windings can have a width that increases in a direction between the air inlet 224 and air outlet 226. Such an arrangement can provide for a reduction in flow barriers of downstream coil windings compared to upstream coil windings, providing for increased flow interaction with the coil windings.

Referring now to FIG. 8, a set of plots illustrates some exemplary computational fluid dynamics (CFD) simulations during operation of a conventional heater 290 and the heating assembly 120 (FIG. 3). The conventional heater 290 includes an outer steel housing 292 having an air inlet 294 and an air outlet 296, and also includes a central steel heating element or plate 298 with no fins present. The heating assembly 120 includes the aluminum housing 122, the air inlet 124, the air outlet 126, and the steel plate 140 as described above.

More specifically, a first plot 301 and a second plot 302 each illustrate a side-view CFD simulation for the conventional heater SS, and a third plot 303 and a fourth plot 304 each illustrate a side-view CFD simulation for the heating assembly 120. It will be understood that aspects of the third and fourth plots 303, 304 can also be applied to the heating assembly 220 (FIG. 7). For each of the plots 301-304, an air flow direction between each air inlet 124, 294 and the corresponding air outlet 126, 296 is indicated with an arrow.

As shown in the first plot 301, air enters the air inlet 294 of the conventional heater 290 at a first inlet temperature T1_i and exits the air outlet 296 at a first outlet temperature T10. The first inlet temperature T1_i can be in a range between 10-150° C., including between 50-70° C., including 64° C., in some non-limiting examples. The first outlet temperature T1_o can be in a range between 200-900° C., including between 200-400° C., including 338° C., in non-limiting examples.

As shown in the second plot 302, air enters the air inlet 294 of the conventional heater 290 at a second inlet temperature T2_i and exits the air outlet 296 at a second outlet temperature T2_o. The second inlet temperature T2_i can be in a range between 10-150° C., including between 50-70° C., including 64° C., in some non-limiting examples. The second outlet temperature T2_o can be in a range between 200-1100° C., including between 200-400° C., including 338° C., in non-limiting examples. In addition, the first inlet temperature T1_i can be the same as, or different from, the second inlet temperature T2_i. The first outlet temperature T1_o can be the same as, or different from, the second outlet temperature T2_o.

As shown in the third plot 303, air enters the air enters the air inlet 124 of the heating assembly 120 at a third inlet temperature T3_i and exits the air outlet 126 at a third outlet temperature T3_o. The third inlet temperature T3_i can be in a range between 10-150° C., including between 50-80° C., including 73° C., in non-limiting examples. The third outlet temperature T3_o can be in a range between 200-900° C., including between 300-400° C., including 387° C., in non-limiting examples.

As shown in the fourth plot 302, air enters the air enters the air inlet 124 of the heating assembly 120 at a fourth inlet temperature T4_i and exits the air outlet 126 at a fourth outlet temperature T4_o. The fourth inlet temperature T4_i can be in a range between 10-150° C., including between 50-80° C., including 73° C., in non-limiting examples. The fourth outlet temperature T4_o can be in a range between 200-1100° C., including between 300-400° C., including 387° C., in non-limiting examples. In addition, the third inlet temperature T3_i can be the same as, or differ from, the fourth inlet temperature T4i. The third outlet temperature T3_o can be the same as, or differ from, the fourth outlet temperature T4_o.

With general reference to the plots 301-304, air within the conventional heater housing 292 and the heating assembly housing 122 is hottest in the immediate vicinity of the respective central heating plate 298 and the plate 140. The air temperature inside each of the conventional heater housing 292 and the heating assembly housing 122 also becomes generally warmer in a downstream direction toward the respective air outlet 296, 126.

In addition, as shown by the plots 301-304, the overall outlet air temperature is higher for the heating assembly 120 (as shown in the third and fourth plots 303, 304) as compared to the conventional heater 290 (as shown in the first and second plots 301, 302). Furthermore, the housing temperature for the heating assembly 120 (as shown in the third and fourth plots 303, 304) is cooler than the housing temperature of the conventional heater 290 (as shown in the first and second plots 301, 302).

Turning to FIG. 9, additional plots illustrate some additional CFD simulations for the conventional heater housing 292 and for the heating assembly housing 122. More specifically, a first plot 401 and a second plot 402 each illustrate a perspective CFD simulation for the housing 292 of the conventional heater 290. A third plot 403 and a fourth plot 404 each illustrate perspective CFD simulations for the housing 122 of the heating assembly 120. It will be understood that aspects of the third and fourth plots 403, 404 can also be applied to the heating assembly 220 (FIG. 7).

As shown in the first plot 401, the housing 292 temperature for the conventional heater 290 ranges between a first minimum temperature T1_min and a first maximum temperature T1_max. The first minimum temperature T1_min can be in a range between 150-350° C., including between 190-250° C., including 220° C., in some non-limiting examples. The first maximum temperature T1_max can be in a range between 700-900° C., including between 750-950° C., including 800° C., in non-limiting examples.

As shown in the second plot 402, the housing 292 temperature for the conventional heater 290 ranges between a second minimum temperature T2_min and a second maximum temperature T2_max. The second minimum temperature T2_min can be in a range between 100-300° C., including between 150-250° C., including 200° C., in some non-limiting examples. The second maximum temperature T2_max can be in a range between 600-900° C., including between 650-750° C., including 700° C., in non-limiting examples. In addition, the first minimum temperature T1_min can be the same as, or different from, the second minimum temperature T2_min. The first maximum temperature T1_max can be the same as, or different from, the second maximum temperature T2_max.

As shown in the third plot 403, the housing 122 temperature for the heating assembly 120 ranges between a third minimum temperature T3_min and a third maximum temperature T3_max. The third minimum temperature T3_min can be in a range between 100-300° C., including between 200-300° C., including 247° C., in non-limiting examples. The third maximum temperature T3_max can be in a range between 400-700° C., including between 550-650° C., including 572° C., in non-limiting examples.

As shown in the fourth plot 404, the housing 122 temperature for the heating assembly 120 ranges between a fourth minimum temperature T4_min and a fourth maximum temperature T4_max. The fourth minimum temperature T4_min can be in a range between 100-300° C., including between 200-300° C., including 250° C., in non-limiting examples. The fourth maximum temperature T4_max can be in a range between 500-800° C., including between 650-800° C., including 750° C., in non-limiting examples. In addition, the third minimum temperature T3_min can be the same as, or differ from, the fourth minimum temperature T4_min. The third maximum temperature T3_max can be the same as, or differ from, the fourth maximum temperature T4_max.

It will be understood that the temperatures shown in the plots 401, 402, 403, 404 can be the same or different compared to the temperatures shown in the respective plots 301, 302, 303, 304 (FIG. 8).

With general reference to the plots 401-404, the housing 122 of the heating assembly 120 has an overall lower temperature compared to the housing 292 of the conventional heater 290. In addition, a smaller proportion of the housing 122 is warmed to near the peak temperature (e.g. the third maximum temperature T3_max or the fourth maximum temperature T4_max) as compared to the conventional housing 292 (e.g. the first maximum temperature T1_max or the second maximum temperature T2_max).

Aspects of the disclosure provide for a variety of benefits. In an example where a supply of power to the heating assembly is constant, the increased air temperature at the air outlet can provide for increased drum inlet temperature, which can reduce drying time and energy consumption. In an example where a supply of power to the heating assembly is constant over a fixed drying time interval, the increased air temperature at the air outlet can reduce energy consumption for that drying time interval.

In addition, the use of a staggered set of fins extending from the central plate can provide for higher flow turbulence, increased surface area contact, and increased heat transfer to the air flowing through the heating assembly. The use of a lower-emissivity housing compared to the central place can further provide for increased heat retention within the heating assembly, lower heat losses to the surroundings, and a more efficient heat transfer to process air within the housing.

In addition, the use of a wedge-shaped housing or a housing with non-constant cross-sectional area can provide for better air flow interaction with the heating coils and center plate. As upstream coil windings can be offset or differently sized from downstream coil windings, the process air can more readily interact with all coil windings with a reduction in flow barrier effects. In addition, the use of a diverging housing with larger outlet and smaller inlet can additionally increase flow interaction with the coils and central plate, as the airflow is slowed toward the outlet. Such a diverging housing can more efficiently transfer heat to the process air compared to traditional heating assemblies.

To the extent not already described, the different features and structures of the various aspects can be used in combination with each other as desired, or can be used separately. That one feature can not be illustrated in all of the aspects is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different aspects can be mixed and matched as desired to form new aspects, whether or not the new aspects are expressly described.

While the present disclosure has been specifically described in connection with certain specific aspects thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the present disclosure. Hence, specific dimensions and other physical characteristics relating to the aspects disclosed herein are not to be considered as limiting, unless expressly stated otherwise.

Claims

1. A laundry treating appliance, comprising:

a chassis defining an interior;

a treating chamber located within the interior;

a drying circuit within the interior and comprising an air recirculation conduit fluidly coupled to the treating chamber, and a blower supplying process air to the air recirculation conduit; and

a heating assembly in thermal interaction with the process air supplied to the treating chamber, the heating assembly comprising:

a housing extending along an axial direction and defining an air inlet and an air outlet, with the air outlet configured to fluidly couple to an air recirculation conduit in the laundry treating appliance;

an air flow path extending through the housing from the air inlet to the air outlet;

a heat exchange plate disposed within the housing and having a first side radially opposite a second side, with each of the first and second sides thermally coupled to the air flow path;

a first heating element positioned within the housing and spaced from the first side of the heat exchange plate; and

a set of fins extending from at least the first side of the heat exchange plate, with a fin in the set of fins comprising a distal end radially spaced between the first heating element and the first side of the heat exchange plate.

2. The laundry treating appliance of claim 1, wherein the set of fins comprises a first fin with a first distal end defining a first fin height with respect to the heat exchange plate, and a second fin with a second distal end defining a second fin height smaller than the first fin height.

3. The laundry treating appliance of claim 2, wherein the first fin is positioned closer to the air outlet than the second fin.

4. The laundry treating appliance of claim 1, further comprising a second heating element spaced from and overlying the second side of the heat exchange plate, wherein the first heating element and the second heating element define, respectively, a first spacing distance and a second spacing distance from the heat exchange plate.

5. The laundry treating appliance of claim 4, wherein the set of fins extends radially from each of the first side and the second side.

6. The laundry treating appliance of claim 5, further comprising a set of spacers extending through a corresponding set of apertures in the heat exchange plate, wherein a spacer in the set of spacers extends between a first end coupled to the first heating element and a second end coupled to the second heating element to define the respective first spacing distance and the second spacing distance.

7. The laundry treating appliance of claim 4, wherein the first heating element comprises a first coil and the second heating element comprises a second coil, wherein the first coil and the second coil radially define a first coil distance and a second coil distance, respectively, from an interior surface of the housing, with the second coil distance being greater than the first coil distance.

8. The laundry treating appliance of claim 1, further comprising a washing circuit comprising at least one liquid conduit and at least one treating chemistry dispenser each fluidly coupled to the treating chamber.

9. A heating assembly for heating process air in a laundry treating appliance, comprising:

a housing extending along an axial direction and defining an air inlet and an air outlet, with the air outlet configured to fluidly couple to an air recirculation conduit in the laundry treating appliance;

an air flow path extending through the housing from the air inlet to the air outlet;

a heat exchange plate disposed within the housing and having a first side radially spaced from a second side, with each of the first and second sides thermally coupled to the air flow path;

a first heating element positioned within the housing and spaced from the first side of the heat exchange plate; and

a set of fins extending from at least the first side of the heat exchange plate, with each fin in the set of fins comprising a distal end radially spaced from the heating element.

10. The heating assembly of claim 9, wherein the set of fins comprises a first fin with a first distal end defining a first fin height with respect to the heat exchange plate, and a second fin with a second distal end defining a second fin height smaller than the first fin height;

wherein the first fin is positioned closer to the air outlet than the second fin.

11. The heating assembly of claim 9, further comprising a second heating element spaced from and overlying the second side of the heat exchange plate, wherein the first heating element and the second heating element define, respectively, a first spacing distance and a second spacing distance from the heat exchange plate.

12. The heating assembly of claim 11, wherein the set of fins extends radially from each of the first side and the second side.

13. The heating assembly of claim 12, further comprising a set of spacers extending through a corresponding set of apertures in the heat exchange plate, wherein a spacer in the set of spacers extends between a first end coupled to the first heating element and a second end coupled to the second heating element to define the respective first spacing distance and the second spacing distance.

14. The heating assembly of claim 13, wherein an aperture in the set of apertures comprises a first width and a second width smaller than the first width, and wherein the spacer in the set of spacers comprises protruding legs insertable through the first width, whereby rotation of the spacer within the aperture to the second width engages the protruding legs with the heat exchange plate to define a twist-lock arrangement.

15. The heating assembly of claim 11, wherein the first heating element comprises a first coil and the second heating element comprises a second coil, wherein at least one of the first coil or the second coil defines a coil width that increases in the axial direction from the air inlet toward the air outlet.

16. A heating assembly for heating process air in a laundry treating appliance, comprising:

a housing extending along an axial direction and defining an interior surface, an air inlet, and an air outlet, with the interior surface defining a cross-sectional area, and with the air outlet configured to fluidly couple to an air recirculation conduit in the laundry treating appliance;

an air flow path extending through the housing from the air inlet to the air outlet;

a heat exchange plate disposed within the housing;

a first heating element positioned within the housing, with the first heating element spaced from the heat exchange plate to define a first spacing distance;

wherein at least one of the first spacing distance or the cross-sectional area increases along the axial direction from the air inlet toward the air outlet.

17. The heating assembly of claim 16, wherein the first heating element comprises a first coil and defines a first coil distance from the interior surface of the housing.

18. The heating assembly of claim 17, further comprising a second heating element, with the second heating element comprising a second coil defining a second coil distance from the interior surface and a second spacing distance from the heat exchange plate.

19. The heating assembly of claim 18, wherein the second coil distance is greater than the first coil distance.

20. The heating assembly of claim 18, wherein at least one of the first coil distance, the second coil distance, or the second spacing distance is non-constant along the axial direction.