CHECK VALVES FOR GRAVITY DRAIN FLUID BOTTLE MOUNTED IN BASEMENT OF A HEAT PUMP DRYER MACHINE

Abstract

A laundry appliance includes a cabinet, a drum, a heat exchanger, a sump, a removable, gravity-fed fluid bottle, and a fluid level sensor. The drum is rotatably supported within the cabinet and defines a laundry compartment therein. The heat exchanger is disposed in the cabinet. The sump is disposed in the cabinet below the heat exchanger and positioned to collect condensed water vapor falling from the heat exchanger. The removable, gravity-fed fluid bottle is slidingly received in the cabinet below the heat exchanger and is positioned in fluid communication with the sump. The fluid level sensor is positioned in the sump and configured to pause operation of the laundry appliance when a fluid level detected in the sump exceeds a threshold fluid level.

Description

FIELD

The present disclosure relates to a heat pump dryer machine and more specifically, to a check valve for a gravity drain fluid bottle mounted in a basement of a heat pump dryer.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

Laundry appliances are prolific in both residential and commercial settings. The laundry appliance may be a dryer machine that is used to dry laundry after it has been cleaned in a washing machine. In some examples, the laundry appliance may be a washer and dryer combination appliance where a single machine performs both the washing and drying functions. There are a number of different names used to describe washer and dryer combination appliances, including without limitation, “washer/dryer combos” and “all-in-one washer dryers.”

Many laundry appliances include a cabinet (i.e., an appliance housing) with an opening that is accessed by an appliance door. A drum is positioned in the cabinet and is rotatable with respect to the cabinet. The drum typically has a drum opening that provides access to a laundry compartment inside the drum.

Additionally, traditional laundry appliances include a heater, a drain pump, and a plurality of hoses. The heater is configured to heat air prior to air flowing into the laundry compartment. A sump is positioned near a bottom end of the laundry appliance and collects fluids released from the heater. A fluid bottle is positioned near a top end of the laundry appliance and is removable from the laundry appliance. The drain pump is configured to pump fluids from the sump to the fluid bottle. However, the drain pump often fails, consumes significant amount of energy, and leads to customer complaints. The plurality of hoses are used to carry fluids from the sump to the fluid bottle. However, the plurality of hoses often leak fluid and consume vital packaging space. Solutions that effectively move fluids from the sump to the fluid bottle in face of these challenges are needed.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

In accordance with one aspect of the present disclosure, a laundry appliance is provided that comprises a cabinet and a drum. The drum is rotatably supported within the cabinet and defines a laundry compartment therein. A heat exchanger is disposed in the cabinet. A sump is disposed in the cabinet below the heat exchanger and positioned to collect condensed water vapor falling from the heat exchanger. A removable, gravity-fed fluid bottle is slidingly received in the cabinet below the heat exchanger and is positioned in fluid communication with the sump. A fluid level sensor is positioned in the sump and configured to pause operation of the laundry appliance when a fluid level detected in the sump exceeds a threshold fluid level.

In accordance with another aspect of the present disclosure, the fluid level sensor includes a float that is floatable in the fluid of the sump.

In accordance with another aspect of the present disclosure, the fluid level sensor includes a fluid level switch that is movable between a deactivated position and an activated position.

In accordance with another aspect of the present disclosure, the fluid level sensor is configured to detect the threshold fluid level in the sump when the float contacts the fluid level switch.

In accordance with another aspect of the present disclosure, the fluid level switch transitions from the deactivated position to the activated position when a portion of the float contacts the fluid level switch.

In accordance with another aspect of the present disclosure, when the fluid level switch is in the activated position, the fluid level switch is configured to pause operation of the laundry appliance.

In accordance with another aspect of the present disclosure, the laundry appliance further comprising a check valve mounted to the fluid bottle and configured to control fluid flow between the sump and the fluid bottle.

In accordance with another aspect of the present disclosure, the fluid bottle extends between a front bottle end and a rear bottle end that is opposite the front bottle end. The check valve is disposed at the rear bottle end of the fluid bottle.

In accordance with another aspect of the present disclosure, the check valve is movable between an open valve position allowing fluid flow between the sump and the fluid bottle and a closed valve position restricting fluid flow between the sump and the fluid bottle.

In accordance with another aspect of the present disclosure, a laundry appliance is provided that comprises a cabinet and a drum. The cabinet includes a front cabinet wall and a rear cabinet wall that is opposite to the front cabinet wall. The drum is rotatably supported within the cabinet and defines a laundry compartment therein. A heat exchanger is disposed in the cabinet below the drum. A sump is disposed in the cabinet below the heat exchanger and positioned to collect condensed water vapor falling from the heat exchanger. A removable bottle that is slidingly received in the cabinet below the heat exchanger and is positioned in fluid communication with the sump. A check valve is mounted to the fluid bottle, movable between an open valve position and a closed valve position such that the check valve is configured to control a fluid flow between the sump and the fluid bottle. A docking station is disposed within the sump and is at least partially aligned with the check valve. The docking station includes a docking station housing positioned within a wall of the sump and a docking station plunger that is arranged in movable contact with the docking station housing such that the docking station plunger is moveable between an open plunger position and a closed plunger position.

In accordance with another aspect of the present disclosure, a fluid level sensor is located in the sump that is configured to pause operation of the laundry appliance when a fluid level detected in the sump exceeds a threshold fluid level.

In accordance with another aspect of the present disclosure, the fluid level sensor includes a float that is buoyant and configured to float in the fluid of the sump and a fluid level switch movable between a deactivated position and an activated position.

In accordance with another aspect of the present disclosure, the fluid level sensor is configured to detect the threshold fluid level in the sump when the float contacts the fluid level switch and moves the fluid level switch from the deactivated position to the activated position.

In accordance with another aspect of the present disclosure, the docking station plunger is sealingly engaged with docking station housing when the docking station plunger is in the closed plunger position to restrict fluid flow from sump to the docking station housing. The docking station plunger is spaced from the docking station housing when the docking station plunger is in the open plunger position to allow fluid flow from the sump to the docking station housing.

In accordance with another aspect of the present disclosure, when the fluid bottle is inserted into the cabinet, the check valve is received in the docking station housing, the check valve is in the open valve position and the docking station is in the open plunger position to allow fluid flow from the sump, through the docking station and check valve, and to the fluid bottle.

In accordance with another aspect of the present disclosure, when the fluid bottle is removed the cabinet, the check valve is removed from the docking station housing, the check valve is in the closed valve position and the docking station is in the closed plunger position to restrict fluid flow between the sump and the fluid bottle.

In accordance with another aspect of the present disclosure, the check valve includes a valve housing and a valve shaft movable within the valve housing.

In accordance with another aspect of the present disclosure, the valve shaft is sealingly engaged with the valve housing when the check valve is in the closed valve position and the valve shaft is spaced from the valve housing when the check valve is in the open valve position.

In accordance with another aspect of the present disclosure, the heat exchanger includes a first exchanger and a second exchanger. The first exchanger is positioned adjacent to the front cabinet wall and configured to condense air flowing through the first exchanger. The second exchanger is positioned adjacent to the rear cabinet wall and configured to heat air flowing through the second exchanger.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is a front perspective view of a laundry appliance constructed in accordance with the present disclosure;

FIG. 2 is a rear perspective view of the exemplary laundry appliance shown in FIG. 1;

FIG. 3 is a partial side cross-sectional view of the exemplary laundry appliance shown in FIG. 1;

FIG. 4 is a side cross-sectional view of a heat exchanger of the exemplary laundry appliance shown in FIG. 1;

FIG. 5 is a front perspective view of an appliance base of the exemplary laundry appliance shown in FIG. 1;

FIG. 6 is a partial side cross-sectional view of a check valve and a fluid level sensor of the exemplary laundry appliance shown in FIG. 1, where the check valve is in a closed valve position and the fluid level sensor is in an activated position; and

FIG. 7 is a partial side cross-sectional view of the check valve and the fluid level sensor of the exemplary laundry appliance shown in FIG. 1, where the check valve is in an open valve position and the fluid level sensor is in a deactivated position.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

The module may include one or more interface circuits. In some examples, the interface circuits may include wired or wireless interfaces that are connected to a local area network (LAN), the Internet, a wide area network (WAN), or combinations thereof. The functionality of any given module of the present disclosure may be distributed among multiple modules that are connected via interface circuits. For example, multiple modules may allow load balancing. In a further example, a server (also known as remote, or cloud) module may accomplish some functionality on behalf of a client module.

With reference to FIGS. 1-3, a laundry appliance 50 is illustrated. The laundry appliance 50 is a dryer machine and more specifically, a heat pump dryer machine. The laundry appliance 50 is illustrated as having a front-load configuration, though may alternatively have a top-load configuration.

The laundry appliance 50 includes a cabinet 52 that is rectangular in shape. The cabinet 52 includes a front cabinet wall 54 having a front cabinet opening 56, a rear cabinet wall 58 opposite the front cabinet wall 54, a set of cabinet sidewalls 60 that extend between the front cabinet wall 54 and the rear cabinet wall 58, a top cabinet wall 62, and a bottom cabinet wall 64. The front cabinet wall 54, rear cabinet wall 58, set of cabinet sidewalls 60, top cabinet wall 62, and bottom cabinet wall 64 cooperate to define a cabinet cavity 68 inside the cabinet 52.

In some configurations, the laundry appliance 50 may include a control panel 70 that is attached to the front cabinet wall 54. The control panel 70 may be positioned adjacent to the top cabinet wall 62. The control panel 70 may include a display 72, a speaker 74, a control 76, and a control module 78. The display 72 may be used to display information, adjust features or settings of the laundry appliance 50, present prompts to users of the laundry appliance 50, and to perform one or more other functions. The display 72 may be a touch screen display. The speaker 74 may be used to output audible sounds and to perform one or more other functions. The control 76 may be used to adjust features or settings of the laundry appliance 50 and to perform one or more other functions. The control module 78 may receive input from the user (e.g., via the display 72 or the control 76). The control module 78 may be configured to operate a cycle (e.g., a drying cycle) of the laundry appliance 50 according to the user's input and may perform one or more other functions. Additional functions of the control module 78 will be described below. It should be appreciated that the display 72, speaker 74, the control 76 and control module 78 may be positioned in another suitable location of the laundry appliance 50.

A front appliance door 84 is pivotally connected to the cabinet 52, and more specifically, to the front cabinet wall 54 of the cabinet 52. The front appliance door 84 swings between an open door position and a closed door position. In the open door position, the front appliance door 84 provides access to the front cabinet opening 56. In the closed door position, the front appliance door 84 shuts or closes the front cabinet opening 56. When in the closed door position, the front appliance door 84 may be flush with or positioned adjacent to a front facia 86 of the cabinet 52. Although other materials can be used, in the illustrated example, the front appliance door 84 is composed of metal.

The laundry appliance 50 includes a drum 90 that is positioned in the cabinet cavity 68 and is rotatable with respect to the cabinet 52 about an axis 92. The drum 90 has a cylindrical shape and extends between a front drum end 94 and a rear drum end 96. The drum 90 includes a front drum opening 98 at the front drum end 94, a rear drum wall 100 at the rear drum end 96, and a drum sidewall 102 that extends between the front and rear drum ends 94, 96. One or more drum inlets 104 extend through the rear drum wall 100.

The front drum end 94, the drum sidewall 102, and the rear drum wall 100 cooperate to define a laundry compartment 110 inside the drum 90. The front cabinet opening 56 in the front cabinet wall 54 and the front drum opening 98 at the front drum end 94 are at least partially aligned with one another and therefore provide access to the laundry compartment 110 inside the drum 90 when the front appliance door 84 is in the open door position. In the illustrated example, the front cabinet opening 56 in the front cabinet wall 54 and the front drum opening 98 at the front drum end 94 are aligned with the axis 92. It should be appreciated that in use, laundry (e.g., clothes, towels, and/or bedding, etc.) is placed inside the laundry compartment 110 where it is dried during the drying cycle of the laundry appliance 50.

With additional reference to FIGS. 4-5, the laundry appliance 50 includes an appliance base 116 (e.g., basement) disposed between the drum 90 and the bottom cabinet wall 64. The appliance base 116 is attached to the bottom cabinet wall 64. The appliance base 116 extends between a front base end 118 and a rear base end 120 that is opposite the front base end 118. The front base end 118 is positioned adjacent to and attached to the front cabinet wall 54. The rear base end 120 is positioned adjacent to and attached to the rear cabinet wall 58. The appliance base 116 extends laterally between a first base end 122 and a second base end 123 opposite the first base end 122. The first base end 122 is positioned adjacent to one of the cabinet sidewalls 60 and the second base end 123 is positioned adjacent to another one of the cabinet sidewalls 60.

The appliance base 116 includes a base inlet 124 disposed at the front base end 118. The base inlet 124 is positioned between the first and second base ends 122, 123. The base inlet 124 is arranged in fluid communication with the laundry compartment 110 of the drum 90 via a first base opening 126 in the appliance base 116.

The laundry appliance 50 includes a removable lint screen 130 (shown in FIG. 4) disposed within the appliance base 116. More specifically, the removable lint screen 130 is disposed within a removable lint screen cavity 132 of the appliance base 116. The removable lint screen cavity 132 is arranged in fluid communication with the base inlet 124 via a second base opening 134 of the appliance base 116. The removable lint screen cavity 132 is disposed at the front base end 118 of the appliance base 116. The removable lint screen cavity 132 is positioned between the base inlet 124 and the second base end 123.

The removable lint screen 130 is configured to collect lint passing through the appliance base 116, and more specifically the removable lint screen cavity 132. A user may clean or replace the removable lint screen 130. The removable lint screen 130 is attached to a lint screen door 136 (shown in FIG. 1). When the removable lint screen 130 is positioned within the removable lint screen cavity 132, the lint screen door 136 is disposed within a lint screen slot 138 of the appliance base 116. The lint screen door 136 is positioned adjacent to or flush with the front facia 86 of the laundry appliance 50. The lint screen door 136 includes a lint screen handle 140 that is used to move the removable lint screen 130 into and out of the laundry appliance 50.

In the illustrated example, the lint screen handle 140 is a pull cup type handle. A user may pull the lint screen handle 140 of the lint screen door 136 to remove the removable lint screen 130 from the removable lint screen cavity 132 of the appliance base 116 and may push the lint screen door 136 using the lint screen handle 140 to re-insert the removable lint screen 130 into the removable lint screen cavity 132 of the appliance base 116. However, the removable lint screen 130 may have another suitable type of lint screen handle 140 and another suitable configuration to remove and re-insert the removable lint screen 130.

The laundry appliance 50 includes a heat exchanger 144 disposed within a sump 146 of the appliance base 116. The heat exchanger is configured to heat air flowing through the appliance base 116. The sump 146 is positioned adjacent the second base end 123 and between the front and rear base ends 118, 120 of the appliance base 116. The sump 146 includes a front sump wall 148, a rear sump wall 150, sump sidewalls 152 extending between the front and rear sump walls 148, 150, and a bottom sump wall 154. The front sump wall 148 is positioned adjacent to the front base end 118 of the appliance base 116. The rear sump wall is positioned adjacent to the rear base end 120 of the appliance base 116. The sump 146 is arranged in fluid communication with the removable lint screen cavity 132 via a first sump opening 156 in the front sump wall 148. The sump 146 includes a second sump opening 158 in the rear sump wall 150 and a third sump opening 160 in the rear sump wall 150. The third sump opening 160 is positioned inboard of the second sump opening 158. The bottom sump wall 154 is inclined such that the bottom sump wall 154 in a position adjacent to the rear sump wall 150 is positioned lower (e.g., closer to the bottom cabinet wall 64) than the bottom sump wall 154 in a position adjacent to the front sump wall 148. In other words, the bottom sump wall 154 in a position adjacent to the front sump wall 148 is positioned higher (e.g., closer to the top cabinet wall 62) than the bottom sump wall 154 in a position adjacent to the rear sump wall 150.

A plurality of supports 164 is disposed on the bottom sump wall 154 and create a leveled surface. The plurality of supports 164 extend between a front support end 166 and a rear support end 168 that is opposite the front support end 166. The front support end 166 is positioned adjacent to the front sump wall 148. The rear support end 168 is positioned adjacent to the rear sump wall 150. Each of the plurality of supports 164 are positioned parallel to each other and spaced apart between the sump sidewalls 152. In the illustrated example, the plurality of supports 164 includes six supports 164. However, another suitable number of supports 164 may be used. The heat exchanger 144 is disposed on top of and is supported by the plurality of supports 164.

The heat exchanger 144 includes a first exchanger 172 and a second exchanger 174. The first and second exchangers 172, 174 are positioned adjacent to each other. More specifically, the first exchanger 172 is positioned adjacent to the front cabinet wall 54, and more specifically, the front sump wall 148. The second exchanger 174 is positioned adjacent to the rear cabinet wall 58, and more specifically, the rear sump wall 150. In some examples, the first and second exchanger 172, 174 may abut each other.

The first exchanger 172 is configured to condense air flowing from the removable lint screen cavity 132 and through the first exchanger 172. The air is condensed before the air reaches the second exchanger 174. The first exchanger 172 includes a first pipe 176 extending through the first exchanger 172. The first pipe 176 is configured to carry refrigerant or another suitable fluid to aid in condensing the air. Fluid (e.g., water vapor) may be released from the first exchanger 172 when the first exchanger 172 condenses air passing through the first exchanger 172. More specifically, when air is condensed using the first exchanger, moisture is removed from the air and fluid gravitationally falls from the first exchanger 172 to the bottom sump wall 154 of the sump 146.

The second exchanger 174 is configured to heat the air flowing from the first exchanger 172 and out the sump 146 of the appliance base 116. The second exchanger 174 includes a second pipe 178 extending through the second exchanger 174. The second pipe 178 is configured to carry refrigerant or another suitable fluid. Accordingly, air flows through the heat exchanger 144 to first be condensed by the first exchanger 172 and subsequently heated by the second exchanger 174 to create heated air.

The first and second pipes 176, 178 of the first and second exchangers 172, 174 of the heat exchanger 144 are configured to receive refrigerant or another suitable fluid from a compressor 180. The compressor 180 is attached to a compressor base 182 of the appliance base 116. The compressor base 182 is positioned adjacent to the front base end 118 and the first base end 122.

Additionally, the sump 146 includes a reservoir 190. The reservoir 190 is positioned to collect fluid flowing from the sump 146. More specifically, the reservoir 190 is positioned adjacent to the rear base end 120 and the second base end 123. The reservoir 190 includes a front reservoir wall 192, a rear reservoir wall 194, reservoir sidewalls 196 extending between the front and rear reservoir walls 192, 194, and a bottom reservoir wall 198. The front reservoir wall 192 includes a first reservoir opening 200 arranged in fluid communication with a fluid channel 204. The fluid channel 204 extends between the rear sump wall 150 and the front reservoir wall 192. The second sump opening 158 of the sump 146 is an inlet of the fluid channel 204 and the first reservoir opening 200 of the reservoir 190 is an outlet of the fluid channel 204. Accordingly, fluid is configured to flow from the bottom sump wall 154 gravitationally to the fluid channel 204 due to the incline of the bottom sump wall 154, and from the fluid channel 204 into the reservoir 190.

The appliance base 116 includes an airflow channel 210 disposed adjacent to the sump 146. The airflow channel 210 extends between a first channel end 212 and a second channel end 214 that is opposite the first channel end 212. The first channel end 212 is arranged in fluid communication with the sump 146 via the third sump opening 160. The second channel end 214 is positioned at the rear base end 120 of the appliance base 116 and adjacent to the first base end 122 of the appliance base 116. The second channel end 214 is arranged in fluid communication with the laundry compartment 110 of the drum 90 via a connector channel 218. The connector channel 218 extends between a first connector end 220 and a second connector end 222 that is opposite the first connector end 220. The first connector end 220 is arranged in fluid communication with the second channel end 214 of the airflow channel 210. The second connector end 222 is arranged in fluid communication with the laundry compartment 110 of the drum 90 via one or more drum inlets 104 (shown in FIG. 3).

A blower 230 is configured to blow heated air from the airflow channel 210 to the laundry compartment 110 of the drum 90. The blower 230 is attached to the appliance base 116 and more specifically, is attached to a blower base 232 of the appliance base 116. The blower base 232 is positioned adjacent to the rear base end 120 and the first base end 122 of the appliance base 116. The blower base 232 is positioned between the airflow channel 210 and the compressor base 182.

A base cover 238 is sealingly engaged with the appliance base 116 and disposed on top of the appliance base 116. More specifically, the base cover 238 extends over and encloses the sump 146 and the airflow channel 210. The base cover 238 and the sump 146 cooperate to define a sump cavity 240. The base cover 238 and the airflow channel 210 cooperate to define an airflow cavity 242.

The appliance base 116 includes a fluid bottle slot 248 that extends through the front base end 118. The fluid bottle slot 248 slidably receives a fluid bottle 250 (e.g., a gravity-fed fluid bottle). The fluid bottle slot 248 is positioned between the bottom sump wall 154 of the sump 146 and the bottom cabinet wall 64 of the cabinet 52. In other words, the fluid bottle slot 248 is positioned below the lint screen slot 138 of the appliance base 116. The fluid bottle slot 248 extends laterally between a first slot end 252 and a second slot end 254 that is opposite the first slot end 252. A plurality of bottle supports 256 (shown in FIG. 4) is attached to the bottom sump wall 154 of the sump 146 and support the fluid bottle 250. Each of the plurality of the bottle supports 256 are formed in an L-shape. However, another suitable shape may be used. A first set of bottle supports 256 are aligned with the first slot end 252 of the fluid bottle slot 248 and a second set of bottle supports 256 are aligned with the second slot end 254 of the fluid bottle slot 248. The first and second sets of bottle supports 256 face each other to receive the fluid bottle 250. In the illustrated example, the first set of bottle supports 256 include six first bottle supports 256 spaced apart between the fluid bottle slot 248 and the front reservoir wall 192 of the reservoir 190. The second set of bottle supports 256 include six second bottle supports 256 spaced apart between the fluid bottle slot 248 and the front reservoir wall 192 of the reservoir 190. However, the first and second sets of bottle supports 256 may include another suitable number of bottle supports 256 and may be positioned in another suitable arrangement.

The fluid bottle 250 is slidably positioned within the fluid bottle slot 248 and supported by the plurality of the bottle supports 256. The fluid bottle 250 extends between a front bottle end 258 and a rear bottle end 260 that is opposite the front bottle end 258. The fluid bottle 250 includes a fluid bottle cavity 262 therein. When the fluid bottle 250 is inserted into the laundry appliance 50 and more specifically, the appliance base 116, the fluid bottle cavity 262 is arranged in fluid communication with the reservoir 190 and collects fluid flowing from the reservoir 190. The front bottle end 258 of the fluid bottle 250 may be positioned flush with or adjacent to the front facia 86 of the laundry appliance 50 when the fluid bottle is inserted into the appliance base 116.

The fluid bottle 250 includes a fluid bottle handle 264 disposed at the front bottle end 258. In the illustrated example, the fluid bottle handle 264 is a pull-type handle. A user may slidingly pull the fluid bottle handle 264 of the fluid bottle 250 to remove the fluid bottle 250 from the appliance base 116 and may slidingly push the fluid bottle 250 to re-insert the fluid bottle 250 into the appliance base 116. However, the fluid bottle 250 may have another suitable type of fluid bottle handle 264 and another suitable configuration to remove and re-insert the fluid bottle 250.

With additional reference to FIGS. 6-7, a check valve 270 is disposed at the rear bottle end 260 of the fluid bottle 250. The check valve 270 is movable between an open valve position and a closed valve position. In the open valve position, the check valve 270 allows fluid to flow from the reservoir 190 into the fluid bottle 250. In the closed valve position, the check valve 270 restricts fluid from flowing from the reservoir 190 to the fluid bottle 250. The check valve 270 includes a valve housing 272, a valve shaft 274, and a valve spring 276. The valve housing 272 includes a valve channel 278, a first valve arm 280, and a second valve arm 282. The valve channel 278 is positioned at least partially within the fluid bottle 250 and at least partially outside the fluid bottle 250. The valve channel 278 includes an inner channel surface 284 and an outer channel surface 286 that is opposite the inner channel surface 284. The valve channel 278 extends between a first valve channel end 288 and a second valve channel end 290 that is opposite the first valve channel end 288. The first channel end 212 is positioned outside the fluid bottle 250. The second valve channel end 290 is positioned inside the fluid bottle 250.

A first annular valve seal 296 extends annularly about the valve channel 278 and extends radially outward from the outer channel surface 286 of the valve channel 278. The first annular valve seal 296 is positioned adjacent to the first valve channel end 288 of the valve channel 278. An annular valve lip 298 extends annularly about the inner channel surface 284 of the valve channel 278 and is positioned between the first annular valve seal 296 and the second valve channel end 290 of the valve channel 278. The annular valve lip 298 extends radially inward from the inner channel surface 284 of the valve channel 278. A valve base 300 is disposed within the valve channel 278. The valve base 300 is attached to the inner channel surface 284 of the valve channel 278 and extends across the valve channel 278. The valve base 300 is positioned adjacent to the second valve channel end 290 of the valve channel 278. The valve base 300 includes a plurality of valve openings 302 to allow fluid flow from the valve channel 278 of the check valve 270 to the fluid bottle 250.

The valve shaft 274 is disposed within the valve channel 278 and is movable between a first shaft position and a second shaft position. When the check valve 270 is in the closed valve position, the valve shaft 274 is in the first shaft position and disposed between the valve base 300 and the first valve channel end 288 of the valve channel 278. When the check valve 270 is in the open valve position, the valve shaft 274 is in the second shaft position, extends through one of the plurality of valve openings 302 and is positioned adjacent to the second valve channel end 290 of the valve channel 278. An annular shaft rim 304 extends annularly about the valve shaft 274 and radially outward from the valve shaft 274. The annular shaft rim 304 may be radially spaced from the inner channel surface 284 of the valve channel 278. The annular shaft rim 304 is positioned between the valve base 300 and the annular valve lip 298. A second annular valve seal 308 is positioned between the annular shaft rim 304 and the annular valve lip 298. The second annular valve seal 308 is sealingly engaged with the annular valve lip 298. When the check valve 270 is in the closed valve position, the annular shaft rim 304 is sealingly engaged with the second annular valve seal 308 to restrict fluid flow through the check valve 270. When the check valve 270 is in the open valve position, the annular shaft rim 304 is spaced apart from the second annular valve seal 308 to allow fluid flow between the annular valve lip 298 and the annular shaft rim 304. One or more rim passageways 310 may extend through the annular shaft rim 304. The rim passageway 310 is radially aligned with the second annular valve seal 308 such that fluid flows through the one or more rim passageways 310 when the check valve 270 is in the open valve position.

The valve spring 276 extends between and is attached to the valve base 300 and the annular shaft rim 304 of the shaft. The valve spring 276 is movable between a relaxed position and a compressed position as the check valve 270 moves between the closed and open valve positions. When the check valve 270 is in the closed valve position, the valve spring 276 is in the relaxed position. When the check valve 270 is in the open valve position, the valve spring 276 is the compressed position.

The first and second valve arms 280, 282 of the valve housing 272 extend from the outer channel surface 286 of the valve channel 278 and wrap around the rear bottle end 260 of the fluid bottle 250. The first and second valve arms 280, 282 are disposed on opposing sides of the valve channel 278 and positioned between the first and second valve channel ends 288, 290. The first and second valve arms 280, 282 attach the valve channel 278 to the fluid bottle 250.

A docking station 320 is positioned within the front reservoir wall 192 of the reservoir 190. The docking station 320 is positioned adjacent to the bottom reservoir wall 198 and positioned below the first reservoir opening 200. The docking station 320 is aligned with the check valve 270 such that the check valve 270 is in movable contact with the docking station 320. The docking station 320 includes a docking station housing 322 and a docking station plunger 324. The docking station housing 322 extends between a first station end 326 and a second station end 328 that is opposite the first station end 326. The docking station housing 322 extends through the front reservoir wall 192. The first station end 326 is positioned within the reservoir 190 and the second station end 328 is positioned outside the reservoir 190. In some configurations, the second station end 328 may be positioned flush with the front reservoir wall 192 of the reservoir 190. The docking station housing 322 includes a docking station channel 330 that extends between the first and second station ends 326, 328.

The docking station plunger 324 includes a back wall 332 and a protrusion 334. The back wall 332 is disposed at the second station end 328 of the docking station housing 322 and extends radially to close the docking station channel 330. The back wall 332 in in movable contact with the docking station housing 322 between an open plunger position and a closed plunger position. When the docking station plunger 324 is in the open plunger position, the back wall 332 is spaced from the second station end 328 of the docking station housing 322 to allow fluid flow from the reservoir 190 to the docking station channel 330 and between the back wall 332 and the first station end 326 of the docking station housing. When the docking station plunger 324 in the closed plunger position, the back wall 332 is sealingly engaged with the docking station housing 322 to restrict fluid flow from the reservoir 190 to the docking station channel 330.

The back wall 332 includes a first wall side 338 and a second wall side 340 that is opposite the first wall side 338. The first wall side 338 faces the rear reservoir wall 194 of the reservoir 190. The second wall side 340 faces the front reservoir wall 192 of the reservoir 190. The protrusion 334 is disposed at the second wall side 340 of the back wall 332. The protrusion 334 extends from the back wall 332 in a direction toward the second station end 328 of the docking station housing 322. The protrusion 334 is at least partially aligned with the shaft of the check valve 270.

The back wall 332 of the docking station plunger 324 is attached to a support spring 344. The support spring 344 extends between a first spring end 346 and a second spring end 348 that is opposite the first spring end 346. The first spring end 346 is attached to a post 350 that extends from the rear reservoir wall 194 of the reservoir 190. The first spring end 346 coils around the post 350. The second spring end 348 is attached to the first wall side 338 of the back wall 332 of the docking station plunger 324. The support spring 344 supports the back wall 332 as the docking station plunger 324 moves between the open plunger position and the closed plunger position.

When the fluid bottle 250 is inserted into the appliance base 116, the valve channel 278 of the check valve 270 is received within the docking station housing 322 and more specifically, within the docking station channel 330. The first annular valve seal 296 is sealingly engaged with the docking station channel 330. The valve shaft 274 of the check valve 270 is pressed against the protrusion 334 of the docking station plunger 324. Contact of the valve shaft 274 and protrusion 334 moves the docking station plunger 324 from the closed plunger position to the open plunger position and moves the valve shaft 274 of the check valve 270 from the first shaft position to the second shaft position. Fluid flows from the reservoir 190 to the fluid bottle cavity 262 via the docking station channel 330 and the valve channel 278 of the check valve 270.

A fluid level sensor 358 is disposed within the reservoir 190 and configured to detect a fluid level in the reservoir 190. The fluid level sensor 358 includes a float 360 that is buoyant and therefore configured to float within the fluid of the reservoir 190. The float 360 extends between a first float end 362 and a second float end 364 that is opposite the first float end 362. The float 360 includes a base portion 366 disposed at the second float end 364 and a shaft portion 368 that extends from the base portion 366 to the first float end 362. An annular rim 370 extends annularly about the shaft portion 368 of the float 360 and is positioned adjacent to the first float end 362.

A platform 374 extends across the reservoir 190. More specifically, the platform 374 is attached to the front reservoir wall 192 and the rear reservoir wall 194. In some configurations, the platform 374 may also be attached to the reservoir sidewalls 196. The platform 374 includes a platform opening 376 disposed between the front and rear reservoir walls 192, 194. The shaft portion 368 of the float 360 is positioned within the platform opening 376 and is movable within the platform opening 376. The annular rim 370 and the base portion 366 of the float 360 are positioned on opposing sides of the platform 374. More specifically, the annular rim 370 of the float 360 is positioned above the platform 374 and the base portion 366 of the float 360 is positioned below the platform 374. Contact between the annular rim 370 of the float 360 and the platform 374 limits further movement of the float 360 in a direction toward the bottom reservoir wall 198 of the reservoir 190. Contact between the base portion 366 of the float and the platform 374 limits further movement of the float 360 in a direction away from the bottom reservoir wall 198.

The fluid level sensor 358 includes a fluid level switch 380 that is in communication with the control module 78 of the laundry appliance 50. The fluid level switch 380 is movable between a deactivated switch position (shown in FIG. 7) and an activated switch position (shown in FIG. 6). The fluid level switch 380 is attached to at least one of the front reservoir wall 192, the rear reservoir wall 194, and the reservoir sidewall 196. In the illustrated example, the fluid level switch 380 is attached to the rear reservoir wall 194. The fluid level switch 380 includes a switch base 382 and a switch lever 384. The switch base 382 is fixedly attached to the reservoir 190. The switch lever 384 is pivotally attached to the switch base 382 and extends away from the switch base 382. The switch lever 384 is at least partially aligned with the shaft portion 368 of the float 360.

As shown in FIG. 6, when the fluid in the reservoir 190 reaches a threshold fluid level, the float 360 floats within the fluid of the reservoir 190 and, the shaft portion 368 of the float 360 presses against the switch lever 384 of the fluid level switch 380. The shaft portion 368 of the float 360 moves the fluid level switch 380 from the deactivated switch position (shown in FIG. 7) to the activated switch position (shown in FIG. 6). When the fluid level switch 380 is in the activated switch position, the control module 78 of the laundry appliance 50 is configured to pause operation of the laundry appliance 50. More specifically, the control module 78 is configured to pause the drying cycle of the laundry appliance 50 based on the activated switch position of the fluid level switch 380. Accordingly, additional fluid is not released by the heat exchanger 144.

With reference to FIGS. 3-7, an airflow path and fluid flow path will now be described. The blower 230 blows air from the second channel end 214 of the airflow channel 210 to the connector channel 218. Air flows from the connector channel 218 to the laundry compartment 110 of the drum 90 via the drum inlet 104. Air flows from the laundry compartment 110 of the drum 90, through the front drum opening 98 of the drum 90, and to the first base opening 126 of the base inlet 124 of the appliance base 116. Air flows from the base inlet 124 to the removable lint screen cavity 132 via the second base opening 134. Lint may flow from the laundry compartment 110, through the base inlet 124, and to the removable lint screen 130. Air is able to pass through the removable lint screen 130 from the base inlet 124 and to the sump 146. However, lint is trapped in the removable lint screen 130. Accordingly, lint is collected within and on the removable lint screen 130.

Air flows from the removable lint screen cavity 132 to the first exchanger 172 of the heat exchanger 144. The first exchanger 172 is configured to condense the air using the compressor 180. Condensed water vapor falls from the first exchanger 172 into the sump 146 of the appliance base 116. Air flows from the first exchanger 172 to the second exchanger 174 of the heat exchanger 144. The second exchanger 174 is configured to heat the air. Heated air flows from the second exchanger 174 to the airflow channel 210 via the third sump opening 160 of the appliance base 116. Heated air flows from the airflow channel 210 to the laundry compartment 110 via the drum inlet 104. Heated air is used to dry laundry disposed within the laundry compartment 110.

Water vapor flows from the sump 146 of the appliance base 116 to the fluid channel 204 via the second sump opening 158. Water vapor flows from the fluid channel 204 to the reservoir 190 via the first reservoir opening 200. Water vapor is collected in the reservoir 190.

As shown in FIG. 6, when the fluid bottle 250 is removed from the appliance base 116, the docking station plunger 324 is in the closed plunger position and restricts condensed water vapor (i.e., water vapor condensate) from flowing out the reservoir 190. If a fluid level of the water vapor condensate exceeds the threshold fluid level, the float 360 floats in the water vapor condensate and the shaft portion 368 of float 360 contacts the switch lever 384 of the fluid level switch 380. The fluid level switch 380 transitions from the deactivated switch position to the activated switch position. The fluid level switch 380 communicates with the control module 78 and the control module 78 pauses operation of the laundry appliance 50 based on the activated switch position of the fluid level switch 380. The control module 78 activates at least one of the display 72 and the speaker 74 to alert the user of the laundry appliance 50 that the fluid bottle 250 has not been inserted into the appliance base 116 and the reservoir 190 is full.

When the fluid bottle 250 is inserted into the appliance base 116, the check valve 270 is in the open valve position and the docking station plunger 324 is in the open station position. Accordingly, water vapor condensate flows from the reservoir 190 to the fluid bottle cavity 262 of the fluid bottle 250. When the fluid bottle cavity 262 reaches a threshold cavity level, the water vapor condensate begins to collect in the reservoir 190. When a fluid level of the water vapor condensate in the reservoir 190 exceeds the threshold fluid level, the shaft portion 368 of float 360 contacts the switch lever 384 of the fluid level switch 380 and transitions the fluid level switch 380 from the deactivated switch position to the activated switch position. The fluid level switch 380 communicates with the control module 78 and the control module 78 pauses operation of the laundry appliance 50, and more specifically the drying cycle of the laundry appliance 50. The control module 78 activates at least one of the display 72 and the speaker 74 to alert the user of the laundry appliance 50 that the fluid bottle 250 is full and requires servicing (i.e., emptying of the water vapor condensate).

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. A laundry appliance, comprising:

a cabinet;

a drum rotatably supported within the cabinet and defining a laundry compartment therein;

a heat exchanger disposed in the cabinet;

a sump disposed in the cabinet below the heat exchanger and positioned to collect condensed water vapor falling from the heat exchanger;

a removable, gravity-fed fluid bottle that is slidingly received in the cabinet below the heat exchanger and is positioned in fluid communication with the sump; and

a fluid level sensor positioned in the sump and configured to pause operation of the laundry appliance when a fluid level detected in the sump exceeds a threshold fluid level.

2. The laundry appliance of claim 1, wherein the fluid level sensor includes a float that is positioned in the sump.

3. The laundry appliance of claim 2, wherein the fluid level sensor includes a fluid level switch that is movable between a deactivated position and an activated position.

4. The laundry appliance of claim 3, wherein the fluid level sensor is configured to detect the threshold fluid level in the sump when a portion of the float contacts the fluid level switch.

5. The laundry appliance of claim 3, wherein the fluid level switch transitions from the deactivated position to the activated position when a portion of the float contacts the fluid level switch.

6. The laundry appliance of claim 3, wherein when the fluid level switch is in the activated position, the fluid level switch is configured to pause operation of the laundry appliance.

7. The laundry appliance of claim 1, further comprising a check valve mounted to the fluid bottle and configured to control fluid flow between the sump and the fluid bottle.

8. The laundry appliance of claim 7, wherein the fluid bottle extends between a front bottle end and a rear bottle end that is opposite the front bottle end and wherein the check valve is disposed at the rear bottle end of the fluid bottle.

9. The laundry appliance of claim 7, wherein the check valve is movable between an open valve position allowing fluid flow between the sump and the fluid bottle and a closed valve position restricting fluid flow between the sump and the fluid bottle.

10. A laundry appliance, comprising:

a cabinet including a front cabinet wall and a rear cabinet wall opposite to the front cabinet wall;

a drum rotatably supported within the cabinet and defining a laundry compartment therein;

a heat exchanger disposed in the cabinet;

a sump disposed in the cabinet below the heat exchanger and positioned to collect condensed water vapor falling from the heat exchanger;

a removable fluid bottle that is slidingly received in the cabinet below the heat exchanger and is positioned in fluid communication with the sump;

a check valve that is mounted to the removable fluid bottle and is movable between an open valve position and a closed valve position such that the check valve is configured to control a fluid flow between the sump and the fluid bottle; and

a docking station disposed within the sump and at least partially aligned with the check valve, the docking station including a docking station housing positioned within a wall of the sump and a docking station plunger positioned in movable contact with the docking station housing, wherein the docking station plunger is moveable between an open plunger position and a closed plunger position.

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

a fluid level sensor located in the sump that is configured to pause operation of the laundry appliance when a fluid level detected in the sump exceeds a threshold fluid level.

12. The laundry appliance of claim 11, wherein the fluid level sensor includes a float that is buoyant and configured to float in the fluid of the sump and a fluid level switch movable between a deactivated position and an activated position.

13. The laundry appliance of claim 12, wherein the fluid level sensor is configured to detect the threshold fluid level in the sump when the float contacts the fluid level switch and moves the fluid level switch from the deactivated position to the activated position.

14. The laundry appliance of claim 10, wherein the docking station plunger is sealingly engaged with docking station housing when the docking station plunger is in the closed plunger position to restrict fluid flow from sump to the docking station housing.

15. The laundry appliance of claim 10, wherein the docking station plunger is spaced from the docking station housing when the docking station plunger is in the open plunger position to allow fluid flow from the sump to the docking station housing.

16. The laundry appliance of claim 10, wherein when the removable fluid bottle is inserted into the cabinet, the check valve is received in the docking station housing, the check valve is in the open valve position and the docking station is in the open plunger position to allow fluid flow from the sump, through the docking station and check valve, and to the fluid bottle.

17. The laundry appliance of claim 10, wherein when the removable fluid bottle is removed the cabinet, the check valve is removed from the docking station housing, the check valve is in the closed valve position and the docking station is in the closed plunger position to restrict fluid flow between the sump and the fluid bottle.

18. The laundry appliance of claim 10, wherein the check valve includes a valve housing and a valve shaft movable within the valve housing.

19. The laundry appliance of claim 18, wherein the valve shaft is sealingly engaged with the valve housing when the check valve is in the closed valve position and the valve shaft is spaced from the valve housing when the check valve is in the open valve position.

20. The laundry appliance of claim 10, wherein the heat exchanger includes:

a first exchanger positioned adjacent to the front cabinet wall and configured to condense air flowing through the first exchanger; and

a second exchanger positioned adjacent to the rear cabinet wall and configured to heat air flowing through the second exchanger.