TOP LOAD WASHER SPINNING WITH WATER

A washing machine appliance comprises a wash tub within a cabinet, a wash basket rotatably mounted in the wash tub, a pump fluidly coupled to the wash tub, and a motor mechanically coupled to the wash basket. A controller is configured to provide wash fluid for processing a laundry load, executing a laundry cycle, operate the pump to drain a portion of the wash fluid until the remaining portion partially submerges a bottom wall of the wash basket, accelerate the wash basket to a first rotational speed, and operate the drain pump while continuing to accelerate the wash basket to a dwell speed.

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Description
FIELD OF THE INVENTION

The present disclosure relates generally to top load washing machines, in particular a method of operating a spin cycle in a top loading washing machine to mitigate the effects of an out of balance load in a spin cycle.

BACKGROUND OF THE INVENTION

Washing machine appliances generally include a cabinet which supports a tub for containing wash fluid, e.g., wash water and detergent, bleach and/or other wash additives. A basket is mounted within the tub and defines a wash chamber for receipt of articles for washing. During operation of such washing machine appliances, wash fluid is directed into the tub and onto articles within the wash chamber of the basket. The basket or an agitation element can rotate at various speeds to agitate articles within the wash chamber in the wash fluid. A spin cycle is often included at the end of some cycles, for example at the end of a wash cycle or a rinse cycle. During the spin cycle, the basket spins at a high speed to urge wash fluid from articles within the wash chamber.

In some cases, an uneven distribution of weight during a spin cycle in a top load washing machines may cause excessive displacement of the tub and basket. In minor cases, a slight imbalance may cause vibration or noise. In extreme cases, the tub may contact the cabinet of the appliance. These impacts or “cabinet strikes” are noisy and can cause the washing machine to “walk” on the floor. Over time, the impacts can cause damage to the appliance. Accordingly, improvements that lessen the effects of out of balance spinning loads in top load washing machines may be desirable.

BRIEF DESCRIPTION OF THE INVENTION

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

In one exemplary aspect, a washing machine appliance comprises a wash tub positioned within a cabinet, a drain pump fluidly coupled to the wash tub, a wash basket rotatably mounted within the wash tub, a motor mechanically coupled to the wash basket, and a controller operably coupled to the drain pump, the motor, and a wash fluid supply. The controller is configured to provide the wash tub with a total amount of wash fluid for processing a laundry load in the wash basket, execute a laundry cycle processing the laundry load, operate the drain pump to drain a portion of the total amount of wash fluid from the wash tub until a remaining portion of wash fluid remains in the wash tub wherein the remaining portion of wash fluid partially submerges the bottom wall. The controller is further configured to initiate a spin cycle, wherein initiating the spin cycle comprises operating the motor to accelerate the wash basket to a first rotational speed and operating the drain pump to an on condition, wherein operating the drain pump to the on condition coincides with the wash basket reaching the first rotational speed. The controller is further configured to continue to accelerate the wash basket to a dwell speed while operating the drain pump to drain the remaining portion of wash fluid.

In another exemplary aspect, a method of operating a washing machine appliance is disclosed, the washing machine appliance a wash tub positioned within a cabinet, a wash basket rotatably mounted within the wash tub, the wash basket including a side wall and a bottom wall, a drain pump fluidly coupled to the wash tub, a motor mechanically coupled to the wash basket, and a controller operably coupled to the motor and a wash fluid supply. The method comprises providing the wash tub with a total amount of wash fluid for processing a laundry load in the wash basket, executing a laundry cycle processing the laundry load in the wash basket with the total amount of wash fluid, operating the drain pump to drain a portion of the total amount of wash fluid from the wash tub until the remaining portion of wash fluid partially submerges the bottom wall. The method further comprises initiating a spin cycle, wherein initiating the spin cycle comprises, operating the motor to accelerate the wash basket to a first rotational speed, and operating the drain pump to an on condition, wherein operating the drain pump to the on condition coincides with the wash basket reaching the first rotational speed. The method further comprises continuing to accelerate the wash basket to a dwell speed while operating the drain pump to drain the remaining portion of wash fluid.

In another exemplary aspect, a method of operating a spin cycle of a washing machine appliance is disclosed. The method comprising initiating the spin cycle, operating a motor to accelerate a wash basket in a wash tub to a first rotational speed, the wash tub containing a remaining portion of a total amount of wash fluid, wherein a bottom wall of the wash basket is partially submerged in the remaining portion, and operating a drain pump to drain the remaining portion of wash fluid in the wash tub. The method further comprises continuing operation of the motor to accelerate the rotational speed of the wash basket from the first rotational speed to a first dwell speed, operating the motor to accelerate the rotational speed of the wash basket from the first dwell speed to a second dwell speed, operating the motor to accelerate the rotational speed of the wash basket from the second dwell speed to a third dwell speed, and operating the drain pump to drain the remaining portion of wash fluid from the wash tub during at least one of the first dwell speed, the second dwell speed, or the third dwell speed.

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

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 provides a perspective view of a washing machine appliance according to an exemplary embodiment of the present subject matter with a lid of the exemplary washing machine appliance shown in a closed position;

FIG. 2 provides a perspective view of the exemplary washing machine appliance of FIG. 1 with the lid of the washing machine appliance shown in an open position;

FIG. 3 provides a side cross-sectional view of the exemplary washing machine appliance of FIG. 1 taken along III-III; and

FIG. 4 provides a flowchart illustrating an exemplary method of operating a washing machine appliance in accordance with one or more exemplary embodiments of the present disclosure.

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

DETAILED DESCRIPTION OF THE INVENTION

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

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

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

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

Turning to the figures, FIGS. 1 through 3 illustrate an exemplary embodiment of a vertical axis washing machine appliance 100. Specifically, FIGS. 1 and 2 illustrate perspective views of washing machine appliance 100 with the lid in a closed and an open position, respectively. FIG. 3 provides a side cross-sectional view of washing machine appliance 100. Washing machine appliance 100 generally defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular, such that an orthogonal coordinate system is generally defined.

It will be understood that aspects of the present subject matter may be used in any other suitable washing machine appliances. As will be generally understood by one of ordinary skill in the art, modifications and variations may be made to vertical axis washing machine appliance 100, including different configurations, different appearances, or different features while remaining within the scope of the present disclosure.

As illustrated in the figures, washing machine appliance 100 comprises a cabinet 102 that extends between a top portion 104 and a bottom portion 106 along the vertical direction V, between a first (left) side panel 103 and a second (right) side panel 105 along the lateral direction L, and between a front panel 107 and a rear panel 109 along the transverse direction T. As best shown in FIG. 3, a wash tub 108 is positioned within cabinet 102, the wash tub 108 defining a wash chamber 110, and generally configured for retaining wash fluids during an operating cycle. As used herein, “wash fluid” means water, or water with additives (for example detergent, fabric softener, or bleach) used in any part of a laundry appliance operation or cycle. Without limitation, “wash fluid” includes fluid used in wash, rinse, or drain and spin cycles.

Further, washing machine appliance 100 includes a wash basket 114 positioned within wash tub 108 and generally defining an opening 116 for receipt of laundry articles for washing. Wash basket 114 is defined by a side wall 115 and a bottom wall 117 with side wall and bottom wall 115, 117 defining a wash chamber 110. Wash basket 114 is supported within wash tub 108 for rotation about an axis of rotation A. According to the illustrated embodiment, the axis of rotation A is substantially parallel to the vertical direction V and runs through the center of the wash tub 108 and wash basket 114. In this regard, washing machine appliance 100 is generally referred to as a “vertical axis” or “top load” washing machine appliance 100.

As illustrated, cabinet 102 of washing machine appliance 100 has a top panel 118 which defines a top panel opening 112 (FIG. 2) that coincides with opening 116 of wash basket 114 to permit a user access to wash basket 114. Washing machine appliance 100 further includes a lid 120 which is rotatably mounted to top panel 118 to permit selective access to wash basket 114 through opening 116. Lid 120 selectively rotates between the closed position (FIG. 1) and the open position (FIG. 2). In the closed position, lid 120 blocks access to wash basket 114. Conversely, in the open position, a user can access wash basket 114. A window 122 in lid 120 permits viewing of wash basket 114 when lid 120 is in the closed position, for example, during operation of washing machine appliance 100. Lid 120 may also include a handle 124 that may facilitate opening and closing lid 120. Further, although lid 120 is illustrated as mounted to top panel 118, lid 120 may alternatively be mounted to cabinet 102 or any other suitable support.

As illustrated in FIGS. 2 and 3, wash basket 114 further defines a plurality of perforations 126 formed in side wall 115 to facilitate fluid communication between an interior of wash basket 114 and wash tub 108. For at least this purpose, wash basket 114 is spaced apart from wash tub 108 to define a space for wash fluid to escape wash chamber 110. During a spin cycle, wash fluid within articles of clothing and within wash chamber 110 is urged through perforations 126 and may collect in a sump 128 defined between the lower portions of wash basket 114 and wash tub 108. Washing machine appliance 100 may further include a pump assembly 130 (FIG. 3) that is located beneath wash tub 108 and wash basket 114 for gravity assisted flow when draining wash tub 108. Pump assembly may include a drain pump 131 and associated conduit or tubing 135 to couple the drain pump 13 to the wash tub 108 and to the external environment 10, for example an external drain (not shown). The first end 136 of tubing 135 may fluidly couple pump assembly 130 to the wash tub 108, for example at sump 128, to facilitate removal of wash fluid. Second end 137 of tubing 135 may be fluidly coupled to an external drain (not shown) to accept effluent from the wash tub 108. Drain pump 131 may be operably coupled to the controller 156 to accept operating instructions (for example on or off commands or speed control) to drain wash fluid from wash tub 108 and provide feedback to the controller 156.

In some embodiments, an impeller or agitation element 132 (FIG. 3), such as a vane agitator, may be disposed in wash basket 114 to impart an oscillatory motion to laundry articles and liquid in wash basket 114. More specifically, agitation element 132 extends into wash basket 114 and assists agitation of articles disposed within wash basket 114 during operation of washing machine appliance 100 to, for example, facilitate improved cleaning. In different embodiments, agitation element 132 includes a single action element (i.e., oscillatory only), a double action element (oscillatory movement at one end, single direction rotation at the other end) or a triple action element (oscillatory movement plus single direction rotation at one end, single direction rotation at the other end). As illustrated in FIG. 3, agitation element 132 and wash basket 114 are oriented to rotate about axis of rotation A, which is substantially parallel to vertical direction V and centrally located in wash tub 108.

As best illustrated in FIG. 3, washing machine appliance 100 includes a motor assembly 138 in mechanical communication with (i.e., mechanically coupled to) wash basket 114 and agitation element 132 (if present) to selectively rotate wash basket 114, for example during an agitation or a rinse cycle of washing machine appliance 100. In addition, motor assembly 138 may also be in mechanical communication with agitation element 132. In this manner, motor assembly 138 may be configured for selectively rotating or oscillating wash basket 114 and/or agitation element 132 during various operating cycles of washing machine appliance 100.

Motor assembly 138 may generally include one or more of a drive motor 140 and a transmission assembly 142, for example a clutch assembly for engaging and disengaging wash basket 114 and/or agitation element 132 with the drive motor 140. The drive motor 140 may be a brushless DC electric motor, e.g., a pancake motor as illustrated. However, according to alternative embodiments, drive motor 140 may be any other suitable type or configuration of motor. For example, drive motor 140 may be an AC motor, an induction motor, a permanent magnet synchronous motor, or any other suitable type of motor. In addition, motor assembly 138 may include any other suitable number, types, and configurations of support bearings or drive mechanisms.

Generally, the motor assembly 138 is fixed to the wash tub 108 with appropriate sealing elements (not shown) to achieve a watertight seal to contain wash fluid in the wash tub 108. In many cases, the wash tub 108, the wash basket 114, the agitation element 132, and the motor assembly 138 are collectively referred to as a subwasher assembly. This nomenclature may be used throughout the present disclosure.

The subwasher assembly 134 may be suspended from the cabinet 102 and supported by a vibration damping suspension system. The damping suspension system operates to damp dynamic motion as the wash basket 114 rotates within the tub 108, for example during a spin cycle. The damping suspension system can include one or more suspension assemblies 144 coupled between and to the cabinet 102 and subwasher assembly 134. Generally, the suspension assemblies 144 comprise a suspension rod 146 and a spring damper 148. Typically, four suspension assemblies 144 are utilized, and are spaced apart about the subwasher assembly 134. In the illustrative example of FIG. 3, four suspension assemblies 144 are provided, two are visible in the figure and two are hidden by the visible suspension assemblies 144.

The suspension assemblies 144 may be distributed around the subwasher assembly 134 in any suitable manner to provide support and motion damping to the subwasher assembly 134. For example, each suspension assembly 144 may be rotatably attached at one end proximate a corner of the cabinet 102. At an opposite end, the suspension assembly 144 may be rotatably attached to the subwasher assembly 134 as illustrated. In other embodiments, the suspension assemblies 144 may be rotatably attached to the cabinet 102 and subwasher assembly 134 in other locations. In the exemplary embodiment of FIG. 3, the spring damper 148 is disposed between the subwasher assembly 134 and the suspension rod 146. In other embodiments, the spring damper 148 may be disposed between the cabinet 102 and the suspension rod 146. In still other embodiments, the spring damper 148 may be disposed in other locations along the length of the suspension rod 146.

Operation of washing machine appliance 100 is controlled by a controller 156 that is operatively coupled (e.g., electrically coupled or connected) to at least one user input selector 152 located on control panel 150 (FIG. 1) for user manipulation to select washing machine cycles and features. Control panel 150 and input selector 152 collectively form a user interface input for operator selection of machine cycles and features. In response to user manipulation of the user input selector 152, controller 156 operates the various components of washing machine appliance 100 to execute selected machine cycles and features. A display 154 on control panel 150 indicates selected features, operation mode, a countdown timer, and/or other items of interest to appliance users regarding operation. In addition to the visual display 154, control panel 150 may also include auditory signaling devices, such as a speaker.

The controller 156 may be operably coupled to a wash fluid supply assembly 158 to supply wash fluid to the wash tub 108. Wash fluid supply assembly may include a water supply 160, for example from a municipal water source, a valve 162, and associated piping. The valve 162 may be operably coupled to the controller 156 to open and close as needed to supply wash water to the wash tub 108. The wash fluid supply assembly 158 may also be fluidly coupled to dispensers (not shown) for detergent, bleach, or other water treatments that may be combined with the supplied water to produce a wash fluid. The dispensers may be operably coupled to the controller 156 to selectively introduce water treatments to the water in producing wash fluid.

A sensor 164, for example a pressure sensor, may be provided in the wash tub 108 to sense the amount of wash fluid present in the tub 108. The sensor may be operably coupled to the controller 156 and send a signal corresponding to the pressure of the water within the tub 108. Accordingly, sensor 164 may be located at or close to the bottom of tub 108. The pressure signal may be converted to a wash fluid depth at the sensor 164 and transmitted to the controller 156 or it may be sent to the controller 156 for processing and converting into a wash fluid depth. Determining the depth of wash fluid may be useful in determining when the wash basket 114 has received a sufficient amount (or total amount) of wash fluid to properly process a laundry load. Determining the wash fluid depth may also be useful in operating the washing machine appliance 100 during various cycles, such as during a spin cycle. To maintain a proper amount of wash fluid in the tub 114, the controller may selectively operate the drain pump 131 to an on or an off condition in response to a sensor signal from the sensor 164.

Controller 156 may include a memory (e.g., non-transitory storage media) and microprocessor, such as a general or special purpose microprocessor operable to execute programming instructions or micro-control code associated with a washing operation or cycle. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In embodiments, the controller 156 executes programming instructions stored in memory (e.g., as software). The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 156 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software. Control panel 150 and other components of washing machine appliance 100 may be in operative communication with controller 156 via one or more signal lines or shared communication busses to provide signals to and/or receive signals from the controller 156. For example, the controller 156 may communicate with the motor assembly 138 to selectively rotate the wash basket 114 at various speeds or directions of rotation.

Referring back to FIG. 1, a schematic illustration of an external communication system 166 will be described according to an exemplary embodiment of the present subject matter. In general, external communication system 166 is configured for permitting interaction, data transfer, and other communications between washing machine appliance 100 and one or more external devices. For example, this communication may be used to provide and receive operating parameters, user instructions or notifications, performance characteristics, user preferences, or any other suitable information for improved performance of washing machine appliance 100. In addition, it should be appreciated that external communication system 166 may be used to transfer data or other information to improve performance of one or more external devices or appliances and/or improve user interaction with such devices.

For example, external communication system 166 permits controller 156 of washing machine appliance 100 to communicate with a separate device external to washing machine appliance 100, referred to generally herein as an external device 168. As described in more detail below, these communications may be facilitated using a wired or wireless connection, such as via a network 170. In general, external device 168 may be any suitable device separate from washing machine appliance 100 that is configured to provide and/or receive communications, information, data, or commands from a user. In this regard, external device 168 may be, for example, a personal phone, a smartphone, a tablet, a laptop or personal computer, a wearable device, a smart home system, or another mobile or remote device.

In addition, a remote server 172 may be in communication with washing machine appliance 100 and/or external device 168 through network 170. In this regard, for example, remote server 172 may be a cloud-based server 172, and is thus located at a distant location, such as in a separate state, country, etc. According to an exemplary embodiment, external device 168 may communicate with a remote server 172 over network 170, such as the Internet, to transmit/receive data or information, provide user inputs, receive user notifications or instructions, interact with or control washing machine appliance 100, etc. In addition, external device 168 and remote server 172 may communicate with washing machine appliance 100 to communicate similar information.

In general, communication between washing machine appliance 100, external device 168, remote server 172, and/or other user devices or appliances may be carried using any type of wired or wireless connection and using any suitable type of communication network, non-limiting examples of which are provided below. For example, external device 168 may be in direct or indirect communication with washing machine appliance 100 through any suitable wired or wireless communication connections or interfaces, such as network 170. For example, network 170 may include one or more of a local area network (LAN), a wide area network (WAN), a personal area network (PAN), the Internet, a cellular network, any other suitable short-or long-range wireless networks, etc. In addition, communications may be transmitted using any suitable communications devices or protocols, such as via Wi-Fi®, Bluetooth®, Zigbee®, wireless radio, laser, infrared, Ethernet type devices and interfaces, etc. In addition, such communication may use a variety of communication protocols (e.g., TCP/IP, HTTP, SMTP, FTP), encodings or formats (e.g., HTML, XML), and/or protection schemes (e.g., VPN, secure HTTP, SSL).

External communication system 166 is described herein according to an exemplary embodiment of the present subject matter. However, it should be appreciated that the exemplary functions and configurations of external communication system 166 provided herein are used only as examples to facilitate description of aspects of the present subject matter. System configurations may vary, other communication devices may be used to communicate directly or indirectly with one or more associated appliances, other communication protocols and steps may be implemented, etc. These variations and modifications are contemplated as within the scope of the present subject matter.

Now that the construction of a laundry appliance in accordance with this disclosure has been presented, an exemplary method 200 of operation for a laundry appliance will be described with reference to FIG. 4.

The method 200 begins at 202 with providing the wash tub 108 with a total amount of wash fluid for processing a laundry load. The wash fluid may be wash water or wash water with additives, such as detergent, fabric softener, bleach or other laundry wash water additives. The total amount is an amount necessary to effectively process the laundry load and may be determined by the size of the laundry load, the material, or the characteristics of the cycle. Sensor 164 is operably coupled to the controller 156 determine the volume of wash fluid in the tub 108.

The wash fluid may be provided from a municipal water supply or other water source, and delivered to the wash tub via a wash fluid supply assembly 158 with or without laundry additives as determined by controller 156. Supply assembly 158 includes a valve 162 operably connected to the controller 156 to selectively provide wash fluid to the drum 108 to maintain a depth as determined by the controller 156 with sensor 164.

At 204, a laundry cycle is executed for processing the laundry load in the wash basket 114. Controller 156 may store one or more laundry cycles for processing a laundry load. Stored laundry cycles may include predetermined processing parameters such as the amount of wash liquid, additives, agitation cycle profile, spin conditions, and order of operations (for example, sequence of operating valves 162, agitation element 132, motor operation to rotate wash basket 114, and the like). The one or more laundry cycles may include parameters for each cycle within the overall laundry cycle. According to embodiments of the present disclosure, the executed laundry cycle may be one of a wash cycle, a rinse cycle, or a drain and spin cycle, although the controller 156 may include other and different laundry cycles. Wash and rinse cycles commonly include a spin cycle to remove an amount of wash fluid from the laundry articles. Generally, the spin cycle is subsequent to one of, or both, the wash or rinse cycle. These cycles may be subject to load imbalance and may benefit from presently disclosed methods of laundry appliance and spin cycle operation.

At 206, method 200 operates the drain pump 131 to remove a portion of the total amount of wash fluid. The drain pump 131 is operated until a remaining portion of wash fluid remains in the wash tub 108, with the remaining portion of wash fluid sufficient to partially submerge the bottom wall 117 of the wash basket 114. “Partially submerge” or “partially submerging” the bottom wall and similar forms are used in this disclosure to indicate the remaining portion of wash fluid in the wash tub 108, when not moving, has a vertical depth such that the wash fluid contacts the bottom wall 117 and extends along a vertical dimension of the bottom wall 117 to place a portion of the bottom wall 117 in the wash fluid. As wash fluid is drained from the wash tub 108, some water may escape (i.e., “drip down”) from the wet laundry articles, adding to the remaining portion of standing wash fluid in the wash tub 108. Sensor 164, in cooperation with the controller 156, monitors the remaining portion of wash fluid level in the tub 108. The controller maintains the wash fluid level in the tub such that the remaining portion of wash fluid partially submerges the bottom wall 117 by periodically operating the drain pump 131 if the wash fluid level increases beyond a predetermined range. The controller 156 selectively operates the drain pump 131 to an on or off condition in response to a sensor signal to maintain a wash fluid level in a predetermined range to partially submerging the bottom wall 117. In some embodiments, the predetermined range is from about 0.1 inch to 3.0 inches, or from 0.1 inch to 2.0 inches, or from 0.1 inch to 1.0 inch, or from 0.1 inch to 0.5 inch. The wash fluid level is maintained in the above-mentioned range such that the bottom wall 117 of the wash basket 114 is submerged by between 0.1 inch and 1.0 inch, or between about 0.1 inch and about 0.5 inch. The wash fluid level is maintained below the level of laundry articles in the wash basket 114, so rewetting of the laundry articles does not occur. The wash fluid level is sufficient to touch the bottom wall 117 without touching the laundry articles in the basket 114.

At 208, a spin cycle is initiated which operates the motor to accelerate the wash basket to a first rotational speed. Notably, in embodiments of this disclosure, the method initiates the spin cycle with the drain pump 131 in an off condition and the remaining portion of the wash fluid in the wash tub 108 at a level below the level of laundry articles in the wash basket 114. According to the present disclosure, unbalanced loads of wet laundry articles in the wash basket 114 during acceleration of the basket 114 up to about 100 revolutions per minute (RPM) produce a large out of balance response from the subwasher assembly 134. This corresponds to an out of balance response during initiation of the spin cycle. According to the present disclosure, partially submerging the bottom wall 117 of the wash basket 114 in wash fluid mitigates the out of balance response without overly burdening the motor from excess wash fluid weight or friction from the wash fluid.

The first rotational speed is reached at step 210 at which point the drain pump is operated (i.e., the drain pump 131 is selectively operated to an on condition) to drain the remaining portion of wash fluid. The first rotational speed may be less than a dwell speed used to wring additional wash fluid from the wet laundry articles. For example, the first rotational speed may be in the range of 40 to 60 RPM, for example 50 RPM while dwell speeds may be in excess of 100 RPM. In some embodiments, multiple dwell speeds are used sequentially in a spin cycle to wring wash fluid from the laundry articles. For example a first dwell speed may be in the range of about 120 RPM to about 140 RPM and used in a first step in wringing wash fluid from the laundry articles. A second dwell speed may be in the range of about 350 RPM to 450 RPM to further wring wash fluid from the wet laundry articles. In some embodiments, a third dwell speed may be in the range of 800 RPM to 900 RPM to wring additional wash fluid from the laundry articles. Dwell speeds presented above are exemplary and not limiting. In some embodiments. more or fewer dwell speeds may be used and the dwell speeds may be different than the exemplary dwell speeds above. The controller 156 may continue to accelerate the wash basket 114, after reaching the first rotational speed, to a dwell speed while operating the drain pump 131 to drain the remaining portion of the wash fluid from the wash tub 108.

In embodiments of methods in accordance with this disclosure, during rotation of the wash basket 114 at one or more dwell speeds during the spin cycle, the controller may operate the drain pump 131 continuously (i.e., in a continuous drain process) for a period of time to pump or drain the wash fluid wrung from the laundry articles out of the wash tub 108. The continuous period of time for operation of the drain pump may correspond to one or more of the dwell periods (for example, a first, second, or third dwell period or any combination of dwell periods). In some embodiments, the continuous period of time for operation of the drain pump may be shorter or longer than one or more of the dwell periods (i.e., shorter or longer than the total time of one or more of the dwell periods).

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

Claims

1. A washing machine appliance defining a vertical direction, a lateral direction, and a transverse direction, the washing machine appliance comprising:

a wash tub positioned within a cabinet;
a drain pump fluidly coupled to the wash tub;
a wash basket rotatably mounted within the wash tub, the wash basket including a side wall and a bottom wall;
a motor mechanically coupled to the wash basket; and
a controller operably coupled to the drain pump, the motor, and a wash fluid supply, the controller configured to: provide the wash tub with a total amount of wash fluid for processing a laundry load in the wash basket; execute a laundry cycle processing the laundry load in the wash basket with the total amount of wash fluid; operate the drain pump to drain a portion of the total amount of wash fluid from the wash tub until a remaining portion of wash fluid remains in the wash tub wherein the remaining portion of wash fluid partially submerges the bottom wall; initiate a spin cycle, wherein initiating the spin cycle comprises: operating the motor to accelerate the wash basket to a first rotational speed; and operating the drain pump to an on condition, wherein operating the drain pump to the on condition coincides with the wash basket reaching the first rotational speed; and continue to accelerate the wash basket to a dwell speed while operating the drain pump to drain the remaining portion of wash fluid.

2. The washing machine appliance of claim 1, further comprising a sensor disposed in the wash tub and operably coupled to the controller, the sensor providing a sensor signal to the controller corresponding to a depth of the remaining portion of wash fluid in the wash tub.

3. The washing machine appliance of claim 2, wherein the controller selectively operates the drain pump to an on or off condition in response to the sensor signal to maintain the remaining portion of was water partially submerging the bottom wall.

4. The washing machine appliance of claim 3, wherein the spin cycle is initiated with the drain pump in an off condition.

5. The washing machine appliance of claim 2, wherein the sensor is a pressure sensor disposed at a bottom of the wash tub.

6. The washing machine appliance of claim 1, wherein the first rotational speed is less than the dwell speed.

7. The washing machine appliance of claim 1, wherein the wash basket is rotatably mounted within the wash tub for rotation about an axis parallel to the vertical direction.

8. The washing machine appliance of claim 1, wherein the laundry cycle is one of a wash cycle and a rinse cycle.

9. The washing machine appliance of claim 1, wherein the controller is further configured to operate the wash basket at a dwell speed to drain the remaining portion of wash fluid from the wash tub in a continuous drain process.

10. A method of operating a washing machine appliance, the washing machine appliance comprising a wash tub positioned within a cabinet, a wash basket rotatably mounted within the wash tub, the wash basket including a side wall and a bottom wall, a drain pump fluidly coupled to the wash tub, a motor mechanically coupled to the wash basket, and a controller operably coupled to the motor and a wash fluid supply, the method comprising:

providing the wash tub with a total amount of wash fluid for processing a laundry load in the wash basket;
executing a laundry cycle processing the laundry load in the wash basket with the total amount of wash fluid;
operating the drain pump to drain a portion of the total amount of wash fluid from the wash tub until a remaining portion of wash fluid remains in the wash tub, wherein the remaining portion of wash fluid partially submerges the bottom wall;
initiating a spin cycle, wherein initiating the spin cycle comprises: operating the motor to accelerate the wash basket to a first rotational speed; and operating the drain pump to an on condition, wherein operating the drain pump to the on condition coincides with the wash basket reaching the first rotational speed; and continuing to accelerate the wash basket to a dwell speed while operating the drain pump to drain the remaining portion of wash fluid.

11. The method of claim 10, wherein:

the washing machine appliance further comprises a sensor disposed in the wash tub and operably coupled to the controller; and
the method further comprises receiving a sensor signal from the sensor corresponding to a depth of the remaining portion of wash fluid in the wash tub.

12. The method of claim 11, wherein the method comprises selectively operating the drain pump to an on or off condition in response to the sensor signal to maintain the remaining portion of wash water partially submerging the bottom wall.

13. The method of claim 12, wherein the method initiates the spin cycle with the drain pump in an off condition.

14. The method of claim 11, wherein the sensor is a pressure sensor disposed at a bottom of the wash tub and the method further comprises receiving a pressure signal corresponding to the depth of the wash fluid in the wash tub.

15. The method of claim 10, wherein draining the remaining portion of wash fluid comprises accelerating the rotational speed of the wash basket from the first rotational speed to a first dwell speed.

16. The method of claim 15, wherein the controller is further configured to operate the wash basket at the first dwell speed and drain wash fluid from the wash tub in a continuous drain process.

17. The method of claim 10, wherein executing the laundry cycle processing the laundry load in the wash basket with the total amount of wash fluid comprises executing one of a wash cycle and a rinse cycle.

18. A method of operating a spin cycle of a washing machine appliance comprising:

initiating the spin cycle;
operating a motor to accelerate a wash basket in a wash tub to a first rotational speed, the wash tub containing a remaining portion of a total amount of wash fluid, wherein a bottom wall of the wash basket is partially submerged in the remaining portion;
operating a drain pump to drain the remaining portion of wash fluid in the wash tub;
continuing operation of the motor to accelerate the rotational speed of the wash basket from the first rotational speed to a first dwell speed;
operating the motor to accelerate the rotational speed of the wash basket from the first dwell speed to a second dwell speed;
operating the motor to accelerate the rotational speed of the wash basket from the second dwell speed to a third dwell speed; and
operating the drain pump to drain the remaining portion of wash fluid from the wash tub during at least one of the first dwell speed, the second dwell speed, or the third dwell speed.

19. The method of claim 18, wherein the method comprises initiating the spin cycle subsequent to one of a wash cycle and a rinse cycle.

20. The method of claim 18, wherein operating the wash basket in the spin cycle comprises draining wash fluid during the first dwell speed, the second dwell speed, or the third dwell speed in a continuous drain process.

Patent History
Publication number: 20250066970
Type: Application
Filed: Aug 25, 2023
Publication Date: Feb 27, 2025
Inventor: Cody Ewing (Floyds Knobs, IN)
Application Number: 18/456,278
Classifications
International Classification: D06F 33/34 (20060101); D06F 33/42 (20060101); D06F 37/12 (20060101);