HEAT PUMP DRYER INCLUDING A COMPRESSOR COOLING SYSTEM WITHOUT AN AUXILIARY FAN

Abstract

A heat pump dryer includes a cabinet including an appliance base and a basement supported on the appliance base. The basement includes a basement inlet and a basement outlet. A drum is rotatably supported in the cabinet. A heat exchanger is arranged in the basement between the basement inlet and the basement outlet. The basement outlet is connected to the drum. The heat exchanger includes an evaporator having an evaporator coil and a condenser having a condenser coil. A refrigerant system is connected to the heat exchanger. The refrigerant system includes a compressor having a refrigerant inlet and a refrigerant outlet. A blower is arranged in the cabinet supported on the appliance base. The blower includes a blower inlet and a blower outlet connected to the basement inlet. A compressor cooling system is operable to lower compressor temperatures without using an auxiliary fan.

Description

FIELD

The present disclosure relates to the art of heat pump dryers and, more particularly, to a heat pump dryer including a compressor cooling system without an auxiliary fan.

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. The appliances also include a blower that directs airflow into the drum. In a heat exchanger dryer, that airflow is passed through an evaporator including evaporator and a condenser including condenser coils prior to entering the drum. The evaporator and the condenser coils remove moisture from and heat the airflow.

The evaporator and condenser coils are connected to a refrigerant system including a compressor. The compressor is connected in fluid communication with the evaporator and the condenser. The compressor directs pressurized refrigerant through the evaporator and the condenser which, in turn heats air flowing over the evaporator and condenser coils. The amount of work required by the compressor varies and may depend upon ambient temperature. The lower the ambient temperature, the more work required from the compressor to heat the airflow. While in operation, the compressor generates heat. Heat in the compressor may detract from an overall operational efficiency of the system. As such, many heat pump dryers include an auxiliary fan that directs an airflow over the compressor to reduce compressor temperatures.

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.

A heat pump dryer, in accordance with the present disclosure, includes a cabinet including an appliance base and a basement supported on the appliance base. The basement includes a basement inlet and a basement outlet. A drum is rotatably supported in the cabinet. A heat exchanger is arranged in the basement between the basement inlet and the basement outlet. The basement outlet is connected in fluid communication with the drum. The heat exchanger includes an evaporator having an evaporator coil and a condenser having a condenser coil. A refrigerant system is connected in fluid communication with the heat exchanger. The refrigerant system includes a compressor having a refrigerant inlet and a refrigerant outlet. A blower is arranged in the cabinet supported on the appliance base. The blower includes a blower inlet and a blower outlet connected in fluid communication with the basement inlet. A compressor cooling system is operable to lower compressor temperatures without using an auxiliary fan. The compressor cooling system includes a water jacket, where the compressor is arranged in a heat exchange relationship with cooling liquid in the water jacket to lower compressor temperatures. The water jacket includes an exposed open top to facilitate evaporation of the cooling liquid in the water jacket.

A method of cooling a compressor of a heat pump dryer without an auxiliary fan includes activating the heat pump dryer, passing air from a blower through an airflow channel into a heat exchanger, detecting a compressor outlet temperature, increasing blower speed if the compressor outlet temperature is greater than a first temperature value and less than a second temperature value, and opening a damper in the airflow channel if the compressor outlet temperature is greater than the second temperature value.

A method of cooling a compressor of a heat pump dryer without an auxiliary fan includes activating the heat pump dryer, passing air from a blower through an airflow channel into a fluid flow path of a heat exchanger, and directing a cooling liquid from the heat exchanger in a heat exchange relationship with the compressor.

The present disclosure presents a number of embodiments directed to systems and method for removing an auxiliary fan from a heat pump dryer. Removal of the auxiliary fan increases available real estate in a lower portion of a heat pump dryer. However, the removal of the auxiliary fan requires other systems and methodologies to cool the compressor in order to maintain and/or enhance refrigeration operation efficiencies.

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.

BRIEF DESCRIPTION OF THE 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 including a compressor cooling system, in accordance with the present disclosure;

FIG. 2 is a rear perspective view of the exemplary laundry appliance shown in FIG. 1, in accordance with the present disclosure;

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

FIG. 4 is a perspective view of the basement arranged in the laundry appliance of FIG. 1 including a compressor cooling system, in accordance with the present disclosure;

FIG. 5 is a top view of the basement of FIG. 4, in accordance with an aspect of the disclosure;

FIG. 6 is a flow chart illustrating a method of maintaining operating temperatures of a compressor arranged in the basement of FIG. 4, in accordance with a first aspect of the present disclosure;

FIG. 7 is a flow chart illustrating a method of maintaining operating temperatures of a compressor arranged in the basement of FIG. 4, in accordance with a first aspect of the present disclosure;

FIG. 8 is a perspective view of the basement arranged in the laundry appliance of FIG. 1 including a compressor cooling system, in accordance with another aspect of the present disclosure;

FIG. 9 is a perspective view of a drain pan of the compressor cooling system of FIG. 8;

FIG. 10 is a perspective view of a compressor cooling jacket of a compressor cooling system, in accordance with yet another aspect of the present disclosure;

FIG. 11 is a plan view of a microchannel heat exchanger of the laundry appliance of FIG. 1, in accordance with a non-limiting example;

FIG. 12 is a partial cross-sectional view of a header of the microchannel heat exchanger of FIG. 11, in accordance with a non-limiting example;

FIG. 13 is a cross-sectional end view of a flow passage of the microchannel heat exchanger of FIG. 11, in accordance with a non-limiting example;

FIG. 14 depicts a heat exchanger of the dryer of FIG. 1 including a condenser, an evaporator, and a compressor arranged between the condenser and the evaporator, in accordance with a non-limiting example;

FIG. 15 depicts a heat exchanger of the dryer of FIG. 1 including a condenser, an evaporator, and a compressor arranged between the condenser and the evaporator, in accordance with another non-limiting example; and

FIG. 16 depicts the compressor arranged at an outlet of the condenser, in accordance with a non-limiting example.

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.

While the auxiliary fan serves to lower compressor temperatures and increase appliance efficiency, the presence of the fan does not come without a cost. Operating the auxiliary fan requires additional power use by the appliance. Further, when in operation, the auxiliary fan produces noise. While the noise may be minimal, some consumers prefer a quieter appliance. Accordingly, the compressor cooling systems described herein are designed to lower compressor temperatures without increasing power requirements or a noise signature of the appliance.

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 (FIG. 3) inside the cabinet 52. In accordance with a non-limiting example, front cabinet wall 54 includes a vent 69 (FIG. 1) that facilitates air flow into cabinet cavity 68 as will be detailed more fully herein.

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 selector 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 selector 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 selector 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 display 72, speaker 74, control selector 76, and control module 78 may be positioned in another suitable location on 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 a drum 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 drum end 94 and rear drum end 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 drum 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.

Referring to FIG. 4 and with continued reference to FIGS. 1-3, the laundry appliance 50 includes an appliance base 116 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 laundry appliance 50 includes a heat exchanger system 144 disposed within a basement 146 of the appliance base 116. The heat exchanger is configured to heat air flowing through the appliance base 116 towards laundry compartment 110. The basement 146 is positioned adjacent to the first base end 122 and between the front base end 118 and rear base end 120 of the appliance base 116. The basement 146 includes a front basement wall 148, a rear basement wall 150, basement sidewalls 152 extending between the front basement wall 148 and rear basement wall 150, and a bottom basement wall 154.

The front basement wall 148 is positioned adjacent to the front base end 118 of the appliance base 116. The rear basement wall 150 is positioned adjacent to the rear base end 120 of the appliance base 116. The basement 146 is arranged in fluid communication with laundry compartment 110 via a first basement opening 156 in the rear basement wall 150. The basement 146 includes a second basement opening 158 (FIG. 5) in the front basement wall 148. The bottom basement wall 154 is inclined such that the bottom basement wall 154 in a position adjacent to the rear basement wall 150 is positioned lower (e.g., closer to the bottom cabinet wall 64) than the bottom basement wall 154 in a position adjacent to the front basement wall 148. In other words, the bottom basement wall 154 in a position adjacent to the front basement wall 148, is positioned higher (e.g., closer to the top cabinet wall 62) than the bottom basement wall 154 in a position adjacent to the rear basement wall 150.

Referring to FIG. 5, the heat exchanger system 144 includes a first heat exchanger 172 and a second heat exchanger 174. In accordance with the present disclosure, first heat exchanger 172 is an evaporator (not separately labeled) and second heat exchanger 174 is a condenser (also not separately labeled). In accordance with one exemplary aspect, the first heat exchanger 172 and second heat exchanger 174 are positioned adjacent to each other. More specifically, the first heat exchanger 172 is positioned adjacent to the front cabinet wall 54, and more specifically, the front basement wall 148. The second heat exchanger 174 is positioned adjacent to the rear cabinet wall 58, and more specifically, the rear basement wall 150. In some examples, the first heat exchanger 172 and second heat exchanger 174 may abut each other.

The first heat exchanger 172 is configured to condense air flowing through vent 69 from ambient. The air is condensed before the air reaches the second heat exchanger 174. The first heat exchanger 172 includes a first pipe 176 extending through the first heat 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 heat exchanger 172 when the first heat exchanger 172 condenses air passing through the first heat exchanger 172. More specifically, when air is condensed using the first heat exchanger, moisture is removed from the air and fluid gravitationally falls from the first heat exchanger 172 to the bottom basement wall 154 of the basement 146. The condensate is collected and delivered to a condensate holding tank 177 where it may evaporate, be withdrawn, or be used in other systems as will become more fully evident herein.

The second heat exchanger 174 is configured to heat the air flowing from the first heat exchanger 172 and out the basement 146 of the appliance base 116. The second heat exchanger 174 includes a second pipe 178 extending through the second heat exchanger 174. The second pipe 178 is configured to carry refrigerant or another suitable fluid. Accordingly, air flows through the heat exchanger system 144 to first be condensed by the first heat exchanger 172 and subsequently heated by the second heat exchanger 174 to create heated air that is passed into drum 90 via first basement opening 156.

The first pipe 176 and second pipe 178 of the first heat exchanger 172 and second heat exchanger 174 of the heat exchanger system 144 are configured to receive refrigerant or another suitable fluid from a compressor 180. The compressor 180 is attached to a compressor base 182 and to the appliance base 116. The compressor base 182 is positioned adjacent to the rear base end 120 and the second base end 123. Compressor 180 includes a refrigerant outlet 186 connected in fluid communication with second pipe 178 and a refrigerant inlet 188 connected in fluid communication with first pipe 176.

Compressor 180 pressurizes the refrigerant flowing through heat exchanger system 144. When compressed, the temperature of the refrigerant increases. The increase in temperature is passed into the airflow passing through heat exchanger system 144. A temperature probe 190 is mounted at compressor outlet 188. Temperature probe 190 is operatively connected to control module 178. Control module 78 monitors the temperature of the refrigerant passing into heat exchanger system 144.

The appliance base 116 includes an airflow channel 210 disposed adjacent to the basement 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. A sidewall 216 extends between and connects the first channel end 212 with the second channel end 214 through a bend portion 217. The first channel end 212 is arranged in fluid communication with the basement 146 via the second basement opening 158. The second channel end 214 is positioned at the front base end 118 the appliance base 116 and adjacent to the second base end 123 of the appliance base 116. More specifically, second channel end 214 is arranged adjacent to vent 69 and receives ambient air that is directed into basement 146. As shown in FIG. 2, basement 146 is connected in fluid communication with drum 90 via a connector channel 218. More specifically, first basement opening 156 is connected in fluid communication with connector channel 218 which, in turn, is connected in fluid communication with drum 90 as will be detailed herein.

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 first basement opening 156. 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).

In a non-limiting example, a filter 224 is positioned across second basement opening 158 and includes an effective filter area of at least about 400 millimeters (mm) by about 175 millimeters (mm). This effective filter area of filter 224 ensures that a robust flow of air will pass through heat exchanger system 144. The robust flow of air reduces operational stress on compressor 180 that may lead to elevated refrigerant temperatures. Filter 224 captures and prevents particulate that may be entrained in air passing through airflow channel 210 from entering heat exchanger system 144. Appliance 50 may include an additional filter (not shown) in the form of a lint trap arranged in airflow channel 210 upstream from filter 224. The lint trap may be accessible through front facia 86.

A blower 230 (FIG. 4) is configured to blow air through the airflow channel 210, through basement 146 across first heat exchanger 172 and second heat exchanger 174, and into drum 90. The blower 230 includes a squirrel cage 232 arranged at second channel end 214 of airflow channel 210. Squirrel cage 232 is operatively connected to a blower motor 234 that is positioned in the appliance base 116. The blower motor 234 is positioned adjacent to the front base end 118 and the second base end 123 of the appliance base 116.

The blower motor 234 is positioned between the airflow channel 210 and the compressor base 182. In accordance with an exemplary aspect, blower motor 234 may be a variable speed motor that is operatively connected to control module 78. Squirrel cage 232 may be connected in fluid communication with vent 69 in front facia 86 in the case of an open loop system or may be connected to front drum opening 98 via a duct (not shown) in the case of a closed loop system.

A base cover 238 is sealingly engaged with (i.e., seals against) the appliance base 116 and is disposed on top of the appliance base 116. More specifically, the base cover 238 extends over and encloses the basement 146 and the airflow channel 210. The base cover 238 and the basement 146 cooperate to define a basement cavity 240. Blower 230 includes an outlet 242 that directs air through airflow channel 210 into basement cavity 240. The air passes in heat exchange relationship with first heat exchanger 172 and second heat exchanger 174. First heat exchanger 172 removes moisture from the air and second heat exchanger 174 increases a temperature of the air. The air is then directed back into laundry compartment 110.

In accordance with the present disclosure, appliance 50 is devoid of an auxiliary fan directed at compressor 180. Appliance 50 includes a compressor cooling system 256 that is designed to lower operational temperatures of compressor 80 without the need of the auxiliary fan. In accordance with an exemplary aspect, compressor cooling system 256 includes a damper 258 mounted in sidewall 216 of airflow channel 210. Damper 258 is selectively opened to allow a portion of the air passing through airflow channel 210 to flow into an open area 262 before being expelled to ambient. By diverting a portion of the airflow away from basement 146, the workload on compressor 180 is reduced. By reducing the workload, compressor operating temperatures are likewise lowered.

Reference will now follow to FIG. 6 in describing a method 270 of cooling compressor 180 be selectively opening damper 258. In block 272, appliance 50 is activated to dry a load, e.g., clothes, in laundry compartment 110. In block 274 a determination is made whether refrigerant temperature at compressor refrigerant outlet 186 is greater than 80° C. If refrigerant temperature at compressor refrigerant outlet 186 is greater than 80° C., control module 78 opens damper 258 in block 276. After opening damper 258, control module 78 continues to monitor refrigerant temperature at compressor outlet 186 in block 278. If the refrigerant temperature remains above 80° C., damper 258 remains open. When the refrigerant temperature, as measured at compressor outlet 186, falls below 75° C. control module 78 closes damper 258 in block 280. Of course, if refrigerant temperature at compressor outlet 186 measured in block 274 is below 80° C., damper 258 remains closed. Method 270 will continue until the load in laundry compartment 110 is dry at which time the cycle is ended in block 282.

In accordance with another aspect of the present disclosure if blower motor 234 is a variable speed motor, compressor cooling system 256 may implement a method 290 as shown in FIG. 7. In block 292, appliance 50 is activated to dry a load, e.g., clothes, in laundry compartment 110. In block 294 a determination is made whether refrigerant temperature at compressor refrigerant outlet 186 is greater than 70° C. and less than 85° C. If refrigerant temperature at compressor refrigerant outlet 186 is greater 70° C. and less than 85° C., control module 78 increases an operational speed of blower motor 234 by about 200 RPM in block. Control module 78 continues to monitor refrigerant temperature at compressor outlet 186 in block 294.

If the refrigerant temperature measured at refrigerant outlet 186 is less than 70° C. or greater than 85° C. rises above 85° C., method 290 shifts to block 300. If refrigerant temperature as measured at compressor outlet 186 rises above 85° C., as measured in block 300, control module 78 increases operational speed of blower motor 234 and opens damper 258 in block 302. If refrigerant temperature as measured at compressor outlet 186 is below 85° C., as measured in block 300, method 292 returns to block 294. Method 292 will continue until the load in laundry compartment 110 is dry.

Reference will now follow to FIG. 8 in describing a compressor cooling system 320 in accordance with another aspect of the present disclosure. In FIG. 8 compressor 180 is shown to include a base portion 324, a head portion 326, and a substantially annular side wall 328. Base portion 324 is connected to appliance base 116 through fasteners 332. Base portion 324 also rests in a water jacket 336 connected to appliance base 116.

As shown in FIG. 9, water jacket 336 includes a base 338, a plurality of side walls 340, and an exposed top 342. Base 338 and sidewalls 340 define a reservoir 344 that may contain liquid condensate. Base 338 also include anchors, one of which is indicated at 347 that may be used to secure water jacket 336 to appliance base 116. Reservoir 344 is connected to condensate holding tank 177 via a conduit 349. Conduit 349 may support a siphon that transfers a cooling liquid (e.g., liquid condensate) from condensate holding tank 177 into reservoir 344. The siphon maintains a selected amount of liquid condensate in reservoir 344. By positioning base portion 324 of compressor 180 in a heat exchange relationship with liquid condensate in reservoir 344, operational temperatures of compressor 180 may be lowered without the need for a dedicated compressor cooling fan. Further, the use of a siphon to maintain condensate levels in reservoir 344 of water jacket 336 facilitates additional energy and cost savings. That is, no additional mechanical elements are used to maintain fluid levels in reservoir 344.

FIG. 10 depicts a compressor cooling system 350 in accordance with another exemplary aspect of the present disclosure. Compressor cooling system 350 is shown to include a water jacket 356 secure about substantially annular side wall 338. Water jacket 356 includes a base 352, a plurality of side walls 354, and an exposed top 358. Two of the plurality of side walls 354 include a curvature that conform to the substantially annular side wall 338 of compressor 180. Base 352 and the plurality of side walls 354 form a reservoir 360 that holds liquid condensate. Liquid condensate is introduced into reservoir 360 from condensate holding tank 177 in a manner similar to that discussed herein.

In a non-limiting example, head portion 326 of compressor 180 includes a mounting bracket 372. Water jacket 356 includes a mounting tab 376 that projects radially inwardly from exposed top 358. Mounting tab 376 includes two flexible fingers, one of which is indicated at 378 which detachably secure water jacket 356 to compressor 180 with substantially annular side wall 338 being in a heat exchange relationship with liquid condensate in reservoir 360 through one of the plurality of side walls 354. With this construction, operating temperatures of compressor 180 are lowered by through the use of the liquid condensate without the need for additional energy consuming cooling features.

Reference will now follow to FIGS. 11-13 in describing second heat exchanger 174 in accordance with a non-limiting example. Second heat exchanger 174 takes the form of a microchannel condenser 376. Microchannel condenser 376 includes a first header 380, a second header 382, and a plurality of flow passages or fins 384 that extend between first header 380 and second header 382. Plurality of flow passages 384 include a plurality of delivery passage 386a, 386b, 386c, 386d, and 386e, and a plurality of return passages 388a, 388b, and 388c. Delivery passages 386a-386e carry refrigerant from first header 380 to second header 382. Return passages 388a-388c carry refrigerant from second header 382 back to first header 380.

Referring to FIG. 12 and with continued reference to FIG. 11, first header 380 includes an upper header portion 388 and a lower header portion 390. Upper header portion 388 is fluidically isolated from lower header portion 390 by a dividing wall 392. Upper header portion 388 includes a refrigerant inlet 394 and lower header portion includes a refrigerant outlet 396. As shown in FIGS. 12 and 13, each flow passage 384 includes a plurality of microchannels 398. By passing the refrigerant through microchannel 398 formed in flow passages 384 a heat exchange efficiency is increased. That is, heat exchange between air flowing across flow passages 384 with the refrigerant flowing through microchannels 398 is improved as compared to flow passages having a single passage. Improving heat exchange between air flowing across flow passages 394 with the refrigerant flowing through microchannels 398 reduces the amount of work needed by compressor 180 to compress the refrigerant.

Reference will now follow to FIG. 14 in describing a compressor cooling system 395 in accordance with another aspect of the present disclosure. In the exemplary aspect illustrated in FIG. 14, compressor cooling system 395 is integrated into heat exchanger system 144. Second heat exchanger of heat exchanger system 144 includes a condenser 400 having a C-shaped cross-section. Condenser 400 may take the form of a microchannel condenser and includes a first side 402, a second side 404, and a rear side 406. First side 402 and second side 404 project outwardly from rear side 406 towards first heat exchanger 172. A recess 408 is formed in condenser 400 defined by first side 402, second side 404, and rear side 406. Compressor 180 is arranged between first heat exchanger 172 and second heat exchanger 174 in basement 146.

In a non-limiting example, compressor 180 is arranged in recess 408. More specifically, first side compressor 180 is arranged between first side 402 and second side 404. Compressor 180 is spaced from rear side 406. Compressor 180 is thus surrounded on three sides by condenser 400. Compressor 180 includes a first conduit 410 connected to first pipe 176 extending through first heat exchanger 172 and a second conduit 412 connected to second pipe 178 extending through second heat exchanger 174. With this arrangement, not only are refrigerant carrying conduits made shorter but compressor 180 is positioned directly in the airflow path defined within basement 146. Thus, compressor cooling system 395 removes the need for an auxiliary cooling fan mounted to appliance base 116.

As shown in FIG. 15, instead of a condenser including a C-shaped cross-section, compressor cooling system 395 may simply position compressor 180 between first heat exchanger 172 and second heat exchanger 174. Second heat exchanger 174 may take the form of a microchannel condenser 418. In a manner similar to that discussed herein, compressor 180 includes a first conduit 410 connected to first pipe 176 extending through first heat exchanger 172 and a second conduit 412 connected to second pipe 178 extending through second heat exchanger 174. With this arrangement, not only are refrigerant carrying conduits made shorter but compressor 180 is positioned directly in the airflow path defined within basement 146. Thus, compressor cooling system 395 removes the need for an auxiliary cooling fan mounted to appliance base 116.

In FIG. 16, compressor cooling system 395 positions compressor 180 downstream of second heat exchanger 174. Second heat exchanger 174 may take the form of a microchannel condenser 418. In a manner similar to that discussed herein, compressor 180 includes a first conduit 410 connected to first pipe 176 extending through first heat exchanger 172 and a second conduit 412 connected to second pipe 178 extending through second heat exchanger 174. With this arrangement, compressor 180 is positioned directly in the airflow path defined within basement 146. Thus, compressor cooling system 395 removes the need for an auxiliary cooling fan mounted to appliance base 116.

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 heat pump dryer comprising:

a cabinet including an appliance base;

a basement supported on the appliance base, the basement including a basement inlet and a basement outlet;

a drum rotatably supported in the cabinet;

a heat exchanger arranged in the basement between the basement inlet and the basement outlet, the basement outlet connected in fluid communication with the drum, the heat exchanger including an evaporator having an evaporator coil and a condenser having a condenser coil;

a refrigerant system connected in fluid communication with the heat exchanger, the refrigerant system including a compressor having a refrigerant inlet and a refrigerant outlet;

a blower arranged in the cabinet supported on the appliance base, the blower including a blower inlet and a blower outlet connected in fluid communication with the basement inlet; and

a compressor cooling system including a water jacket, the compressor arranged in a heat exchange relationship with cooling liquid in the water jacket to lower compressor temperatures, the water jacket including an exposed open top to facilitate evaporation of the cooling liquid in the water jacket.

2. The heat pump dryer according to claim 1, wherein the compressor cooling system includes the heat exchanger, the compressor being mounted in the basement between the evaporator and the condenser.

3. The heat pump dryer according to claim 2, wherein the condenser includes a C-shaped cross-section including a first side, a second side, and a recess arranged between the first side and the second side, the compressor being arranged in the recess.

4. The heat pump dryer according to claim 1, wherein the condenser includes a condenser outlet connected in fluid communication with the drum, the compressor being arranged downstream of the condenser outlet.

5. The heat pump dryer according to claim 1, wherein the evaporator includes an evaporator inlet and a filter arranged at the evaporator inlet, the filter having a filter area of at least 400 millimeters wide by at least 175 millimeters tall or at least 400 millimeters tall by at least 175 millimeters wide.

6. The heat pump dryer according to claim 1, wherein the water jacket includes a base and a plurality of side walls that extend up from the base and terminate at the exposed open top of the water jacket.

7. The heat pump dryer according to claim 6, wherein the compressor is supported on the base of the water jacket and is cooled by the cooling liquid in the water jacket without using an auxiliary fan.

8. The heat pump dryer according to claim 6, wherein the compressor includes a base portion, a head portion and a substantially annular side wall, the water jacket being connected at the head portion.

9. The heat pump dryer according to claim 8, wherein at least one of the plurality of side walls includes a curvature that conform to the substantially annular side wall of the compressor.

10. The heat pump dryer according to claim 6, further comprising a condensate collection tank connected in fluid communication with the condenser, wherein the water jacket is connected to the condensate collection tank through a siphon.

11. A heat pump dryer comprising:

a cabinet including an appliance base;

a basement supported on the appliance base, the basement including a basement inlet and a basement outlet;

a drum rotatably supported in the cabinet;

a heat exchanger arranged in the basement between the basement inlet and the basement outlet, the basement outlet connected in fluid communication with the drum, the heat exchanger including an evaporator having an evaporator coil and a condenser having a condenser coil;

a refrigerant system connected in fluid communication with the heat exchanger, the refrigerant system including a compressor having a refrigerant inlet and a refrigerant outlet;

a blower arranged in the cabinet supported on the appliance base, the blower including a blower inlet and a blower outlet connected in fluid communication with the basement inlet;

an airflow channel in fluid communication with the blower and the basement, the airflow channel including a sidewall; and

a damper mounted in the sidewall, the damper being selectively opened to discharge air from the blower towards the compressor.

12. The heat pump dryer according to claim 11, further comprising: a temperature probe mounted to the refrigerant outlet of the compressor.

13. The heat pump dryer according to claim 12, further comprising a damper controller operatively connected to the damper and the temperature probe, the damper controller selectively operating the damper based on compressor discharge temperature sensed by the temperature probe.

14. The heat pump dryer according to claim 13, wherein the damper controller is configured to increase blower speed after opening the damper.

15. The heat pump dryer according to claim 14, wherein the damper controller is configured to increase blower speed by 200 RPM after opening the damper.

16. The heat pump dryer according to claim 14, wherein the damper controller is configured to increase blower speed if the compressor outlet temperature, as detected by the temperature probe, is greater than a first temperature value and less than a second temperature value.

17. The heat pump dryer according to claim 16, wherein the damper controller is configured to increase blower speed if the compressor outlet temperature, as detected by the temperature probe, is greater than 78° C. and less than 85° C.

18. A method of cooling a compressor of a heat pump dryer without an auxiliary fan, the method comprising:

activating the heat pump dryer;

passing air from a blower through an airflow channel into a fluid flow path of a heat exchanger; and

directing a cooling liquid from heat exchanger in a heat exchange relationship with the compressor.

19. The method of claim 18, wherein directing the cooling liquid includes arranging the compressor in the heat exchanger in the fluid flow path.

20. The method of claim 18, wherein directing the cooling liquid includes directing liquid condensate from a condenser of the heat exchanger in a heat exchange relationship with the compressor.