Thermal exchange system for an appliance

Abstract

A thermal transfer system for an appliance includes a first blower that delivers process air through an airflow path. A first vapor compression loop delivers internal thermal energy via a first flow of media from a first evaporator and to a condenser that are within the airflow path. A second vapor compression loop delivers ambient thermal energy via a second flow of media from a second evaporator that is outside the airflow path to a thermal exchange structure within the airflow path. A second blower directs ambient air over the second evaporator for capturing ambient thermal energy. The first blower directs the process air over the thermal exchange structure to deliver ambient thermal energy to the condenser to define a preheat sequence of the condenser. Further, the internal thermal energy and the ambient thermal energy are delivered by the process air to a processing space.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit under 35 U.S.C. § 119 (e) of U.S. Provisional Patent Application No. 63 / 670,487 filed on Jul. 12, 2024, entitled “THERMAL EXCHANGE MODULE THAT INCORPORATES A PHASE CHANGE MATERIAL.” The present application is related to copending, commonly owned U.S. application Ser. No. 18 / 151,732 filed Jan. 9, 2023, which claims the benefit of U.S. Application No. 63 / 312,127 filed Feb. 21, 2022, both of which are entitled “LAUNDRY APPLIANCE HAVING A THERMAL STORAGE MECHANISM FOR CAPTURING EXCESS HEAT FROM ONE OR MORE HEAT SOURCES.” The present application is also related to copending, commonly owned U.S. application Ser. No. 18 / 098,261 filed Jan. 18, 2023, which claims the benefit of priority of U.S. Pat. No. 63,312,133 filed Feb. 21, 2022, both of which are entitled “THERMAL STORAGE MECHANISM FOR A LAUNDRY APPLIANCE THAT UTILIZES RECOVERY HEAT AND RENEWABLE ENERGY SOURCES.” The disclosures of the foregoing are hereby incorporated herein by reference in their entirety.BACKGROUND OF THE DISCLOSURE

[0002] The present disclosure generally relates to thermal exchange mechanisms and, more specifically, a thermal exchange system that can be incorporated within an appliance, and where the thermal exchange system utilizes ambient air for preheating a condenser of a vapor compression loop within the appliance.SUMMARY OF THE DISCLOSURE

[0003] According to a first aspect of the disclosure, a thermal transfer system for an appliance includes a first blower, a first vapor compression loop, a second vapor compression loop, and a second blower. The first blower delivers process air through an airflow path that includes a processing space. The first vapor compression loop delivers a first flow of thermal exchange media through a first evaporator and a condenser for delivering internal thermal energy from the first evaporator to the condenser. The first evaporator and the condenser are disposed within the airflow path. The second vapor compression loop delivers a second flow of thermal exchange media through a second evaporator and a thermal exchange structure disposed within the airflow path. The second evaporator is disposed outside of the airflow path. The second blower directs ambient air over the second evaporator. The second vapor compression loop captures ambient thermal energy from the ambient air and delivers the ambient thermal energy to the thermal exchange structure. The first blower directs the process air over the thermal exchange structure to capture the ambient thermal energy from the thermal exchange structure. The ambient thermal energy from the thermal exchange structure is delivered via the process air to the condenser to define a preheat sequence of the condenser. Further, the internal thermal energy and the ambient thermal energy are delivered by the process air to the processing space to define a duty cycle.

[0004] According to another aspect of the disclosure, an appliance includes an outer cabinet, a first blower, a first vapor compression loop, a second vapor compression loop, and a second blower. The outer cabinet has a processing space defined therein for treating articles. The first blower delivers process air through an airflow path that includes the processing space. The first vapor compression loop delivers a first flow of thermal exchange media through a first evaporator and a condenser that are positioned within the airflow path and upstream of the processing space. The first blower delivers the process air across the first evaporator to extract internal thermal energy that cools and dehumidifies the process air. The first blower further delivers the process air across the condenser to absorb the internal thermal energy that heats the process air before entering the processing space. The second vapor compression loop delivers a second flow of thermal exchange media through a second evaporator and a thermal exchange structure. The thermal exchange structure is positioned within the airflow path between the first evaporator and the condenser. The second evaporator is positioned outside of the airflow path. The second blower directs ambient air over the second evaporator. The second vapor compression loop captures ambient thermal energy from the ambient air and delivers the ambient thermal energy to the thermal exchange structure. The second blower directs the process air over the thermal exchange structure to capture the ambient thermal energy from the thermal exchange structure. Further, the ambient thermal energy from the thermal exchange structure is delivered via the process air to the condenser to define a preheat sequence of the condenser.

[0005] According to yet another aspect of the present disclosure, a method for operating a laundry appliance includes steps of activating an ambient vapor compression loop that delivers external ambient thermal energy from ambient air outside of an airflow path to a thermal exchange structure within the airflow path, delivering the ambient thermal energy from the thermal exchange structure to a condenser of a drying vapor compression loop to define stored ambient thermal energy to define a preheated condenser, activating the drying vapor compression loop to deliver internal thermal energy to the preheated condenser, and delivering the stored ambient thermal energy and the internal thermal energy from the preheated condenser through the airflow path and to a processing space.

[0006] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In the drawings:

[0008] FIG. 1 is a schematic perspective view of an appliance that incorporates an aspect of the vapor compression loop that utilizes ambient air for preheating a condenser;

[0009] FIG. 2 is a schematic perspective view of an appliance that incorporates an aspect of the vapor compression loop that utilizes ambient air for preheating a condenser;

[0010] FIG. 3 is a schematic diagram illustrating an exemplary appliance that incorporates an aspect of the thermal exchange structure into a dedicated vapor compression loop that delivers thermal energy to a primary vapor compression loop for the appliance, and utilizes a single compressor for the first and second vapor compression loops;

[0011] FIG. 4 is a schematic diagram illustrating an exemplary appliance that incorporates a first vapor compression loop and a second vapor compression loop having dedicated compressors and where the second vapor compression loop includes an aspect of the thermal exchange module for delivering thermal energy into the first vapor compression loop;

[0012] FIG. 5 is a linear flow diagram illustrating a method for operating a thermal transfer system for an appliance; and

[0013] FIG. 6 is a linear flow diagram illustrating a method for operating a thermal transfer system for an appliance.

[0014] The components in the figures are not necessary to scale, emphasis instead being placed upon illustrating the principles described therein.DETAILED DESCRIPTION

[0015] The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a thermal exchange system that utilizes ambient thermal energy from ambient air to pre-heat a condenser for an vapor compression loop of an appliance. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0016] For purposes of description herein, the terms “upper,”“lower,”“right,”“left,”“rear,”“front,”“vertical,”“horizontal,” and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise, the term “front” shall refer to the surface of the element closer to an intended viewer, and the term “rear” shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0017] The terms “including,”“comprises,”“comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0018] Referring to FIGS. 1-4, reference numeral 10 generally refers to a thermal transfer system that is incorporated within an appliance 12 for receiving thermal energy 14 from ambient air 16 within a first location 18, and delivering the absorbed thermal energy 14 to a separate second location 20 for heating a certain area within an appliance 12, typically a processing space 22 of an appliance 12. According to the various aspects of the device, the thermal transfer system 10 includes a refrigerant path, also referred to as a thermal exchange path 24, that operates to deliver thermal energy 14 from one location, typically outside of an outer cabinet 26 for the appliance 12, to a thermal exchange structure 28 located within the appliance 12. The thermal exchange structure 28 is used to store thermal energy 14, including ambient thermal energy 30, for usage within the thermal transfer system 10.

[0019] According to the various aspects of the device, as exemplified in FIGS. 1-4, the thermal transfer system 10 includes a first blower 222 that delivers process air 154 through an airflow path 50 that includes the processing space 22. A first vapor compression loop 212 delivers a first flow 220 of thermal exchange media 92 through a first evaporator 214 and a condenser 216 for delivering internal thermal energy 60 from the first evaporator 214 to the condenser 216. The first evaporator 214 and the condenser 216 are disposed within the airflow path 50 of the appliance 12. A second vapor compression loop 226 delivers a second flow 232 of thermal exchange media 92 through a second evaporator 228 and the thermal exchange structure 28 that is disposed within the airflow path 50. The second evaporator 228 is disposed outside of the airflow path 50. A second blower 234 directs ambient air 16 over the second evaporator 228. The second vapor compression loop 226 captures ambient thermal energy 30 from the ambient air 16 and delivers this ambient thermal energy 30 to the thermal exchange structure 28. The first blower 222 directs the process air 154 over the thermal exchange structure 28 to capture the ambient thermal energy 30 from the thermal exchange structure 28. The ambient thermal energy 30 from the thermal exchange structure 28 is then delivered, via the process air 154, to the condenser 216 to define a preheat sequence of the condenser 216. The internal thermal energy 60 and the ambient thermal energy 30 are then delivered by the process air 154 to the processing space 22 to define a duty cycle 62 of the appliance 12.

[0020] In certain aspects of the device, the ambient air 16 can be directed across the second evaporator 228 using the first blower 222. In such an aspect of the device, the first blower 222 can be used in combination with a plurality of baffles, or other similar airflow directing devices, to direct the air, contemporaneously or alternatively, through the airflow path 50 and across the second evaporator 228. These airflow redirecting devices can be operated in combination with the operation of the appliance 12 to direct the process air 154 and the ambient air 16 needed to capture and transfer the thermal energy 14 through the thermal transfer system 10, as described herein.

[0021] As exemplified in FIG. 3, the first vapor compression loop 212 and the second vapor compression loop 226 include a common compressor 250 that delivers a single common thermal exchange media 92 through each of the first vapor compression loop 212 and the second vapor compression loop 226. Using the single thermal exchange media 92, a valve assembly 252 directs the single thermal exchange media 92, alternatively, through the first vapor compression loop 212 and the second vapor compression loop 226. Accordingly, a single compressor operates with the valve assembly 252 to direct thermal exchange media 92 through the thermal transfer system 10 to capture thermal energy 14 from the ambient air 16 and deliver this thermal energy 14 to the thermal exchange structure 28 to perform the preheat sequence of the condenser 216. The condenser 216 and the valve assembly 252 subsequently operate to perform a heat exchange function through operation of the first vapor compression loop 212 to transfer this stored ambient thermal energy 30 from the thermal exchange structure 28 to the condenser 216, thereby preheating the condenser 216. In this manner, the preheat sequence is operated through use of the condenser 216, and is activated in advance of the duty cycle 62 for the appliance 12. In certain aspects of the device, the preheat sequence is operated in advance of the duty cycle 62 for the appliance 12.

[0022] According to the various aspects of the device, as exemplified in FIGS. 3 and 4, the thermal exchange structure 28 includes a phase change material (“PCM”) 70 that receives and stores the ambient thermal energy 30 from the second evaporator 228. As the ambient thermal energy 30 accumulates within the PCM 70, this PCM 70 changes states of matter, typically from a solid to a liquid, from a liquid to a gas, or from a solid to a gas. During operation of the first blower 222, process air 154 is delivered through the thermal exchange structure 28 and the stored ambient thermal energy 30 is absorbed by the process air 154 for delivery to a primary condenser 224. In this manner, the stored ambient thermal energy 30 is transferred from the PCM 70 to the process air 154. This transfer of the stored ambient thermal energy 30 results in a cooling of the PCM 70. This cooling, in turn, results in the PCM 70 returning to the previous state of manner, typically a solid. The PCM 70 of the thermal exchange structure 28 can be stored within one or more thermal exchange modules 72. Where multiple thermal exchange modules 72 are present within the thermal exchange structure 28, these thermal exchange modules 72 are typically attached together in an array configuration. Using this array configuration, the process air 154 moving through the thermal exchange structure 28 is able to engage multiple surfaces for transferring the stored ambient thermal energy 30 from the PCM 70 of the thermal exchange structure 28 to the process air 154 moving therethrough.

[0023] Referring again to FIGS. 1-4, the appliance 12 includes the outer cabinet 26 having the processing space 22 defined therein for treating articles. The first blower 222 delivers process air 154 through the airflow path 50 that includes the processing space 22. The first vapor compression loop 212 delivers the first flow 220 of thermal exchange media 92 through the first evaporator 214 and the primary condenser 224 that are positioned within the airflow path 50 and upstream of the processing space 22. The first blower 222 delivers the process air 154 across the first evaporator 214 to extract internal thermal energy 60 that cools and dehumidifies the process air 154. The first blower 222 further delivers the process air 154 across the primary condenser 224 to absorb the internal thermal energy 60 that heats the process air 154 before entering the processing space 22. The second vapor compression loop 226 delivers the second flow 232 of thermal exchange media 92 through the second evaporator 228 and the thermal exchange structure 28. The thermal exchange structure 28 is positioned within the airflow path 50 between the first evaporator 214 and the primary condenser 224. The second evaporator 228 is positioned outside of the airflow path 50.

[0024] In certain aspects of the device, the second evaporator 228 can also be positioned outside of the outer cabinet 26. An ambient second blower 234 directs ambient air 16 over the second evaporator 228. The second vapor compression loop 226 captures ambient thermal energy 30 from the ambient air 16 and delivers the ambient thermal energy 30 to the thermal exchange structure 28. The first blower 222 directs the process air 154 over the thermal exchange structure 28 to capture the ambient thermal energy 30 from the thermal exchange structure 28. This ambient thermal energy 30, in turn, is delivered from the thermal exchange structure 28 to the primary condenser 224 via the process air 154. This process of moving the ambient thermal energy 30 from the thermal exchange structure 28 to the primary condenser 224 is referred to as the preheat sequence of the primary condenser 224.

[0025] Referring again to FIGS. 1-4, a thermal transfer system 10 can utilize a thermal exchange structure 28 that can include one or more thermal exchange modules 72 for delivering thermal energy 14 within an appliance 12 or other fixture. The first vapor compression loop 212 includes the first evaporator 214 and at least one condenser 216. A first refrigerant path 218 recycles a first flow 220 of thermal exchange media 92, such as a refrigerant, through the first evaporator 214 and through the at least one condenser 216. As described herein, the first blower 222 delivers the process air 154 over the first evaporator 214 and the primary condenser 224 of the least one condenser 216. A second vapor compression loop 226 includes the second evaporator 228 and an aspect of the thermal exchange structure 28. The second vapor compression loop 226 also includes a second refrigerant path 230 that recycles the second flow 232 of thermal exchange media 92 through the second evaporator 228 and the thermal exchange structure 28. The ambient second blower 234 operates to direct ambient air 16 over the second evaporator 228. The second vapor compression loop 226, via the second evaporator 228, captures the ambient thermal energy 30 from the ambient air 16. The second flow 232 of thermal exchange media 92 within the second refrigerant path 230 delivers this captured ambient thermal energy 30 to the thermal exchange structure 28.

[0026] Referring again to FIGS. 1-4, as described herein, the thermal exchange structure 28 absorbs this ambient thermal energy 30 from the second flow 232 of thermal exchange media 92 and retains this ambient thermal energy 30, at least temporarily, within the PCM 70 contained within the thermal exchange structure 28. In this manner, the thermal exchange structure 28 of the second vapor compression loop 226 acts as a condenser structure where ambient thermal energy 30 is rejected from the thermal exchange media 92 and is delivered into the PCM 70 of the thermal exchange structure 28. The first blower 222 directs the process air 154 over the thermal exchange structure 28 to capture the absorbed ambient thermal energy 30 that is contained within the PCM 70. The ambient thermal energy 30 from the thermal exchange structure 28 is then delivered via the process air 154 to the primary condenser 224 of the least one condenser 216. In this manner, the ambient thermal energy 30 captured from the thermal exchange media 92 can provide a preheat phase 236 of the primary condenser 224.

[0027] Typically, within conventional vapor compression appliances, a warm up or preheat of a condenser for a vapor compression loop may be slow and may take an extended period of time. This can result in extending the time to complete a drying operation of the conventional vapor compression appliance.

[0028] As exemplified in FIGS. 3 and 4, by utilizing the ambient thermal energy 30 captured from the ambient air 16 that is delivered into the primary condenser 224, the time passed to initiate and complete the preheat phase 236 of the primary condenser 224 can be accelerated greatly when activating a heating cycle or drying cycle of the first vapor compression loop 212.

[0029] Referring again to FIG. 3, the first vapor compression loop 212 and the second vapor compression loop 226 can include the common compressor 250. In such an aspect of the device, the first flow 220 of thermal exchange media 92 and the second flow 232 of thermal exchange media 92 are defined by a single common thermal exchange media 92 that is alternatively delivered through the first vapor compression loop 212 and the second vapor compression loop 226 via a valve assembly 252. This valve assembly 252 can be in the form of a series of two-way valves, three-way valves, and / or check valves that can be activated and deactivated depending upon which of the first vapor compression loop 212 and the second vapor compression loop 226 is to be activated. The valve assembly 252 can be positioned upstream, downstream, or on both sides of the common compressor 250 to direct the thermal exchange media 92 as needed. A controller 270 can operate the common compressor 250 as well as the valve assembly 252 for delivering thermal exchange media 92 through the appropriate vapor compression loop.

[0030] Typically, the second vapor compression loop 226 is operated in advance of the first vapor compression loop 212. Through this configuration, ambient thermal energy 30 can be absorbed into the thermal exchange structure 28 and the PCM 70 contained therein during operation of the second vapor compression loop 226. Once the PCM 70 is charged with ambient thermal energy 30, the second vapor compression loop 226 can be deactivated. The first vapor compression loop 212 can then be activated and the ambient thermal energy 30 can be absorbed or otherwise transferred into the process air 154 for delivery into the primary condenser 224. As described herein, this ambient thermal energy 30 delivered into the primary condenser 224 can provide the preheat phase 236 for activating the thermal exchange cycle of the first vapor compression loop 212. It is also contemplated that the second vapor compression loop 226 can be operated contemporaneously with the first vapor compression loop 212. In such an aspect of the device, the second vapor compression loop 226 can be operated to provide internal thermal energy 60 from the first evaporator 214. This internal thermal energy 60 is then delivered to the primary condenser 224. From the primary condenser 224, the internal thermal energy 60, along with the ambient thermal energy 30, is delivered via the process air 154 to the processing space 22.

[0031] Referring now to FIG. 10, it is contemplated that the first vapor compression loop 212 can include a first compressor 290 and the second vapor compression loop 226 can include a second compressor 292 that is separate from the first compressor 290. Where the first compressor 290 and the second compressor 292 are utilized, it is contemplated that the first compressor 290 and the second compressor 292 can be operated by a common controller 270. It is also contemplated that separate controllers 270 can be used to activate and deactivate the first compressor 290 and the second compressor 292.

[0032] Referring to FIGS. 3 and 4, each of the first vapor compression loop 212 and the second vapor compression loop 226 can include expansion devices 310 that are positioned between the common compressor 250 (or dedicated compressors) and the respective first and second evaporators 214, 228 of the first vapor compression loop 212 and the second vapor compression loop 226. Additionally, during operation of the thermal transfer system 10, the second blower 234 is configured to deliver the ambient air 16 across the second evaporator 228. This ambient air 16 can be from within a building or other structure or from the outside environment. As the ambient air 16 moves through the second evaporator 228, the second flow 232 of the thermal exchange media 92 absorbs ambient thermal energy 30 from the ambient air 16. This absorbed ambient thermal energy 30 is then transferred to the thermal exchange structure 28 via the second flow 232 of the thermal exchange media 92. Within the thermal exchange structure 28, the PCM 70 receives and stores the ambient thermal energy 30. Once the PCM 70 of the thermal exchange structure 28 is charged with the stored ambient thermal energy 30, the second vapor compression loop 226 operates to deliver the first flow 220 of the thermal exchange media 92 from the first evaporator 214 and to the primary condenser 224 of the first vapor compression loop 212. As described herein, the first vapor compression loop 212 operates to collect internal thermal energy 60 within the thermal exchange media 92 via the first evaporator 214. This internal thermal energy 60 is then delivered to the primary condenser 224. The primary condenser 224, via the process air 154, rejects the internal thermal energy 60, along with the ambient thermal energy 30. The process air 154 absorbs the ambient thermal energy 30 and the internal thermal energy 60 and delivers this combined thermal energy to the processing space 22.

[0033] As described herein, the first blower 222 of the first vapor compression loop 212 delivers the process air 154 over this thermal exchange structure 28 to absorb the ambient thermal energy 30 from the PCM 70. The process air 154 then delivers this thermal energy 14 to the primary condenser 224 to operate the preheat phase 236. The preheat phase 236 makes the delivery of the internal thermal energy 60 from the first evaporator 214 to the primary condenser 224 more efficient as the primary condenser 224 is preheated through the incorporation of the ambient thermal energy 30. The heated process air 154 is then delivered to the processing space 22.

[0034] Referring again to FIGS. 3 and 4, the process air 154 can be recycled through the appliance 12 and over the first evaporator 214 of the first vapor compression loop 212. This first evaporator 214 absorbs thermal energy 14 from process air 154 leaving the processing space 22. In turn, the process air 154 is dehumidified and cooled. This now-cooled and dehumidified process air 154 is then returned to the thermal exchange structure 28 to absorb more ambient thermal energy 30 therefrom.

[0035] During the course of the preheat phase 236, the process air 154 absorbs less and less ambient thermal energy 30 from the PCM 70 as the temperature of the PCM 70 lowers to be equal or substantially equal to that of the process air 154 passing therethrough. After the preheat phase236 is complete, the primary condenser 224, and the remainder of the first vapor compression loop 212, is typically adequately warmed to provide sufficient amounts of internal thermal energy 60 to the process air 154 for delivery to the processing space 22.

[0036] In certain aspects of the device, the second vapor compression loop 226 can operate contemporaneously with the first vapor compression loop 212. By way of example, and not limitation, where the first vapor compression loop 212 and the second vapor compression loop 226 are operated by dedicated compressors, the first vapor compression loop 212 and the second vapor compression loop 226 can operate contemporaneously to deliver a first thermal exchange media 92 through the first vapor compression loop 212 and deliver a second thermal exchange media 92 through the second vapor compression loop 226. In this aspect of the device, the second vapor compression loop 226 can continually provide ambient thermal energy 30 to the thermal exchange structure 28. Accordingly, the process air 154 is able to accumulate both ambient thermal energy 30 from the thermal exchange structure 28 and internal thermal energy 60 from the primary condenser 224 for delivery into the processing space 22 of the appliance 12. The first and second thermal exchange media 92 can be the same material, or can be different materials that are separately delivered through the first vapor compression loop 212 and the second vapor compression loop 226, respectively.

[0037] Where the first vapor compression loop 212 and the second vapor compression loop 226 are operated by a common compressor, the valve assembly 252 can selectively alternate between operating the first vapor compression loop 212 and the second vapor compression loop 226 to deliver and recycle a common thermal exchange media 92 therethrough. Through this configuration, the second vapor compression loop 226 can periodically and selectively provide additional ambient thermal energy 30 to the thermal exchange structure 28. As described herein, this stored ambient thermal energy 30 can then be delivered by the process air 154 from the thermal exchange structure 28 and to the primary condenser 224. The process air 154, as described herein, can then provide both the ambient thermal energy 30 and the internal thermal energy 60 to the processing space 22 for performing the duty cycle 62.

[0038] It is contemplated that the first vapor compression loop 212 can also include an auxiliary condenser 330 as well as an auxiliary blower 332 for rejecting additional amounts of thermal energy 14 into the processing space 22, to other portions of the appliance 12, or to areas outside of the outer cabinet 26 of the appliance 12. Typically, the auxiliary condenser 330 for the first vapor compression loop 212 is positioned between the primary condenser 224 and first evaporator 214. Accordingly, in this position, the auxiliary condenser 330 can reject additional amounts of thermal energy 14 from the thermal exchange media 92. By rejecting additional amounts of thermal energy 14, the thermal exchange media 92 is able to absorb greater amounts of internal thermal energy 60 within the first evaporator 214 of the first vapor compression loop 212. It is contemplated that the auxiliary condenser 330 can provide for a more efficient transfer of internal thermal energy 60 as the thermal exchange media 92 moves through the first evaporator 214 and the primary condenser 224.

[0039] According to the various aspects of the device, as exemplified in FIGS. 3 and 4, the first vapor compression loop 212 includes a first expansion device that is positioned upstream of the first evaporator 214. Similarly, the second vapor compression loop 226 includes a second expansion device that is positioned upstream of the second evaporator 228. The first expansion device and the second expansion device can be utilized in situations where the first vapor compression loop 212 and the second vapor compression loop 226 are operated by a common compressor 250 or through dedicated compressors. Additionally, the configuration of the first expansion device and the second expansion device can vary depending upon the design of the appliance 12 and the design of the various vapor compression loops. Accordingly, various valves and other commonly known mechanisms can be utilized as the first expansion device and or the second expansion device.

[0040] According to various aspects of the device, the thermal transfer system 10 described herein can be incorporated within any one of various appliances 12. Such appliances can include, but are not limited to, laundry washers, laundry dryers, combination washers and dryers, other laundry appliances, dishwashers, air conditioners, water heaters, other air handling systems, refrigerating appliances, and other appliances that utilize the transfer of thermal energy 14 from one location to another.

[0041] According to the various aspects of the device, it is contemplated that the first vapor compression loop 212 and the second vapor compression loop 226 do not overlap with one another and remain physically separated. The only interaction typically occurs through a thermal communication within the thermal exchange structure 28 for the plurality of thermal exchange modules 72 that form the thermal exchange structure 28.

[0042] Referring now to FIGS. 1-5, having described various aspects of the device, a method 400 is disclosed for operating an appliance 12 that incorporates a thermal exchange structure 28, as described herein. According to the various aspects of the device, the method 400 includes a step 402 that includes activating an ambient vapor compression loop 226 that delivers external thermal energy 14 from ambient air 16 outside of an airflow path 50 to a thermal exchange structure 28 that is located within the airflow path 50. As described herein, the ambient vapor compression loop 226 is also referred to as the second vapor compression loop 226. When the ambient thermal energy 30 is stored within the thermal exchange structure 28, the ambient thermal energy 30 is delivered from the thermal exchange structure 28 to a condenser 216 of a drying vapor compression loop 212 to define stored ambient thermal energy 30 (step 404). With the ambient thermal energy 30 stored within the condenser 216, the condenser 216 defines a preheated condenser 216 of the drying vapor compression loop 212, which is also referred to as the first vapor compression loop 212. The drying vapor compression loop 212 is then activated to deliver internal thermal energy 60 from an evaporator of the drying vapor compression loop 212 to the preheated condenser 216 (step 406). The stored thermal energy 14 and the internal thermal energy 60 are then delivered from the preheated condenser 216 and through the airflow path 50 to a processing space 22 via the process air 154 (step 408).

[0043] According to the various aspects of the device, these steps 402 and 404 are performed using a common compressor 250 and a common thermal exchange media 92 that is recycled through each of the ambient vapor compression loop 226 and the drying vapor compression loop 212. It is also contemplated, as described herein, that the ambient vapor compression loop 226 and the drying vapor compression loop 212 can be operated using dedicated compressors as well as dedicated thermal exchange media 92 that is delivered through each vapor compression loop, respectively.

[0044] Referring now to FIGS. 1-4 and 6, having described the various aspects of the device, a method 500 is disclosed for operating an appliance 12 that incorporates an aspect of the thermal transfer system 10. According to the method 500, a step 502 includes heating a thermal exchange structure 28 using ambient thermal energy 30 from outside of an airflow path 50. Step 504 includes preheating a condenser 216 using the ambient thermal energy 30 to define a preheated condenser 216. Once the preheated condenser 216 is defined, internal thermal energy 60 from inside of the airflow path 50 is delivered to the preheated condenser 216 (step 506). The ambient thermal energy 30 and the internal thermal energy 60 are then delivered to the processing space 22 for operating a duty cycle 62 of the appliance 12 (step 508). As described herein, the duty cycle 62 of the appliance 12 can be in the form of a drying cycle for a laundry appliance 12, a drying cycle of a combination washing and drying appliance, a drying cycle of a dishwashing appliance, chilling cycle of a refrigerator, a defrost cycle of an evaporator of a refrigerating appliance, or other similar cycle for an appliance that includes transferring heat from one location to another.

[0045] It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

[0046] For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

[0047] It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and / or members or connectors or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and / or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0048] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

Examples

Embodiment Construction

[0015]The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a thermal exchange system that utilizes ambient thermal energy from ambient air to pre-heat a condenser for an vapor compression loop of an appliance. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0016]For purposes of description herein, the terms “upper,”“lower,”“right,”“left,”“rear,”“front,”“vertical,”“horizontal,” and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise,...

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit under 35 U.S.C. § 119 (e) of U.S. Provisional Patent Application No. 63 / 670,487 filed on Jul. 12, 2024, entitled “THERMAL EXCHANGE MODULE THAT INCORPORATES A PHASE CHANGE MATERIAL.” The present application is related to copending, commonly owned U.S. application Ser. No. 18 / 151,732 filed Jan. 9, 2023, which claims the benefit of U.S. Application No. 63 / 312,127 filed Feb. 21, 2022, both of which are entitled “LAUNDRY APPLIANCE HAVING A THERMAL STORAGE MECHANISM FOR CAPTURING EXCESS HEAT FROM ONE OR MORE HEAT SOURCES.” The present application is also related to copending, commonly owned U.S. application Ser. No. 18 / 098,261 filed Jan. 18, 2023, which claims the benefit of priority of U.S. Pat. No. 63,312,133 filed Feb. 21, 2022, both of which are entitled “THERMAL STORAGE MECHANISM FOR A LAUNDRY APPLIANCE THAT UTILIZES RECOVERY HEAT AND RENEWABLE ENERGY SOURCES.” The disclosures of the foregoing are hereby incorporated herein by reference in their entirety.BACKGROUND OF THE DISCLOSURE

[0002] The present disclosure generally relates to thermal exchange mechanisms and, more specifically, a thermal exchange system that can be incorporated within an appliance, and where the thermal exchange system utilizes ambient air for preheating a condenser of a vapor compression loop within the appliance.SUMMARY OF THE DISCLOSURE

[0003] According to a first aspect of the disclosure, a thermal transfer system for an appliance includes a first blower, a first vapor compression loop, a second vapor compression loop, and a second blower. The first blower delivers process air through an airflow path that includes a processing space. The first vapor compression loop delivers a first flow of thermal exchange media through a first evaporator and a condenser for delivering internal thermal energy from the first evaporator to the condenser. The first evaporator and the condenser are disposed within the airflow path. The second vapor compression loop delivers a second flow of thermal exchange media through a second evaporator and a thermal exchange structure disposed within the airflow path. The second evaporator is disposed outside of the airflow path. The second blower directs ambient air over the second evaporator. The second vapor compression loop captures ambient thermal energy from the ambient air and delivers the ambient thermal energy to the thermal exchange structure. The first blower directs the process air over the thermal exchange structure to capture the ambient thermal energy from the thermal exchange structure. The ambient thermal energy from the thermal exchange structure is delivered via the process air to the condenser to define a preheat sequence of the condenser. Further, the internal thermal energy and the ambient thermal energy are delivered by the process air to the processing space to define a duty cycle.

[0004] According to another aspect of the disclosure, an appliance includes an outer cabinet, a first blower, a first vapor compression loop, a second vapor compression loop, and a second blower. The outer cabinet has a processing space defined therein for treating articles. The first blower delivers process air through an airflow path that includes the processing space. The first vapor compression loop delivers a first flow of thermal exchange media through a first evaporator and a condenser that are positioned within the airflow path and upstream of the processing space. The first blower delivers the process air across the first evaporator to extract internal thermal energy that cools and dehumidifies the process air. The first blower further delivers the process air across the condenser to absorb the internal thermal energy that heats the process air before entering the processing space. The second vapor compression loop delivers a second flow of thermal exchange media through a second evaporator and a thermal exchange structure. The thermal exchange structure is positioned within the airflow path between the first evaporator and the condenser. The second evaporator is positioned outside of the airflow path. The second blower directs ambient air over the second evaporator. The second vapor compression loop captures ambient thermal energy from the ambient air and delivers the ambient thermal energy to the thermal exchange structure. The second blower directs the process air over the thermal exchange structure to capture the ambient thermal energy from the thermal exchange structure. Further, the ambient thermal energy from the thermal exchange structure is delivered via the process air to the condenser to define a preheat sequence of the condenser.

[0005] According to yet another aspect of the present disclosure, a method for operating a laundry appliance includes steps of activating an ambient vapor compression loop that delivers external ambient thermal energy from ambient air outside of an airflow path to a thermal exchange structure within the airflow path, delivering the ambient thermal energy from the thermal exchange structure to a condenser of a drying vapor compression loop to define stored ambient thermal energy to define a preheated condenser, activating the drying vapor compression loop to deliver internal thermal energy to the preheated condenser, and delivering the stored ambient thermal energy and the internal thermal energy from the preheated condenser through the airflow path and to a processing space.

[0006] These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In the drawings:

[0008] FIG. 1 is a schematic perspective view of an appliance that incorporates an aspect of the vapor compression loop that utilizes ambient air for preheating a condenser;

[0009] FIG. 2 is a schematic perspective view of an appliance that incorporates an aspect of the vapor compression loop that utilizes ambient air for preheating a condenser;

[0010] FIG. 3 is a schematic diagram illustrating an exemplary appliance that incorporates an aspect of the thermal exchange structure into a dedicated vapor compression loop that delivers thermal energy to a primary vapor compression loop for the appliance, and utilizes a single compressor for the first and second vapor compression loops;

[0011] FIG. 4 is a schematic diagram illustrating an exemplary appliance that incorporates a first vapor compression loop and a second vapor compression loop having dedicated compressors and where the second vapor compression loop includes an aspect of the thermal exchange module for delivering thermal energy into the first vapor compression loop;

[0012] FIG. 5 is a linear flow diagram illustrating a method for operating a thermal transfer system for an appliance; and

[0013] FIG. 6 is a linear flow diagram illustrating a method for operating a thermal transfer system for an appliance.

[0014] The components in the figures are not necessary to scale, emphasis instead being placed upon illustrating the principles described therein.DETAILED DESCRIPTION

[0015] The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a thermal exchange system that utilizes ambient thermal energy from ambient air to pre-heat a condenser for an vapor compression loop of an appliance. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0016] For purposes of description herein, the terms “upper,”“lower,”“right,”“left,”“rear,”“front,”“vertical,”“horizontal,” and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise, the term “front” shall refer to the surface of the element closer to an intended viewer, and the term “rear” shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0017] The terms “including,”“comprises,”“comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “comprises a . . . ” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0018] Referring to FIGS. 1-4, reference numeral 10 generally refers to a thermal transfer system that is incorporated within an appliance 12 for receiving thermal energy 14 from ambient air 16 within a first location 18, and delivering the absorbed thermal energy 14 to a separate second location 20 for heating a certain area within an appliance 12, typically a processing space 22 of an appliance 12. According to the various aspects of the device, the thermal transfer system 10 includes a refrigerant path, also referred to as a thermal exchange path 24, that operates to deliver thermal energy 14 from one location, typically outside of an outer cabinet 26 for the appliance 12, to a thermal exchange structure 28 located within the appliance 12. The thermal exchange structure 28 is used to store thermal energy 14, including ambient thermal energy 30, for usage within the thermal transfer system 10.

[0019] According to the various aspects of the device, as exemplified in FIGS. 1-4, the thermal transfer system 10 includes a first blower 222 that delivers process air 154 through an airflow path 50 that includes the processing space 22. A first vapor compression loop 212 delivers a first flow 220 of thermal exchange media 92 through a first evaporator 214 and a condenser 216 for delivering internal thermal energy 60 from the first evaporator 214 to the condenser 216. The first evaporator 214 and the condenser 216 are disposed within the airflow path 50 of the appliance 12. A second vapor compression loop 226 delivers a second flow 232 of thermal exchange media 92 through a second evaporator 228 and the thermal exchange structure 28 that is disposed within the airflow path 50. The second evaporator 228 is disposed outside of the airflow path 50. A second blower 234 directs ambient air 16 over the second evaporator 228. The second vapor compression loop 226 captures ambient thermal energy 30 from the ambient air 16 and delivers this ambient thermal energy 30 to the thermal exchange structure 28. The first blower 222 directs the process air 154 over the thermal exchange structure 28 to capture the ambient thermal energy 30 from the thermal exchange structure 28. The ambient thermal energy 30 from the thermal exchange structure 28 is then delivered, via the process air 154, to the condenser 216 to define a preheat sequence of the condenser 216. The internal thermal energy 60 and the ambient thermal energy 30 are then delivered by the process air 154 to the processing space 22 to define a duty cycle 62 of the appliance 12.

[0020] In certain aspects of the device, the ambient air 16 can be directed across the second evaporator 228 using the first blower 222. In such an aspect of the device, the first blower 222 can be used in combination with a plurality of baffles, or other similar airflow directing devices, to direct the air, contemporaneously or alternatively, through the airflow path 50 and across the second evaporator 228. These airflow redirecting devices can be operated in combination with the operation of the appliance 12 to direct the process air 154 and the ambient air 16 needed to capture and transfer the thermal energy 14 through the thermal transfer system 10, as described herein.

[0021] As exemplified in FIG. 3, the first vapor compression loop 212 and the second vapor compression loop 226 include a common compressor 250 that delivers a single common thermal exchange media 92 through each of the first vapor compression loop 212 and the second vapor compression loop 226. Using the single thermal exchange media 92, a valve assembly 252 directs the single thermal exchange media 92, alternatively, through the first vapor compression loop 212 and the second vapor compression loop 226. Accordingly, a single compressor operates with the valve assembly 252 to direct thermal exchange media 92 through the thermal transfer system 10 to capture thermal energy 14 from the ambient air 16 and deliver this thermal energy 14 to the thermal exchange structure 28 to perform the preheat sequence of the condenser 216. The condenser 216 and the valve assembly 252 subsequently operate to perform a heat exchange function through operation of the first vapor compression loop 212 to transfer this stored ambient thermal energy 30 from the thermal exchange structure 28 to the condenser 216, thereby preheating the condenser 216. In this manner, the preheat sequence is operated through use of the condenser 216, and is activated in advance of the duty cycle 62 for the appliance 12. In certain aspects of the device, the preheat sequence is operated in advance of the duty cycle 62 for the appliance 12.

[0022] According to the various aspects of the device, as exemplified in FIGS. 3 and 4, the thermal exchange structure 28 includes a phase change material (“PCM”) 70 that receives and stores the ambient thermal energy 30 from the second evaporator 228. As the ambient thermal energy 30 accumulates within the PCM 70, this PCM 70 changes states of matter, typically from a solid to a liquid, from a liquid to a gas, or from a solid to a gas. During operation of the first blower 222, process air 154 is delivered through the thermal exchange structure 28 and the stored ambient thermal energy 30 is absorbed by the process air 154 for delivery to a primary condenser 224. In this manner, the stored ambient thermal energy 30 is transferred from the PCM 70 to the process air 154. This transfer of the stored ambient thermal energy 30 results in a cooling of the PCM 70. This cooling, in turn, results in the PCM 70 returning to the previous state of manner, typically a solid. The PCM 70 of the thermal exchange structure 28 can be stored within one or more thermal exchange modules 72. Where multiple thermal exchange modules 72 are present within the thermal exchange structure 28, these thermal exchange modules 72 are typically attached together in an array configuration. Using this array configuration, the process air 154 moving through the thermal exchange structure 28 is able to engage multiple surfaces for transferring the stored ambient thermal energy 30 from the PCM 70 of the thermal exchange structure 28 to the process air 154 moving therethrough.

[0023] Referring again to FIGS. 1-4, the appliance 12 includes the outer cabinet 26 having the processing space 22 defined therein for treating articles. The first blower 222 delivers process air 154 through the airflow path 50 that includes the processing space 22. The first vapor compression loop 212 delivers the first flow 220 of thermal exchange media 92 through the first evaporator 214 and the primary condenser 224 that are positioned within the airflow path 50 and upstream of the processing space 22. The first blower 222 delivers the process air 154 across the first evaporator 214 to extract internal thermal energy 60 that cools and dehumidifies the process air 154. The first blower 222 further delivers the process air 154 across the primary condenser 224 to absorb the internal thermal energy 60 that heats the process air 154 before entering the processing space 22. The second vapor compression loop 226 delivers the second flow 232 of thermal exchange media 92 through the second evaporator 228 and the thermal exchange structure 28. The thermal exchange structure 28 is positioned within the airflow path 50 between the first evaporator 214 and the primary condenser 224. The second evaporator 228 is positioned outside of the airflow path 50.

[0024] In certain aspects of the device, the second evaporator 228 can also be positioned outside of the outer cabinet 26. An ambient second blower 234 directs ambient air 16 over the second evaporator 228. The second vapor compression loop 226 captures ambient thermal energy 30 from the ambient air 16 and delivers the ambient thermal energy 30 to the thermal exchange structure 28. The first blower 222 directs the process air 154 over the thermal exchange structure 28 to capture the ambient thermal energy 30 from the thermal exchange structure 28. This ambient thermal energy 30, in turn, is delivered from the thermal exchange structure 28 to the primary condenser 224 via the process air 154. This process of moving the ambient thermal energy 30 from the thermal exchange structure 28 to the primary condenser 224 is referred to as the preheat sequence of the primary condenser 224.

[0025] Referring again to FIGS. 1-4, a thermal transfer system 10 can utilize a thermal exchange structure 28 that can include one or more thermal exchange modules 72 for delivering thermal energy 14 within an appliance 12 or other fixture. The first vapor compression loop 212 includes the first evaporator 214 and at least one condenser 216. A first refrigerant path 218 recycles a first flow 220 of thermal exchange media 92, such as a refrigerant, through the first evaporator 214 and through the at least one condenser 216. As described herein, the first blower 222 delivers the process air 154 over the first evaporator 214 and the primary condenser 224 of the least one condenser 216. A second vapor compression loop 226 includes the second evaporator 228 and an aspect of the thermal exchange structure 28. The second vapor compression loop 226 also includes a second refrigerant path 230 that recycles the second flow 232 of thermal exchange media 92 through the second evaporator 228 and the thermal exchange structure 28. The ambient second blower 234 operates to direct ambient air 16 over the second evaporator 228. The second vapor compression loop 226, via the second evaporator 228, captures the ambient thermal energy 30 from the ambient air 16. The second flow 232 of thermal exchange media 92 within the second refrigerant path 230 delivers this captured ambient thermal energy 30 to the thermal exchange structure 28.

[0026] Referring again to FIGS. 1-4, as described herein, the thermal exchange structure 28 absorbs this ambient thermal energy 30 from the second flow 232 of thermal exchange media 92 and retains this ambient thermal energy 30, at least temporarily, within the PCM 70 contained within the thermal exchange structure 28. In this manner, the thermal exchange structure 28 of the second vapor compression loop 226 acts as a condenser structure where ambient thermal energy 30 is rejected from the thermal exchange media 92 and is delivered into the PCM 70 of the thermal exchange structure 28. The first blower 222 directs the process air 154 over the thermal exchange structure 28 to capture the absorbed ambient thermal energy 30 that is contained within the PCM 70. The ambient thermal energy 30 from the thermal exchange structure 28 is then delivered via the process air 154 to the primary condenser 224 of the least one condenser 216. In this manner, the ambient thermal energy 30 captured from the thermal exchange media 92 can provide a preheat phase 236 of the primary condenser 224.

[0027] Typically, within conventional vapor compression appliances, a warm up or preheat of a condenser for a vapor compression loop may be slow and may take an extended period of time. This can result in extending the time to complete a drying operation of the conventional vapor compression appliance.

[0028] As exemplified in FIGS. 3 and 4, by utilizing the ambient thermal energy 30 captured from the ambient air 16 that is delivered into the primary condenser 224, the time passed to initiate and complete the preheat phase 236 of the primary condenser 224 can be accelerated greatly when activating a heating cycle or drying cycle of the first vapor compression loop 212.

[0029] Referring again to FIG. 3, the first vapor compression loop 212 and the second vapor compression loop 226 can include the common compressor 250. In such an aspect of the device, the first flow 220 of thermal exchange media 92 and the second flow 232 of thermal exchange media 92 are defined by a single common thermal exchange media 92 that is alternatively delivered through the first vapor compression loop 212 and the second vapor compression loop 226 via a valve assembly 252. This valve assembly 252 can be in the form of a series of two-way valves, three-way valves, and / or check valves that can be activated and deactivated depending upon which of the first vapor compression loop 212 and the second vapor compression loop 226 is to be activated. The valve assembly 252 can be positioned upstream, downstream, or on both sides of the common compressor 250 to direct the thermal exchange media 92 as needed. A controller 270 can operate the common compressor 250 as well as the valve assembly 252 for delivering thermal exchange media 92 through the appropriate vapor compression loop.

[0030] Typically, the second vapor compression loop 226 is operated in advance of the first vapor compression loop 212. Through this configuration, ambient thermal energy 30 can be absorbed into the thermal exchange structure 28 and the PCM 70 contained therein during operation of the second vapor compression loop 226. Once the PCM 70 is charged with ambient thermal energy 30, the second vapor compression loop 226 can be deactivated. The first vapor compression loop 212 can then be activated and the ambient thermal energy 30 can be absorbed or otherwise transferred into the process air 154 for delivery into the primary condenser 224. As described herein, this ambient thermal energy 30 delivered into the primary condenser 224 can provide the preheat phase 236 for activating the thermal exchange cycle of the first vapor compression loop 212. It is also contemplated that the second vapor compression loop 226 can be operated contemporaneously with the first vapor compression loop 212. In such an aspect of the device, the second vapor compression loop 226 can be operated to provide internal thermal energy 60 from the first evaporator 214. This internal thermal energy 60 is then delivered to the primary condenser 224. From the primary condenser 224, the internal thermal energy 60, along with the ambient thermal energy 30, is delivered via the process air 154 to the processing space 22.

[0031] Referring now to FIG. 10, it is contemplated that the first vapor compression loop 212 can include a first compressor 290 and the second vapor compression loop 226 can include a second compressor 292 that is separate from the first compressor 290. Where the first compressor 290 and the second compressor 292 are utilized, it is contemplated that the first compressor 290 and the second compressor 292 can be operated by a common controller 270. It is also contemplated that separate controllers 270 can be used to activate and deactivate the first compressor 290 and the second compressor 292.

[0032] Referring to FIGS. 3 and 4, each of the first vapor compression loop 212 and the second vapor compression loop 226 can include expansion devices 310 that are positioned between the common compressor 250 (or dedicated compressors) and the respective first and second evaporators 214, 228 of the first vapor compression loop 212 and the second vapor compression loop 226. Additionally, during operation of the thermal transfer system 10, the second blower 234 is configured to deliver the ambient air 16 across the second evaporator 228. This ambient air 16 can be from within a building or other structure or from the outside environment. As the ambient air 16 moves through the second evaporator 228, the second flow 232 of the thermal exchange media 92 absorbs ambient thermal energy 30 from the ambient air 16. This absorbed ambient thermal energy 30 is then transferred to the thermal exchange structure 28 via the second flow 232 of the thermal exchange media 92. Within the thermal exchange structure 28, the PCM 70 receives and stores the ambient thermal energy 30. Once the PCM 70 of the thermal exchange structure 28 is charged with the stored ambient thermal energy 30, the second vapor compression loop 226 operates to deliver the first flow 220 of the thermal exchange media 92 from the first evaporator 214 and to the primary condenser 224 of the first vapor compression loop 212. As described herein, the first vapor compression loop 212 operates to collect internal thermal energy 60 within the thermal exchange media 92 via the first evaporator 214. This internal thermal energy 60 is then delivered to the primary condenser 224. The primary condenser 224, via the process air 154, rejects the internal thermal energy 60, along with the ambient thermal energy 30. The process air 154 absorbs the ambient thermal energy 30 and the internal thermal energy 60 and delivers this combined thermal energy to the processing space 22.

[0033] As described herein, the first blower 222 of the first vapor compression loop 212 delivers the process air 154 over this thermal exchange structure 28 to absorb the ambient thermal energy 30 from the PCM 70. The process air 154 then delivers this thermal energy 14 to the primary condenser 224 to operate the preheat phase 236. The preheat phase 236 makes the delivery of the internal thermal energy 60 from the first evaporator 214 to the primary condenser 224 more efficient as the primary condenser 224 is preheated through the incorporation of the ambient thermal energy 30. The heated process air 154 is then delivered to the processing space 22.

[0034] Referring again to FIGS. 3 and 4, the process air 154 can be recycled through the appliance 12 and over the first evaporator 214 of the first vapor compression loop 212. This first evaporator 214 absorbs thermal energy 14 from process air 154 leaving the processing space 22. In turn, the process air 154 is dehumidified and cooled. This now-cooled and dehumidified process air 154 is then returned to the thermal exchange structure 28 to absorb more ambient thermal energy 30 therefrom.

[0035] During the course of the preheat phase 236, the process air 154 absorbs less and less ambient thermal energy 30 from the PCM 70 as the temperature of the PCM 70 lowers to be equal or substantially equal to that of the process air 154 passing therethrough. After the preheat phase236 is complete, the primary condenser 224, and the remainder of the first vapor compression loop 212, is typically adequately warmed to provide sufficient amounts of internal thermal energy 60 to the process air 154 for delivery to the processing space 22.

[0036] In certain aspects of the device, the second vapor compression loop 226 can operate contemporaneously with the first vapor compression loop 212. By way of example, and not limitation, where the first vapor compression loop 212 and the second vapor compression loop 226 are operated by dedicated compressors, the first vapor compression loop 212 and the second vapor compression loop 226 can operate contemporaneously to deliver a first thermal exchange media 92 through the first vapor compression loop 212 and deliver a second thermal exchange media 92 through the second vapor compression loop 226. In this aspect of the device, the second vapor compression loop 226 can continually provide ambient thermal energy 30 to the thermal exchange structure 28. Accordingly, the process air 154 is able to accumulate both ambient thermal energy 30 from the thermal exchange structure 28 and internal thermal energy 60 from the primary condenser 224 for delivery into the processing space 22 of the appliance 12. The first and second thermal exchange media 92 can be the same material, or can be different materials that are separately delivered through the first vapor compression loop 212 and the second vapor compression loop 226, respectively.

[0037] Where the first vapor compression loop 212 and the second vapor compression loop 226 are operated by a common compressor, the valve assembly 252 can selectively alternate between operating the first vapor compression loop 212 and the second vapor compression loop 226 to deliver and recycle a common thermal exchange media 92 therethrough. Through this configuration, the second vapor compression loop 226 can periodically and selectively provide additional ambient thermal energy 30 to the thermal exchange structure 28. As described herein, this stored ambient thermal energy 30 can then be delivered by the process air 154 from the thermal exchange structure 28 and to the primary condenser 224. The process air 154, as described herein, can then provide both the ambient thermal energy 30 and the internal thermal energy 60 to the processing space 22 for performing the duty cycle 62.

[0038] It is contemplated that the first vapor compression loop 212 can also include an auxiliary condenser 330 as well as an auxiliary blower 332 for rejecting additional amounts of thermal energy 14 into the processing space 22, to other portions of the appliance 12, or to areas outside of the outer cabinet 26 of the appliance 12. Typically, the auxiliary condenser 330 for the first vapor compression loop 212 is positioned between the primary condenser 224 and first evaporator 214. Accordingly, in this position, the auxiliary condenser 330 can reject additional amounts of thermal energy 14 from the thermal exchange media 92. By rejecting additional amounts of thermal energy 14, the thermal exchange media 92 is able to absorb greater amounts of internal thermal energy 60 within the first evaporator 214 of the first vapor compression loop 212. It is contemplated that the auxiliary condenser 330 can provide for a more efficient transfer of internal thermal energy 60 as the thermal exchange media 92 moves through the first evaporator 214 and the primary condenser 224.

[0039] According to the various aspects of the device, as exemplified in FIGS. 3 and 4, the first vapor compression loop 212 includes a first expansion device that is positioned upstream of the first evaporator 214. Similarly, the second vapor compression loop 226 includes a second expansion device that is positioned upstream of the second evaporator 228. The first expansion device and the second expansion device can be utilized in situations where the first vapor compression loop 212 and the second vapor compression loop 226 are operated by a common compressor 250 or through dedicated compressors. Additionally, the configuration of the first expansion device and the second expansion device can vary depending upon the design of the appliance 12 and the design of the various vapor compression loops. Accordingly, various valves and other commonly known mechanisms can be utilized as the first expansion device and or the second expansion device.

[0040] According to various aspects of the device, the thermal transfer system 10 described herein can be incorporated within any one of various appliances 12. Such appliances can include, but are not limited to, laundry washers, laundry dryers, combination washers and dryers, other laundry appliances, dishwashers, air conditioners, water heaters, other air handling systems, refrigerating appliances, and other appliances that utilize the transfer of thermal energy 14 from one location to another.

[0041] According to the various aspects of the device, it is contemplated that the first vapor compression loop 212 and the second vapor compression loop 226 do not overlap with one another and remain physically separated. The only interaction typically occurs through a thermal communication within the thermal exchange structure 28 for the plurality of thermal exchange modules 72 that form the thermal exchange structure 28.

[0042] Referring now to FIGS. 1-5, having described various aspects of the device, a method 400 is disclosed for operating an appliance 12 that incorporates a thermal exchange structure 28, as described herein. According to the various aspects of the device, the method 400 includes a step 402 that includes activating an ambient vapor compression loop 226 that delivers external thermal energy 14 from ambient air 16 outside of an airflow path 50 to a thermal exchange structure 28 that is located within the airflow path 50. As described herein, the ambient vapor compression loop 226 is also referred to as the second vapor compression loop 226. When the ambient thermal energy 30 is stored within the thermal exchange structure 28, the ambient thermal energy 30 is delivered from the thermal exchange structure 28 to a condenser 216 of a drying vapor compression loop 212 to define stored ambient thermal energy 30 (step 404). With the ambient thermal energy 30 stored within the condenser 216, the condenser 216 defines a preheated condenser 216 of the drying vapor compression loop 212, which is also referred to as the first vapor compression loop 212. The drying vapor compression loop 212 is then activated to deliver internal thermal energy 60 from an evaporator of the drying vapor compression loop 212 to the preheated condenser 216 (step 406). The stored thermal energy 14 and the internal thermal energy 60 are then delivered from the preheated condenser 216 and through the airflow path 50 to a processing space 22 via the process air 154 (step 408).

[0043] According to the various aspects of the device, these steps 402 and 404 are performed using a common compressor 250 and a common thermal exchange media 92 that is recycled through each of the ambient vapor compression loop 226 and the drying vapor compression loop 212. It is also contemplated, as described herein, that the ambient vapor compression loop 226 and the drying vapor compression loop 212 can be operated using dedicated compressors as well as dedicated thermal exchange media 92 that is delivered through each vapor compression loop, respectively.

[0044] Referring now to FIGS. 1-4 and 6, having described the various aspects of the device, a method 500 is disclosed for operating an appliance 12 that incorporates an aspect of the thermal transfer system 10. According to the method 500, a step 502 includes heating a thermal exchange structure 28 using ambient thermal energy 30 from outside of an airflow path 50. Step 504 includes preheating a condenser 216 using the ambient thermal energy 30 to define a preheated condenser 216. Once the preheated condenser 216 is defined, internal thermal energy 60 from inside of the airflow path 50 is delivered to the preheated condenser 216 (step 506). The ambient thermal energy 30 and the internal thermal energy 60 are then delivered to the processing space 22 for operating a duty cycle 62 of the appliance 12 (step 508). As described herein, the duty cycle 62 of the appliance 12 can be in the form of a drying cycle for a laundry appliance 12, a drying cycle of a combination washing and drying appliance, a drying cycle of a dishwashing appliance, chilling cycle of a refrigerator, a defrost cycle of an evaporator of a refrigerating appliance, or other similar cycle for an appliance that includes transferring heat from one location to another.

[0045] It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

[0046] For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

[0047] It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and / or members or connectors or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and / or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0048] It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

Examples

Embodiment Construction

[0015]The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a thermal exchange system that utilizes ambient thermal energy from ambient air to pre-heat a condenser for an vapor compression loop of an appliance. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

[0016]For purposes of description herein, the terms “upper,”“lower,”“right,”“left,”“rear,”“front,”“vertical,”“horizontal,” and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise,...

Claims

1. A thermal transfer system for an appliance, the thermal transfer system comprising:a first blower that delivers process air through an airflow path that includes a processing space;a first vapor compression loop that delivers a first flow of thermal exchange media through a first evaporator and a condenser for delivering internal thermal energy from the first evaporator to the condenser, the first evaporator and the condenser disposed within the airflow path;a second vapor compression loop that delivers a second flow of thermal exchange media through a second evaporator and a thermal exchange structure disposed within the airflow path, the second evaporator disposed outside of the airflow path; anda second blower that directs ambient air over the second evaporator; whereinthe second vapor compression loop captures ambient thermal energy from the ambient air and delivers the ambient thermal energy to the thermal exchange structure;the first blower directs the process air over the thermal exchange structure to capture the ambient thermal energy from the thermal exchange structure;the ambient thermal energy from the thermal exchange structure is delivered via the process air to the condenser to define a preheat sequence of the condenser; andthe internal thermal energy and the ambient thermal energy are delivered by the process air to the processing space to define a duty cycle.

2. The thermal transfer system of claim 1, wherein the first vapor compression loop and the second vapor compression loop include a common compressor that delivers a single thermal exchange media through each of the first vapor compression loop and the second vapor compression loop.

3. The thermal transfer system of claim 2, wherein a valve assembly directs the single thermal exchange media, alternatively, through the first vapor compression loop and the second vapor compression loop.

4. The thermal transfer system of claim 1, wherein the preheat sequence of a primary condenser is operated in advance of the duty cycle.

5. The thermal transfer system of claim 4, wherein the first vapor compression loop includes an auxiliary condenser and an auxiliary blower that operate to reject additional internal thermal energy from the airflow path, wherein the auxiliary condenser is positioned between the primary condenser and the first evaporator.

6. The thermal transfer system of claim 1, wherein the first vapor compression loop includes a first expansion device upstream of the first evaporator and the second vapor compression loop includes a second expansion device upstream of the second evaporator.

7. The thermal transfer system of claim 1, wherein the thermal exchange structure includes one or more thermal exchange modules that are attached together in an array configuration.

8. The thermal transfer system of claim 3, further comprising a controller that operates the common compressor and the valve assembly.

9. The thermal transfer system of claim 1, wherein the first vapor compression loop includes a first compressor and a first thermal exchange media, and wherein the second vapor compression loop includes a second compressor and a second thermal exchange media.

10. The thermal transfer system of claim 9, wherein a common controller operates the first compressor and the second compressor.

11. An appliance comprising:an outer cabinet having a processing space defined therein for treating articles;a first blower that delivers process air through an airflow path that includes the processing space;a first vapor compression loop that delivers a first flow of thermal exchange media through a first evaporator and a condenser that are positioned within the airflow path and upstream of the processing space, wherein the first blower delivers the process air across the first evaporator to extract internal thermal energy that cools and dehumidifies the process air, and wherein the first blower further delivers the process air across the condenser to absorb the internal thermal energy that heats the process air before entering the processing space;a second vapor compression loop that delivers a second flow of thermal exchange media through a second evaporator and a thermal exchange structure, wherein the thermal exchange structure is positioned within the airflow path between the first evaporator and the condenser, and wherein the second evaporator is positioned outside of the airflow path; anda second blower that directs ambient air over the second evaporator; whereinthe second vapor compression loop captures ambient thermal energy from the ambient air and delivers the ambient thermal energy to the thermal exchange structure;the second blower directs the process air over the thermal exchange structure to capture the ambient thermal energy from the thermal exchange structure; andthe ambient thermal energy from the thermal exchange structure is delivered via the process air to the condenser to define a preheat sequence of the condenser.

12. The appliance of claim 11, wherein a common compressor is in communication with the first vapor compression loop and the second vapor compression loop to deliver a common thermal exchange media to define the first flow of thermal exchange media and the second flow of thermal exchange media.

13. The appliance of claim 12, wherein the first vapor compression loop and the second vapor compression loop are attached to the common compressor through a valve assembly that directs the common thermal exchange media through the first vapor compression loop and the second vapor compression loop.

14. The appliance of claim 11, wherein the second evaporator is positioned outside of the outer cabinet.

15. The appliance of claim 11, wherein the thermal exchange structure includes one or more thermal exchange modules that are attached together in an array configuration.

16. The appliance of claim 13, further comprising a controller that operates the common compressor and the valve assembly.

17. The appliance of claim 11, wherein the first vapor compression loop includes a first compressor, and wherein the second vapor compression loop includes a second compressor, and wherein the first flow of thermal exchange media and the second flow of thermal exchange media are separated from one another.

18. The appliance of claim 11, wherein the preheat sequence is performed before activation of a duty cycle of the processing space, wherein the ambient thermal energy is delivered to the thermal exchange structure and the process air delivers the ambient thermal energy to the condenser to define stored ambient thermal energy within the condenser and within the thermal exchange structure, wherein the first vapor compression loop is operated during the duty cycle, and wherein the stored ambient thermal energy and the internal thermal energy of the condenser are delivered by the process air to the processing space.

19. A method for operating a laundry appliance, the method comprising steps of:activating an ambient vapor compression loop that delivers external ambient thermal energy from ambient air outside of an airflow path to a thermal exchange structure within the airflow path;delivering the ambient thermal energy from the thermal exchange structure to a condenser of a drying vapor compression loop to define stored ambient thermal energy to define a preheated condenser;activating the drying vapor compression loop to deliver internal thermal energy to the preheated condenser; anddelivering the stored ambient thermal energy and the internal thermal energy from the preheated condenser through the airflow path and to a processing space.

20. The method of claim 19, wherein the steps of activating the ambient vapor compression loop and activating the drying vapor compression loop are performed using a common compressor and a recycled thermal exchange media that is delivered through each of the ambient vapor compression loop and the drying vapor compression loop.

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