Heat pump dryer including a horizontally mounted blower assembly

Abstract

A laundry appliance includes a cabinet having an appliance base and a drum rotatably supported within the cabinet and defining a laundry compartment therein. A basement compartment is positioned in the cabinet below the drum and above the appliance base. A heat exchanger is disposed in the basement compartment of the cabinet. An airflow channel is positioned in the basement compartment of the cabinet. The heat exchanger is arranged in fluid communication with the airflow channel. A blower assembly is arranged in the cabinet positioned adjacent to the basement compartment. The blower assembly has a blower outlet that is fluidically connected to basement compartment through the airflow channel and a blower inlet fluidically connected to ambient. The blower assembly has a blower fan with an axis of rotation that is substantially vertical relative to the appliance base.

Description

FIELD

[0001] The present disclosure relates to the art of laundry appliances and, more particularly, to a heat pump dryer having a horizontally mounted blower assembly.BACKGROUND

[0002] This section provides background information related to the present disclosure which is not necessarily prior art.

[0003] 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.”

[0004] 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 passes through a duct and over an evaporator and condenser coils prior to entering the drum. The evaporator and the condenser heat and remove moisture from the airflow. The duct imparts a number of directional changes to the air flow that reduce airflow efficiency.SUMMARY

[0005] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0006] A laundry appliance, in accordance with the present disclosure, includes a cabinet having an appliance base and a drum rotatably supported within the cabinet and defining a laundry compartment therein. A basement compartment is positioned in the cabinet below the drum and above the appliance base. A heat exchanger is disposed in the basement compartment of the cabinet. An airflow channel is positioned in the basement compartment of the cabinet. The heat exchanger is arranged in fluid communication with the airflow channel. A blower assembly is arranged in the cabinet and positioned adjacent to the basement compartment. The blower assembly has a blower outlet that is fluidically connected to the airflow channel and a blower inlet fluidically connected to ambient. The blower assembly has a blower fan with an axis of rotation that is substantially vertical relative to the appliance base.

[0007] Arranging the blower assembly such that the axis of rotation is substantial horizontal relative to the appliance bases reduces an overall length of the airflow channel. Further, the horizontal mounting of the blower assembly eliminates the need to include multiple bends in the airflow channel to guide the air into the basement to be heated. Eliminating the bends leads to a more direct airflow path into basement thereby reducing the overall length of airflow channel. Shortening the airflow channel and eliminating bends reduces a pressure drop in the air flowing through basement and heat exchanger thereby facilitating a more efficient heat exchange.

[0008] 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 DRAWINGS

[0009] 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.

[0010] FIG. 1 is a front perspective view of a laundry appliance including a basement equipped with a horizontally mounted blower assembly, in accordance with the present disclosure;

[0011] FIG. 2 is a rear perspective glass view of the exemplary laundry appliance shown in FIG. 1;

[0012] FIG. 3 is a perspective view of the basement arranged in the laundry appliance of FIG. 1, in accordance with the present disclosure;

[0013] FIG. 4 is a cross-sectional top view of the basement of FIG. 4, in accordance with the present disclosure; and

[0014] FIG. 5 is a cross-sectional top view of the basement of FIG. 4, in accordance with another aspect of the present disclosure.

[0015] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.DETAILED DESCRIPTION

[0016] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] With reference to FIGS. 1 and 2, 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.

[0023] The laundry appliance 50 includes a cabinet 52 that is rectangular in shape. The cabinet 52 includes a front cabinet wall 54 having a front cabinet opening 56, a rear cabinet wall 58 opposite the front cabinet wall 54, a set of cabinet sidewalls 60 that extend between the front cabinet wall 54 and the rear cabinet wall 58, a top cabinet wall 62, and a bottom cabinet wall 64. The front cabinet wall 54, rear cabinet wall 58, set of cabinet sidewalls 60, top cabinet wall 62, and bottom cabinet wall 64 cooperate to define a cabinet cavity 68 inside the cabinet 52. Front cabinet wall 54 is shown to include an air inlet 69 that facilitates an inflow of air into cabinet cavity 68 as will be detailed herein.

[0024] 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 the display 72, speaker 74, the control selector 76 and control module 78 may be positioned in another suitable location on the laundry appliance 50.

[0025] 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.

[0026] Referring to FIG. 2 and with continued reference to FIG. 1, 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 (not shown) at the front drum end 94, a rear drum wall (also not shown) at the rear drum end 96, and a drum sidewall 102 that extends between the front drum end 94 and rear drum end 96.

[0027] 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 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 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.

[0028] Referring to FIG. 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.

[0029] The laundry appliance 50 includes a heat exchanger 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. The basement 146 is positioned adjacent to the second base end 123 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, a first basement sidewall 151 extends between the front basement wall 148 and rear basement wall 150. A second basement sidewall 152 extends between the front basement wall 148 and rear basement wall 150 and is arranged opposite to first basement sidewall 151. Basement 146 also includes a bottom basement wall 154.

[0030] Second basement sidewall 152 is arranged directly adjacent to one of the cabinet sidewalls 60. The front basement wall 148 is positioned adjacent to the front base end 118 of the appliance base 116. The rear basement wall 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 also includes a second basement opening 158 (FIG. 4) in the front basement wall 148. First basement opening 156 defines a basement compartment outlet (not separately labeled) and second basement opening 158 defines a basement compartment inlet (also not separately labeled).

[0031] The bottom basement wall 154 is inclined such that the bottom basement wall 154 in a position adjacent to the rear basement wall 150 and 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.

[0032] Referring to FIG. 4 and with continued reference to FIGS. 2 and 3, the heat exchanger 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). 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.

[0033] The first heat exchanger 172 is configured to condense air flowing through air inlet 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 175 extending through the first heat exchanger 172. The first pipe 175 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.

[0034] 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 176 extending through the second heat exchanger 174. The second pipe 176 is configured to carry refrigerant or another suitable fluid. Thus, first pipe 175 defines a refrigerant inlet 178 of heat exchanger 144 and second pipe 176 defines a refrigerant outlet 179 of heat exchanger 144. Accordingly, air flows through the heat exchanger 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.

[0035] The first pipe 175 of first heat exchanger 172 and second pipe 176 of the second heat exchanger 174 of the heat exchanger 144 are configured to pass refrigerant or another suitable fluid between heat exchanger 144 and a compressor 180. The compressor 180 is attached to a compressor base 182 of the appliance base 116. The compressor base 182 is positioned adjacent to the front base end 118 and the first base end 122.

[0036] As shown in FIG. 2, a connector channel 186 extends between a first connector channel end 188 and a second connector channel end 190 that is opposite the first connector channel end 188. The first connector channel end 188 is arranged in fluid communication with first basement opening 156 as will be detailed more fully herein. The second connector channel end 190 is arranged in fluid communication with the laundry compartment 110 of the drum 90 via openings (not shown) in rear drum end 96. A lint trap (not shown) may be arranged in air inlet 69. The lint trap would be positioned to capture and prevents lint and other debris that may exist in an incoming airstream from passing into first heat exchanger 172 and second heat exchanger 174.

[0037] A blower assembly 206 is fluidically connected between basement 146 and air inlet 69. Blower assembly 206 includes a blower inlet 208 and a blower outlet 210. Blower inlet 208 is fluidically connected to ambient via air inlet 69. Blower outlet 210 is connected to second basement opening 158 formed in front basement wall 148 via an airflow channel 214. More specifically, airflow channel 214 extends between blower assembly 206 and the basement compartment inlet and includes a first airflow channel end 216 fluidically connected to blower outlet 210 of blower assembly 206 and a second airflow channel end 218 fluidically connected to basement 146 through second basement opening 158.

[0038] Blower assembly 206 is configured to draw in air from ambient via air inlet 69, drive the air through airflow channel 214 into basement 146 across first heat exchanger 172 and second heat exchanger 174, and then direct the air into drum 90 via connector channel 186. The blower assembly 206 is mounted horizontally and includes a squirrel cage or blower fan 220 that is positioned to rotate about a vertical axis “A”. Vertical axis “A” extends substantially perpendicularly relative to appliance base 116, more specifically, to bottom cabinet wall 64.

[0039] Blower fan 220 is operatively connected to a blower motor 222 (FIG. 3) that is positioned in the appliance base 116. The blower motor 222 is positioned between bottom cabinet wall 64 and blower fan 220. The blower motor 222 is positioned between front basement wall 148 and front base end 118 of appliance base 116. Arranging blower assembly 206 horizontally reduces an overall length of airflow channel 214. Further, the horizontal mounting of blower assembly 206 eliminates the need to include multiple bends in airflow channel 214 leading to a more direct airflow path into basement 146. Reducing the overall length of airflow channel 214 and eliminating bends reduces a pressure drop in the air flowing through basement 146 and heat exchanger 144.

[0040] In accordance with the present disclosure, compressor 180 includes a compressor outlet 224 fluidically connected to first pipe 175 of heat exchanger 144 and a compressor inlet 225 fluidically connected to second pipe 176 of heat exchanger 144. Compressor outlet 224 passes into basement 146 via a first pass through 228 and compressor inlet 225 passes from basement 146 via a second pass through 230. In accordance with the present disclosure, a filter dryer 233 is connected between first heat exchanger 172 and second heat exchanger 174 as shown in FIG. 4. Filter dryer 233 includes an inlet port 236 fluidically connected to first heat exchanger 172 and an outlet port 238 fluidically connected to second heat exchanger 174.

[0041] In accordance with the present disclosure, filter dryer 233 is arranged within basement 146 adjacent to second basement sidewall 152. Filter dryer 233 is connected between first heat exchanger 172 and second heat exchanger 174. Filter dryer 233 removes any contaminants that might exist in refrigerant leaving first heat exchanger 172 before entering second heat exchanger 174. Filter dryer 233 is accessible through an opening 242 formed in second basement sidewall 152. Opening 242 includes an access panel 245. Cabinet sidewall 60 includes a first cover 247 arranged at opening 242 adjacent to first basement sidewall 151. First cover 247 provides access to access panel 245 and opening 242. With this construction, users and or maintenance personnel may access filter dryer 233 when needed.

[0042] In accordance with another aspect of the present disclosure illustrated in FIG. 5, filter dryer 233 may be arranged within basement 146 adjacent to first basement sidewall 151. Filter dryer 233 is connected between first heat exchanger 172 and second heat exchanger 174. Filter dryer 233 removes any contaminants that might exist in refrigerant leaving first heat exchanger 172 before entering second heat exchanger 174. Filter dryer 233 is accessible through an opening 248 formed in first basement sidewall 151. Opening 248 includes an access panel 250. With this construction, users and / or maintenance personnel may access filter dryer 233 and any other components that lie within basement 146 when needed. A second cover 260 may be arranged in cabinet sidewall 60 adjacent to first basement sidewall 151 as shown in FIG. 2. In addition to providing access to service filter dryer 233, second cover 260 may also provide access to, for example, compressor 180 and other components in appliance base 116.

Examples

Embodiment Construction

[0016]Example embodiments will now be described more fully with reference to the accompanying drawings.

[0017]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.

[0018]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” m...

FIELD

[0001] The present disclosure relates to the art of laundry appliances and, more particularly, to a heat pump dryer having a horizontally mounted blower assembly.BACKGROUND

[0002] This section provides background information related to the present disclosure which is not necessarily prior art.

[0003] 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.”

[0004] 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 passes through a duct and over an evaporator and condenser coils prior to entering the drum. The evaporator and the condenser heat and remove moisture from the airflow. The duct imparts a number of directional changes to the air flow that reduce airflow efficiency.SUMMARY

[0005] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0006] A laundry appliance, in accordance with the present disclosure, includes a cabinet having an appliance base and a drum rotatably supported within the cabinet and defining a laundry compartment therein. A basement compartment is positioned in the cabinet below the drum and above the appliance base. A heat exchanger is disposed in the basement compartment of the cabinet. An airflow channel is positioned in the basement compartment of the cabinet. The heat exchanger is arranged in fluid communication with the airflow channel. A blower assembly is arranged in the cabinet and positioned adjacent to the basement compartment. The blower assembly has a blower outlet that is fluidically connected to the airflow channel and a blower inlet fluidically connected to ambient. The blower assembly has a blower fan with an axis of rotation that is substantially vertical relative to the appliance base.

[0007] Arranging the blower assembly such that the axis of rotation is substantial horizontal relative to the appliance bases reduces an overall length of the airflow channel. Further, the horizontal mounting of the blower assembly eliminates the need to include multiple bends in the airflow channel to guide the air into the basement to be heated. Eliminating the bends leads to a more direct airflow path into basement thereby reducing the overall length of airflow channel. Shortening the airflow channel and eliminating bends reduces a pressure drop in the air flowing through basement and heat exchanger thereby facilitating a more efficient heat exchange.

[0008] 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 DRAWINGS

[0009] 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.

[0010] FIG. 1 is a front perspective view of a laundry appliance including a basement equipped with a horizontally mounted blower assembly, in accordance with the present disclosure;

[0011] FIG. 2 is a rear perspective glass view of the exemplary laundry appliance shown in FIG. 1;

[0012] FIG. 3 is a perspective view of the basement arranged in the laundry appliance of FIG. 1, in accordance with the present disclosure;

[0013] FIG. 4 is a cross-sectional top view of the basement of FIG. 4, in accordance with the present disclosure; and

[0014] FIG. 5 is a cross-sectional top view of the basement of FIG. 4, in accordance with another aspect of the present disclosure.

[0015] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.DETAILED DESCRIPTION

[0016] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] With reference to FIGS. 1 and 2, 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.

[0023] The laundry appliance 50 includes a cabinet 52 that is rectangular in shape. The cabinet 52 includes a front cabinet wall 54 having a front cabinet opening 56, a rear cabinet wall 58 opposite the front cabinet wall 54, a set of cabinet sidewalls 60 that extend between the front cabinet wall 54 and the rear cabinet wall 58, a top cabinet wall 62, and a bottom cabinet wall 64. The front cabinet wall 54, rear cabinet wall 58, set of cabinet sidewalls 60, top cabinet wall 62, and bottom cabinet wall 64 cooperate to define a cabinet cavity 68 inside the cabinet 52. Front cabinet wall 54 is shown to include an air inlet 69 that facilitates an inflow of air into cabinet cavity 68 as will be detailed herein.

[0024] 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 the display 72, speaker 74, the control selector 76 and control module 78 may be positioned in another suitable location on the laundry appliance 50.

[0025] 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.

[0026] Referring to FIG. 2 and with continued reference to FIG. 1, 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 (not shown) at the front drum end 94, a rear drum wall (also not shown) at the rear drum end 96, and a drum sidewall 102 that extends between the front drum end 94 and rear drum end 96.

[0027] 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 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 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.

[0028] Referring to FIG. 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.

[0029] The laundry appliance 50 includes a heat exchanger 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. The basement 146 is positioned adjacent to the second base end 123 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, a first basement sidewall 151 extends between the front basement wall 148 and rear basement wall 150. A second basement sidewall 152 extends between the front basement wall 148 and rear basement wall 150 and is arranged opposite to first basement sidewall 151. Basement 146 also includes a bottom basement wall 154.

[0030] Second basement sidewall 152 is arranged directly adjacent to one of the cabinet sidewalls 60. The front basement wall 148 is positioned adjacent to the front base end 118 of the appliance base 116. The rear basement wall 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 also includes a second basement opening 158 (FIG. 4) in the front basement wall 148. First basement opening 156 defines a basement compartment outlet (not separately labeled) and second basement opening 158 defines a basement compartment inlet (also not separately labeled).

[0031] The bottom basement wall 154 is inclined such that the bottom basement wall 154 in a position adjacent to the rear basement wall 150 and 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.

[0032] Referring to FIG. 4 and with continued reference to FIGS. 2 and 3, the heat exchanger 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). 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.

[0033] The first heat exchanger 172 is configured to condense air flowing through air inlet 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 175 extending through the first heat exchanger 172. The first pipe 175 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.

[0034] 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 176 extending through the second heat exchanger 174. The second pipe 176 is configured to carry refrigerant or another suitable fluid. Thus, first pipe 175 defines a refrigerant inlet 178 of heat exchanger 144 and second pipe 176 defines a refrigerant outlet 179 of heat exchanger 144. Accordingly, air flows through the heat exchanger 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.

[0035] The first pipe 175 of first heat exchanger 172 and second pipe 176 of the second heat exchanger 174 of the heat exchanger 144 are configured to pass refrigerant or another suitable fluid between heat exchanger 144 and a compressor 180. The compressor 180 is attached to a compressor base 182 of the appliance base 116. The compressor base 182 is positioned adjacent to the front base end 118 and the first base end 122.

[0036] As shown in FIG. 2, a connector channel 186 extends between a first connector channel end 188 and a second connector channel end 190 that is opposite the first connector channel end 188. The first connector channel end 188 is arranged in fluid communication with first basement opening 156 as will be detailed more fully herein. The second connector channel end 190 is arranged in fluid communication with the laundry compartment 110 of the drum 90 via openings (not shown) in rear drum end 96. A lint trap (not shown) may be arranged in air inlet 69. The lint trap would be positioned to capture and prevents lint and other debris that may exist in an incoming airstream from passing into first heat exchanger 172 and second heat exchanger 174.

[0037] A blower assembly 206 is fluidically connected between basement 146 and air inlet 69. Blower assembly 206 includes a blower inlet 208 and a blower outlet 210. Blower inlet 208 is fluidically connected to ambient via air inlet 69. Blower outlet 210 is connected to second basement opening 158 formed in front basement wall 148 via an airflow channel 214. More specifically, airflow channel 214 extends between blower assembly 206 and the basement compartment inlet and includes a first airflow channel end 216 fluidically connected to blower outlet 210 of blower assembly 206 and a second airflow channel end 218 fluidically connected to basement 146 through second basement opening 158.

[0038] Blower assembly 206 is configured to draw in air from ambient via air inlet 69, drive the air through airflow channel 214 into basement 146 across first heat exchanger 172 and second heat exchanger 174, and then direct the air into drum 90 via connector channel 186. The blower assembly 206 is mounted horizontally and includes a squirrel cage or blower fan 220 that is positioned to rotate about a vertical axis “A”. Vertical axis “A” extends substantially perpendicularly relative to appliance base 116, more specifically, to bottom cabinet wall 64.

[0039] Blower fan 220 is operatively connected to a blower motor 222 (FIG. 3) that is positioned in the appliance base 116. The blower motor 222 is positioned between bottom cabinet wall 64 and blower fan 220. The blower motor 222 is positioned between front basement wall 148 and front base end 118 of appliance base 116. Arranging blower assembly 206 horizontally reduces an overall length of airflow channel 214. Further, the horizontal mounting of blower assembly 206 eliminates the need to include multiple bends in airflow channel 214 leading to a more direct airflow path into basement 146. Reducing the overall length of airflow channel 214 and eliminating bends reduces a pressure drop in the air flowing through basement 146 and heat exchanger 144.

[0040] In accordance with the present disclosure, compressor 180 includes a compressor outlet 224 fluidically connected to first pipe 175 of heat exchanger 144 and a compressor inlet 225 fluidically connected to second pipe 176 of heat exchanger 144. Compressor outlet 224 passes into basement 146 via a first pass through 228 and compressor inlet 225 passes from basement 146 via a second pass through 230. In accordance with the present disclosure, a filter dryer 233 is connected between first heat exchanger 172 and second heat exchanger 174 as shown in FIG. 4. Filter dryer 233 includes an inlet port 236 fluidically connected to first heat exchanger 172 and an outlet port 238 fluidically connected to second heat exchanger 174.

[0041] In accordance with the present disclosure, filter dryer 233 is arranged within basement 146 adjacent to second basement sidewall 152. Filter dryer 233 is connected between first heat exchanger 172 and second heat exchanger 174. Filter dryer 233 removes any contaminants that might exist in refrigerant leaving first heat exchanger 172 before entering second heat exchanger 174. Filter dryer 233 is accessible through an opening 242 formed in second basement sidewall 152. Opening 242 includes an access panel 245. Cabinet sidewall 60 includes a first cover 247 arranged at opening 242 adjacent to first basement sidewall 151. First cover 247 provides access to access panel 245 and opening 242. With this construction, users and or maintenance personnel may access filter dryer 233 when needed.

[0042] In accordance with another aspect of the present disclosure illustrated in FIG. 5, filter dryer 233 may be arranged within basement 146 adjacent to first basement sidewall 151. Filter dryer 233 is connected between first heat exchanger 172 and second heat exchanger 174. Filter dryer 233 removes any contaminants that might exist in refrigerant leaving first heat exchanger 172 before entering second heat exchanger 174. Filter dryer 233 is accessible through an opening 248 formed in first basement sidewall 151. Opening 248 includes an access panel 250. With this construction, users and / or maintenance personnel may access filter dryer 233 and any other components that lie within basement 146 when needed. A second cover 260 may be arranged in cabinet sidewall 60 adjacent to first basement sidewall 151 as shown in FIG. 2. In addition to providing access to service filter dryer 233, second cover 260 may also provide access to, for example, compressor 180 and other components in appliance base 116.

Examples

Embodiment Construction

[0016]Example embodiments will now be described more fully with reference to the accompanying drawings.

[0017]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.

[0018]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” m...

Claims

1. A laundry appliance, comprising:a cabinet having an appliance base;a drum rotatably supported within the cabinet and defining a laundry compartment therein;a basement compartment positioned in the cabinet below the drum and above the appliance base;a heat exchanger disposed in the basement compartment of the cabinet;a connector channel fluidically connecting the basement compartment and the drum;an airflow channel positioned in the basement compartment of the cabinet, the heat exchanger arranged in fluid communication with the airflow channel; anda blower assembly arranged in the cabinet positioned adjacent to the basement compartment, the blower assembly having a blower outlet that is fluidically connected to the basement compartment through the airflow channel and a blower inlet fluidically connected to ambient, the blower assembly having a blower fan with an axis of rotation that is substantially vertical relative to the appliance base.

2. The laundry appliance according to claim 1, wherein the basement compartment includes at least one basement compartment wall, the at least one basement compartment wall forming a housing for the heat exchanger.

3. The laundry appliance according to claim 2, wherein the basement compartment includes a basement inlet that is arranged in fluid communication with the blower outlet and a basement outlet that is arranged in fluid communication with the connector channel and the laundry compartment of the drum.

4. The laundry appliance according to claim 1, wherein the blower assembly includes a blower motor.

5. The laundry appliance according to claim 4, wherein the blower motor is arranged between the appliance base and the blower fan is connected to the blower motor by a motor shaft.

6. The laundry appliance according to claim 3, wherein the connector channel extends along a portion of a rear cabinet wall and includes an airflow channel inlet fluidically connected to the basement outlet.

7. The laundry appliance according to claim 6, further comprising a vent formed in the cabinet, the vent being fluidically connected with the blower inlet.

8. The laundry appliance according to claim 1, wherein the blower fan has a squirrel cage configuration.

9. A laundry appliance, comprising:a cabinet having an appliance base;a drum rotatably supported within the cabinet and defining a laundry compartment therein;a basement compartment positioned in the cabinet below the drum and above the appliance base;a heat exchanger positioned in the basement compartment, the heat exchanger including a refrigerant inlet and a refrigerant outlet;a compressor positioned in the cabinet external to the basement compartment;a compressor inlet line passing into the basement compartment through a first pass-through opening and connected in fluid communication with the refrigerant inlet of the heat exchanger;a compressor outlet line passing into the basement compartment through a second pass-through opening; anda filter dryer positioned in the basement compartment, the filter dryer being fluidically connected with the heat exchanger and the compressor.

10. The laundry appliance according to claim 9, wherein the basement compartment includes at least one basement compartment wall, the first pass-through opening and the second pass-through opening extending through the at least one basement compartment wall.

11. The laundry appliance according to claim 10, wherein the filter dryer is arranged adjacent to a sidewall of the cabinet such that the heat exchanger is positioned between the compressor and the filter dryer.

12. The laundry appliance according to claim 11, wherein the at least one basement compartment wall includes a removeable panel that provides access to the filter dryer.

13. The laundry appliance according to claim 10, wherein no more than two refrigerant lines pass through the at least one basement compartment wall.

14. The laundry appliance according to claim 9, wherein the compressor inlet line includes a first charge port, and the compressor outlet line includes a second charge port.

15. The laundry appliance according to claim 14, wherein the first charge port and the second charge port are outside of the basement compartment.

16. The laundry appliance according to claim 9, wherein the cabinet includes a removable access panel that provides access to the compressor.

17. The laundry appliance according to claim 9, wherein the heat exchanger includes an evaporator coil and a condenser coil, the evaporator coil including an evaporator inlet line defining the refrigerant inlet of the heat exchanger and an evaporator outlet line.

18. The laundry appliance according to claim 17, wherein the condenser coil includes a condenser inlet line fluidically connected to the evaporator outlet line and a condenser outlet line defining the refrigerant outlet of the heat exchanger.

19. The laundry appliance according to claim 18, wherein the filter dryer is fluidly connected between the evaporator outlet line and the condenser inlet line.

20. A laundry appliance, comprising:a cabinet having an appliance base;a drum rotatably supported within the cabinet and defining a laundry compartment therein;a basement compartment positioned in the cabinet below the drum and above the appliance base, the basement compartment including at least one basement compartment wall;a heat exchanger positioned in the basement compartment, the heat exchanger including a refrigerant inlet and a refrigerant outlet;a compressor positioned in the cabinet external to the basement compartment;a compressor inlet line passing into the basement compartment through a first pass-through opening in the at least one basement compartment wall and connected in fluid communication with the refrigerant inlet of the heat exchanger;a filter dryer positioned in the basement compartment, the filter dryer including an inlet port connected in fluid communication with the refrigerant outlet of the heat exchanger and an outlet port;a compressor outlet line passing into the basement compartment through a second pass-through opening in the at least one basement compartment wall and that is connected in fluid communication with the outlet port of the filter dryer;an airflow channel positioned in the cabinet, the heat exchanger being arranged in fluid communication with the drum; anda blower assembly arranged in the cabinet positioned adjacent to the basement compartment, the blower assembly having a blower outlet that is fluidically connected to the basement compartment through the airflow channel and a blower inlet fluidically connected to ambient, the blower assembly having a blower fan with an axis of rotation that is substantially vertical relative to the appliance base.

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