Laundry appliance drum idler arm assembly

Abstract

A laundry appliance includes a cabinet and drum rotatably mounted within the cabinet. The drum defines a chamber for receipt of articles. The appliance also includes a motor for rotating the drum and a belt coupled between the motor and drum. The belt rotates the drum during operation of the motor. Additionally, the appliance includes an idler assembly that includes an arm rotatably coupled to a pivot joint. A surface of the arm moves across a surface of the pivot joint during rotation of the arm. Furthermore, the assembly includes a pulley coupled to the arm. A portion of a surface of the pulley is in contact with a portion of the belt. Moreover, the assembly includes a bushing including first and second plates spaced apart from each other. A gap is defined between the first and second plates and the arm is positioned within the gap.

Description

FIELD

[0001] The present subject matter relates generally to laundry appliances, and more particularly to drum idler arm assemblies of laundry appliances.BACKGROUND

[0002] Dryer appliances generally include a cabinet with a drum mounted within the cabinet. Typically, a motor rotates the drum during operation of the dryer appliance, e.g., to tumble articles located within a chamber defined by the drum. Dryer appliances also generally include a heater assembly that passes heated air through the chamber of the drum to dry moisture-laden articles disposed within the chamber. This internal air then passes from the chamber through a vent duct to an exhaust conduit, through which the air is exhausted from the dryer appliance.

[0003] The motor of the dryer appliance is generally in mechanical communication with the drum of the dryer appliance via a drive belt, such that in operation, the motor rotates the drive belt, and the drive belt in turn transfers this rotation to the drum. Rotating the drum may cause articles to be dried within the drum to tumble within the drum, increasing the contact area of the articles with the heated air passing through the chamber. Increasing the contact area of the articles with the heated air passing through the chamber may provide decreased drying time for the articles and more even thermal distribution across the articles.

[0004] However, idler arms utilized to guide the belt as the belt rotates the drum are oftentimes noisy and are prone to quick wear as the idler arms move, especially for reverse rotating drum dryer appliance models.

[0005] Accordingly, improved laundry appliances that include improved features for reducing or eliminating the noise and wear created by movement of the idler arms would be beneficial.BRIEF DESCRIPTION

[0006] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0007] In one aspect, a laundry appliance is provided. The laundry appliance includes a cabinet and a drum rotatably mounted within the cabinet. The drum defines a chamber for receipt of articles for drying. The laundry appliance also includes a motor. The motor is configured to rotate the drum. Additionally, the laundry appliance includes a belt. The belt is coupled between the motor and the drum. The belt rotates the drum during operation of the motor. Furthermore, the laundry appliance includes an idler assembly. The idler assembly includes a first arm. The first arm is rotatably coupled to a pivot joint at one end of the first arm. Moreover, the idler assembly includes a first pulley. The first pulley is coupled to the first arm. Additionally, the first pulley includes a surface. A portion of the surface of the first pulley is in contact with a portion of the belt. Furthermore, the idler assembly includes a second arm. The second arm is rotatably coupled to the pivot joint at one end of the second arm. Moreover, the idler assembly includes a second pulley. The second pulley is coupled to the second arm. Additionally, the second pulley includes a surface. A portion of the surface of the second pulley is in contact with a portion of the belt. Furthermore, the idler assembly includes a bushing. The bushing includes a plate positioned between the first arm and the second arm.

[0008] In another aspect, a laundry appliance is provided. The laundry appliance includes a cabinet and a drum rotatably mounted within the cabinet. The drum defines a chamber for receipt of articles for drying. The laundry appliance also includes a motor. The motor is configured to rotate the drum. Additionally, the laundry appliance includes a belt. The belt is coupled between the motor and the drum. The belt rotates the drum during operation of the motor. Furthermore, the laundry appliance includes an idler assembly. The idler assembly includes an arm. The arm is rotatably coupled to a pivot joint at one end of the arm. A surface of the arm moves across a surface of the pivot joint during rotation of the arm. Moreover, the idler assembly includes a pulley. The pulley is coupled to the arm. Additionally, the pulley includes a surface. A portion of the surface of the pulley is in contact with a portion of the belt. Furthermore, the idler assembly includes a bushing. The bushing includes a first plate and a second plate spaced apart from each other. A gap is defined between the first plate and the second plate. Moreover, the arm is positioned within the gap between the first plate and the second plate.

[0009] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

[0011] FIG. 1 provides a perspective view of a laundry appliance in accordance with one or more exemplary embodiments of the present disclosure.

[0012] FIG. 2 provides a perspective view of the example laundry appliance of FIG. 1 with portions of a cabinet of the laundry appliance removed to reveal certain components of the laundry appliance.

[0013] FIG. 3 provides a perspective view of an example drum and drum rotational assembly of a laundry appliance.

[0014] FIG. 4 provides a perspective view of an idler assembly of the example drum rotational assembly of FIG. 3.

[0015] FIG. 5 provides an exploded perspective view of an idler arm of the idler assembly of FIG. 4.

[0016] FIG. 6 provides a perspective view of a bushing of the idler assembly of FIG. 4.

[0017] FIG. 7 provides a perspective view of the bushing of FIG. 6.

[0018] FIG. 8 provides a perspective view of the bushing of FIG. 6.

[0019] FIG. 9 provides a perspective view of an idler bearing of the idler assembly of FIG. 4.

[0020] FIG. 10 provides a perspective view of a shoulder bolt of the idler assembly of FIG. 4.

[0021] The use of the same reference numbers in the figures denotes the same or similar features unless the context indicates otherwise.DETAILED DESCRIPTION

[0022] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0023] As used herein, the terms “first,”“second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). The term “at least one of” in the context of, e.g., “at least one of A, B, and C” refers to only A, only B, only C, or any combination of A, B, and C. In addition, here and throughout the specification and claims, range limitations may be combined and / or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,”“an,” and “the” include plural references unless the context clearly dictates otherwise.

[0024] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,”“about,”“approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and / or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.

[0025] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0026] FIGS. 1 and 2 provide perspective views of a laundry appliance 10 according to exemplary embodiments of the present disclosure. Laundry appliance 10 is a dryer appliance in the illustrated embodiments and may also, in additional embodiments, include features for washing articles, e.g., the laundry appliance 10 may also or instead be a combination laundry appliance. In particular, FIG. 1 provides a perspective view of dryer appliance 10 and FIG. 2 provides another perspective view of dryer appliance 10 with a portion of a housing or cabinet 12 of dryer appliance 10 removed in order to show certain components of dryer appliance 10. As depicted, dryer appliance 10 defines a vertical direction V, a lateral direction L, and a transverse direction T, each of which is mutually perpendicular such that an orthogonal coordinate system is defined. While described in the context of a specific embodiment of dryer appliance 10, using the teachings disclosed herein it will be understood that dryer appliance 10 is provided by way of example only. Other laundry appliances having different appearances and different features may also be utilized with the present subject matter as well. For instance, in some embodiments, laundry appliance 10 can be a combination washing machine / dryer appliance.

[0027] Cabinet 12 includes a front panel 14, a rear panel 16, a pair of side panels 18 and 20 spaced apart from each other by front and rear panels 14 and 16 along the lateral direction L, a bottom panel 22, and a top cover 24. Cabinet 12 defines an interior volume 29. A container or drum 26 is mounted for rotation about a substantially horizontal axis within the interior volume 29 of cabinet 12. Drum 26 defines a chamber 25 for receipt of articles for tumbling and / or drying. Drum 26 extends between a front portion 37 and a back portion 38, e.g., along the transverse direction T. Drum 26 also includes a back or rear wall 34, e.g., at back portion 38 of drum 26. A supply duct 41 may be mounted to rear wall 34. Supply duct 41 receives heated air and provides the heated air to drum 26 via one or more holes defined in rear wall 34.

[0028] As used herein, the terms “clothing” or “articles” includes but need not be limited to fabrics, textiles, garments, linens, papers, or other items from which the extraction of moisture is desirable. Furthermore, the term “load” or “laundry load” refers to the combination of clothing that may be washed together in a washing machine or dried together in a dryer appliance (e.g., clothes dryer) and may include a mixture of different or similar articles of clothing of different or similar types and kinds of fabrics, textiles, garments and linens within a particular laundering process.

[0029] In some embodiments, a motor 31 is provided to rotate drum 26 about the horizontal axis, e.g., via a pulley and a belt described below. Drum 26 is generally cylindrical in shape. Drum 26 has a cylindrical outer wall 28 and a front flange or wall 30 that defines an opening 32 of drum 26, e.g., at front portion 37 of drum 26, for loading and unloading of articles into and out of chamber 25 of drum 26. Drum 26 includes a plurality of lifters or baffles 27 that extend into chamber 25 to lift articles therein and then allow such articles to tumble back to a bottom of drum 26 as drum 26 rotates. Baffles 27 may be mounted to drum 26 such that baffles 27 rotate with drum 26 during operation of dryer appliance 10.

[0030] Rear wall 34 of drum 26 is rotatably supported within cabinet 12 by a suitable bearing. Rear wall 34 can be fixed or can be rotatable. Rear wall 34 may include, for instance, a plurality of holes that receive hot air. Heated air is drawn from drum 26 by an air handler, such as a blower fan 48, which generates a negative air pressure within drum 26. The heated air passes through a duct 44 enclosing screen filter 46, which traps lint particles. After the clothing articles have been dried, they are removed from the drum 26 via opening 32. A door 33 provides for closing or accessing drum 26 through opening 32.

[0031] In some embodiments, one or more selector inputs 70, such as knobs, buttons, touchscreen interfaces, etc., may be provided or mounted on a cabinet 12 (e.g., on a backsplash 71) and are communicatively coupled with (e.g., electrically coupled or coupled through a wireless network band) a processing device or controller 56. Controller 56 may also be communicatively coupled with various operational components of dryer appliance 10, such as motor 31, blower fan 48, and / or other components. In turn, signals generated in controller 56 direct operation of motor 31, blower fan 48, and / or other components in response user inputs to selector inputs 70. As used herein, “processing device” or “controller” may refer to one or more microprocessors, microcontrollers, application-specific integrated controllers (ASICS), or semiconductor devices and is not restricted necessarily to a single element. The controller 56 may be programmed to operate dryer appliance 10 by executing instructions stored in memory (e.g., non-transitory media). The controller 56 may include, or be associated with, one or more memory elements such as RAM, ROM, or electrically erasable, programmable read only memory (EEPROM). For example, the instructions may be software or any set of instructions that when executed by the processing device, cause the processing device to perform operations. It should be noted that controller 56 as disclosed herein is capable of and may be operable to perform any methods or associated method steps as disclosed herein. For example, in some embodiments, methods disclosed herein may be embodied in programming instructions stored in the memory and executed by the controller 56.

[0032] Although dryer appliance 10 is depicted and described herein as a standalone dryer appliance, in at least some embodiments, dryer appliance 10 may be a heat pump dryer appliance, combination washer / dryer appliance, or any other suitable dryer appliance.

[0033] Referring now to FIGS. 3 through 10, various views of a drum rotational assembly 100 (FIG. 3) of a dryer appliance, such as the dryer appliance 10, and an idler assembly 200 (FIGS. 3-10) of the drum rotational assembly 100 are illustrated. As described herein, the drum rotational assembly 100 is utilized to rotate the drum 26 bi-directionally, e.g., in a clockwise direction and in a counterclockwise direction. As such a dryer appliance utilizing the drum rotational assembly 100 is called a reversing drum model dryer appliance. Such dryer appliances are utilized to detangle articles within the drum.

[0034] The drum rotational assembly 100 includes the drum 26, the motor 31, a motor housing 35, a belt 36, and the idler assembly 200. As illustrated in FIG. 3, the belt 36 may be looped around the cylindrical outer wall 28 of the drum 26 and also around a drive shaft 39 of the motor 31. As such, during operation of the motor 31, the drive shaft 39 rotates the belt 36, which pulls on and rotates the drum 26. For the reversing drum model dryer appliance described herein, the motor 31 may be a bi-directional motor 31 that rotates the drive shaft 39 bi-directionally, e.g., in a clockwise direction and in a counterclockwise direction. The belt 36 may be any suitable belt for rotating the drum 26, such as a V-belt, round belt, and / or the like. As will be described below, the idler assembly 200 ensures that the belt 36 is taut to inhibit the belt 36 from sliding along or off the drum 26 and / or the drive shaft 39 of the motor 31 and to provide adequate force to rotate the drum 26. The motor housing 35 supports the motor 31 therein and may include a front bracket 42 through which the drive shaft 39 of the motor 31 extends externally of the motor housing 35. The idler assembly 200 may be coupled to an exterior surface 43 of the front bracket 42 and such that the idler assembly 200 may be positioned adjacent to the drive shaft 39 for keeping the belt 36 taut between the idler assembly 200 and the drive shaft 39.

[0035] For the reversing drum model dryer appliance described herein, as illustrated in FIGS. 3 and 4, the idler assembly 200 of the drum rotational assembly 100 includes a first (lower) idler arm 202 and a second (upper) idler arm 204. The first idler arm 202 and the second idler arm 204 may be rotatably coupled to a common pivot joint of the idler assembly 200 which, as will be described below, may be an idler bearing 240 (FIG. 9). For example, a first or fixed end (not shown) of the first idler arm 202, which is on the lower half of the first idler arm 202, may define an aperture (not shown) through which the pivot joint is received. In this respect, the first idler arm 202 may be fixed / coupled to and rotate about the pivot joint at its fixed end. During rotation of the first idler arm 202, an aperture surface (not shown) that surrounds the aperture of the first idler arm 202 moves across an interface surface 221 (FIG. 9) of the pivot joint. Likewise, a first or fixed end 206 (FIG. 5) of the second idler arm 204, which is on the lower half of the second idler arm 204, may also define an aperture 210 (FIG. 5) that is axially aligned with the aperture of the first idler arm 202. In this respect, the pivot joint is simultaneously received through the aperture of the first idler arm 202 and the aperture 210 of the second idler arm 204. In this respect, the second idler arm 204 may be fixed / coupled to and rotate about the pivot joint at its fixed end 206 relative to the first idler arm 202. During rotation of the second idler arm 204, an aperture surface 211 (FIG. 5) that surrounds the aperture 210 of the second idler arm 204 moves across the interface surface 221 of the pivot joint.

[0036] The first idler arm 202 includes a first sheave or pulley 212 that is rotatably coupled to the first idler arm 202 in an upper half of the first idler arm 202. The first pulley 212 is rotatable about a first central axis A1 relative to the first idler arm 202. Likewise, the second idler arm 204 includes a second sheave or pulley 214 that is rotatably coupled to the second idler arm 204 in an upper half of the second idler arm 204. For example, as best illustrated in FIG. 5, the second pulley 214 may be coupled to the second idler arm 204 by a fastener bearing and nut assembly 205. The first pulley 212 may likewise be coupled to the first idler arm 202 in the same or similar manner. The second pulley 214 is rotatable about a second central axis A2 relative to the second idler arm 204. As illustrated, the first pulley 212 and the second pulley 214 each include two spaced apart and aligned outer ends 213 that define outer circumferential edges or boundaries of the first pulley 212 and the second pulley 214. Additionally, the first pulley 212 and the second pulley 214 each include a circumferential belt surface 216, a portion of which is contacted by the belt 36 at any given moment. During rotation of the drum 26, linear movement of the belt 36 along the circumferential belt surfaces 216 of the pulleys 212, 214 rotates the pulleys 212, 214 relative to the first and second idler arms 202, 204. Additionally, the outer circumferential edges prevent or inhibit the belt 36 from sliding off the pulleys 212, 214 and, thus, are guides for the belt 36.

[0037] Sometimes, during rotation of the drum 26, the belt 36 may apply a force to, e.g., pull up and / or down on, one of the pulleys 212, 214, thereby causing the pulley 212, 214 to which the force is applied to rotate about the pivot joint. The first pulley 212 and the second pulley 214 may be connected or coupled by a biasing element 222, such as a torsion spring 222. For example, as illustrated in FIGS. 3 and 4, the torsion spring 222 may be coupled to a second or free end 224 of the first idler arm 202 and a second or free end 226 of the second idler arm 204. As such, when the belt 36 applies the force, e.g., downward force, to the first pulley 212, downward rotation of the first idler arm 202 results in the torsion spring 222 applying a downward force to the second idler arm 204 and, thus, causing the second idler arm 204 to rotate downward about the pivot joint. Likewise, when the belt 36 applies the force, e.g., upward force, the second pulley 214, upward rotation of the second idler arm 204 results in the torsion spring 222 applying an upward force to the first idler arm 202 and, thus, causing the first idler arm 202 to rotate upward about the pivot joint. Thus, the torsion spring 222 keeps the pulleys 212, 214 close together so that the belt 36 remains taut.

[0038] According to some exemplary embodiments, the idler assembly 200 also includes a bushing 230. As illustrated in FIGS. 6 through 8, the bushing 230 may include a first plate 232, a second plate 234, and a third plate 236 spaced apart from each other. As will be described below, the second plate 234 and the third plate 236 may be movable relative to the first plate 232. However, when the idler assembly 200 is assembled, the first plate 232, the second plate 234, and the third plate 236 are all generally in a fixed position and are generally parallel to each other. Furthermore, the first plate 232, the second plate 234, and the third plate 236 may each define an aperture 231 and be axially aligned with each other and with the first idler arm 202 and the second idler arm 204 such that the pivot joint, e.g., idler bearing 240 described below, may be simultaneously received through the apertures 231 of the first, second, and third plates 232, 234, 236 and the aperture (not shown) of the first idler arm 202 and the aperture 210 of the second idler arm 204 to connect the bushing 230 and the idler arms 202, 204 together.

[0039] According to some exemplary embodiments, the first plate 232 of the bushing 230 may be positioned between the second plate 234 and the third plate 236 of the bushing 230. A first gap 233 may be defined between the first plate 232 and the second plate 234. Likewise, a second gap 235 may be defined between the second plate 234 and the third plate 236. Furthermore, when the idler assembly 200 is assembled, the second idler arm 204 is positioned within the first gap 233 between the first plate 232 and the second plate 234. Likewise, the first idler arm 202 is positioned within the second gap 235 between the first plate 232 and the third plate 236. In this respect, the first plate 232 is positioned between the first idler arm 202 and the second idler arm 204 and is an interface that rubs the first idler arm 202 during rotation of the first idler arm 202 and rubs the second idler arm 204 during rotation of the second idler arm 204. Moreover, during rotation of the second idler arm 204, the second idler arm 204 may rub the second plate 234. Likewise, during rotation of the first idler arm 202, the first idler arm 202 may rub the third plate 236.

[0040] The bushing 230 described herein may reduce noise created by components of the idler assembly 200 moving relative to each other, such as the first idler arm 202 and the second idler arm 204. Generally, idler arms of laundry appliances are made partially or entirely of metal material, e.g., steel alloy, and rub against other metal components of the idler assembly, such as each other. Notably, the bushing 230 described herein is made entirely up of non-metal material, such as partially or entirely of polymer, e.g., polyvinyl chloride (PVC). As such, since the first and second idler arms 202, 204 are positioned between and rub against plates made entirely of non-metal material such as PVC during rotation of the idler arms 202, 204, noise created by rotation of the idler arms 202, 204 is reduced.

[0041] According to some exemplary embodiments, the first plate 232, the second plate 234, and the third plate 236 of the bushing 230 may all be integrally formed together as a single piece to provide ease of manufacturing of the bushing 230. As such, prior to assembly of the idler assembly 200, the second plate 234 and the third plate 236 may be positioned generally perpendicular to the first plate 232 to form a T-like shape of the bushing 230 as illustrated in FIG. 8. However, the second plate 234 and the third plate 236 may both be connected to the first plate 232 by separate living hinges 238 at the bottoms or bases of the first, second, and third plates 232, 234, 236. One living hinge 238 may connect the first plate 232 and the second plate 234 together, while a different living hinge 238 may connect the first plate 232 and the third plate 236 together. The living hinges 238 are flexible and thin non-metal material, such as PVC, which permit a user to easily rotate / fold the second plate 234 relative to the first plate 232 and the third plate 236 relative to the first plate 232 using their hands.

[0042] As described briefly above, the drum rotational assembly 100 includes the motor housing 35 that supports the motor 31 within the dryer appliance 10. The motor housing 35 includes the front bracket 42. The drive shaft 39 of the motor 31 extends from a motor base 45 of the motor 31 through the front bracket 42, including the exterior surface 43 of the front bracket 42, to the exterior of the motor housing 35.

[0043] The idler assembly 200 may be coupled to the exterior surface 43 of the front bracket 42 and positioned adjacent to the drive shaft 39. For example, as illustrated in FIG. 2, the idler assembly 200 may be coupled to the exterior surface 43 of the front bracket 42 and positioned such that the drive shaft 39 is between the first idler arm 202 and the second idler arm 204. In this respect, as best illustrated in FIGS. 6 and 7, the second plate 234 may include a couple of locating protrusions 237 that protrude from an exterior surface 239 of the second plate 234. The locating protrusions 237 may be laterally spaced apart from each other, one on each lateral side of the exterior surface 239 of the second plate 234. The locating protrusions 237 may be aligned with and received through a pair of corresponding apertures (not shown) defined through the exterior surface 43 of the front bracket 42 to locate / position and attach the bushing 230 and, thus, the idler assembly 200, to the front bracket 42. While described herein as including a couple of locating protrusions 237, it should be appreciated that the bushing 230 may include any suitable number of locating protrusions, such as one locating protrusion or more than two locating protrusions, e.g., three locating protrusions. Additionally, while described herein as protruding from the exterior surface 239 of the second plate 234, the locating protrusions may protrude from any suitable surface of any suitable plate of the bushing 230, e.g., an exterior surface of the third plate 236. Furthermore, while described herein is protruding from the bushing 230, it should be appreciated that one or more of the locating protrusions 237 may protrude from the exterior surface 43 of the front bracket 42 and the corresponding apertures may be defined through the bushing 230 for locating / positioning and attaching the bushing 230 and, thus, the idler assembly 200, to the front bracket 42.

[0044] According to some exemplary embodiments, and as briefly described above, the pivot joint is the idler bearing 240. As illustrated in FIG. 9, the idler bearing 240 includes an insert portion 241 and a washer portion 242, which may both define a cylindrical shape. The insert portion 241 of the idler bearing 240 is received simultaneously through the apertures 231 of the bushing 230, the aperture (not shown) of the first idler arm 202, and the aperture 210 of the second idler arm 204 to couple the bushing 230, the first idler arm 202, and the second idler arm 204 together. The washer portion 242 of the idler bearing 240 may define a greater diameter than a diameter of the insert portion 241 and a diameter of the apertures 231 of the bushing 230, the aperture of the first idler arm 202, and the aperture 210 of the second idler arm 204. In this respect, the washer portion 242 of the idler bearing 240 limits receipt of the idler bearing 240 through the apertures described above.

[0045] According to some exemplary embodiments, the interface surface 221 of the idler bearing 240 may define an exterior 243 of the insert portion 241. The interface surface 221 may define one or more idler bearing lubricant channels 244 along which lubricant may flow. The idler bearing lubricant channels 244 may thus be in contact with an aperture surface (not shown) that surrounds the aperture (not shown) of the first idler arm 202 and with the aperture surface 211 (FIG. 5) that surrounds the aperture 210 of the second idler arm 204. As such, lubricant may be provided between the interface surface 221 of the idler bearing 240 and the aperture surface of the first idler arm 202 and between the interface surface 221 and the aperture surface 211 of the second idler arm 204.

[0046] Furthermore, in some embodiments, surfaces of one or more of the first plate 232, the second plate 234, and the third plate 236 may define plate lubricant channels 246. For example, as illustrated in FIG. 8, the first plate 232 may define a plate lubricant channel 246 that extends linearly along a surface of the first plate 232 that faces the second idler arm 204 when the idler assembly 200 is assembled. Additionally, the third plate 236 may define a plate lubricant channel 246 that extends linearly along a surface of the third plate 236 that faces the first idler arm 202 when the idler assembly 200 is assembled. Likewise, the second plate 234 may define a plate lubricant channel 246 that extends linearly along a surface of the second plate 234 that faces the second idler arm 204 when the idler assembly 200 is assembled. One or more of the plate lubricant channels 246 may be in fluid communication with the idler bearing lubricant channels 244. In this respect, lubricant may flow directly between the idler bearing lubricant channels 244 and the plate lubricant channels 246.

[0047] Moreover, as best illustrated in FIG. 7, an exterior surface of the third plate 236 may define one of the plate lubricant channels 246, which may be semicircular instead of linear. The plate lubricant channel 246 on the exterior surface of the third plate 236 may be utilized to provide lubricant between the washer portion 242 of the idler bearing 240 and the bushing 230. The plate lubricant channel 246 on the exterior surface of the third plate 236 may be in fluid communication with the idler bearing lubricant channels 244 such that lubricant flows directly between the plate lubricant channel 246 on the exterior surface of the third plate 236 and the idler bearing lubricant channels 244.

[0048] Furthermore, in some embodiments, the idler bearing 240 may include a lubricant nozzle inlet 248. The lubricant nozzle inlet 248 may define an inlet aperture 249 through which lubricant is received, such as from a standard grease gun. The lubricant nozzle inlet 248 may be in fluid communication with the idler bearing lubricant channels 244. As such, lubricant received through the lubricant nozzle inlet 248 may flow directly to the idler bearing lubricant channels 244.

[0049] Moreover, as illustrated in FIG. 9, a fastener slot 250 may be defined through the idler bearing 240. When the idler assembly 200 is assembled, the idler bearing 240 may be oriented such that the fastener slot 250 is axially aligned with the apertures 231 of the bushing 230, the aperture of the first idler arm 202, and the aperture 210 of the second idler arm 204. A fastener, such as a shoulder bolt 252 (FIG. 10), may be received through the fastener slot 250 of the idler bearing 240 fixedly attach the idler assembly 200 to the front bracket 42 of the motor housing 35. As illustrated in FIG. 10, the shoulder bolt 252 may include a threaded portion 254. The threaded portion 254 may define a threaded portion diameter. Additionally, the shoulder bolt 252 may include a shoulder portion 256. The shoulder portion 256 may be concentric with the threaded portion 254. The shoulder portion 256 may define a shoulder portion diameter that is greater than the threaded portion diameter. In this respect, when the shoulder bolt 252 is rotated or screwed into place with the threaded portion 254, the shoulder portion 256 may act as a washer that prevents overtightening of the shoulder bolt 252.

[0050] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A laundry appliance, comprising:a cabinet;a drum rotatably mounted within the cabinet, the drum defining a chamber for receipt of articles for drying;a motor configured to rotate the drum;a belt coupled between the motor and the drum, whereby the belt rotates the drum during operation of the motor; andan idler assembly, comprising:a first arm rotatably coupled to a pivot joint at one end of the first arm;a first pulley coupled to the first arm, the first pulley comprising a surface, a portion of the surface in contact with a portion of the belt;a second arm rotatably coupled to the pivot joint at one end of the second arm;a second pulley coupled to the second arm, the second pulley comprising a surface, a portion of the surface in contact with a portion of the belt; anda bushing comprising a plate positioned between the first arm and the second arm.

2. The laundry appliance of claim 1, wherein:the bushing comprises an interface that contacts the first arm and the second arm; andthe interface of the bushing is comprised exclusively of non-metal material.

3. The laundry appliance of claim 1, wherein:the plate of the bushing is a first plate;the bushing further comprises a second plate spaced apart from the first plate whereby a gap is defined between the first plate and the second plate; andthe second arm is positioned in the gap between the first plate and the second plate.

4. The laundry appliance of claim 3, wherein:the first plate and the second plate are integrally formed together as a single piece.

5. The laundry appliance of claim 4, the bushing further comprising:a hinge integrally forming the first plate and the second plate together as a single piece, whereby the hinge permits rotation of the first plate and the second plate relative to each other.

6. The laundry appliance of claim 3, further comprising:a bracket for supporting the motor within the laundry appliance; anda locating protrusion protruding from a surface of the second plate of the bushing,wherein, the locating protrusion is received within a locating aperture defined through the bracket for positioning the bushing on the bracket.

7. The laundry appliance of claim 3, wherein:the bushing further comprises a third plate spaced apart from the first plate such that a gap is defined between the first plate and the third plate, the first plate positioned between the third plate and the second plate; andthe first arm is positioned in the gap between the first plate and the third plate.

8. The laundry appliance of claim 1, wherein:the pivot joint comprises an idler bearing, the idler bearing simultaneously received through apertures defined through the first arm and the second arm; andthe surface of the idler bearing defines an idler bearing lubricant channel along which lubricant flows, whereby the lubricant is provided between surfaces of the first arm and the second arm and the surface of the idler bearing.

9. The laundry appliance of claim 8, wherein:the idler bearing comprises a lubricant nozzle inlet, the lubricant nozzle inlet defining an aperture whereby lubricant is received; andthe lubricant nozzle inlet is in fluid communication with the idler bearing lubricant channel such that the lubricant flows between the lubricant nozzle inlet and the idler bearing lubricant channel.

10. The laundry appliance of claim 9, wherein:the idler bearing defines a fastener slot therethrough; anda shoulder bolt is received through the fastener slot of the idler bearing, the shoulder bolt comprising a threaded portion defining a threaded portion diameter and a shoulder portion concentric with the threaded portion and defining a shoulder portion diameter greater than the threaded portion diameter.

11. A laundry appliance, comprising:a cabinet;a drum rotatably mounted within the cabinet, the drum defining a chamber for receipt of articles for drying;a motor configured to rotate the drum;a belt coupled between the motor and the drum, whereby the belt rotates the drum during operation of the motor; andan idler assembly, comprising:an arm rotatably coupled to a pivot joint at one end of the arm, wherein a surface of the arm moves across a surface of the pivot joint during rotation of the arm;a pulley coupled to the arm, the pulley comprising a surface, a portion of the surface in contact with a portion of the belt; anda bushing comprising a first plate and a second plate spaced apart from each other, whereby a gap is defined between the first plate and the second plate, the arm positioned within the gap between the first plate and the second plate.

12. The laundry appliance of claim 11, wherein:the arm is a second arm; andthe idler assembly further comprises:a first arm rotatably coupled to the pivot joint at one end of the first arm, wherein a surface of the first arm moves across the surface of the pivot joint during rotation of the first arm; andthe first plate of the bushing is positioned between the first arm and the second arm.

13. The laundry appliance of claim 11, wherein the bushing is comprised exclusively of non-metal material.

14. The laundry appliance of claim 11, wherein:the first plate and the second plate are integrally formed together as a single piece.

15. The laundry appliance of claim 14, the bushing further comprising:a hinge integrally forming the first plate and the second plate together as a single piece, whereby the hinge permits rotation of the first plate and the second plate relative to each other.

16. The laundry appliance of claim 11, further comprising:a bracket for supporting the motor within the laundry appliance; anda locating protrusion protruding from a surface of the second plate of the bushing,wherein, the locating protrusion is received within a locating aperture defined through the bracket for positioning the bushing on the bracket.

17. The laundry appliance of claim 11, wherein:the bushing further comprises a third plate spaced apart from the first plate such that a gap is defined between the first plate and the third plate, the first plate positioned between the third plate and the second plate; andthe arm is positioned in the gap between the first plate and the third plate.

18. The laundry appliance of claim 11, wherein:the pivot joint comprises an idler bearing, a surface of the idler bearing defining an idler bearing lubricant channel along which lubricant flows and whereby the lubricant is provided between the surface of the arm and the surface of the idler bearing.

19. The laundry appliance of claim 18, wherein:the bushing further comprises a third plate spaced apart from the first plate such that a gap is defined between the first plate and the third plate, the first plate positioned between the third plate and the second plate;the arm is positioned in the gap between the first plate and the third plate; andat least one of the first plate, the second plate, or the third plate defines a plate lubricant channel, the plate lubricant channel in fluid communication with the idler bearing lubricant channel such that lubricant flows between the plate lubricant channel and the idler bearing lubricant channel.

20. The laundry appliance of claim 19, wherein:the idler bearing comprises a lubricant nozzle inlet, the lubricant nozzle inlet defining an aperture whereby lubricant is received; andthe idler bearing lubricant channel is in fluid communication with the lubricant nozzle inlet and the plate lubricant channel such that the lubricant flows directly between the lubricant nozzle inlet and the idler bearing lubricant channel and directly between the idler bearing lubricant channel and the plate lubricant channel.

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