Compact Steam Generator Layout for Drum Washer Splash Control
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Solution Overview
Problem
Conventional steam generators in drum-type washing machines are oversized, leading to increased power consumption, inefficiency, and damage to laundry due to splashing hot water, while also causing water level sensor malfunctions and high production costs due to mineral deposits.
Innovation Solution
A compact steam generator design with a vertically oriented heater within a recessed portion of the case, guided water supply, and a water splash prevention partition to prevent hot water from entering the drum, along with a secure bracket to minimize mineral deposits and improve efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the heater is horizontally oriented and completely submerged in water, then steam generation capacity is sufficient, but the steam generator exceeds necessary capacity leading to increased power consumption and reduced efficiency
Solution Approach 1:
The heater is changed from horizontal orientation to vertical orientation, transitioning from a planar configuration to a three-dimensional space-utilizing structure. This dimensional change allows the heater to achieve sufficient heating capacity with reduced surface area, thereby reducing power consumption while maintaining steam generation effectiveness.
Solution Approach 2:
The heater dimensions and orientation are modified as key parameters. By changing from a horizontal fully-submerged configuration to a vertical partially-submerged configuration, the heater achieves optimal heat transfer efficiency with reduced material and power requirements, resolving the contradiction between capacity and energy use.
2Power
If the heater is horizontally oriented and completely submerged, then steam generation is adequate, but the size of the cabinet must increase to accommodate the steam generator
Solution Approach 1:
The vertical orientation of the heater utilizes the height dimension of the steam generator, allowing for compact horizontal footprint. This enables sufficient steam generation capacity within a smaller overall cabinet volume, eliminating the need for increased cabinet size.
Solution Approach 2:
The vertically oriented heater is nested within the steam generator chamber in a space-efficient manner, allowing the heating element to be contained within the existing cabinet footprint without requiring additional space, thus maintaining compact overall dimensions.
3Power
If the heater is horizontally oriented, then steam generation is sufficient, but hot water splashes and is supplied to the drum causing damage to laundry fabrics
Solution Approach 1:
Changing the heater orientation from horizontal to vertical fundamentally alters the water flow dynamics and steam generation pattern. The vertical configuration prevents horizontal splashing motion, eliminating the harmful effect of hot water being projected onto the drum and laundry while maintaining effective steam generation.
4Power
If the heater is horizontally oriented and completely submerged, then steam generation is adequate, but bubbles generated during heating cause water level sensor malfunction
Solution Approach 1:
The vertical heater orientation changes the bubble generation pattern and water agitation characteristics. Bubbles rise more vertically and coalesce differently, reducing their interference with the water level sensor operation and improving measurement reliability while maintaining steam generation capacity.
5Power
If the heater is horizontally oriented and completely submerged, then steam generation is sufficient, but the bracket is highly susceptible to mineral deposits leading to increased power consumption
Solution Approach 1:
The vertical heater configuration changes the water flow patterns and mineral deposition characteristics. Minerals tend to deposit differently on vertical surfaces compared to horizontal surfaces, potentially reducing accumulation on critical heating surfaces and maintaining energy efficiency over time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The compact design enhances steam generation efficiency, reduces the overall size of the washing machine, prevents water level sensor malfunctions, and decreases production costs by minimizing mineral deposits and foreign substance accumulation.
Implementation Method 1
a heater (102) that heats water to generate steam
Implementation Method 2
the heater (102) heats water to generate steam
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a steam generator (16). More particularly, the present invention relates to a steam generator which has a compact design to enhance efficiency, and to a drum-type washing machine with this steam generator. The steam generator includes a heater (32) that heats water to generate steam; a lower case (28) that holds water for steam generation, having a heater holding part in which the heater is vertically oriented in the heater holding part, and an upper case (30) coupled to an upper portion of the lower case (28) to form a predetermined space.