Dryer Vent Grill Moisture Sensor With Interdigitated Leads
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Solution Overview
Problem
Existing dryer appliances face challenges in accurately measuring moisture content due to limited sensing area and the requirement for physical contact between moisture sensors and rotating clothing, which reduces measurement accuracy.
Innovation Solution
A moisture sensor system with interdigitated conductive fingers formed additively on a vent grill within the dryer, allowing for increased contact frequency with clothing without physical contact, enhancing measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two metal rods are used as moisture sensors, then the sensing area is limited and physical contact with rotating clothing is required, but measurement accuracy deteriorates due to reduced contact frequency
Solution Approach 1:
The patent divides the sensing area into multiple interdigitated conductive fingers instead of using a single rod or two separate rods. This segmentation increases the total sensing perimeter and surface area available for contact with rotating clothing, thereby improving measurement accuracy through increased contact frequency while maintaining the electrical isolation requirement
Solution Approach 2:
The patent transitions from linear rod sensors to planar interdigitated finger structures. This dimensional change from 1D to 2D arrangement significantly increases the sensing area within the same spatial envelope, allowing more frequent contact with rotating laundry while maintaining the same overall sensor footprint
2Reliability
If two separate metal rods are mounted to a non-conductive plastic component, then electrical isolation is achieved, but device complexity increases and manufacturing precision requirements increase
Solution Approach 1:
The patent merges the electrical isolation function into the conductive leads themselves by using non-conductive material sections between the conductive fingers. This eliminates the need for separate non-conductive plastic mounting components, reducing assembly complexity while maintaining reliable electrical isolation between the two conductive leads
Solution Approach 2:
The conductive leads serve multiple functions: they provide the sensing function through their conductive fingers, maintain electrical isolation through their non-conductive sections, and serve as the structural element of the sensor assembly. This multi-functionality reduces the number of separate components needed in the system
3Ease of manufacture
If two metal rods are positioned on non-rotating components, then the sensor structure is simplified, but measurement accuracy deteriorates due to reduced contact frequency with rotating clothing
Solution Approach 1:
The patent positions the interdigitated conductive fingers on the rotating drum surface rather than on stationary components. This dynamic positioning ensures that the sensing elements rotate with the drum, maintaining continuous contact frequency with the rotating laundry and improving measurement accuracy while keeping the mounting structure relatively simple
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 solution improves moisture content measurement accuracy and reliability by increasing contact frequency between the sensor and clothing, addressing the limitations of traditional two-metal-rod systems.
Implementation Method 1
The first and second conductive leads are additively formed with the grating of the vent grill
Implementation Method 2
As the clothing tumbles within the dryer appliance, the clothing bridges the two metal rods, and a response of a circuit coupled to the two metal rod changes
Data Source
AI summary
A method for forming a unitary component with a moisture sensor is provided. The method includes establishing three-dimensional information of the unitary component, converting the three-dimensional information into a plurality of slices, and successively forming each slice of the unitary component with an additive process. The moisture sensor of the unitary component includes a first conductive lead and a second conductive lead. A related dryer appliance is also provided.