Washer Basket Float Valve for Smaller Tub Liquid Control
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Solution Overview
Problem
Traditional fabric treating appliances, such as vertical axis washing machines, are limited by the size of the tub and basket, requiring excessive water for filling and restricting the volume of laundry that can be treated due to the need for the tub to capture all liquid escaping from the basket during spin cycles.
Innovation Solution
A vertically-oriented tub with a rotating basket and a float valve system that allows for selective opening and closing of a drain opening, enabling efficient liquid management and reducing the need for the tub to contain all liquid, thus allowing for a smaller tub design and increased capacity of the treating chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tub is made large enough to capture all liquid escaping from the basket during spin cycles, then liquid containment is improved, but the device complexity and water usage increase
Solution Approach 1:
The drain opening is segmented into multiple states (open and closed) through the float valve mechanism, allowing the system to manage liquid containment in a controlled manner rather than requiring the tub to be continuously sealed. This segmentation enables the tub to be smaller while still maintaining reliable liquid containment during spin cycles.
Solution Approach 2:
The float valve introduces dynamic control to the drain opening, transitioning from a static open state during wash cycles to a closed state during spin cycles. This dynamic adjustment allows the system to optimize liquid containment only when necessary, reducing the overall tub size requirement while maintaining reliability.
2Quantity of substance
If the tub is made large enough to hold all liquid during wash cycles, then water storage capacity is improved, but the volume available for laundry treatment is reduced
Solution Approach 1:
The water storage function is segmented from the laundry treatment chamber by introducing the float valve-controlled drain opening. This allows the tub to serve dual purposes: holding water during wash cycles and providing treatment space during spin cycles, effectively increasing laundry treatment capacity without sacrificing water storage capacity.
Solution Approach 2:
The dynamic float valve mechanism allows the tub to transition between different functional states, optimizing the volume available for laundry treatment at different cycle stages. During wash cycles, the valve opens to allow water storage; during spin cycles, the valve closes to enable effective liquid handling, thereby increasing overall treatment capacity.
3Ease of operation
If the pump is sealed to fill the entire tub volume with water, then filling control is improved, but water usage increases by up to five gallons per cycle
Solution Approach 1:
The float valve mechanism extracts the excess water problem from the system by providing a controlled drain opening that opens during wash cycles to allow water to escape. This extraction mechanism enables the pump to fill only the necessary volume, reducing water usage by up to five gallons per cycle while maintaining ease of filling control.
Solution Approach 2:
The float valve provides automatic feedback control for water level management during wash cycles. As water level rises, the float valve opens to drain excess water, creating a self-regulating system that prevents overfilling and reduces water usage without requiring complex pump control mechanisms.
4Adaptability or versatility
If separate drain and recirculation pumps are used, then liquid management functionality is improved, but device complexity increases
Solution Approach 1:
The float valve mechanism provides multi-functionality by serving both drain and recirculation functions through a single component. During wash cycles, it enables water drainage; during spin cycles, it provides liquid containment. This universal mechanism reduces device complexity while maintaining versatile liquid management functionality.
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
This solution allows for a more compact tub design, reducing water usage by up to five gallons per cycle and increasing the capacity of the treating chamber, while maintaining effective liquid handling during wash and spin cycles.
Implementation Method 1
a float valve having a valve body located within the tub interior and moveable between an opened position, where the valve body is spaced from the drain opening enabling fluid flow through the drain opening, and a closed position, where the valve body closes the drain opening to prohibit fluid flow through the drain opening, in response to the level of liquid in the tub interior
Data Source
AI summary
A fabric treating appliance includes a rotatable basket defining a treating chamber for receiving a load of laundry items for treatment. A float valve can be incorporated into the basket structure, selectively opening or closing the valve based upon the liquid level in a tub. As liquid fills the tub, the float valve will rise until it moves into a closed position, permitting the basket and treating chamber to fill with liquid. As the tub drain, the float valve can fall, opening the valve and permitting liquid to drain from the basket or treating chamber. The opened or closed positions can be selectively operated by opening or closing a pump or sump and allowing a tub to drain or fill, respectively.