SYSTEMS AND METHODS FOR MONITORING DRY TIME IN DRYER APPLIANCES

Abstract

A method includes receiving a user input comprising a timed dry cycle selection, and activating a timed dry cycle in response to the user input. The timed dry cycle is configured to operate for an amount of time. The method also includes determining a notification window of the timed dry cycle before activating the timed dry cycle, activating the heating system of the dryer appliance during the timed dry cycle of the dryer appliance, calculating a drying time to reach a pre-determined dryness threshold, comparing the calculated drying time to a remaining time of the timed drying cycle, and providing a user notification when the calculated drying time exceeds the remaining time of the cycle.

Claims

1. A method of operating a dryer appliance, the dryer appliance comprising a cabinet, a drum rotatably mounted within the cabinet, the drum defining a chamber for the receipt of articles for drying, and a heating system fluidly coupled to the drum whereby heated air flows from the heating system to the chamber of the drum for drying of articles within the chamber, the method comprising: receiving a user input comprising a timed dry cycle selection; activating a timed dry cycle in response to the user input, the timed dry cycle configured to operate for an amount of time; determining a notification window of the timed dry cycle before activating the timed dry cycle; activating the heating system of the dryer appliance during the timed dry cycle of the dryer appliance; calculating a drying time to reach a pre-determined dryness threshold; comparing the calculated drying time to a remaining time of the timed drying cycle; and providing a user notification when the calculated drying time exceeds the remaining time of the cycle.

2. The method of claim 1, further comprising extending the timed dry cycle via the user notification.

3. The method of claim 2, wherein extending the dry time comprises extending the timed dry cycle by a flat amount of time, the flat amount of time depending on the calculated drying time.

4. The method of claim 1, further comprising monitoring remaining moisture content throughout the timed dry cycle, wherein the calculated drying time is a known drying time when the remaining moisture content reaches a predetermined threshold prior to the notification window.

5. The method of claim 1, further comprising monitoring remaining moisture content throughout the timed dry cycle, wherein the calculated drying time is a forecasted drying time when the remaining moisture content is greater than a predetermined threshold at the notification window.

6. The method of claim 5, wherein the forecasted drying time is based on at least one of a moisture score and a progression of a moisture sensor signal.

7. The method of claim 5, wherein the forecasted drying time is further based on relevant parameters of the dryer appliance and data from other connected appliance.

8. The method of claim 7, wherein the relevant parameters of the dryer appliance comprises one or more of airflow condition, load size, and water content.

9. The method of claim 5, wherein the predetermined threshold comprises a moisture score of no more than twenty percent.

10. A method of operating a dryer appliance, the dryer appliance comprising a cabinet, a drum rotatably mounted within the cabinet, the drum defining a chamber for the receipt of articles for drying, and a heating system fluidly coupled to the drum whereby heated air flows from the heating system to the chamber of the drum for drying of articles within the chamber, the method comprising: receiving a user input comprising a timed dry cycle selection; activating a timed dry cycle in response to the user input, the timed dry cycle configured to operate for an amount of time; determining a notification window of the timed dry cycle; activating the heating system of the dryer appliance during the timed dry cycle of the dryer appliance; calculating a drying time to reach a pre-determined dryness threshold; comparing the calculated drying time to a remaining time of the timed drying cycle; and providing a user notification when the remaining time of the cycle exceeds the calculated drying time.

11. The method of claim 10, further comprising terminating the timed dry cycle via the user notification before the amount of time has elapsed.

12. The method of claim 10, further comprising monitoring remaining moisture content throughout the timed dry cycle, wherein the calculated drying time is a known drying time when the remaining moisture content reaches a predetermined threshold prior to the notification window.

13. The method of claim 10, further comprising monitoring remaining moisture content throughout the timed dry cycle, wherein the calculated drying time is a forecasted drying time when the remaining moisture content is greater than a predetermined threshold at the notification window.

14. The method of claim 13, wherein the forecasted drying time is based on at least one of a moisture score and a progression of a moisture sensor signal.

15. The method of claim 13, wherein the predetermined threshold comprises a moisture score of no more than twenty percent.

16. The method of claim 13, wherein the forecasted drying time is further based in part on relevant parameters of the dryer appliance and data from other connected appliance.

17. The method of claim 16, wherein the relevant parameters of the dryer appliance comprises one or more of airflow condition, load size, and water content.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] 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.

[0010] FIG. 1 provides a perspective view of a dryer appliance in accordance with example embodiments of the present disclosure.

[0011] FIG. 2 provides a perspective view of the example dryer appliance of FIG. 1 with portions of a cabinet of the dryer appliance removed to reveal certain components of the dryer appliance.

[0012] FIG. 3 provides a flow chart of an example method of operating a dryer appliance.

[0013] FIG. 4 provides a flow chart of an another example method of operating a dryer appliance.

[0014] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0015] 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.

[0016] As used herein, terms of approximation, such as generally, or about include values within ten percent greater or less than the stated value. 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. For example, generally vertical includes directions within ten degrees of vertical in any direction, e.g., clockwise or counter-clockwise.

[0017] Turning now to the figures, FIG. 1 provides a perspective view of dryer appliance 10 according to one or more example embodiments of the present disclosure. FIG. 2 provides another perspective view of dryer appliance 10 with a portion of a cabinet or housing 12 of dryer appliance 10 removed in order to show certain components of dryer appliance 10. Dryer appliance 10 generally 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 dryer appliances having different appearances and different features may also be utilized with the present subject matter as well.

[0018] 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, a bottom panel 22, and a top cover 24. Within cabinet 12, an interior volume 29 is defined. A drum or container 26 is mounted for rotation about a substantially horizontal axis within the interior volume 29. Drum 26 defines a chamber 25 for receipt of articles of clothing for tumbling and/or drying. Drum 26 extends between a front portion 37 and a back portion 38. 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 and receives heated air that has been heated by a heating assembly or system 40.

[0019] 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 10 (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.

[0020] A motor 31 is provided in some embodiments to rotate drum 26 about the horizontal axis, e.g., via a pulley and a belt (not pictured). Drum 26 is generally cylindrical in shape, having an outer cylindrical 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. A plurality of lifters or baffles 27 are provided within chamber 25 of drum 26 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.

[0021] Drum 26 includes a rear wall 34 rotatably supported within cabinet 12 by a suitable fixed 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 that has been heated by a heating assembly or system 40, as will be described further below. Motor 31 is also in mechanical communication with an air handler 48 such that motor 31 rotates a fan 49, e.g., a centrifugal fan, of air handler 48. Air handler 48 is configured for drawing air through chamber 25 of drum 26, e.g., in order to dry articles located therein. In alternative example embodiments, dryer appliance 10 may include an additional motor (not shown) for rotating fan 49 of air handler 48 independently of drum 26.

[0022] Drum 26 is configured to receive heated air that has been heated by a heating assembly 40, e.g., via holes in the rear wall 34 as mentioned above, in order to dry damp articles disposed within chamber 25 of drum 26. For example, heating assembly 40 may include a heating element (not shown), such as a gas burner, an electrical resistance heating element, or heat pump, for heating air. In particular embodiments, the heating assembly 40 may be or include an electric heater comprising a plurality of electric resistance heating elements with a plurality of relays for selectively providing or obstructing electrical power to the heating elements, such as two relays which permit operation of the heating assembly 40 at various power levels, such as fifty percent (50%) power when only one of two relays is closed. As discussed above, during operation of dryer appliance 10, motor 31 rotates drum 26 and fan 49 of air handler 48 such that air handler 48 draws air through chamber 25 of drum 26 when motor 31 rotates fan 49. In particular, ambient air enters heating assembly 40 via an inlet 51 due to air handler 48 urging such ambient air into inlet 51. Such ambient air is heated within heating assembly 40 and exits heating assembly 40 as heated air. Air handler 48 draws such heated air through supply duct 41 to drum 26. The heated air enters drum 26 through a plurality of outlets of supply duct 41 positioned at rear wall 34 of drum 26.

[0023] Within chamber 25, the heated air may accumulate moisture, e.g., from damp clothing disposed within chamber 25. In turn, air handler 48 draws moisture-saturated air through a screen filter (not shown) which traps lint particles. Such moisture-statured air then enters an exit duct 46 and is passed through air handler 48 to an exhaust duct 52. From exhaust duct 52, such moisture-statured air passes out of dryer appliance 10 through a vent 53 defined by cabinet 12. After the clothing articles have been dried, they are removed from the drum 26 via opening 32. A door 33 (FIG. 1) provides for closing or accessing drum 26 through opening 32. The door 33 may be movable between an open position and a closed position, the open position for access to the chamber 25 defined in the drum 26, and the closed position for sealingly enclosing the chamber 25 defined in the drum 26.

[0024] 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 of the cabinet 12) and are in operable communication (e.g., electrically coupled or coupled through a wireless network band) with a processing device or controller 100. A display 56 may also be provided on the backsplash 71 and may also be in operable communication with the controller 100. Controller 100 may also be provided in operable communication with motor 31, air handler 48, and/or heating assembly 40. In turn, signals generated in controller 100 direct operation of motor 31, air handler 48, and/or heating assembly 40 in response to the position of inputs 70. In the example illustrated in FIG. 2, the inputs 70 are provided as knobs. In other embodiments, inputs 70 may also or instead include buttons, switches, touchpads and/or a touch screen type interface.

[0025] Controller 100 is a processing device or controller and may be embodied as described herein. As used herein, processing device or controller may refer to one or more microprocessors, microcontrollers, application-specific integrated circuits (ASICS), or semiconductor devices and is not restricted necessarily to a single element. The controller 100 may be programmed to operate dryer appliance 10 by executing instructions stored in memory (e.g., non-transitory media). The controller 100 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. Controller 100 may include one or more processor(s) and associated memory device(s) configured to perform a variety of computer-implemented functions and/or instructions (e.g. performing the methods, steps, calculations and the like and storing relevant data as disclosed herein). It should be noted that controllers as disclosed herein are capable of and may be operable to perform any methods and 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.

[0026] In some example embodiments, the dryer appliance 10 may include one or more temperature sensors, such as inlet temperature sensor 43 and/or outlet temperature sensor 47. The temperature sensor(s) may be in operative communication with the controller 100. For example, in various embodiments, the controller 100 may be operable to detect, measure, and/or monitor one or more temperatures within the dryer appliance 10. Such temperatures which may be detected, measured, and/or monitored include, for example, an inlet temperature measured with the inlet temperature sensor 43 and/or an outlet temperature measured with the outlet temperature sensor 47. The temperature sensors 43 and 47 may be, in some embodiments, thermistors.

[0027] In some example embodiments, the dryer appliance 10 may include one or more moisture sensors, such as moisture sensor 50. The moisture sensor(s) may be in operative communication with controller 100. For example, in various embodiments, the controller 100 may be operable to detect, measure, and/or monitor a moisture score within the dryer appliance 10. The moisture score indicative of a percent moisture within the dryer appliance 10. The moisture score monitored by controller 100 may be plotted into a progression, or slope, indicative of the moisture score generally decreasing.

[0028] Referring now to FIGS. 3 and 4, flow diagrams of example embodiments of a method 300, 400 of operating a dryer appliance are illustrated in accordance with aspects of the present subject matter. In general, methods 300, 400 will be described herein with reference to the embodiments of dryer appliance 10 described above with reference to FIGS. 1-2. However, it should be appreciated by those of ordinary skill in the art that the disclosed methods 300, 400 may generally be utilized in association with apparatuses and systems having any other suitable configuration. In addition, although FIGS. 3 and 4 depict steps performed in a particular order for purposes of illustration and discussion, the methods discussed herein are not limited to any particular order or arrangement. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods disclosed herein can be omitted, rearranged, combined, and/or adapted in various ways without deviating from the scope of the present disclosure.

[0029] As shown in FIG. 3, at (310), method 300 may generally include receiving a user input that includes a timed dry cycle selection. For example, the user input may be user manipulation of the user interface inputs 70, and the timed dry cycle selection may include selecting from varying heat capacities such as low-heat or high-heat drying cycles. At (320), method 300 may generally include activating a timed dry cycle in response to the user input. In some embodiments, the timed dry cycle may operate for a predetermined amount of time, e.g., in one example, the timed dry cycle may operate for sixty (60) minutes. In additional embodiments, the timed dry cycle may operate for a user-selected amount of time, such as based on a load size input, a time input, or another similar input. In some embodiments, the user may pay a certain amount per unit of time, e.g., one dollar for every twenty minutes, of the timed dry cycle time amount. As will be described further below, in embodiments where the user pays per unit of time, and when the cycle is terminated early, the user may receive a refund or credit for unused amount of time. At (330), method 300 may generally include determining a notification window of the timed dry cycle, before activating the timed dry cycle. The notification window may be predetermined, e.g., dryer appliance 10 may have the notification window set to five (5) minutes before the timed cycle ends. For example, the notification window may occur fifty-five (55) minutes into a sixty (60) minute timed dry cycle.

[0030] Moreover, at (340), method 300 may generally include activating the heating system, e.g., heating assembly 40 of the dryer appliance 10, during the timed dry cycle of the dryer appliance 10. At (350), method 300 may generally include calculating a drying time to reach a pre-determined dryness threshold. The predetermined threshold may include the moisture score reaching a value of no more than twenty percent (20%). At (360), method 300 may generally include comparing the calculated drying time to the remaining time of the timed drying cycle. For example, the calculated drying time may be twenty (20) minutes to reach the predetermined threshold, while the remaining time in the timed dry cycle may be five (5) minutes. Thus, at (370), method 300 may generally include providing a user notification when the calculated drying time exceeds the remaining time of the cycle. As in the example provided above, the calculated drying time may be twenty (20) minutes to reach the predetermined threshold, while the remaining time in the timed dry cycle may be five (5) minutes, thus the calculated drying time exceeds the remaining time of the cycle by fifteen (15) minutes.

[0031] In some example embodiments, method 300 may additionally include, at (380), extending the timed dry cycle via the user notification provided at step (370). For example, the timed dry cycle may be extended by a flat amount of time. The flat amount of time may depend on the calculated drying time, e.g., a sixty (60) minute timed dry cycle that is determined to require an additional fifteen (15) minutes may be extended by a flat amount of time of fifteen (15) minutes. However, in some example embodiments, the cycle may be terminated sooner if the moisture sensor reaches the threshold value in less time than initially calculated.

[0032] In some example embodiments, method 300 may additionally include, at (390), monitoring the remaining moisture content throughout the timed dry cycle. The calculated drying time may be considered a known drying time when the remaining moisture content reaches a predetermined threshold prior to the notification window. However, the calculated drying time is a forecasted drying time when the remaining moisture content is greater than the predetermined threshold at the notification window. In other words, the moisture score must be at least eighty percent (80%) of the target dryness, e.g., the target dryness being one hundred percent (100%), to know the cycle will end at an appropriate time, and when the remaining moisture content is greater than the predetermined threshold at the notification window the calculated drying time is a forecasted drying time, e.g., estimating the end of the cycle.

[0033] Moreover, the forecasted drying time may be based on at least one of the moisture score and a progression of the moisture sensor signal, e.g., a trend of the moisture score. The forecasted drying time may also be based in part on relevant parameters of the dryer appliance and data from other connected appliance. The relevant parameters of the dryer appliance, including the data from other connected appliance, may include one or more of airflow condition, load size, and water content. The airflow condition may be the rate at which a volume of air passes through drum 26 in dryer appliance 10. The load size and water content may be measured by a connected washing machine appliance and transferred to dryer appliance 10 through cloud data transfer or other suitable means.

[0034] As shown in FIG. 4, at (410), method 400 may generally include receiving a user input that includes a timed dry cycle selection. For example, the user input may be user manipulation of the user interface inputs 70, and the timed dry cycle selection may include selecting from varying heat capacities such as low-heat or high-heat drying cycles. At (420), method 400 may generally include activating a timed dry cycle in response to the user input. In general, the timed dry cycle may operate for a predetermined amount of time, e.g., in one example, the timed dry cycle may operate for sixty (60) minutes. At (430), method 400 may generally include determining a notification window of the timed dry cycle, before activating the timed dry cycle. The notification window may be predetermined, e.g., dryer appliance 10 may have the notification window set to five (5) minutes before the timed cycle ends. For example, the notification window may occur fifty-five (55) minutes into a sixty (60) minute timed dry cycle.

[0035] Moreover, at (440), method 400 may generally include activating the heating system, e.g., heating assembly 40 of the dryer appliance 10, during the timed dry cycle of the dryer appliance 10. At (450), method 400 may generally include calculating a drying time to reach a pre-determined dryness threshold. The predetermined threshold may include the moisture score reaching a value of no more than twenty percent (20%). At (460), method 400 may generally include comparing the calculated drying time to the remaining time of the timed drying cycle. For example, the calculated drying time may be five (5) minutes to reach the predetermined threshold, while the remaining time in the timed dry cycle may be twenty (20) minutes. Thus, at (470), method 400 may generally include providing a user notification when the remaining time of the cycle exceeds the calculated drying time. As in the example provided above, the calculated drying time may be five (5) minutes to reach the predetermined threshold, while the remaining time in the timed dry cycle may be twenty (20) minutes, thus the remaining time of the cycle exceeds the calculated drying time by fifteen (15) minutes.

[0036] In some example embodiments, method 400 may additionally include, at (480), terminating the timed dry cycle via the user notification provided at step (470). For example, the timed dry cycle may be terminated when the remaining time of the cycle exceeds the calculated drying time. In other words, a sixty (60) minute timed dry cycle that is determined to require fifteen (15) minutes less than the full (60) may be terminated early as to avoid unnecessary operation of the dryer appliance 10 for fifteen (15) minutes. However, in some example embodiments, the cycle may be further extended if the moisture sensor does not reach the threshold value in the initially calculated time. As stated above, in embodiments where the user pays per unit of time, and when the cycle is terminated early, the user may receive a refund or credit for unused amount of time. As in the example described above where a timed dry cycle is determined to require fifteen (15) minutes less than the full time, the timed dry cycle may be terminated early which may advantageously result in a refund to the user for the unused time. In some example embodiments, the user may have an account with a balance of funds particularly for use with suitable washing and drying machines. Thus, users may receive refunds credited back to the account of the user from the unused time of the dryer appliance.

[0037] In some example embodiments, method 400 may additionally include, at (490), monitoring the remaining moisture content throughout the timed dry cycle. The calculated drying time may be considered a known drying time when the remaining moisture content reaches a predetermined threshold prior to the notification window. However, the calculated drying time is a forecasted drying time when the remaining moisture content is greater than the predetermined threshold at the notification window. In other words, the moisture score must be at least eighty percent (80%) of the target dryness, e.g., the target dryness being one hundred percent (100%), to know the cycle will end at an appropriate time, and when the remaining moisture content is greater than the predetermined threshold at the notification window the calculated drying time is a forecasted drying time, e.g., estimating the end of the cycle.

[0038] As may be seen from the above, a dryer appliance may predict either a known time to dry or a forecasted time to dry. The prediction is compared to the actual remaining time on the timed dry cycle, and if the load in the dryer appliance needs additional time to dry, the user may be notified and add time remotely, or if the load needs less time to dry, the user may be notified and terminate the cycle remotely. This may be advantageous to increase throughput of the dryer appliances in the commercial setting, such as a laundromat. The methods may further save consumers time and hassle of having to re-reserve dryer appliances and start new cycles, as well as prevent customer dissatisfaction with under-dried loads. Moreover, the methods could advantageously be further employed to watch for excessively long timed cycles, thus preventing wasted time and energy for excessively long timed cycles.

[0039] 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.