SELF-CLEANING LINT FILTER FOR COMBINATION WASHING AND DRYING MACHINE
20250207318 ยท 2025-06-26
Inventors
- John P. Monsen (Ayer, MA, US)
- Madeline R. Hickman (Arlington, MA, US)
- Noa M. Rensing (West Newton, MA, US)
- Stuart E. Schechter (Newton, MA, US)
- Nathaniel Mandosa Winslow (Chatsworth, CA, US)
Cpc classification
D06F58/45
TEXTILES; PAPER
D06F33/63
TEXTILES; PAPER
International classification
D06F58/45
TEXTILES; PAPER
D06F33/63
TEXTILES; PAPER
Abstract
An autonomously cleanable lint filter assembly disposed in a closed air loop for a combination washing and drying machine includes a housing disposed upstream of a fan configured to pull airflow through the lint filter assembly from an air outlet of the combination washing and drying machine, two or more mesh filters spaced apart and disposed within the housing, a spring loaded axle extending through the housing and receiving thereabout the two or more mesh filters, three or more drain holes disposed within a lower half of the housing, two or more annular flanges disposed on an inner surface of the housing configured to receive thereon in a reversible face seal mating under force imparted by airflow one of the two or more mesh filters, and at least two spray nozzles disposed within the housing configured to deliver sprays of liquid to one of the two or more mesh filters.
Claims
1) An autonomously cleanable lint filter assembly disposed in a closed air loop for a combination washing and drying machine comprising: a housing disposed upstream of a blower configured to pull an airflow through the lint filter assembly from an air outlet of the combination washing and drying machine; two or more mesh filters spaced apart and disposed within the housing such that an upstream mesh filter of the two or more mesh filters comprises a less dense mesh than a downstream one of the two or more mesh filters in a direction of airflow; an axle configured to extend through a length of the housing between an airflow inlet and an airflow outlet and receive thereabout the two or more mesh filters, the axle being spring loaded at at least one end for bidirectional movement along a longitudinal axis; three drain holes disposed within a lower half of the housing in alignment with three or more volumes partitioned by the two or more mesh filters; two or more annular flanges disposed on an inner surface of the housing and extending inward radially, each of the two or more annular flanges being configured to receive thereon in a reversible face seal mating one of the two or more mesh filters under an application of force imparted by an airflow through the housing; and at least two spray nozzles disposed within the housing adjacent the two or more mesh filters, each of the at least two spray nozzles being configured to deliver a spray of liquid to one of the two or more mesh filters.
2) The autonomously cleanable lint filter assembly of claim 1, further comprising at least one controller in operative communication with the blower and at least one actuator of the at least two spray nozzles, wherein the at least one controller is configured to instruct the at least one actuator to spray liquid upon receiving a signal indicative of completion of a drying cycle and shutdown of the blower.
3) The autonomously cleanable lint filter assembly of claim 2, wherein the at least one controller is configured to instruct the at least one actuator to deliver 200-400 cubic centimeters of water in each of two or more bursts during the drying cycle based on one or more of: receiving a signal indicative of at least one of the blower shutting down at an end of a drying cycle, the blower shutting down periodically at one or more timed intervals during the drying cycle, and a measured airflow velocity within the closed air loop being at or below a threshold value during the drying cycle.
4) The autonomously cleanable lint filter assembly of claim 1, wherein the three or more drain holes are configured to drain a combined spray liquid and lint solution into a collective drain channel disposed along a bottom of the housing, and wherein the collective drain channel drains the combined spray liquid and lint solution into a collective drain outlet.
5) The autonomously cleanable lint filter assembly of claim 4, wherein the collective drain channel comprises an upper channel portion affixed to the housing and a removable lower portion comprising a slanted bottom angled downward toward the collective drain outlet and wherein a grommet is disposed between rims of the upper channel portion and lower channel portion for watertight sealing.
6) The autonomously cleanable lint filter assembly of claim 1, further comprising a pair of hub and spoke assemblies configured to engage the housing at an airflow inlet end and an airflow outlet end, the hub and spoke assemblies being configured to support each end of the axle.
7) The autonomously cleanable lint filter assembly of claim 6, wherein each end of the axle is supported non-rotationally and wherein the two or more mesh filters comprise annular disc filters each one of which is configured to engage a rotational bearing disposed on the axle for spinning freely about the axle under an application of force from a spray of liquid.
8) The autonomously cleanable lint filter assembly of claim 1, further comprising at least one spring disposed in mated engagement with the at least one end of the axle configured to compress under the application of force imparted by the airflow on the two or more mesh filters thereby translating the axle in along its longitudinal axis until the two or more mesh filters engage corresponding faces of the two or more annular flanges in the reversible face seal mating.
9) The autonomously cleanable lint filter assembly of claim 8, wherein the at least one spring is configured to expand in an absence of the application of force imparted by the airflow on the two or more mesh filters thereby translating the axle in along its longitudinal axis in a second direction opposite the direction of airflow until the two or more mesh filters separate from the two or more annular flanges by a distance of at least between about 5 mm and 10 mm.
10) The autonomously cleanable lint filter assembly of claim 8, wherein the two or more mesh filters are affixed to the axle, the axle is supported on either end by linear bearings, and the axle and two or more mesh filters affixed thereto spin passively within the linear bearings under the application of force of an impinging spray on the two or more mesh filters.
11) The autonomously cleanable lint filter assembly of claim 1, wherein the airflow inlet of the housing is lower than the airflow outlet such that the housing is tilted from horizontal at an angle comprising a range of between about 5 to 40 degrees.
12) The autonomously cleanable lint filter assembly of claim 1, wherein the housing comprises a portion of the closed air loop between an air outlet of the combination washing and drying machine and a cold side heat exchanger.
13) The autonomously cleanable lint filter assembly of claim 12, wherein the at least two spray nozzles are configured to deliver the spray of liquid onto the side of each of the two or more mesh filters facing the airflow inlet which receives air from the air outlet of the combination washing and drying machine.
14) The autonomously cleanable lint filter assembly of claim 13, wherein the spray of liquid is configured to impinge on the mesh filter of the two or more mesh filters in an area disposed aside a vertical centerline, the spray of liquid is configured to impinge the mesh filter at least one of on and about a horizontal centerline, and the spray of liquid hits the mesh filter at an angle comprising a range of between about 35 and 55 degrees from the longitudinal axis of the axle.
15) The autonomously cleanable lint filter assembly of claim 1, further comprising at least two fluid conduits extended through openings in the housing, the at least two fluid conduits terminating at the at least two spray nozzles for delivering the spray of liquid to the two or more mesh filters.
16) A method of autonomously cleaning a lint filter disposed in a closed air loop of a combination washer and dryer comprising: receiving at at least one controller one or more sensor signals indicative of an airflow velocity; determining, based on at least one of the received one or more sensor signals and a time interval, lint filter cleaning is required; instructing, based on a determination that lint filter cleaning is required, a fan to shut off airflow within the closed air loop; instructing, following shutting off the fan, two or more spray nozzles to spray two or more mesh filters affixed to a rotatable axle extending through a central axis of an elongated outer housing of the lint filter; and instructing the fan to restart pulling airflow through the closed air loop following a period of spraying.
17) The method of claim 16, further comprising instructing the two or more nozzles to spray fluid on the two or more mesh filters when airflow is reduced by a range of between about 5-15% of an airflow velocity measured at a start of a drying cycle.
18) The method of claim 16, wherein the controller is configured to instruct the fan to stop airflow and spray at a time interval of every between about 9-15 min throughout a drying cycle.
19) The method of claim 18, wherein each incident of spraying imparts a range of 200-300 cubic centimeters of total fluid on the two or more mesh filters.
20) The method of claim 18 wherein each time interval for spraying lasts in a range of between about 5-10 seconds.
21) The method of claim 16, further comprising instructing the fan to stop pulling airflow and instructing the at least two spray nozzles to spray lint off the at least two mesh filters at end of a drying cycle.
22) The method of claim 16, wherein the axle is retained at both ends by rotatable linear bearings disposed in hubs of hub and spoke assemblies radially attached to the outer housing and the axle is spring loaded at one end such that that under application of airflow force, the axle linearly translates and two or more mesh filters affixed thereto compress against annular flanges mounted to an interior of the outer housing to form a reversible seal.
23) The method of claim 22, further comprising three or more drain holes disposed through a bottom of the outer housing, the three or more holes being configured to drain into a collection channel disposed along a bottom of the housing to drain collected lint laded fluid into a drainpipe.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0078] This disclosure relates to autonomous robotic devices, systems, and methods for handling residential loads of laundry and energy efficiencies associated with the drying process.
[0079] The systems and assemblies described herein with regard to implementations comprise features dedicated to reducing energy and resource consumption while effectively and efficiently laundering loads of residential laundry across a plurality of washing and drying robots serviced by a centralized heat pump. At each washing and drying robot, a fan circulates a closed loop of process air, drawing moist, warm air from the drum of the washing and drying robot. The moist, warm air passes through a self-cleaning lint filter before entering a cold side heat exchanger. The cold side heat exchanger lowers the temperature of the air below the dew point to remove water through condensation, and then the air, drawn by a blower, passes through a hot heat exchanger where it is reheated and returned to the drum to continue drying one or more laundry articles disposed within the drum. The system comprises a closed air loop such that heated process air used in the drying cycle is not vented to ambient and instead is pulled through a series of local heat exchangers such that energy from the process air is reclaimed for reuse by a central heat pump. The system comprises a controller and one or more sensors configured to monitor air temperature, humidity, and airflow velocity within the closed air loop. Upon at least one of reaching a timed interval during a drying process, reaching the end of a drying process, and receiving a sensor signal indicative of airflow restriction, the controller is configured to initiate automated cleaning of the lint filter one or more times in a drying cycle to prevent air restriction and associated energy inefficiencies. Not having to start and stop a combination washing and drying robot for a long period of time to manually clean a lint filter preserves the energy efficiencies and load balancing achieved with the use of local heat exchangers and facility wide heat pumps servicing a plurality of combination washing and drying robots.
[0080] As shown in
[0081] The separating and sorting robot 3000 outputs one or more intelligently sorted batches of deformable laundry articles to one or more washing and drying robots 4000 for laundering. The one or more washing and drying robots 4000 output the clean laundry articles to a clean laundry separating robot 5000. Implementations of the clean laundry separating robot 5000 can be similar or identical to the separating and sorting robot 3000. The clean laundry separating robot 5000 is configured to separate a load of clean laundry into individual deformable laundry articles for introduction into a repositioning robot 6000. In implementations, the repositioning robot 6000 receives a single deformable laundry article and manipulates and repositions it for automated introduction into a folding robot 7000, which automatically folds the laundry article for introduction to a packing robot 8000. In implementations, the packing robot 8000 automatically and autonomously packs the clean load of laundry comprising the plurality of clean and folded deformable laundry articles in a shipping container for return to the customer. In implementations, the shipping container is a reusable container. In implementations, the shipping container is a disposable container. In implementations, the shipping container is a non-deformable container with an ingress protection rating that includes an intrusion protection rating of 5 or 6 and a moisture protection rating of any and all of 1 through 6 in accordance with the Ingress Protection Code, IEC standard 60529.
[0082] Implementations of the process line 100a of household laundry cleaning robots can comprise one or more of each of the robots depicted in
[0083] Additionally or alternatively, in implementations, the autonomous process line 100b includes a plurality of washing and drying robots 4000a-n shared by two or more sets of automated intake robots 2000 and dirty laundry separating and sorting robots 3000 and two or more sets of clean laundry separating robots 5000, repositioning robots 6000, folding robots 7000, and packing robots 8000. Additionally or alternatively, the process line 100b can include a plurality of folding robots 7000a-n (where n represents a count of robots greater than 1) configured to receive spread apart and/or repositioned clean laundry articles from one or more repositioning robots 6000. In implementations, having the number of folding robots 7000a-n exceed a number of repositioning robots can prevent a process bottleneck at the folding step. In implementations, having one repositioning robot 6000 delivering spread laundry articles to at least 2 folding robots results in a throughput time savings in a range of between about 30% to 50% over a one-to-one pairing of a repositioning robot 6000 to a single folding robot 7000. Additionally or alternatively, in implementations, a plurality of folding robots 7000a-n can be stacked, or tiered, to reduce overall floor space (e.g., floor 10) occupancy of the process line 100, 100a-b within a facility. Additionally, two or more of the robots in a process line 100, 100a-b (collectively referred to hereinafter as the process line 100) can be combined in a single module in alternate implementations.
[0084] In other implementations, as shown in
[0085] In implementations, one or more of the robots 2000-9000 in the process line 100, 100a-c are configured to communicate over wired connections or wireless communication protocols. For example, in implementations, one or more robots in a process line 100, 100a-c can communicate with another one or more robots in the process line 100a-c over a wired BUS, LAN, WLAN, 4G, 5G, LTE, Ethernet, BLUETOOTH, or other IEEE 801.11 standard.
[0086] Referring to
[0087] For example, in implementations, the washing and drying robot 4000 includes a controller 4005. The controller 4005 includes a processor 4015 in communication with a memory 4010, a network interface 4020, and a sensor interface 4025. The processor 4015 can be a single microprocessor, multiple microprocessors, a many-core processor, a microcontroller, and/or any other general purpose computing system that can be configured by software and/or firmware. In implementations, the memory 4010 contains any of a variety of software applications, data structures, files and/or databases. In one implementation, the controller 4005 includes dedicated hardware, such as single-board computers, application specific integrated circuits (ASICs), and field programmable gate arrays (FPGAs).
[0088] A network interface 4020 is configured to couple the controller 4005 to a network 230. The network 230 may include both private networks, such as local area networks, and public networks, such as the Internet. It should be noted that, in some examples, the network 230 may include one or more intermediate devices involved in the routing of packets from one endpoint to another. In implementations, the network interface 4020 is coupled to the network 230 via a networking device, such as a bridge, router, or hub. In other implementations, the network 230 may involve only two endpoints that each have a network connection directly with the other. In implementations, the network interface 4020 supports a variety of standards and protocols, examples of which include USB (via, for example, a dongle to a computer), TCP/IP, Ethernet, Wireless Ethernet, BLUETOOTH, ZigBee, M-Bus, CAN-bus, IP, IPV6, UDP, DTN, HTTP, FTP, SNMP, CDMA, NMEA and GSM. To ensure data transfer is secure, in some examples, the controller 4005 can transmit data via the network interface 4020 using a variety of security protocols including, for example, TLS, SSL or VPN. In implementations, the network interface 4020 includes both a physical interface configured for wireless communication and a physical interface configured for wired communication. According to various embodiments, the network interface 4020 enables communication between the controller 4005 of the washing and drying robot 4000 and at least one of the plurality of robots 2000, 3000, 5000, 6000, 7000, 8000, 9000 of the process line 100, 100a-c.
[0089] Additionally or alternatively, the network interface 4020 is configured to facilitate the communication of information between the processor 4015 and one or more other devices or entities over the network 230. For example, in implementations, the network interface 4020 is configured to communicate with a remote computing device such as a computing terminal 205 (alternatively referred to herein as CPU 205), database 235, server 240, smartphone 245, and server farm 250. In implementations, the network interface 4020 can include communications circuitry for at least one of receiving data from a database 235 and transmitting data to a remote server 240, 250. In some implementations, the network interface 4020 can communicate with a remote server over any of the wired protocols previously described, including a WI-FI communications link based on the IEEE 802.11 standard.
[0090] In some implementations in accordance with
[0091] Although the controller 4005 of a washing and drying robot 4000 is described herein in particular, one or more of the plurality of robots 2000, 3000, 5000, 6000, 7000, 8000, 9000 of the process line 100 includes similar components having similar functionality.
[0092] Returning to
[0093] As shown in
[0094] In implementations, the cold side heat exchanger 4526 comprises a plurality of segments of tube-fin heat exchangers, and as air flows through the cold side heat exchanger 4526, a fluid-to-air heat transfer occurs at the fins. The process air travels though the closed air loop 4320 to the cold side heat exchanger 4626 and moisture condensed therein falls under gravity to the condensate outlet 4535 where it exits the exhaust duct 4325. In implementations, the condensed water runs along the fins as it descends, entrapping and removing lint in the process. In implementations, the at least one controller 4005, 205 is configured to stop the fan 4830 for one or more periods in a range of between 10-120 seconds (e.g., 10 seconds, 20 seconds, 30 seconds, 40 seconds, 50 seconds, 60 seconds, 70 seconds, 80 seconds, 90 seconds, 100 seconds, 110 seconds, 120 seconds) to allow condensation to drain from cold side heat exchanger 4526. Additionally, in implementations, the fins and tubes of the cold side heat exchanger 4526 comprise a surface coating that reduces adhesion force and allows drops of condensation to flow off and down to the condensation outlet 4535.
[0095] In the implementation of
[0096] In implementations, as shown in the schematic side view cross section of a closed air loop 4320 in
[0097] As shown in
[0098] As will be described subsequently in detail with regard to the schematic controls diagram of
[0099] Turning now to lint mitigation in the closed air loop 4230, as depicted in at least
[0100] As shown in
[0101] In implementations, as shown in
[0102] As shown in the full assembly view of
TABLE-US-00001 TABLE A Example mesh dimensions Size Opening Size Open Area Wire Diameter 16 16 0.045 (1143 m) 51% 0.018 18 18 0.039 (990.6 m) 48% 0.017 28 28 0.0257 (652.78 m) 52% 0.01 40 40 0.015 (381 m) 36% 0.01 150 150 0.0041 (104.14 m) 38% 0.0026 250 250 0.0024 (60.96 m) 36% 0.0016
[0103] For example, in implementations, the upstream mesh filter 4915a comprises a less dense mesh 4920a comprising a grid having openings in a range of between about 350 m to 1150 m and the downstream mesh filter 4915b comprises a relatively denser mesh 4920b comprising a grid having openings in a range of between about 50 m to 110 m. In implementations, the upstream mesh filter 4915a comprises a less dense mesh 4920a comprising a 4040 grid having openings of about 381 m and the downstream mesh filter 4915b comprises a relatively denser mesh 4920b comprising a 150150 grid having openings of about 104 m.
[0104] The two or more mesh filters 4915a-b are spaced apart within the filter assembly 4900 thereby delineating volumes on either side of each of the mesh filters. For example, as shown in the implementation of
[0105] In implementations, as shown in
[0106] In implementations, as shown in
[0107] In implementations, the collective channel 4947 is removable from the housing 4905 for at least one of servicing, cleaning, and replacement. The collective channel 4947 further comprises a gasket disposed between a mating rim of the channel 4947 and the housing for an airtight, watertight seal. Additionally or alternatively, in implementations, as shown in
[0108] In implementations, the three or more drain holes 4945a-c through which lint laden fluid enters the collective channel 4947 are round. In implementations, they are oval shaped. Additionally or alternatively, in implementations, the three or more drain holes are oblong. Each one of the three or more drain holes 4945a-c aligns with the three or more volumes 4922a-c partitioned by the two or more mesh filters 4915a-b.
[0109] In implementations, the three or more drain holes 4945 drain into the collective channel 4947 configured to route the effluent to a water treatment system for cleaning and recycling for reuse of the liquid component by one or more of the combination washing and drying robots 4000, 4000a-n. The lint laden water can be output to and treated by a water treatment system 4048 (
[0110] In implementations, as shown in
[0111] In implementations, the collective drain outlet 4535 has a diameter between about 0.5 inch to 4 inches. In implementations, the collective drain outlet 4535 has a diameter of between about 0.75 inch or greater. Additionally, in implementations, the filter assembly 4900 comprises one or more additional nozzles (not shown) configured to spray liquid at at least one of a lower wall portion adjacent the outlet 4535 and the outlet 4535 to facilitate at least one of the removal and de-clumping of any lint 4907 rinsed from the two or more mesh filters 4915a-b. Additionally or alternatively, in implementations, periodically (e.g., at a rate of between about 10-30 minutes, e.g., mid-cycle and at the end of the drying cycle, e.g., one third of the way through a drying cycle and two thirds of the way through the drying cycle, etc.) throughout the drying process, the fan 4830 will shut off and stop the airflow 4910 for a pause ranging between about 30 seconds to two minutes to enable any moisture in the cold side heat exchanger 4526 to condense and fall through the exhaust duct 4325 near the outlet end 4928 of the filter housing 4905. Simultaneously, the two or more spray nozzles 4935 can spray rinse liquid on the two or more mesh filters 4915a-b. This lessens the amount of lint 4907 accumulating between rinses and ensures maximum fluid flow through the collective drain outlet 4535 to assist with preventing the rinsed off lint from clogging the drain outlet 4535. Additionally, this intermittent process prevents pooling near the one or more drain holes 4945a-c.
[0112] In implementations, as shown in
[0113] In implementations, a spray of liquid 4940a-b is at least one of flat fan shaped and conical shaped. As shown in
[0114] As shown in
[0115] In implementations, as shown in
[0116] In implementations, as shown in
[0117] As shown in
[0118] In implementations, as shown in the controls schematic of
[0119] Additionally or alternatively, in implementations, the at least one controller 205, 4005 is configured to actuate the at least two spray nozzles 4935a-b at regular intervals, shutting down the fan 4830 and pausing airflow during a rinse burst so that fluid is not introduced into the airflow 4910. In implementations, the at least two spray nozzles 4935a-b eject two or more bursts of rinse liquid throughout a drying cycle. In implementations, the at least two spray nozzles 4935a-b eject bursts of spray at time intervals in a range of between about every 9-15 minutes during a drying cycle and at the end of a drying cycle, with each burst (e.g., spray time interval) lasting in a range of between about 5-10 seconds. In implementations, the at least two spray nozzles eject a total maximum volume in a range of 5000-7000 cubic centimeters throughout the duration of a complete drying cycle and approximately between about 200-400 cubic centimeters combined during each rinse burst. In implementations, the at least one controller 205, 4005 is configured to delay restarting the fan for a period of between about 10-30 seconds following a rinse burst to allow water to drain from the housing 4905 before reintroducing airflow therethrough.
[0120] Additionally or alternatively, in implementations, each duration of a spray burst is comprised of 10-20 pulses of spray (e.g., 10-20 pulses of spray over a period of between 5-10 seconds). During a pulse, a spray nozzle 4935, 4935a-b opens for 0.5 seconds and then closes. Because force of spray diminishes over time the longer a control valve of a spray nozzle 4935, 4935a-b remains open, pulsing produces a longer period of maximum force impinging a spray 4940 of fluid upon a mesh filter 4915, 4915a-b thereby more effectively facilitating lint removal. Pulsing sprays 4940 of rinse fluid (e.g., water) uses less volume than spraying continuously and has the advantage of eliminating or reducing puddling in the drain outlet 4535 and/or the low point of the tilted housing 4905.
[0121] Additionally, in implementations, the lint filter assembly 4900 further comprises two or more air nozzles (not shown) configured to provide air that is at least one of dry and heated to the at least two mesh filters 4915a-b to dry them with bursts of air following rinsing. Drying the at least two mesh filters 4915a-b prevents lint from sticking to the a wet mesh and clogging it more quickly to block airflow. Drying the at least two mesh filters 4915a-b also prevents the addition of humidity into the process air airflow 4910 exiting the lint filter assembly 4900. In implementations, the at least one controller can actuate the nozzles periodically to provide bursts of air in a range of between about every 9-15 minutes. In implementations, the at least two spray nozzles 4935a-b are configured alternately to spray fluid and direct airflow toward the at least two 4915a-b mesh filters. In implementation, the two or more air nozzles are in addition to the at least two spray nozzles 4935a-b and similarly constructed, angled, and mounted within the housing. 4905.
[0122] In implementations, the drain outlet 4535 is in fluid communication with a trap (e.g., a J-trap) to prevent any disruption of airflow through the housing 4905. Additionally, in implementations, the trap is configured to be filled with water during airflow to prevent air from entering the drain outlet 4535. Alternatively, in implementations, the three or more drain holes 4945a-c are selectively sealed, and the at least one controller 205, 4005 is configured to instruct an actuator 4919a-n of one or more selectively movable valves (not shown) to expose the three or more drain holes 4945a-c to drain a combined spray liquid and lint solution. In implementations, the combined spray liquid and lint solution drains into a collective drain outlet 4535 disposed through at or adjacent a lowest point of the housing 4905 or drains first into a collective conduit 4947 (e.g., a channel, a trough, a drainpipe, etc.) in fluid communication with the three or more selectively sealed drains holes 4925a-c. In implementations, the one or more selectively movable valves comprise three or more valves, each one of which is aligned with the three or more selectively sealed drain holes 4945a-c such that the drains are intermittently uncovered to drain effluent and otherwise sealed to prevent any disruption of airflow through the housing 4905.
[0123] Additionally, in implementations, the at least one controller 205, 4005 is configured to rinse the collective drain outlet 4535 with additional water routed from at least one of process water and condensation routed from a cold side heat exchanger 4526 disposed in line with the closed air loop downstream from the filter assembly 4900. In implementations, at least one of the centralized controller 205 and a local controller 4005 is configured to instruct a rinse actuator 4417 of the system to periodically deliver process water to the fins of the cold side heat exchanger 4526 to remove accumulated lint. The lint laden water can be output to and treated by the water treatment system 4048 to remove lint and other contaminants as low volume solid waste and the water reused as process water. Additionally or alternatively, in implementations, each cold side heat exchanger 4526 can be augmented with a cold water mist. Incoming water directly or indirectly via the circulating fluid cooled by the heat pump 4800 may be sprayed or atomized into the exhaust air stream in the exhaust duct 4325. The mist cools the exhaust air and also encourages condensation by nucleating water droplets in the humid exhaust air. Lint is trapped in condensate and drains away through the condensate outlet 4535. The linty condensate would then be processed by the water recycling system to remove lint, and the cleaned and sanitized water recirculated to either the mist generator or the washers for a wash cycle.
[0124] Turning now to
[0125] Turning now to
[0126] In implementations, the filter assembly 4900 comprises an annular seal 4930 disposed about an airflow outlet 4928 of the housing 4905 configured to receive thereon a rim 4916 about an opening of the mesh basket filter 4915 to form an impervious face seal thereon. The mesh basket filter 4915 is configured to move bidirectionally along the longitudinal axis LA to form a face seal impervious to lint in the presence of an airflow.
[0127] In implementations, the filter assembly 4900 comprises at least one spray nozzle (not shown) disposed at least one of within and through the housing 4905 configured to deliver a spray of rinse liquid (not shown) covering a length of the mesh basket filter 4915. In implementations, the mesh basket filter 4915 is configured to spring apart from the annular seal 4930 and rotate about the axle 4925 in an absence of a force F.sub.A imparted by the airflow 4910 (e.g., when the fan 4830 is turned off and airflow has stopped flowing through the housing 4905). The mesh basket filter 4915 is configured to spin (e.g., rotate about the longitudinal axis LA) under a force applied by the spray of rinse liquid. In implementations, an impingement area of the spray of rinse liquid on the mesh basket filter 4915 is offset from a vertical centerline (e.g., longitudinal axis LA) of the mesh basket filter 4915. In implementations, the at least one spray nozzle is disposed with an interior cavity of the mesh basket filter 4915, and the spray of rinse liquid therefore is applied from a non-linted side of the mesh basket filter 4915. In implementations, the at least one spray nozzle and associated fluid conduit is disposed through the housing 4905 at a height above the mesh basket filter 4915. In implementations, the mesh basket filter 4915 comprises a shape that is at least one of conical and cylindrical. In implementations, the mesh basket filter 4915 comprises a truncated cone shape. Cylindrical filters are easy to manufacture, and easy to clean because of the uniformity of shape and distance from a spray nozzle. Conical lint filters present less disruption to the air flow path, especially when partially clogged with lint, and therefore present more efficient utilization of the mesh surface.
[0128] Referring now to
[0129] In implementations, the method 1100 is configured to be executed autonomously by the at least one controller 4005, 205. As previously described with regard to implementations, one or more controllers (e.g., the controller 4005, remote terminal controller 205) is configured to be in operative communication with one or more sensors 4705, 4710, 4715, 4720, 4725, 4730, 4060 disposed at one or more locations comprising at least one of the air inlet 4315, 4315 of each one of the washing and drying machines 4000a-n, the air outlet 4260 of each one of the washing and drying machine, the filter assembly 4900 and the inlet of the at least one heat pump 4800. The one or more sensors 4705, 4710, 4715, 4720, 4725, 4730, 4060 are configured to measure at least one air characteristic such as temperature, air flow velocity, air flow volume, moisture content, and air pressure, and output a signal indicative of at least one air characteristic to the at least one controller 4005a-n, 205.
[0130] In implementations, the method 1100 comprises S1105 receiving at at least one controller one or more sensor signals indicative of an airflow velocity within the closed loop, and S1110 determining, based on at least one of the received one or more sensor signals and a time interval, lint filter cleaning is required. The method 1100 comprises S1115 instructing, based on a determination that lint filter cleaning is required, a fan to shut off airflow within the closed air loop and S1120 instructing, following shutting off the fan, two or more spray nozzles to spray two or more mesh filters affixed to a rotatable axle extending through the central axis of an elongated outer housing of the lint filter. The method 1100 comprises S1125 instructing the fan to restart pulling airflow through the closed air loop following a period of spraying.
[0131] The method 1100 further includes S1130 determining whether the drying cycle has ended based on a received signal (e.g., motor controls) and/or monitoring time elapsed and S1135 instructing the fan to shut off airflow with the closed air loop before S1140 instructing the two or more spray nozzle 4935a-b to spray the two or more mesh filters.
[0132] In implementations, the method 1100 comprises instructing the two or more spray nozzles 4935a-b to spray fluid on the two or more mesh filters 4915a-b when airflow is reduced by a range of between about 5-15% of an airflow velocity as measured at a start of a drying cycle.
[0133] In implementations, the at least one controller 4005, 205 is configured to instruct the fan to stop airflow 4910 and instruct the at least two spray nozzles 4935 to spray repeatedly at a time interval of between about 9-15 min throughout a drying cycle. Each incident of spraying imparts a range of 200-300 cubic centimeters of total fluid on the two or more mesh filters 4915a-b and each time interval for spraying lasts in a range of between about 5-10 seconds.
[0134] In implementations, the axle 4925 is retained at both ends by rotatable linear bearings 4926a-b disposed in hubs of hub and spoke assemblies 4967a-b radially attached to the outer housing 4905 and the axle 4925 is spring loaded at one end such that that under application of airflow force FA, the axle linearly translates and two or more mesh filters 4915a-b affixed thereto compress against annular flanges 4930 mounted to an interior of the outer housing 4905 to form a reversible seal. As previously described with regard to implementations, the outer housing 4905 comprises three or more drain holes disposed through a bottom of the outer housing, the three or more holes 4945a-c being configured to drain into a collection channel 4947 disposed along a bottom of the housing to drain collected lint laded fluid into a drain outlet 4535.
[0135] As previously introduced, the system 400 comprises at least one controller (e.g., controller 205, controller 4005) in operative communication with the one or more air sensors 4705, 4710, 4715, 4720, 4725, 4730, 4060, the heat exchangers 4526, 4527, and the heat pump 4800. In implementations, the at least one controller 205, 4005 is configured to receive the output signal of the one or more air sensors and analyze the at least one air characteristic associated with the one or more air sensors. In implementations, the at least one air characteristic comprises one or more of air temperature, air flow rate, and air humidity. The controller is configured to determine, based on the analysis, whether the at least one air characteristic is within a range of values for at least one of air temperature, air flow, and air humidity, and adjust, in response to determining that at least one air characteristic is not within a range of values, one or more controls for at least one of air temperature, air flow, and air humidity at the one or more locations of the system. The one or more controls can vary depending on measured parameters and/or their rate of change at various stages of a drying cycle. Additionally or alternatively, in response to determining at least one air characteristic is not within a range of values, the at least one controller 205, 4005 is configured to instruct an actuator of one or more spray nozzles to automatically clean the lint filter 4900, which will be described subsequently with regard to implementations.
[0136] Returning to
[0137] The local controller 4005 of each washing and drying robot 4000, is in operative communication with the at least one heater drive 4410, at least one tilt drive 4415, and at least one spin motor drive 4420 of each one of the plurality of autonomous washing and drying machines 4000a-n. Additionally, the controller 4005 is in operative communication with a valve and/or pump actuator 4418 for controlling the application of heated fluid from the heat pump 4800 to the respective heated side heat exchanger 4527, a valve and/or pump actuator 4419 for controlling the application of cooling fluid from the heat pump 4800 to the respective cold side heat exchanger 4526, a fan drive 4416, at least one drive of the heat pump, one or more air sensors, a rinse spray actuator 4917 of the lint filter assembly 4900, and a drain valve actuator 4914 of the lint filter assembly 4900.
[0138] At least one controller 205, 4005 is configured to receive the output signal of the one or more air sensors 4705, 4710, 4715, 4720, 4725, and 4730 disposed at one or more dedicated locations within the closed air loop 4320. Based on the received output signal(s), the controller 4005 analyzes the at least one air characteristic associated with the one or more air sensors, and determines, based on the analysis, whether the at least one air characteristic at the associated location within the air loop 4320 is within a range of values for at least one of air temperature, air flow, and air humidity. The at least one controller 205, 4005 is configured to adjust autonomously, in response to determining at least one air characteristic is not within a range of target values, one or more controls (e.g., drivers) for at least one of air temperature, air flow, and air humidity at the one or more locations of the system 400. Additionally or alternatively, in implementations, the centralized controller 205 is in operative communication with the local controller 4005 and the centralized controller 205 is configured to perform some or all of the above described controls functions.
[0139] Each washing and drying robot 4000, 4000a-n in the cluster 4002 is in operative communication with at least one of their respective controllers 4005a-n and the at least one centralized controller 205 (e.g., CPU 205,
[0140] Taking
[0141] The at least one controller 4005, 205 can control the air flow rate based on temperature and humidity of the exhaust air. In implementations, as shown in
[0142] As shown in
[0143] Although the preceding implementations comprise a centralized heat pump and centralized heating and cooling systems for use with a plurality of combination washing and drying robots 4000a-n, the centralized heat pump and centralized heating and cooling systems can be configured for use with a plurality of standalone drying machines. Additionally or alternatively, the plurality of standalone drying machines can be manually operated machines rather than autonomous robots.
[0144] In implementations, any of the preceding lint filter assemblies for use with a plurality of tilting combination washing and drying robots 4000a-n can be configured for use with a plurality of stationary, non-tilting combination washing and drying machines. Additionally or alternatively, the plurality of stationary, non-tilting combination washing and drying machines can be manually operated machines rather than autonomous robots.
[0145] Although the closed air loop 4320 is described herein with regard to implementations as being dedicated to a single washing and drying robot, in alternative implementations, the closed air loop could be shared among a drum pair or small drum cluster. For example, the heat pump 4800 closed air loop 4320 could be serving one drum while a paired drum is washing. In implementations, a closed air loop can be local to a single washing and drying robot 4000, a plurality of washing and drying robots 4000a-n, and a cluster 4002 of washing and drying robots.
[0146] All of the methods and tasks described herein may be performed and fully automated by a computer system. The computer system may, in some cases, include multiple distinct computers or computing devices (e.g., physical servers, workstations, storage arrays, etc.) that communicate and interoperate over a network to perform the described functions. Each such computing device typically includes a processor (or multiple processors or circuitry or collection of circuits, e.g. a module) that executes program instructions or modules stored in a memory or other non-transitory computer-readable storage medium. The various functions disclosed herein may be embodied in such program instructions, although some or all of the disclosed functions may alternatively be implemented in application-specific circuitry (e.g., ASICs or FPGAs) of the computer system. Where the computer system includes multiple computing devices, these devices may, but need not, be co-located. The results of the disclosed methods and tasks may be persistently stored by transforming physical storage devices, such as solid-state memory chips and/or magnetic disks, into a different state.
[0147] Although the subject matter contained herein has been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that the present disclosure is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present disclosure contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.
[0148] Other examples are within the scope and spirit of the description and claims. Additionally, certain functions described above can be implemented using software, hardware, firmware, hardwiring, or combinations of any of these. Features implementing functions can also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations.