Technical Field
[0001] The present invention relates to a laundry processing apparatus for washing, spin-drying
and/or drying laundry.
Background Art
[0002] A washing machine which supplies steam to sterilize laundry has been developed (c.f.
[0003] Patent Document 1). The washing machine in Patent Document 1 includes a steam generator
which uses a heater immersed in water to generate steam. The steam leaks from the
steam generator to a storage tub which stores laundry. Consequently, the storage tub
is filled with the steam.
[0004] The washing machine of Patent Document 1 includes a housing which stores the storage
tub and the steam generator. The steam generator is attached directly to an inner
surface of the housing. Therefore, the housing becomes a high temperature. A user
may touch the housing while the user operates the washing machine.
Summary of Invention
[0006] It is an object of the present invention to provide a laundry processing apparatus
with a structure to cause little heat transfer to a housing.
[0007] The laundry processing apparatus according to one aspect of the present invention
includes: a storage tub configured to store laundry; a steam generation portion including
a steam generator configured to generate steam which is sprayed into the storage tub;
and a housing which stores the storage tub and the steam generator. The steam generator
is held apart from the housing.
[0008] The laundry processing apparatus according to the present invention may cause little
heat transfer to the housing.
[0009] The objects, features and advantages of the present invention will become more evident
from the following detailed description and the accompanying drawings.
Brief Description of Drawings
[0010]
Fig. 1 is a schematic vertical cross-sectional view of a washing machine exemplified
as the laundry processing apparatus according to the first embodiment.
Fig. 2 is a schematic transparent perspective view of the washing machine shown in
Fig. 1.
Fig. 3 is a schematic perspective view of a steam supply mechanism stored in a housing
of the washing machine shown in Fig. 1.
Fig. 4A is a schematic perspective view of a steam generation portion of the steam
supply mechanism shown in Fig. 3.
Fig. 4B is a schematic perspective view of the steam generation portion of the steam
supply mechanism shown in Fig. 3.
Fig. 5 is a schematic perspective view of an attachment portion for connecting a lid
of the steam generation portion shown in Figs. 4A and 4B to the housing.
Fig. 6 is a schematic perspective view of the steam generation portion, which is fixed
to a housing top wall by the attachment portion shown in Fig. 5.
Fig. 7 is a schematic perspective view of a steam generation portion which is connected
to first and second reinforcing frames.
Fig. 8A is a schematic perspective view of a steam generator of the steam generation
portion shown in Figs. 4A and 4B.
Fig. 8B is a schematic perspective view of the steam generator of the steam generation
portion shown in Figs. 4A and 4B.
Fig. 9 is a schematic perspective view of a main piece of the steam generator shown
in Figs. 8A and 8B.
Fig. 10 is a schematic exploded perspective view of the steam generator shown in Figs.
8A and 8B.
Fig. 11 is a schematic perspective view of a lid piece of the steam generator shown
in Fig. 10.
Fig. 12 is a schematic plan view of the main piece shown in Fig. 9.
Fig. 13 is a schematic view of a water supply mechanism of the steam supply mechanism
shown in Fig. 3.
Fig. 14 is a schematic rear view of a front portion of a storage tub in the washing
machine shown in Fig. 1.
Fig. 15 is a graph schematically showing a relationship between intermittent operation
of a pump of the water supply mechanism shown in Fig 13 and a temperature inside a
chamber space.
Fig. 16 is a graph schematically showing a change in a temperature of the water supplied
to a water tub of the washing machine shown in Fig. 1.
Fig. 17A is a schematic timing chart showing a timing of steam supply during a spin-drying
process.
Fig. 17B is a schematic timing chart showing a timing of steam supply during the spin-drying
process.
Fig. 17C is a schematic timing chart showing a timing of steam supply during the spin-drying
process.
Fig. 18 is a block diagram schematically showing control for a door in response to
a temperature of the steam generator shown in Fig. 8B.
Fig. 19 is a schematic exploded perspective view of a steam generator used in a washing
machine exemplified as the laundry processing apparatus according to the second embodiment.
Fig. 20 is a schematic perspective view of the steam generator shown in Fig. 19.
Description of Embodiments
[0011] Washing machines exemplified as the laundry processing apparatus are described below
with reference to the drawings. Directional terms such as "top", "bottom", "left"
and "right" which are used in the following description are intended to clarify the
explanation, and do not in any way limit principles of the laundry processing apparatus.
The principles of the laundry processing apparatus may be applied to apparatuses (washer/drier)
having functions for washing and drying laundry, and apparatuses (drier) which dry
laundry.
<First Embodiment>
<Washing Machine>
[0012] Fig. 1 is a schematic vertical cross-sectional view of a washing machine 100 according
to the first embodiment. The washing machine 100 is described with reference to Fig.
1.
[0013] The washing machine 100 includes a housing 110 and a storage tub 200, which stores
laundry in the housing 110. The storage tub 200 includes a rotary drum 210 having
a substantially cylindrical peripheral wall 211, which surrounds the rotational axis
RX, and a water tub 220, which stores the rotary drum 210. The storage tub 200 is
substantially cylindrical so that the storage tub 200 surrounds the rotational axis
RX. In the present embodiment, the central axis is exemplified by the rotational axis
RX.
[0014] The housing 110 includes a front wall 111, which is provided with a feed opening
119 for feeding laundry into the storage tub 200, and a rear wall 112 opposite to
the front wall 111. The housing 110 includes a housing top wall 113, which substantially
horizontally extends between the front and rear walls 111, 112, and a housing bottom
wall 114 opposite to the housing top wall 113. The rotary drum 210 and the water tub
220 are provided with openings 213, 227, respectively, in communication with the feed
opening 119 formed in the front wall 111.
[0015] The washing machine 100 includes a door 120 which is attached to the front wall 111.
The door 120 rotates between a closed position, at which the door 120 closes the feed
opening 119 formed in the front wall 111, and an open position, at which the door
120 opens the feed opening 119. A user may rotate the door 120 towards the open position
to feed laundry into the storage tub 200 through the feed opening 119 of the front
wall 111. The user may then move the door 120 towards the closed position to wash
the laundry in the washing machine 100. The door 120 shown in Fig. 1 is situated at
the closed position.
[0016] The rotary drum 210 rotates about the rotational axis RX which extends between the
front and rear walls 111, 112. The laundry fed into the storage tub 200 moves inside
the rotary drum 210 due to rotation of the rotary drum 210, and is subjected to various
processes such as washing, rinsing and/or spin-drying.
[0017] The rotary drum 210 includes a bottom wall 212 facing the door 120 at the closed
position. The water tub 220 includes a bottom portion 221, which surrounds the bottom
wall 212 of the rotary drum 210 and a part of the peripheral wall 211, and a front
portion 222, which surrounds the other portion of the peripheral wall 211 of the rotary
drum 210 between the bottom portion 221 and the door 120.
[0018] The storage tub 200 includes a rotary shaft 230 which is attached to the bottom wall
212 of the rotary drum 210. The rotary shaft 230 extends toward the rear wall 112
along the rotational axis RX. The rotary shaft 230 extends through the bottom portion
221 of the water tub 220 and appears between the water tub 220 and the rear wall 112.
[0019] The washing machine 100 further includes a motor 231 situated below the water tub
220, a pulley 232 attached to the rotary shaft 230 appearing outside the water tub
220, and a belt 233 for transmitting drive power of the motor 231 to the pulley 232.
When the motor 231 operates, the drive power of the motor 231 is transmitted to the
belt 233, the pulley 232 and the rotary shaft 230. Accordingly, the rotary drum 210
rotates inside the water tub 220.
[0020] The washing machine 100 further includes a packing structure 130 situated between
the front portion 222 of the water tub 220 and the door 120. The door 120 compresses
the packing structure 130 when the door 120 is rotated to the closed position. Accordingly,
the packing structure 130 forms a water-tight sealing structure between the door 120
and the front portion 222.
[0021] The washing machine 100 further includes a water supply port 140, which is connected
to a faucet (not shown), and a distribution portion 141 for distributing water supplied
through the water supply port 140. The water supply port 140 appears on the housing
top wall 113 situated above the storage tub 200. The distribution portion 141 is situated
between the housing top wall 113 and the storage tub 200. In the present embodiment,
the top wall is exemplified by the housing top wall 113.
[0022] The washing machine 100 further includes a detergent storage portion (not shown),
in which detergent is stored, and a steam supply mechanism 300 (described below),
which sprays steam into the storage tub 200. The distribution portion 141 includes
water supply valves for supplying water selectively to the storage tub 200, the detergent
storage portion and the steam supply mechanism 300. Fig. 1 does not show water supply
paths to the storage tub 200 and the detergent storage portion. Technologies used
in a conventional washing machine may be suitably used for the water supply to the
storage tub 200 and the detergent storage portion.
<Steam Supply Mechanism>
[0023] Fig. 2 is a schematic transparent perspective view of the washing machine 100. Fig.
3 is a schematic perspective view of the steam supply mechanism 300 which is stored
in the housing 110. The housing 110 is indicated by dotted lines in Figs. 2 and 3.
The storage tub 200 is not shown in Fig. 3. The arrows in Fig. 3 schematically show
a water supply path. The steam supply mechanism 300 is described with reference to
Figs. 1 to 3.
[0024] The steam supply mechanism 300 includes a water supply valve 310, which is used as
a part of the distribution portion 141, and a reservoir tank 320, which is situated
below the storage tub 200. The water supply valve 310 is used to control water supply
to the reservoir tank 320. When the water supply valve 310 is opened, water is supplied
from the water supply port 140 to the reservoir tank 320. The water supply to the
reservoir tank 320 stops when the water supply valve 310 is closed.
[0025] The steam supply mechanism 300 further includes a pump 330, which is attached to
the reservoir tank 320, and a steam generation portion 400, which receives water discharged
from the pump 330. The pump 330 carries out an intermittent or continuous water supply
operation to the steam generation portion 400. During the intermittent water supply
operation, the pump 330 supplies an appropriately adjusted amount of water to the
steam generation portion 400 to cause instantaneous steam generation. If the pump
330 supplies water continuously to the steam generation portion 400, impurities (scale)
contained in the water used to generate steam are flushed from the steam generation
portion 400.
[0026] The steam generation portion 400 is heated to a high temperature in order to generate
steam which is sprayed into the storage tub 200. The storage tub 200 and the steam
generation portion 400 are appropriately isolated from a user since the housing 110
stores the storage tub 200, which contains the rotary drum 210 configured to perform
rotary movement, and a steam generation portion 400, which is heated to a high temperature.
Consequently, the user may safely operate the washing machine 100.
[0027] As shown in Fig. 2, the steam supply mechanism 300 further includes a steam conduit
340 which extends downwards from the steam generation portion 400. As shown in Fig.
1, the front portion 222 of the water tub 220 includes a peripheral wall portion 223,
which surrounds the peripheral wall 211 of the rotary drum 210, and an annular portion
224, which forms a water-tight sealing structure in conjunction with the packing structure
130. The steam conduit 340 is connected to the peripheral wall portion 223. Steam
generated by the steam generation portion 400 is supplied to the storage tub 200 through
the steam conduit 340. It is preferable that the steam conduit 340 may be bellows
configured to transmit little vibration to the steam generation portion 400 under
rotation of the storage tub 200.
[0028] Figs. 4A and 4B are schematic perspective views of the steam generation portion 400.
The steam generation portion 400 is described with reference to Figs. 2 to 4B.
[0029] The steam generation portion 400 includes a substantially rectangular box-shaped
case 410, and a steam generator 420 which is surrounded by the case 410. The case
410 includes a container 411 for storing the steam generator 420, and a lid 412 which
closes the container 411. In the present embodiment, the case 410 is formed from thermally-resistant
resin. The term "thermally-resistant" means that there is no remarkable change in
characteristics such as thermal deformation under heating by the heater 425.
[0030] The steam generator 420 is connected to the pump 330 by a connecting pipe 421 and
a tube (not shown). The steam generator 420 is connected to the steam conduit 340
by an exhaust pipe 422. The container 411 includes a bottom wall portion 414 provided
with an opening 413. The connecting pipe 421 and the exhaust pipe 422 project downwards
through the opening 413.
[0031] The steam generator 420 is situated above the reservoir tank 320 since the pump 330
forcibly supplies water from the reservoir tank 320 to the steam generator 420 inside
the steam generation portion 400. If water is supplied from the reservoir tank 320
to the steam generator 420 without the pump 330, the water in the reservoir tank 320
has to be supplied to the steam generator 420 by the action of gravity. In this case,
the steam generator 420 has to be situated below the reservoir tank 320.
[0032] In the present embodiment, water supply from the reservoir tank 320 to the steam
generator 420 is carried out by the pump 330. Since the water is supplied from the
reservoir tank 320 to the steam generator 420 forcibly by a pressure of the pump 330,
there are few restrictions on a vertical relationship about an arrangement design
of the steam generator 420 and the reservoir tank 320. With increased freedom in a
layout design of the reservoir tank 320 and the steam generator 420, an internal space
of the housing 110 is used efficiently.
[0033] The pump 330 may appropriately supply water from the reservoir tank 320 to the steam
generator 420 although the steam generator 420 is situated above the reservoir tank
320 as shown in Fig. 2.
[0034] If water flows accidentally into a steam generator because of unexpected failures
or other problems, steam is generated unnecessarily. In the present embodiment, the
reservoir tank 320 is situated below the steam generator 420 due to usage of the pump
330. Even if the pump 330 is stopped by failures so that water supply to the steam
generator 420 becomes uncontrollable, water remaining inside a hose connecting the
reservoir tank 320/the pump 330 to the steam generator 420 does not flow into the
steam generator 420 unnecessarily. Without the pump 330, the steam generator 420 has
to be situated below the reservoir tank 320 as described above. For example, if there
are failures of control parts such as on-off valves for controlling water supply from
the reservoir tank 320 to the steam generator 420, water supply to the steam generator
420 becomes out-of-control so that water is supplied unnecessarily from the reservoir
tank 320 to the steam generator 420 because of the action of gravity. In the present
embodiment, unnecessary water supply to the steam generator 420 and the reservoir
tank 320 is less likely to occur due to usage of the pump 330.
[0035] As shown in Fig. 2, the housing 110 includes a right wall 115 standing between the
front and rear walls 111, 112, and a left wall 116 opposite to the right wall 115.
The rotational axis RX extends along the right and left walls 115, 116 (i.e. the rotational
axis RX extends substantially in parallel to the right and left walls 115, 116).
[0036] Single-dotted lines are used in Fig. 2 to depict a vertical plane VP which passes
through the rotational axis RX. The reservoir tank 320 is situated in a space on the
bottom left of the housing 110 (a space between the vertical plane VP and the left
wall 116). The steam generator 420 is situated in a space on the top right of the
housing 110 (a space between the vertical plane VP and the right wall 115). The steam
generator 420 and the reservoir tank 320 are arranged at substantially symmetrical
positions with respect to the central axis of the storage tub 200 (the rotational
axis RX). The reservoir tank 320 is situated near the rear wall 112 whereas the steam
generator 420 is closer to the front wall 111 than the rear wall 112.
[0037] With regard to a general washing machine, a detergent storage portion in which detergent
is stored is situated in one of the left and right portions of an upper front portion
of the housing. A space outside the substantially cylindrical storage tub 200 except
for a position occupied by the detergent portion is used efficiently for arranging
each of the reservoir tank 320 and the steam generator 420. For example, if the detergent
storage portion is situated in a left portion of the upper front portion of the housing
110, the reservoir tank 320 is situated at a rear position in a left lower portion
of the housing 110 as shown in Fig. 2. In this case, if the steam generator 420 is
situated at a front position in an upper right portion of the housing 110, an internal
space between an inner surface of the substantially rectangular housing 110 and an
outer surface of the substantially cylindrical storage tub 200 is utilized efficiently
for arranging the reservoir tank 320 and the steam generator 420. Consequently, the
reservoir tank 320 and the steam generator 420 may be maximally sized in an acceptable
space.
[0038] The reservoir tank 320 may be situated at a position substantially symmetrical with
respect to the detergent storage portion about the central axis (rotational axis RX)
of the storage tub 200 whereas the steam generator 420 may be arranged at a substantially
symmetrical position to the reservoir tank 320 with respect to the horizontal plane
HP containing the rotational axis RX of the storage tub 200 if the detergent storage
portion is arranged at the aforementioned position. Like the aforementioned layout
design, the internal space of the housing 110 is utilized efficiently.
[0039] If the detergent storage portion is arranged at the aforementioned position, the
reservoir tank 320 may be situated below the detergent storage portion. In this case,
the steam generator 420 may be situated above the reservoir tank 320. Accordingly,
the steam generator 420 may be arranged in a substantially symmetrical position to
the reservoir tank 320 with respect to the vertical plane containing the rotational
axis RX of the storage tub 200. Accordingly, like the aforementioned layout design,
the internal space of the housing 110 is utilized efficiently.
[0040] If the rotational axis RX of the storage tub 200 is inclined in the front/rear direction
of the housing 110 (e.g. if the rotational axis RX of the rotary drum 210 is inclined
upwards from the rear wall 112 towards the front wall 111), the reservoir tank 320
and the steam generator 420 may be arranged at substantially symmetrical positions
with respect to the rotational axis RX of the storage tub 200 or the horizontal plane
HP containing the rotational axis RX. If the reservoir tank 320 and the steam generator
420 are arranged at substantially symmetrical positions with respect to the vertical
plane passing through the approximate centre of the housing 110 in the front/rear
direction, an internal space between the inner surface of the housing 110 and the
outer surface of the storage tub 200 is utilized efficiently for arranging the reservoir
tank 320 and the steam generator 420.
<Attachment Structure to Housing>
[0041] Fig. 5 is a schematic perspective view of an attachment portion 150 which is attached
to the lid 412. The attachment portion 150 is described with reference to Figs. 3
and 5.
[0042] The lid 412 includes a substantially rectangular upper wall 415, a lid peripheral
wall 416, which extends downwards from the edges of the upper wall 415, and a projecting
piece 417, which projects forwards from the lid peripheral wall 416. The washing machine
100 further includes the attachment portion 150 which is attached to the lid 412.
The attachment portion 150 includes a first attachment piece 151, which is fixed to
the upper wall 415, and a second attachment piece 152, which is fixed to the projecting
piece 417. The first and second attachment pieces 151, 152 project upwards from the
lid 412. Like the case 410, the attachment portion 150 is formed from thermally-resistant
resin in the present embodiment.
[0043] The first attachment piece 151 includes a first connecting plate 153, which is connected
to the upper wall 415, a first upright plate 154, which projects upwards from the
first connecting plate 153, and a pair of first engagement pieces 155, which project
rightwards from the first upright plate 154. The second attachment piece 152 includes
a second connecting plate 156, which is connected to the projecting piece 417, a second
upright plate 157, which projects upwards from the second connecting plate 156, and
a second engagement piece 158, which projects forwards from the second upright plate
157.
[0044] Fig. 6 is a schematic perspective view of the steam generation portion 400 which
is fixed to the housing top wall 113 by the attachment portion 150. Attachment of
the steam generation portion 400 to the housing top wall 113 is described with reference
to Figs. 3 and 6.
[0045] As shown in Fig. 3, the housing 110 further includes a first reinforcing frame 117
situated along the upper edge of the right wall 115, and a second reinforcing frame
118 situated along the upper edge of the front wall 111. In the present embodiment,
the reinforcing frame is exemplified by the first and second reinforcing frames 117,
118.
[0046] As shown in Fig. 6, the reinforcing frame 117 is provided with openings 171. The
first engagement pieces 155 of the first attachment piece 151 are inserted into the
openings 171. Accordingly, the first attachment piece 151 is engaged with the first
reinforcing frame 117.
[0047] The first attachment piece 151 includes first fins 159 which are formed at the corner
between the first connecting plate 153 and the first upright plate 154. Since a large
part of the heat from the steam generation portion 400 is radiated from the first
fins 159, there is a small heat amount to be transmitted to the first reinforcing
frame 117 and the housing top wall 113.
[0048] The second reinforcing frame 118 is provided with an opening. As shown in Fig. 6,
the second engagement piece 158 of the second attachment piece 152 is inserted into
the opening of the second reinforcing frame 118. Consequently, the second attachment
piece 152 is engaged with the second reinforcing frame 118. Therefore, the steam generation
portion 400 is fixed to the housing top wall 113 by the first and second attachment
pieces 151, 152. The steam generation portion 400 is distant from the housing top
wall 113 due to the first and second upright plates 154, 157 which stand upward. Consequently,
there is an air layer between the lid 412 and the housing top wall 113. Therefore,
there is little heat transfer from the steam generation portion 400 to the housing
top wall 113.
[0049] The projecting piece 417 to which the second connecting plate 156 of the second attachment
piece 152 is connected includes second fins 418 which project downwards. Since a large
part of heat from the steam generation portion 400 is radiated from the second fins
418, there is a small heat amount to be transmitted to the second connecting plate
156. The second upright plate 157 is narrower than the second connecting plate 156.
Therefore, there is a small amount of heat transfer from the second connecting plate
156 to the second upright plate 157. Accordingly, there is a small heat amount to
be transmitted to the second reinforcing frame 118 and the housing top wall 113 through
the second upright plate 157.
[0050] Fig. 7 is a schematic perspective view of the steam generation portion 400 which
is connected to the first and second reinforcing frames 117, 118. The attachment of
the steam generation portion 400 is described with reference to Fig. 7.
[0051] In Fig. 7, the contour of the housing 110 is represented by a single-dotted line.
The first reinforcing frame 117 includes an outer edge 172 near the right wall 115,
which extends downwards from the housing top wall 113, and an inner edge 173, which
is more distant from the right wall 115 than the outer edge 172 is. The first reinforcing
frame 117 further includes a rib 174 which extends downwards from the inner edge 173.
The rib 174 is provided with the aforementioned openings 171. The first engagement
pieces 155 of the first attachment piece 151 are inserted into the openings 171 and
project towards the right wall 115. The first attachment piece 151 is connected along
the right edge of the lid 412. Therefore, the steam generation portion 400 is distant
appropriately from the right wall 115 of the housing 110 due to the first attachment
piece 151. Accordingly, there is little heat transfer from the steam generation portion
400 to the right wall 115. In the present embodiment, the side wall is exemplified
by the right wall 115.
[0052] The front wall 111 adjacent to the right wall 115 projects downwards from the housing
top wall 113. The second attachment piece 152 suspended from the second reinforcing
frame 118 bends in the opposite direction to the front wall 111 and is connected to
the steam generation portion 400. Therefore, the steam generation portion 400 is distant
appropriately from the front wall 111 of the housing 110 due to the second attachment
piece 152. Accordingly, the steam generation portion 400 is distant from the housing
110 and is held by the attachment portion 150.
<Steam Generator>
[0053] Figs. 8A and 8B are schematic perspective views of the steam generator 420. The steam
generator 420 is described with reference to Figs. 8A and 8B.
[0054] The steam generator 420 includes a substantially rectangular main piece 423, a lid
piece 424, which is situated above the main piece 423, and a linear heater 425, which
is situated on the main piece 423. In the present embodiment, the main piece 423 and
the lid piece 424 are made from aluminium. Consequently, the main piece 423 and the
lid piece 424 are heated appropriately by the heater 425.
[0055] The steam generator 420 further includes a thermistor 426. The thermistor 426 is
also attached to the main piece 423, in addition to the abovementioned connecting
pipe 421, exhaust pipe 422 and heater 425. The heater 425 is controlled by means of
the thermistor 426, on the basis of temperature information which is obtained by the
thermistor 426. Therefore, the main piece 423 and the lid piece 424 are kept substantially
at a certain temperature. Instead of the thermistor 426, a thermostat which controls
to turn on and off the heater 425 at a certain temperature may be used to obtain similar
effects.
[0056] Fig. 9 is a schematic perspective view of the main piece 423. The main piece 423
is described with reference to Figs. 8B and 9.
[0057] The main piece 423 includes a main piece lower surface 427, to which the connecting
pipe 421, the exhaust pipe 422 and the thermistor 426 are attached, a peripheral surface
428, to which the heater 425 is attached, and an upper surface 429 opposite to the
main piece lower surface 427. The main piece 423 further includes an outer chamber
wall 431, which stands from the upper surface 429 towards the lid piece 424 to define
a substantially triangular chamber space 430, and a substantially J-shaped inner chamber
wall 432, which defines a flow path of the steam in the chamber space 430.
[0058] Fig. 10 is a schematic exploded perspective view of the steam generator 420. Fig.
11 is a schematic perspective view of the lid piece 424. The steam generator 420 is
described with reference to Figs. 2, 3, 8B to 11.
[0059] The steam generator 420 includes a packing ring 433 which is attached to the main
piece 423 so as to surround the outer chamber wall 431. The packing ring 433 is made
from heat-resistant rubber.
[0060] The lid piece 424 includes a lower surface 434 facing the main piece 423 and an outer
shield wall 435 which has substantially the same shape as the outer chamber wall 431.
The lid piece 424 is pressed against the main piece 423. Accordingly, the outer shield
wall 435 compresses the packing ring 433 to keep the chamber space 430 airtight.
[0061] The main piece 423 is provided with an inflow port 437, through which water supplied
via the connecting pipe 421 flows into the chamber space 430. The inflow port 437
formed at substantially the centre of the chamber space 430 is surrounded by the inner
chamber wall 432. If the pump 330 supplies a prescribed amount of water to the steam
generator 420, the water is injected upwards via the connecting pipe 421 and the inflow
port 437. Consequently, the water hits the inner chamber wall 432, the upper surface
429 of the main piece 423, which is surrounded by the inner chamber wall 432, and/or
the lower surface 434 of the lid piece 424, which is situated above the inflow port
437. The steam generator 420 is heated by the heater 425 (e.g. to approximately 200°C)
so that the steam generator 420 has high thermal energy. The pump 330 which executes
intermittent water supply operation supplies a suitable amount of water for the thermal
energy of the steam generator 420 (e.g. approximately 2 cc every dosage). Therefore,
the water injected upwards from the inflow port 437 evaporates instantaneously. In
the present embodiment, the chamber is exemplified by the chamber space 430 which
is used to generate steam. The wall surface is exemplified by the inner chamber wall
432, the upper surface 429 of the main piece 423 surrounded by the inner chamber wall
432 and/or the lower surface 434 of the lid piece 424 situated above the inflow port
437 which the water supplied via the inflow port 437 hits.
[0062] Impurities contained in water supplied to the steam generator 420 may adhere or be
precipitated at water vaporization onto the wall surfaces which form the chamber space
430. Since an internal pressure of the chamber space 430 rises suddenly as a result
of the instantaneous evaporation of the water, the adhering or precipitated impurities
are easily discharged from the chamber space 430 by an action of a pressure caused
at the vaporization.
[0063] As shown in Fig. 2, the steam generator 420 is situated above the storage tub 200.
As described above, impurities contained in water, which is supplied to the steam
generator 420, may adhere or be precipitated at vaporization onto the wall surfaces
forming the chamber space 430 such as the outer chamber wall 431 of the main piece
423, the inner chamber wall 432, the upper surface 429 and the lower surface 434 of
the lid piece 424. Accumulation of the impurities worsens thermal conductivity between
the wall surfaces and the supplied water. Accordingly, less water evaporates. However,
if the steam generator 420 is situated above the storage tub 200, the adhering or
precipitated impurities are discharged or drop down below the steam generator 420
under a pressure at the vaporization and the action of gravity. Consequently, the
impurities are easily discharged from the chamber space 430 to the storage tub 200.
Accordingly, the accumulation of adhering or precipitated impurities inside the chamber
of the steam generator 420 is removed appropriately. Therefore, a resultant decline
from the accumulation of impurities is less likely to happen to vaporization capability.
[0064] Fig. 12 is a schematic plan view of the main piece 423. The main piece 423 is described
with reference to Figs. 8B and 12.
[0065] The heater 425 extends along a substantially U-shaped path inside the main piece
423. Therefore, the heater 425 surrounds the inflow port 437 to which the connecting
pipe 421 is connected. Consequently, the inner chamber wall 432 and the region surrounded
by the inner chamber wall 432 become the highest temperature in the chamber space
430. Therefore, the water injected through the inflow port 437 evaporates instantaneously.
[0066] Since the substantially J-shaped inner chamber wall 432 extends in the chamber space
430, which is defined by the outer chamber wall 431, the chamber space 430 draws a
whorl flow path. The main piece 423 is provided with an exhaust port 438 formed at
the terminal end of the flow path. Steam generated in the space surrounded by the
inner chamber wall 432 flows towards the exhaust port 438 with an internal pressure
rise in the chamber space 430. The exhaust pipe 422 is connected to the exhaust port
438. The steam arriving at the exhaust port 438 is discharged downward through the
exhaust pipe 422.
[0067] The heater 425 extends in a U-shape along the outer path of the whorl flow path.
Consequently, steam generated in the space surrounded by the inner chamber wall 432
flows towards the exhaust pipe 422 while being heated. Therefore, hot steam is exhausted.
[0068] Since the steam generator 420 injects water onto the heated wall surfaces to evaporate
the water instantaneously, it takes less power to generate a certain amount of steam,
in comparison with conventional technologies with a heater immersed in water for steam
generation.
<Water Supply Mechanism>
[0069] Fig. 13 is a schematic view of the water supply mechanism 500. The water supply mechanism
500 is described with reference to Fig. 13.
[0070] The water supply mechanism 500 which injects water into the chamber space 430 of
the steam generator 420 includes the aforementioned water supply valve 310, reservoir
tank 320, pump 330 and connecting pipe 421. The water supply mechanism 500 further
includes a level sensor 321 configured to measure a water level in the reservoir tank
320. The water supply valve 310 may supply water to the reservoir tank 320 or stop
the water supply to the reservoir tank 320 in response to the water level detected
by the level sensor 321.
[0071] The water supply valve 310 may be controlled in response to an operating time and/or
an operating pattern of the pump 330 (intermittent water supply operation and/or continuous
water supply operation). For example, a water dosage from the water supply valve 310
may be adjusted so that the reservoir tank 320 becomes empty at the end of the operation
of the pump 330. Therefore, the water is less likely to freeze in the reservoir tank
320.
[0072] The pump 330 supplies water stored in the reservoir tank 320 to the chamber space
430 through the connecting pipe 421. The intermittent water supply operation of the
pump 330 is adjusted so as to cause instantaneous evaporation of the water injected
into the chamber space 430.
[0073] As a result of the evaporation of the water in the chamber space 430, impurities
contained in the water may accumulate inside the chamber space 430. The continuous
water supply operation of the pump 330 is adjusted so that water flows into the chamber
space 430 at a sufficient flow rate to flush the accumulated impurities.
[0074] The exhaust pipe 422 is connected to the steam conduit 340. Steam generated in the
chamber space 430 by the intermittent water supply operation of the pump 330 and water
flowing into the chamber space 430 under the continuous water supply operation of
the pump 330 flows into the storage tub 200 through the exhaust pipe 422 and the steam
conduit 340.
<Supply of Steam and Water to Storage Tub >
[0075] Fig. 14 is a schematic rear view of the front portion 222 of the storage tub 200.
Supply of steam and water to the storage tub 200 is described with reference to Figs.
1, 13 and 14.
[0076] As shown in Fig. 1, the annular portion 224 of the front portion 222 includes an
inner surface 225 facing the rotary drum 210 and an outer surface 226 facing the front
wall 111 of the housing 110. Fig. 14 mainly shows the inner surface 225.
[0077] The steam supply mechanism 300 includes a branching pipe 351 and a nozzle 352 which
are fixed to the inner surface 225. The steam supply mechanism 300 further includes
a steam tube 353 which connects the branching pipe 351 to the nozzle 352. The steam
conduit 340 is connected to the branching pipe 351 via the peripheral wall portion
223.
[0078] Steam generated in the chamber space 430 flows into the steam conduit 340 through
the exhaust pipe 422 with a pressure rise inside the chamber space 430. Subsequently,
the steam reaches the branching pipe 351 from the steam conduit 340. The nozzle 352
is situated above the branching pipe 351. Since the steam arriving at the branching
pipe 351 is hot, the steam is guided to the steam tube 353 and then reaches the nozzle
352. Eventually, the steam is sprayed downwards from the nozzle 352. Accordingly,
the steam is blown directly onto the laundry stored in the storage tub 200 via the
opening 213 of the rotary drum 210. In the present embodiment, the steam generated
in the chamber space 430 is led to the nozzle 352 by the exhaust pipe 422, the steam
conduit 340, the branching pipe 351 and the steam tube 353.
[0079] As described above, since the pump 330 injects a suitable amount of water into the
hot chamber space 430 under the intermittent water supply operation, the water evaporates
instantaneously. Therefore, there is a rapid increase in an internal pressure in the
chamber space 430. Consequently, the steam is sprayed at a high pressure from the
nozzle 352 so that the steam vertically traverses the internal space of the storage
tub 200. Laundry is likely to gather near the lower end of the rotary drum 210 due
to the gravity. Since the steam sprayed from the nozzle 352 attached to an upper portion
of the storage tub 200 gets around to the lower end of the rotary drum 210, the steam
is supplied efficiently to the laundry.
[0080] The branching pipe 351 includes a trunk pipe 354 connected to the steam conduit 340,
an upper subsidiary pipe 355, which bends upwards from the trunk pipe 354, and a lower
subsidiary pipe 356, which bends downwards from the trunk pipe 354. The steam or water
flows into the trunk pipe 354 through the steam conduit 340. The upper subsidiary
pipe 355 is connected to the steam tube 353 to define an upward path of the steam
towards the nozzle 352.
[0081] Unlike the upper subsidiary pipe 355, the lower subsidiary pipe 356 defines a downward
path. The water flowing into the branching pipe 351 through the steam conduit 340
under the continuous water supply operation of the pump 330 flows down via the lower
subsidiary pipe 356 due to the action of gravity.
[0082] Fig. 14 shows an included angle θ1 between the trunk pipe 354 and the upper subsidiary
pipe 355. Fig. 14 also shows the included angle θ2 between the trunk pipe 354 and
the lower subsidiary pipe 356. The included angle θ1 is obtuse whereas the included
angle θ2 is acute. Since the included angle θ2 is acute, there is relatively large
flow loss from the trunk pipe 354 to the lower subsidiary pipe 356. Therefore, steam
flowing into the trunk pipe 354 is less likely to flow into the lower subsidiary pipe
356 so that the steam mainly flows into the upper subsidiary pipe 355. On the other
hand, since the upper subsidiary pipe 355 defines an upward flow path, water flowing
into the trunk pipe 354 is less likely to flow into the upper subsidiary pipe 355
so that the water mainly flows into the lower subsidiary pipe 356 due to the action
of gravity. Consequently, the flow path of the steam is separated from the flow path
of the water appropriately.
<Intermittent Pump Operation>
[0083] Fig. 15 is a graph schematically showing a relationship between the intermittent
operation of the pump 330 and a temperature in the chamber space 430. The intermittent
operation of the pump 330 is described with reference to Figs. 10, 13 and 15.
[0084] As shown in Fig. 15, a time length during which the pump 330 is operated (ON period)
is set to be shorter than a time length during which the pump 330 is stopped (OFF
period). Consequently, an appropriate amount of water is injected into the chamber
space 430.
[0085] A prescribed amount of water is supplied to the chamber space 430 during the ON period.
Consequently, the water is evaporated and becomes steam. Vaporization heat resultant
from the phase change from water to steam causes a temporal decrease in a temperature
in the chamber space 430. Since the OFF period is set to be relatively long as described
above, the heater 425 may increase a temperature of the chamber space 430 sufficiently
during the OFF period. Therefore, steam supply at a high pressure to the storage tub
200 continues under the intermittent operation of the pump 330. In short, the chamber
space 430 is heated sufficiently during the OFF period, and a suitable amount of water
for thermal energy of the steam generator 420 including the chamber space 430 is supplied
in the ON period to cause instantaneous evaporation (e.g. approximately 2 cc/dosage),
so that steam supply at an appropriately high pressure to the storage tub 200 continues.
<Use of Steam in Washing Process>
[0086] Fig. 16 is a graph schematically showing a change in a temperature of the water supplied
to the water tub 220 in the washing process. Effects of steam used in the washing
process are described with reference to Figs. 1, 10, 13 and 16.
[0087] As shown in Fig. 1, a water heater 160 is situated in a lower portion of the water
tub 220. The water heater 160 is used to heat water supplied into the water tub 220.
[0088] As shown in Fig. 16, when the washing process is started, water is supplied to the
water tub 220. Meanwhile, a temperature of the water contained in the laundry in the
water tub 220 is substantially uniform. The water in the water tub 220 is then heated
by the water heater 160. Since a large amount of heat is generated by the water heater
160, the temperature of the water contained in the laundry in the water tub 220 rises
rapidly. Heating the water in the water tub 220 is then stopped at a prescribed temperature.
[0089] In Fig. 16, the dotted line shows a change in a temperature of water contained in
the laundry after the water heater 160 stops heating without steam supply. The solid
line shows a change in a temperature of water contained in the laundry after the water
heater 160 stops heating with steam supply to the storage tub 200.
[0090] As described above, since hot steam into the storage tub 200 is supplied directly
to the laundry, a temperature decrease is less likely to happen to the water contained
in the laundry in the water tub 220. The heater 425 used in the steam generator 420
consumes a smaller power amount than the water heater 160 attached to the water tub
220 does. Consequently, in comparison to maintaining a water temperature in the water
tub 220 by means of the water heater 160, the steam supply may achieve smaller power
consumption to maintain a temperature. Therefore, it is preferable that the pump 330
carries out the intermittent water supply operation after the water heater 160 stops.
<Usage of Steam in Spin-Drying Process>
[0091] Effects of steam used in the spin-drying process are described with reference to
Figs. 1, 13 and 14.
[0092] In the spin-drying process, the rotary drum 210 rotates at high speed. As shown in
Fig. 1, the peripheral wall 211 of the rotary drum 210 is provided with a lot of small
holes 219. The laundry stored in the rotary drum 210 is pressed against the peripheral
wall 211 due to a centrifugal force resultant from rotation of the rotary drum 210.
Consequently, moisture contained in the laundry is discharged from the rotary drum
210 through the small holes 219. Therefore, the laundry is suitably spin-dried.
[0093] Fibres of the spin-dried laundry are likely to form hydrogen bonds. The hydrogen
bonds between the fibres result in wrinkles in the laundry. If steam is supplied into
the rotary drum 210, the steam removes the hydrogen bonds between the fibres. Therefore,
there are decreased wrinkles of the laundry. Accordingly, it is preferable that the
pump 330 carries out the intermittent water supply operation while the laundry is
subjected to the spin-drying process. As a result of the intermittent water supply
operation, the steam is sprayed from the nozzle 352 into the rotary drum 210. Since
the steam sprayed from the nozzle 352 traverses the storage tub 200 as described above,
the steam is blown uniformly onto the whole of the laundry which is stuck over the
rotating peripheral wall 211. Therefore, few wrinkles happen to the whole of the laundry
in the rotary drum 210.
[0094] Figs. 17A to 17C are schematic timing charts showing steam supply timings during
the spin-drying process. The timings of the steam supply are described with reference
to Figs. 1, 17A to 17C.
[0095] As shown in Fig. 17A, the steam supply mechanism 300 may start steam supply a prescribed
time period (T1) after the start of the spin-drying process. In this case, since little
water is contained in the laundry, the laundry is humidified efficiently by heat and
moisture of the steam. As shown in Figs. 17B and 17C, the steam supply mechanism 300
may start steam supply in synchronization with the start of the spin-drying process.
In this case, since the laundry is heated at the start of the spin-drying process,
the laundry is humidified efficiently at high temperature. As shown in Figs. 17A and
17B, the steam supply mechanism 300 may supply steam during a part of a period of
the spin-drying process. As shown in Fig. 17C, the time period during which the steam
supply mechanism 300 supplies steam may coincide with the time period from the start
to the end of the spin-drying process.
<Cooling of Steam Generator>
[0096] The cooling process of the steam generator 420 is described with reference to Figs.
10 and 13.
[0097] It is preferable that the steam generator 420 is cooled at the end of processing
laundry with steam. If the steam generator 420 is cooled, hot steam is prevented from
unnecessarily being sprayed into the storage tub 200.
[0098] Power supply to the heater 425 is stopped in order to cool the steam generator 420.
The pump 330 then starts the continuous water supply operation. Consequently, water
flows into the chamber space 430 continuously from the reservoir tank 320. The water
flowing into the chamber space 430 absorbs heat from the steam generator 420, and
then flows into the storage tub 200. Therefore, the steam generator 420 is cooled
in a short period of time.
[0099] Fig. 18 is a block diagram schematically showing control of the door 120 on the
basis of a temperature of the steam generator 420. The control of the door 120 is
described with reference to Figs. 1, 8B and 18.
[0100] The washing machine 100 includes a locking mechanism 121, which locks the door 120
at the closed position, and a controller 122 for controlling locking and unlocking
of the locking mechanism 121. Mechanical and electrical mechanisms of the locking
mechanism 121 may be a structure used in a generally known washing machine.
[0101] As shown in Fig. 8B, the steam generator 420 includes the thermistor 426. The thermistor
426 detects a temperature of the main piece 423 so that signals in correspondence
to the detected temperature are output to the controller 122.
[0102] The controller 122 keeps the door 120 locked by the locking mechanism 121 until the
signals output from the thermistor 426 indicates that a temperature is no more than
a prescribed value. Accordingly, the internal space of the storage tub 200 is isolated
from the outside until the steam generator 420 reaches the prescribed temperature
or lower. Therefore, the washing machine 100 becomes very safe.
<Second Embodiment>
[0103] Fig. 19 is a schematic exploded perspective view of a steam generator 420A used in
a washing machine exemplified as the laundry processing apparatus according to the
second embodiment. The washing machine according to the second embodiment has a similar
structure to the washing machine 100 according to the first embodiment, except for
a structure of the steam generator 420A. Therefore, differences from the first embodiment
are described below. Except for the differences described below, the description in
the first embodiment is applicable to the washing machine according to the second
embodiment. Elements which are the same as the first embodiment are labelled with
the same reference numerals. Therefore, the description of the first embodiment is
also applicable to the elements which are labelled with the same reference numerals.
[0104] The steam generator 420A includes a main piece 423A, a lid piece 424A, and a packing
ring 433 which is sandwiched between the main piece 423A and the lid piece 424A. Unlike
the main piece 423 described in the context of the first embodiment, no heater is
attached to the main piece 423A. Instead, a heater 425A is attached to the lid piece
424A.
[0105] Fig. 20 is a schematic perspective view of the lid piece 424A. An attachment structure
of the heater 425A is described with reference to Figs. 19 and 20.
[0106] The lid piece 424A includes an inner shield wall 436 which is surrounded by an outer
shield wall 435. The inner shield wall 436 has substantially the same shape as the
inner chamber wall 432 of the main piece 423A. The inner shield wall 436 may overlap
with the inner chamber wall 432. Consequently, a whorl flow path is formed in the
chamber space 430. A region of the lower surface 434 which is surrounded by the inner
shield wall 436 faces the inflow port 437 formed in the main piece 423A. Therefore,
the region is called "facing region 439" in the following description. The heater
425A is situated inside the lid piece 424A so as to surround the facing region 439.
If a flow rate of the water is adjusted so that water flowing from the inflow port
437 reaches the lid piece 424A, there is instantaneous evaporation since the facing
region 439 is a very high temperature.
[0107] The aforementioned embodiments mainly include the following features.
[0108] The laundry processing apparatus according to the aforementioned embodiments includes:
a storage tub which stores laundry; a steam generation portion including a steam generator
configured to generate steam which is sprayed into the storage tub; and a housing
configured to store the storage tub and the steam generator. The steam generator is
held apart from the housing.
[0109] According to the aforementioned configuration, the steam generator generates steam.
The steam is sprayed into the storage tub configured to store laundry. Since the housing
stores the storage tub and the steam generation portion, the storage tub and the steam
generation portion are appropriately isolated from the user. Since the steam generator
is held apart from the housing, there is an air layer between the steam generator
and the housing. Therefore, there is little heat transfer from the steam generator
to the housing. Accordingly, the user may safely operate the laundry processing apparatus.
[0110] In the aforementioned configuration, the steam generator may have a wall surface
defining a chamber for generating the steam. The steam generation portion including
a heater which heats the wall surface may be held apart from the housing.
[0111] According to the aforementioned configuration, since the heater of the steam generation
portion heats the wall surface which defines the chamber for generating steam, the
steam is generated appropriately in the chamber. Since the steam generation portion
is held apart from the housing, there is an air layer between the steam generation
portion and the housing. Therefore, there is little heat transfer from the steam generation
portion to the housing. Accordingly, the user may safely operate the laundry processing
apparatus.
[0112] In the aforementioned configuration, the steam generation portion may include a case
surrounding the steam generator; and an attachment portion which fixes the case to
the housing.
[0113] According to the aforementioned configuration, since the case surrounds the steam
generator, there is little heat transfer from the steam generator to the housing.
The attachment portion fixes the case appropriately to the housing. Consequently,
the user may safely operate the laundry processing apparatus.
[0114] In the aforementioned configuration, the laundry processing apparatus may further
include a reinforcing frame situated along an upper edge of the housing. The attachment
portion may be attached to the reinforcing frame.
[0115] According to the aforementioned configuration, since the attachment portion is attached
to the reinforcing frame which is situated along the upper edge of the housing, the
case is fixed stably to the housing. Consequently, the user may safely operate the
laundry processing apparatus.
[0116] In the aforementioned configuration, the housing may include a top wall situated
above the storage tub. The attachment portion connected to the top wall may make the
steam generation portion distant from the top wall.
[0117] According to the aforementioned configuration, since the attachment portion makes
the steam generation portion distant from the top wall situated above the storage
tub, there is little heat transfer from the steam generation portion to the top wall.
Therefore, the user may safely operate the laundry processing apparatus.
[0118] In the aforementioned configuration, the case may include a container, which stores
the steam generation portion, and a lid, which closes the container. The attachment
portion may be fixed to the lid.
[0119] According to the aforementioned configuration, since the lid to which the attachment
portion is fixed closes the container which stores the steam generation portion, the
lid may partition the top wall from the steam storage portion. Since the lid reduces
heat transfer from the steam generation portion to the top wall, the user may safely
operate the laundry processing apparatus.
[0120] In the aforementioned configuration, the housing may include a side wall which extends
downwards from the top wall. The attachment portion may make the steam generation
portion distant from the side wall.
[0121] According to the aforementioned configuration, since the attachment portion makes
the steam generation portion distant from the side wall which extends downwards from
the top wall, there is little heat transfer from the steam generation portion to the
top wall. Therefore, the user may safely operate the laundry processing apparatus.
[0122] In the aforementioned configuration, the storage tub may be cylindrical so that the
storage tub surrounds a central axis extending along the side wall. The steam generation
portion may be situated between a vertical plane passing through the central axis
and the side wall.
[0123] According to the aforementioned configuration, the storage tub is cylindrical so
that the storage tub surrounds a central axis extending along the side wall. The steam
generation portion is situated between a vertical plane passing through the central
axis and the side wall. Since the steam generation portion is situated in a broad
space between the top and/or side walls and the storage tub, the steam generation
portion may be distant significantly from the top and/or side walls. Accordingly,
there is little heat transfer from the steam generation portion to the top and/or
side walls. Therefore, the user may safely operate the laundry processing apparatus.
[0124] In the aforementioned configuration, the housing may include a front wall which extends
downwards next to the side wall from the top wall. The attachment portion may make
the steam generation portion distant from the side wall.
[0125] According to the aforementioned configuration, the front wall adjacent to the side
wall extends downwards from the top wall. Since the attachment portion separates the
steam generation portion from the front wall, there is little heat transfer from the
steam generation portion to the front wall. Therefore, the user may safely operate
the laundry processing apparatus.
[0126] In the aforementioned configuration, the laundry processing apparatus may further
include a nozzle configured to spray the steam downwards inside the storage tub. The
housing may include a rear wall opposite to the front wall. The steam generation portion
may be closer to the front wall than the rear wall. The front wall may be provided
with a feed opening for feeding the laundry into the storage tub. The storage tub
may be provided with an opening in communication with the feed opening. The steam
may be sprayed from the nozzle into the storage tub through the opening.
[0127] According to the aforementioned configuration, since the nozzle of the laundry processing
apparatus sprays steam downwards in the storage tub, the nozzle is situated near the
top wall. Since the attachment portion is connected to the top wall, there is a short
distance between the nozzle and the steam generation portion. Since a temperature
and a flow rate of the steam sprayed into the storage tub are kept at a high level,
the steam is supplied efficiently to the laundry.
[0128] The front wall is provided with a feed opening for feeding the laundry into the storage
tub. The storage tub is provided with an opening in communication with the feed opening.
Since the steam is sprayed into the storage tub from the nozzle through the opening,
the nozzle is situated near the front wall. The housing includes a rear wall opposite
to the front wall. Since the steam generation portion is closer to the front wall
than the rear wall, there is a short distance between the nozzle and the steam generation
portion. Since a temperature and a flow rate of the steam sprayed into the storage
tub are kept at a high level, the steam is supplied efficiently to the laundry.
[0129] In the aforementioned configuration, the attachment portion and the case may be formed
from thermally-resistant resin.
[0130] According to the aforementioned configuration, since the attachment portion and the
case are formed from thermally-resistant resin, the steam generation portion is appropriately
held in the housing under a heated condition for generating steam.
Industrial Applicability
[0131] The principles of the aforementioned embodiments may be applied suitably to devices
which use steam to process laundry.