U.S. patent application number 10/870091 was filed with the patent office on 2004-11-11 for whirlpool bath filter and suction device.
Invention is credited to Mattson, Roy W. JR., Ogden, Paulette C..
Application Number | 20040221381 10/870091 |
Document ID | / |
Family ID | 29418019 |
Filed Date | 2004-11-11 |
United States Patent
Application |
20040221381 |
Kind Code |
A1 |
Mattson, Roy W. JR. ; et
al. |
November 11, 2004 |
Whirlpool bath filter and suction device
Abstract
A whirlpool bath has a combination suction fixture and filter in
the form of a porous faceplate.
Inventors: |
Mattson, Roy W. JR.;
(Longmont, CO) ; Ogden, Paulette C.; (Longmont,
CO) |
Correspondence
Address: |
RICK MARTIN
PATENT LAW OFFICES OF RICK MARTIN, PC
416 COFFMAN STREET
LONGMONT
CO
80501
US
|
Family ID: |
29418019 |
Appl. No.: |
10/870091 |
Filed: |
June 17, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10870091 |
Jun 17, 2004 |
|
|
|
10005953 |
Nov 2, 2001 |
|
|
|
6751814 |
|
|
|
|
Current U.S.
Class: |
4/541.1 |
Current CPC
Class: |
B01D 37/025 20130101;
B01D 2201/34 20130101; B01D 2201/44 20130101; B01D 29/035 20130101;
B01D 29/21 20130101; B01D 29/96 20130101; A61H 33/6073 20130101;
B01D 29/03 20130101; B01D 29/56 20130101; B01D 2201/0415 20130101;
B01D 2201/4046 20130101 |
Class at
Publication: |
004/541.1 |
International
Class: |
A47K 003/00; A47K
003/10 |
Claims
We claim:
1. In a whirlpool bath having a suction inlet, said suction inlet
having a faceplate functioning to filter debris, an improvement
comprising: a chemical chamber situated adjacent to the faceplate;
said chemical chamber having at least one flow-through passage; and
wherein a chemical housed in the chemical chamber augments the germ
killing properties of the whirlpool bath.
2. The apparatus of claim 1, wherein the faceplate further
comprises a plurality of holes including drainage holes along a
bottom peripheral edge.
3. In a whirlpool bath having a suction inlet, said suction inlet
having a porous faceplate means functioning to filter substantially
large objects, an improvement comprising: a chemical chamber means
situated adjacent to the faceplate, said chemical chamber means
functioning to house an antimicrobial chemical means therein; said
chemical-chamber means having at least one flow-through passage
means, said flow-through passage means functioning to pass said
antimicrobial chemical means therethrough; and wherein said
chemical means housed in the chemical chamber means functions to
augment the germ killing properties of the whirlpool bath.
4. The apparatus of claim 3, wherein the faceplate means further
comprises a plurality of holes including drainage holes along a
bottom peripheral edge.
5. The apparatus of claim 3 further comprising a fibrous filter
means located adjacent to said porous faceplate means, said fibrous
filter means functioning to filter objects passing through said
porous faceplate means.
6. The apparatus of claim 5, wherein said fibrous filter means is
compact and can accommodate high water flow.
7. The apparatus of claim 5, wherein said fibrous filter means is
disposable.
8. The apparatus of claim 5, wherein said fibrous filter means is
manufactured with an antimicrobial chemical means impregnated
therein, said chemical means functioning to augment the germ
killing properties of the bath.
9. The apparatus of claim 3, wherein the chemical chamber means
operates at a high water flow rate as generated by said whirlpool
bathtub.
10. The apparatus of claim 3, wherein the antimicrobial chemical
means is a time-release chemical pellet suitable for augmenting the
germ killing properties of the bath.
11. The apparatus of claim 3, wherein the chemical chamber means
operates at a high water flow rate as generated by said whirlpool
bathtub.
12. The apparatus of claim 3, wherein the suction inlet has means
functioning to inhibit water flow if said chemical chamber means is
missing or is improperly installed.
13. The apparatus of claim 5, wherein the suction inlet has means
functioning to inhibit water flow if said fibrous filter means is
missing or is improperly installed.
14. The apparatus of claim 3, wherein said porous faceplate means
has a pop off attachment means functioning to enable the separation
of said porous faceplate from said suction inlet without the use of
a tool.
15. A method of retrofitting a whirlpool bathtub with a chemical
cage, said bathtub having at least one closed loop piping system
component, at least one output jet component, at least one water
pump component, and at least one suction device component, said
suction device component having a housing component and a porous
faceplate component, said method comprising the steps of: removing
the porous faceplate component from the housing component;
providing a retrofit faceplate component having a plurality of
holes including drainage holes along a bottom peripheral edge;
providing a chemical cage having a chemical housed therein, whereby
said chemical is releasable into bath water flowing therethrough;
mounting said cage to a suction device component; and mounting said
retrofit faceplate to said housing component.
16. The method of claim 15, wherein the chemical housed in the
chemical cage comprises a time-release chemical pellet suitable for
augmenting the germ killing properties of the bath.
Description
REFERENCE TO RELATED APPLICATION
[0001] This non-provisional utility application is a continuation
of application Ser. No. 10/005,953 filed Nov. 2, 2001 titled
"Improved Whirlpool Bath and Suction Device," to be issued on Jun.
22, 2004.
[0002] U.S. Pat. No. 6,283,308 (2001) to Patil, et al., U.S. Pat.
No. 4,340,039 (1982) to Hibbard et al., and U.S. Pat. No. 5,799,339
are incorporated herein by reference.
FIELD OF THE INVENTION
[0003] The present invention relates to combining a replaceable
filter and a suction device in a closed loop home or hotel
whirlpool bath, hydrotherapeutic baths, and other bathing
receptacles.
BACKGROUND OF THE INVENTION
[0004] Whirlpool-type baths have been employed to treat discomfort
resulting from strained muscles, joint ailments and the like. More
recently, such baths have been used increasingly as means of
relaxing from the daily stresses of modern life. A therapeutic
effect is derived from bubbling water and swirling jet streams that
create an invigorating to massage the user's body.
[0005] To create the desired whirlpool motion and hydro massage
effect, a motorized water pump draws water in through a suction
fitting in a receptacle, such as a bathtub. The user first fills
the bathtub. Then the user activates the closed loop whirlpool
system. The water travels through a piping system and back out jet
fittings. Jet fittings are typically employed to inject water at a
high velocity into a bathtub. Usually the jet fittings are adapted
to aspirate air so that the water discharged into the receptacle is
aerated to achieve the desired bubbling effect. (See for instance,
U.S. Pat. No. 4,340,039, incorporated herein by reference).
[0006] Whirlpool baths currently do not have a filtration system to
filter debris in the water as do indoor and outdoor spas. Whirlpool
baths are designed as with a normal bathtub to be drained after
each use. However, debris in the form of dead skin, soap, hair and
other foreign material circulates throughout the piping and pump
system. This debris does not completely drain and over time
accumulates in the piping system and may cause a health risk. Also
hair may get twisted and entrapped in the whirlpool bath pumps
impeller. Whirlpool bath manufactures for some time have been
trying to devise a way to incorporate a filtration system on a
closed loop whirlpool bath. The major obstacle they face in using a
filtration system for a whirlpool bath is in complying with the
plumbing codes. There is no filtration system that is specifically
designed for a drain down whirlpool bath that allows a whirlpool
bath to pass requirements set forth by plumbing codes. Another
reason why there are no filtration systems for Whirlpool bathtubs
is because Whirlpool baths must meet stringent drain down code
requirements set up by the American Society of Mechanical Engineers
(ASME). The code that governs whirlpool baths is entitled
"Whirlpool Bath Appliances" (ASME A112.19.7M 1995). Section 5 of
this code covers water retention. It states the "whirlpool bath
appliances shall be of such design as to prevent retention of water
in excess of 44 ml. (11/2 fl oz) for each jet and suction filter.
The average whirlpool bath has a 6-jet. system and has one suction
fitting. This system configuration can only retain 101/2 ounces of
water in the complete whirlpool bath system after draining to meet
code. This is for a six jet one suction whirlpool bath. Most
quality whirlpool baths retain less than 4 ounces of water in the
whirlpool bath system after draining. Therefore, the filter part of
the system cannot retain over six and a half ounces of water,
because the total water retention would exceed 101/2 ounces. These
requirements for whirlpool baths fall under the American Society of
Mechanical Engineers code entitled "Whirlpool Bathtub Appliances."
Currently there are no known filtration systems designed for
whirlpool baths. Currently there are no known filtration systems
designed for whirlpool baths that retain less than 61/2 ounces of
water except for the present invention.
[0007] Another important consideration in developing a filtration
system for whirlpool baths is the ease of replacing the filter. It
needs to be designed so the filter can be replaced from inside the
bath. This way access panels on the underside of the whirlpool bath
to access the filter can be eliminated. The most logical choice for
a filter location is in the suction fitting. Placing the filter in
the suction fitting presents a whole other range of design
concerns. First placing a filter in the suction fitting might cause
undue stress on the pump motor. The suction filter must pass the
codes set up by ASME for suctions. The code for suctions from ASME
is titled Suction Fittings for use in swimming pools, spas, hot
tubs, and whirlpool bathtub appliances (ASME/IAMPO reaffirm 1996).
There are a variety of load and structural tests the suctions have
to pass. The present invention provides a cavity that houses a
filter that could be installed to have the filter replaced from the
inside of a whirlpool bath. The complete filtration system retains
less than 4 ounces of water and as little as 2 ounces of water; so
most whirlpool bath companies could use it on their whirlpool bath
models and pass the drain down codes for whirlpool baths. The
filter had to be made small to meet the drain down requirements.
However, since it was small it had to be very efficient. The
present invention has a specially designed filter core. The core is
engineered with varying spaced and sized holes along the length of
the core. This design allows water to be drawn through just about
the entire filter. Without this design the filter would only pull
water through about 20% of the filter near the outlet.
[0008] The present invention also provides a new faceplate cover.
This cover has to be easily removable. It also has to pass the
heavy load, impact and hair entrapment tests set out by ASME/IAMPO.
One cover embodiment has a radius and back ribbing on it and a
removable insert support to pass the strength tests. One embodiment
of the faceplate is flat with structural fins on its back side,
thus eliminating the removable insert. Each cover has just the
right amount of sized holes to pass the hair entrapment tests. The
result is the fluid suction filter device that is especially made
just for whirlpool baths.
[0009] U.S. Pat. No. 4,340,039 (1982) to Hibbard et al. discloses a
hydromassage apparatus for a whirlpool bath system. It has a closed
loop water circulation system, adjustable nozzles and venturi air
injector, (incorporated herein by reference).
[0010] U.S. Pat. No. 4,637,873 (1987) to DeSousa et al. discloses a
front load skimmer type filter for spas and pools. A skimmer
housing supports a polyester fabric filter having pleated filter
media and a central polyvinyl chloride (PVC) pipe with a porous
core, a solidified potting compound for a solid top, and an open
bottom. It does not support a series of expanding diameter holes
for the porous core as does the present invention, (incorporated by
reference). It does not meet draindown requirements of ASME for
whirlpool baths as does the present invention. It does not meet the
ASME requirements for suction fittings and therefore needs to
operate in conjunction with a below the waterline suction.
[0011] U.S. Pat. No. 4,349,434 (1982) to Jaworski discloses a
filtration system piped in away from a pool, spa, hot tub and the
like. A filter cartridge and filter is used.
[0012] U.S. Pat. No. 4,359,790 (1982) to Chalberg discloses a three
piece whirlpool bath suction outlet assembly.
[0013] U.S. Pat. No. 6,283,308 (2001) to Patil et al. discloses a
bacteriostatic filter cartridge having elements impregnated with an
anti-microbial agent.
[0014] U.S. Pat. No. 6,038,712 (2000) to Charlberg et al. discloses
a whirlpool bath suction device with a cavitation assembly to cause
the pump to lose its prime when hair blocks the faceplate.
[0015] U.S. Pat. No. 5,799,339 (1998) to Perry et al. discloses a
suction device for a spa or jetted tub with a turbulence reduction
design to reduce the possibility of entangling a user's hair in the
faceplate.
SUMMARY OF THE INVENTION
[0016] The main aspect of the present invention is to provide in a
whirlpool bath a suction fixture and replaceable filter combination
apparatus.
[0017] Another aspect of the present invention is to provide a
safety plate for the suction intake which resists hair
entrapment.
[0018] Another aspect of the present invention is to provide a pop
off suction faceplate and a pop out filter core to provide safety
features to prevent drowning.
[0019] Another aspect of the present invention is to provide a
safety/sanitation port to cause cavitation if the filter is absent
or improperly inserted.
[0020] Another aspect of the present invention is to provide a
minimal water retention filter to retain less than 61/2 ounces of
water after draindown.
[0021] Another aspect of the present invention is to provide a
housing which is readily retrofitable and/or incorporated into a
new whirlpool bath that retains minimal water.
[0022] Other aspects of this invention will appear from the
following description and appended claims, reference being made to
the accompanying drawings forming a part of this specification
wherein like reference characters designate corresponding parts in
the several views.
[0023] The housing of the suction filter is generally rectangular
having a length of four inches to two feet. A semi-cylindrical
recess extends behind the installation wall of the tub. The recess
surrounds a disposable cylindrical fiber filter which has a support
tube in its core. The support tube has a plurality of water holes
having increasing diameters extending away from the water outlet.
These holes provide for a water flow along the entire length of the
filter, instead of just making use of the filter at the outlet and
of the filter.
[0024] The housing has a sloped lower shelf and slots to allow
water to drain back into the tub after shutdown. The housing has a
sharp radius end opposite the outlet end, thus allowing the housing
to be fitted into the side wall of a tub through a standard size
opening cut.
[0025] The housing mounting flange has nominally 6-10 counter sunk
holes for bolting to the tub via standard nuts and bolts. Silicone
is used on the back of the housing flange to prevent leaks.
[0026] The original faceplate shown in FIG. 4 slides into the
housing to provide for filter replacement. The faceplate has a
radius shape to prevent a limb from being sucked up against it
which could entrap a body part. ASME hair entrapment standards are
met using a plurality of slots or holes. Impact and load tests are
met.
[0027] In the faceplate embodiment shown in FIG. 25 support bars
are now built into the faceplate and fit into receiving slots in
the housing. This creates a solid part and allows it to pass impact
and load tests called out by ASME code. This is the only suction
for whirlpool bathtubs that is designed for the structured supports
to be removed after the suction is installed and allows a filter to
be installed in the suction housing or replaced and still pass
these test. All other known suctions have the main structured
support as part of the body (housing) and these supports cannot be
removed. See U.S. Pat. No. 5,799,339 which represents all other
known suctions. FIG. 5 of U.S. Pat. No.5,799,339 shows a face view
of the support. FIG. 3 shows how FIG. 5 screws in permanently into
body 20 of FIG. 3. These supports (26b, 28b called a guide) cannot
be removed once the suction is installed.
[0028] This embodiment of the faceplate is larger than standard
faceplates because of the size of the removable filter. The
combination of a filter and a suction in a single device is not
known in the prior art. The faceplate now has slots to allow a
larger volume of water to pass through it. Because of the increased
size of the faceplate the slots have to be designed and engineered
in a radiating pattern. This is very important for the plastic
injected molding process.
[0029] With the present design over a horizontal (see '339 patent)
or vertical design, the pressure of the injected plastic from the
injection point of the mold, (usually the injection point of a mold
is located in the center of the mold) hits the small end of the
slots instead of the wide end of the slots. The shorter end of the
slot can withstand a great deal more pressure over time before
failure than if the pressure were subjected to the wide side of the
slots. This allows for much longer mold life and a more pleasing
finished product. The radiating pattern of slots gives a
straight-line flow to the outer edge of the faceplate part. U.S.
Pat. No. 5,799,339 FIG. 4 shows a standard slot opening arrangement
that represents the arrangement of slots used by manufacturers of
slotted face faceplates. U.S. Pat. No. 6,038,712 FIG. 2 shows
circular hole openings which represents how other faceplates are
made. Slots are preferable over circular holes to increase
flow.
[0030] One embodiment of the housing eliminates the drain down
slots of the original design because water now evacuates through
the bottom slots of the faceplate. The filter core ID is preferably
2" to allow for 200 GPM flow. No other manufacturer makes a filter
for whirlpool bathtubs or a filter that fits into a housing outlet
that has a 2" ID. Without this ID you would not be able to get 200
GPM to run through the filter core allowing a combination filter
suction an overall 200 GPM rating and meets ASME entrapment
requirements.
[0031] The filter core also has two slots cut into the end that
fits into the outlet of one embodiment of the housing. The housing
embodiment has two male ridges. This makes the filter core the only
filter core that fits this embodiment housing. The core is designed
with varying sized holes and slots. The holes furthest from the
outlet port are larger than the holes near the outlet port. This
allows water to pull through the entire filter.
[0032] The male ridges align a gasket to cover a safety/sanitation
port. The core when inserted into the outlet port side of the
filter covers the safety/sanitation port, a hole opening that has a
plastic tube attached. If the filter were removed or if a person
tried to operate the unit without the filter core covering this
hole, air from the tube would be drawn into the pump and the pump
would cavitate (draw more air than water). The whirlpool bathtub
would not operate properly, and people would turn it off. The
importance to this is no user would run the unit without the filter
in place. The feature reduces the chance of drawing contaminates
into the whirlpool bath system. Once contaminates such as hair are
entrapped in the pumps impeller, the entire whirlpool bath system
becomes contaminated until someone opens the whirlpool bath pump (a
long and time consuming process usually requiring a professional),
frees the entrapped hair and sanitizes the complete system.
[0033] Right now by code, every suction faceplate must be
engineered so the faceplate cannot be removed without using a tool.
See U.S. Pat. No. 6,038,712 FIG. 2 that shows screw hole openings
and U.S. Pat. No. 5,799,339 FIG. 3 number 22 that shows the screw.
All known suctions on the market use a form of screw or the like to
attach the faceplate to the housing. There are some suction
manufacturers that have a cavitation device in the faceplate of the
suction, see U.S. Pat. No. 6,038,712. If the face of the suction is
restricted significantly, the unit cavitates and the suction
against the faceplate decreases. These designs are still dangerous.
Hair can still become twisted in the faceplate before the unit
shuts down. Once the hair is trapped, you need a tool by code to
take the faceplate off. In most cases a screwdriver to remove the
screw. The entrapped hair traps the head of the user underwater in
the tub water. People still can drown with these devices. The
reason for this code of needing a tool to remove the faceplate is
that if the faceplate of current suctions are removed, body parts
or hair could get trapped in the exposed housing support cross
members that are an integral part of the suction body
(nonremovable). Since the suction filter embodiment will not
operate without the filter in place, there is no need for the
screw. If the filter were in place and someone did get their hair
caught in the faceplate, the faceplate is held in place by magnets;
and the whole faceplate pops off easily. If hair got caught in the
exposed filter if the unit were run without the faceplate cover,
the filter also pops out easily. There is no chance of getting
entrapped if the filter is removed, because the unit cavitates and
ceases the suction action and trigger no obstructions in the outlet
for anything to become entrapped.
[0034] The filter core has a gasket that slides over the
safety/sanitation port which is a cavitation hole. Without this
gasket, the replaceable plastic filter core would rub against the
plastic housing outlet and could cause wear over the years to the
housing outlet.
[0035] The faceplate now preferably attaches to the housing with
magnets.
[0036] The screw hole openings of the housing are recessed for
flush mounting. They also are flat recessed.
[0037] The filter media is preferably made out of polypropylene.
Others in the spa industry use polyester media. No one has an
approved filtration system for whirlpool baths, so filters are not
used on whirlpool baths. Polypropylene media can be treated in the
manufacturing process with antibacterial agents, whereas polyester
media cannot be treated effectively with antibacterial agents.
[0038] An embodiment of the filter is designed to retain less than
3 ounces of water.
[0039] The suction filter housing is installed by using screws to
attach it to the whirlpool bathtub. No other suction currently uses
screws for installation. All other suctions currently place the
housing behind the hole-opening cut into the sidewall of the
whirlpool bathtub, and a separate threaded base '339 number 14 is
screwed into the housing forming the installation. By using screws
the present invention eliminates this extra plastic injected
part.
[0040] The housing embodiment is the only known housing that has
sloped sides of the inner wall to allow water to drain back into
the whirlpool bathtub when the whirlpool bathtub system is
deactivated whether the unit is installed facing left or right.
[0041] The present suction filter device could be designed in other
configurations than its current rectangular form. The unit could
also be designed in a round form or any other shape or size. The
filter and filter core could also be made shorter, longer, larger
or smaller. The filter could be made smaller for less money to be
disposable after each whirlpool bath use. The filter could even be
designed in such a way to be incorporated into existing suctions
with modification of those suctions. The filter media that filters
the water could be pleated or wrapped without pleating around a
filter core.
[0042] The housing could be designed to incorporate multiple
filters. The ridges and slots at the end of the filter core could
be made in a variety of shapes or locations to ensure the use of
only one filter.
[0043] The main body housing could be vacuum formed and become an
integral part of the whirlpool bathtub.
[0044] The magnets holding the faceplate to the housing could be
larger or smaller and arranged in various other locations on each
part. The amount of magnets used could be increased or decreased.
The faceplate could also be attached using various snap-on
configurations. An installation-sealing gasket could be used. The
slope in the sidewalls of the housing could be increased or
decreased. The overall size of the suction filter could be
increased or decreased.
[0045] The housing body, faceplate or filter core could be made
from other material than injected plastic; it could be stamped or
machined out of metal or other material.
[0046] The radiating slotted design of the faceplate could have a
radiating round hole design.
[0047] The safety cavitation hole could be placed anywhere rearward
on the outlet of the housing and be various sizes or have multiple
openings.
[0048] The filter could have various sanitizing materials in its
core such as slow dissolving chlorine tablets or other sanitizing
material incorporated into the filter core.
[0049] The screw and nuts that attach the housing to the sidewall
of the whirlpool bathtub could have a washer or use locking nuts or
clips and have varying sizes and be made out of a variety of
materials, including plastic and nylon or some space age
material.
[0050] The faceplate back support ribbing is designed in an X
pattern, which offers outstanding structural integrity. The
circular ribbing adds tremendous strength to the center impact
point of the faceplate.
[0051] The faceplate is designed to protrude less than {fraction
(1/2)}" into the tub when attached to the housing. This streamline
design protrudes much less than most current suctions adding more
room to the bathing area of the whirlpool bathtub.
[0052] The slotted holes on the top, sides and bottom of the
faceplate extend out keeping in line with the radiating design
pattern on the face of the faceplate. This makes it an easier part
to inject with plastic.
[0053] The housing has a flange that provides a resting area for
the peripheral ledge of the faceplate when the faceplate is
attached to the housing. This resting area allows for weaker
magnets to be used to keep the faceplate attached to the
housing.
[0054] When a conventional suction fitting is operated under a high
flow rate, the water flow inside of the fitting can become
turbulent or can vortex like a tornado. When the water flow through
such a fitting becomes turbulent or vortexes, hair extending
through the faceplate of the fitting can become entangled within
the fitting, thereby rendering the hair difficult to remove from
the fitting.
[0055] The present invention filter inside the housing disrupts
this vortex. Tests have proved that the GPM actually increase with
the filter installed by eliminating these vortexes than running the
same test with the filter removed. Less vortex results in less of a
chance someone could get his or her hair twisted in the faceplate
and entrapped. Therefore, another feature of the present invention
is to help provide a laminar flow through the suction/filter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] FIG. 1 is a top perspective view of a whirlpool bath having
an alternate embodiment of the suction filter installed
therein.
[0057] FIG. 2 is a top perspective view of the original faceplate
of the suction filter as viewed from the inside of the whirlpool
bath shown in FIG. 1.
[0058] FIG. 3 is an exploded view of the suction filter shown in
FIG. 2.
[0059] FIG. 4 is a back plan view of the faceplate shown in FIG.
2.
[0060] FIG. 5 is a top perspective view of an alternate embodiment
faceplate.
[0061] FIG. 6 is a back perspective view of the housing of the
suction filter shown in FIG. 2.
[0062] FIG. 7 is a plan view of the original porous core of the
filter.
[0063] FIG. 8 is the same view as FIG. 7 with the original porous
core rotated 90.degree. clockwise.
[0064] FIG. 9 is the same view as FIG. 8 with the porous core
rotated another 90.degree. clockwise.
[0065] FIG. 10 is a longitudinal sectional view of the housing and
filter of FIG. 2.
[0066] FIG. 11 is a longitudinal sectional view of an alternate
embodiment filter having a charcoal bag in the porous core.
[0067] FIG. 12 is a cross sectional view taken along line 12-12 of
FIG. 11.
[0068] FIG. 13 is a plan view of the outlet end of the original
housing.
[0069] FIG. 14 is a top perspective view of the original housing
with an optional mounting bracket for the filter.
[0070] FIG. 15 is an exploded view of an alternate embodiment
housing and faceplate design for a suction filter apparatus.
[0071] FIG. 16 is a perspective exploded view of the FIG. 15
embodiment.
[0072] FIG. 17 is a rear perspective view of the FIG. 15
faceplate.
[0073] FIG. 18 is a rear perspective view of the FIG. 15
housing.
[0074] FIG. 19 is a right side plan view of an installed FIG. 15
embodiment.
[0075] FIG. 20 is a top perspective view of a filter core
embodiment.
[0076] FIG. 21 is a perspective view with a partial cutaway of the
FIG. 15 housing, the filter core embodiment of FIG. 20 and showing
the ridge/slot alignment of the filter core inside the housing
outlet.
[0077] FIG. 22 is a longitudinal sectional view taken along line
22-22 of FIG. 15.
[0078] FIG. 23 is a vertical sectional view taken along line 23-23
of FIG. 15.
[0079] FIG. 24 is a top perspective view of a user getting his or
her hair entrapped in an embodiment of the faceplate/housing
design, wherein only the magnets hold the faceplate to the housing,
thereby enabling a safety oriented pop off faceplate as well as a
safety oriented pop off filter core.
[0080] FIG. 25 is a top perspective view of the pop-off
faceplate/housing shown in FIG. 24.
[0081] FIG. 26 is an exploded view of a suction/filter.
[0082] FIG. 27 (prior art) is an exploded view of a suction device
10P.
[0083] FIG. 28 (prior art) is a front plan view of the cover 12P of
the suction device 10P.
[0084] FIG. 29 is an exploded view of a suction/filter 2700, an
alternate embodiment.
[0085] FIG. 30 is a side plan view of the cover 12PP of the suction
filter 2700.
[0086] Before explaining the disclosed embodiment of the present
invention in detail, it is to be understood that the invention is
not limited in its application to the details of the particular
arrangement shown, since the invention is capable of other
embodiments. Also, the terminology used herein is for the purpose
of description and not of limitation.
DETAILED DESCRIPTION OF DRAWINGS
[0087] Referring first to FIG. 1 a whirlpool bath 1 has a tub 5
with a standard faucet and spicket assembly 6 and a standard tub
drain 8. During whirlpool use the no two called out pump 2
circulates water via output pipe 4, air mixing pipe 10 and jets 11.
Water is drawn from the filled tub via pump inlet pipe 3 which is
connected to the suction filter 9, an alternate embodiment. A
switch 7 activates the pump 2.
[0088] Referring next to FIGS. 2, 3, 4 the suction filter 9 is
shown as seen by a bather in the tub in FIG. 2. The jets 11 are
prior art. The only visible portion of the suction filter 9 is
faceplate 20. The faceplate 20 is preferably rectangular but could
have any shape. The faceplate 20 has a peripheral mounting flange
rim 29 which has receiving grooves 23,24 to slidingly engage L
shaped brackets 25,26. The brackets 25,26 are molded into the
mounting flange 30 of the filter housing 31.
[0089] The faceplate 20 has a raised convex center 27 which is
perforated with a plurality of inlet holes 21 to allow the
recirculating water to enter the filter housing 31. The rear of the
faceplate 20 has support ribs 22 to strengthen the center 27 to
prevent crushing. Hair entrapment is prevented typically in a
1-11/2 inch piping system flowing at about 50 gallons per minute
with a hole pattern of about 25 holes per square inch at about 0.25
inches O.D.
[0090] The filter housing 31 has mounting holes 32 on its mounting
flange 30 for attachment to the inner wall of the tub 5 via bolts
(not shown), wherein silicone is used behind the mounting flange
30.
[0091] The floor 35 of the filter housing 31 slopes downward into
the drain slots 36,37,38.
[0092] The replaceable filter 40 has a standard fibrous, folding
membrane 43 supported at its outlet end by an outlet cap 41 and at
its closed end by an end cap 42. The porous core 44 is preferably
an ABS pipe mountable in filter housing outlet 39. The holes range
from small 45 at the outlet end to large 46 at the closed end
adjacent the end cap 42. The slots also range from small 47 to
large 48 in a similar fashion, wherein the increasing hole and slot
sizes from the outlet end distribute the water flow across the
entire length of the membrane 43. Without the hole and slot
enlarging feature, the water would only be filtered by a small
portion of the membrane near the outlet 39.
[0093] Referring next to FIG. 5 an alternate embodiment filter
housing 50 has a flange 51 with receiving holes 52 for bolts 53
which mount a faceplate 54 to the flange 51. Multiple holes 55,52
may be used. All other features of the assembly 59 are the same as
the FIG. 4 embodiment.
[0094] Referring next to FIG. 6 the filter housing 30 is seen to
have an arcuate top rear and rear wall 31 generally shaped like a
semi-cylinder when integrated with the floor 35 (also called a
trapepize shape). The relatively sharp radius R allows the housing
31 to be readily installed into a standard size opening cut or
formed into the sidewall of the tub, by tilting the housing
sideways to allow the outlet 39 to fit.
[0095] Referring next to FIGS. 7, 8, 9 the porous core 44 has an
outlet end 70 and a remote end 71. The holes and/or slots at the
remote end 71 are larger than the holes and/or slots at the outlet
end 70. Also slot groups M,N,O,P,Q have ascending values of slot
numbers as they approach the remote end.
[0096] FIG. 10 shows how the outlet end 70 of the porous core 44
fits into the outlet 39 of the filter housing 31.
[0097] FIGS. 11, 12 show an alternate embodiment filter assembly
115 having a charcoal bag filter and/or a chlorine time release
pellet, and/or a bromine time release pellet and/or any chosen
anti-microbial agent 111 in the center of the porous core 110 and
remote from the outlet end. The crosshairs 112 of the core 110
prevent the bag from entering the outlet 39, wherein the outlet end
700 fits into the outlet 39.
[0098] FIG. 13 shows an outlet end plan view of FIG. 12.
[0099] Referring next to FIG. 14 an alternate embodiment housing
310 has inside notches 141 to receive a U shaped brace 140.
[0100] Referring next to FIGS. 15, 16 a suction/filter 1500
consists of a housing 1501 and a faceplate 1502. The housing 1501
is designed to mount flush with a whirlpool bathtub sidewall
adjacent the bottom of the bathtub. Water flows into the
suction/filter 1500 in direction FI and out the outlet port 1503 in
direction FO. The radiating slot pattern 1504 provides for a high
flow rate as well as facilitating an injection molding process that
allows the molten plastic to migrate radially from a central
injection point. The slots extend into the peripheral edge 1701 of
the faceplate 1502 as shown by number 1505. The slots 1506 along
the bottom edge of the faceplate allow the water to drain out of
the housing 1501 in direction DRAIN. This drain function occurs
when the whirlpool system is shut off. Proper draining is a key
element for water return control as called out by ASME code. Both
the top and the bottom of the housing 1501 are sloped as indicated
by angle .varies., which may be about 10.degree., thereby
facilitating draining. The housing 1501 can be installed with the
outlet port pointing left or right, so the top T and the bottom B
are symmetrical to provide proper draining in either
orientation.
[0101] A disposable filter 1507 is supported by a filter core 1508
shown in FIG. 22. To change the disposable filter faceplate 1502
must be removed. This FIG. 15 embodiment secures the faceplate 1502
to the housing 1501 with magnets 1509 and 1510 (see FIG. 17). A
screw 1511 is also used to fit through hole 1512 and lock into
either screw boss 1513 or 1514, depending on the orientation of the
housing 1501.
[0102] The suction/filter 1500 must pass an ASME heavy load and
impact test to prevent a user from breaking the faceplate 1501
which could cause body entrapment. The housing has a plurality of
grooved retainers 1515 which receive the structural fins 1516 which
are best seen in FIG. 17.
[0103] For attachment to the bathtub wall bolts 1517 are provided
which fit into recessed holes 1518.
[0104] Referring next to FIG. 17 the back of the faceplate 1502 is
shown. A central hub 1700 offers structural support for the
radiating structural fins 1516. The lengths of each structural fin
1516 may differ as may quantity. The peripheral edge 1701 of the
faceplate 1502 forms a support ledge 1702 around the peripheral
edge 1703 of the housing 1501.
[0105] Referring next to FIG. 18 the back of the housing 1501 is
shown. The mounting bolts 1517 have nuts 1800. The outlet port 1503
has two alignment ridges 1801, 1802 which function to align the
receiving grooves 1803, 1804 as shown in FIG. 20. A
safety/sanitation port 1803 is connected to a tube 1804 which has
an open end 1805 that is located at a height h which is above the
waterline of the whirlpool bath. If the filter core 1508 is either
missing from or improperly seated in the outlet port 1503, then the
pump's action pulls AIR down the tube 1804, thereby causing
cavitation. This cavitation stops the whirlpool action of the
system by inhibiting water suction. The safety/sanitation port 1803
forces the user to always operate the whirlpool with a proper
filter properly installed.
[0106] Referring next to FIG. 19 the housing 1501 is shown bolted
to the sidewall 1900 of a whirlpool bath. The placement is close to
the bottom 1901 of the whirlpool bath.
[0107] Referring next to FIG. 20 a filter core 1508 has the same
hole pattern as the embodiment shown in FIGS. 7, 8, 9. The holes
2009 distal to the outlet port 1503 are smaller than the holes 2001
proximal to the outlet port to force the water through the entire
length of filter 1507. The filter core 1508 has a mounting collar
1805. The mounting collar 1805 has a recess 1806 which holds a
gasket 1807 in contact with the safety/sanitation port 1803 to seal
the safety/sanitation port 1803 during use. The gasket 1807 may be
welded and/or glued into the recess 1806. The receiving slots 1803,
1804 align the collar 1805 with alignment ridges 1801, 1802.
[0108] Referring next to FIG. 21 the alignment of the recess 1806
(gasket 1807 is not shown) with the entry port 2100 of the
safety/sanitation port 1803 is shown.
[0109] Referring next to FIG. 22 the gasket 1807 is seen sealing
the entry port 2100 of the safety/sanitation port 1803.
[0110] Referring next to FIG. 23 the faceplate 1502 is shown
mounted to the housing 1501 in a sectional view. The support ledge
1702 is shown overlapping the entire peripheral edge 1703 of the
housing 1501. In the embodiment shown in FIGS. 24, 25 the screw
1511 and screw boss 1513 are deleted. Then the faceplate 1502 is
held in place only with the support ledge 1702 and the magnets
1509, 1510.
[0111] Referring next to FIGS. 24, 25 suction/filter 2499 is shown.
The faceplate 2402 no longer has a mounting hole. Otherwise it is
identical to the FIG. 15 embodiment. The housing 2420 no longer has
screw bosses. Otherwise it is identical to the FIG. 15
embodiment.
[0112] In operation a user 2400 may get his or her hair 2401 sucked
into the faceplate 2402 and entangle both the faceplate 2402.
[0113] Suction/filter 2499 protects the user from drowning in the
whirlpool by providing a pop off faceplate 2402 which is only held
in place by small magnets 1509,1510. Additionally the filter 1507
and filter core 1508 pop out based on the choice of forming a
narrow collar 1805 as well as sloping the outlet wall W inward an
angle SW which may be about 4.degree. as shown in FIG. 15.
[0114] Referring next to FIG. 26 an improved filter core 2600 has
an additional feature of a cage 2601 built into the hollow internal
section of the body. A chemical anti-microbial time release tablet
2603 can be inserted between 2601 and 2602, the end cap of the
filter cartridge. The tablet 2603 augments the germ killing
properties of the entire system.
[0115] The filter core 1508 and/or filter 1507 can be made to
include the anti-microbial features of U.S. Pat. No. 6,283,308. The
filter combination 1507/1508 would include a wet laid polypropylene
membrane, inner perforated core member and yarn and an impregnation
of at least one of these components of a non-leaching
anti-microbial agent selected from the group consisting of
2,4,4-trichloro-2-hydroxy diphenol ether and 5-chloro-2phenol (2,4
dichlorophenoxy) compounds.
[0116] Referring to FIGS. 27, 28 a prior art (U.S. Pat. No.
5,799,339) suction device 10P is shown. The safety cover assembly
is generally referred to by the reference numeral 10P, and includes
a cover 12P, a threaded base 14P, a gasket 16P, a threaded collar
18P, an elbow fitting 20P, a stainless steel screw 22P and a name
plate 24P. As will be described below, the cover 12P and the base
14P have interior walls that act as cooperating guide vanes 26BP
and 28BP to advantageously reduce turbulence and vortexing of the
water passing through the safety cover assembly 10P. Thus, the
guide vanes 26BP and 28BP allow the safety cover assembly lop to
handle high flow rates of approximately 200 gallons per minute
while simultaneously reducing the likelihood that hair from a user
will become entangled inside the cover assembly 10P. The guide
vanes 26BP and 28BP enable the safety cover assembly 10P to have a
relatively small size and yet pass the five pound pull test at high
flow rates. The guide vanes 26BP and 28BP also advantageously
increase the structural integrity of the safety cover assembly
10P.
[0117] The cover 12 of assembly lop has a generally square face
wall 30P and four sidewalls 32P (collectively referred to as
sidewall), all with holes 34P formed therein for water flow
therethrough. The total area of the holes 34P in the sidewalls 32P
is greater than that of the holes 34P in the face wall 30P which
are, in turn, greater than the area of a hole 36P in the base 14P,
which mates with a suction drain. The holes 34P in the cover 12P
are arranged in the aforementioned manner so that the water flow
through the cover 12P is uniformly low, thereby reducing the
suction force adjacent to the cover 12P and reducing the likelihood
that the suction force will cause an object to become lodged
against either the face wall 30P or sidewalls 32P of the cover
12P.
[0118] Because the center 38P of the face wall 30P is an area that
would have a high fluid intake flow, the center 38P of the
face-wall 30P is solid. This solid center section 38P evens out the
water flow across the rest of the face wall 30P so that there are
no areas of high flow that would create unwanted areas of high
suction force.
[0119] Guide vanes 26BP and 28BP are integrally formed on the
underside of the cover 12P. The guide vanes 26BP and 28BP are at
right angles to each other and extend between opposite sidewalls
32P of the cover 12P. The guide vanes 26BP and 28BP do not obstruct
any of the holes 34P formed in the face and sidewalls of cover 12P.
This advantageously prevents hair from entering the same hole and
becoming entangled by wrapping around both sides of a guide vane.
Where the guide vanes 26BP and 28BP intersect, a hole through the
cover 12P is provided for the mounting screw 22P. The two guide
vanes 26BP and 28BP on the underside of the cover 12P are sized to
engage with and align with the guide vanes 26BP and 28BP on the
base 14P, which is described below.
[0120] Guide vane 26BP extends from the face wall 30P of the cover
12P toward base 14P. Guide vanes 26BP and 28BP divide the cover 12P
into four portions. The total area of the holes 34P in each
position of the cover 12P equals the total area of the holes 34P in
each other portion of the cover 12P. Each portion of the cover 12P
includes a portion of the face wall 30P and a portion of the
sidewall 32P of the cover 12P. The total area of the holes in the
portion of the sidewall 32P being greater than the total area of
the holes in the portion of the face wall 32P.
[0121] The base 14P has a generally square upper surface. The upper
surface of the base 14P is sized to mate with the sidewalls 32P of
the cover 12P to form a fluid intake chamber 50P inside of the
assembly 10P between the cover 12P and the base 14P. The base 14P
has an externally threaded end 52P sized to threadedly engage the
collar 18P to mount the assembly 10P to the wall 54P of a jetted
tub or spa. The gasket 16P is sized to fit around the threaded end
52P of the base 14P and abut the rear surface of the base 14P. The
wall 54P of the jetted tub would be located between this gasket 16P
and the threaded collar 18P. The gasket 16P can be made of an
elastometric material to cushion impacts upon the fitting lop. The
components of the assembly 10P can be made of ABS plastic or
polycarbonate material by well known injection molding
techniques.
[0122] A first end 56P of the elbow fitting 10P fits inside the
collar 18P and can be attached by adhesive, as is well known in the
art. The other end 58P of the elbow fitting 10P can be connected to
a suction drain of a water circulation system that requires a
relatively high rate of intake water flow.
[0123] The invention shown in FIGS. 29, 30 modify the cover 12P
with the features of cover 12PP. The new suction filter is denoted
2700. Cover 12PP has four slots 59P along the four quadrants of the
peripheral edge 3000 of the cover 12PP. Each slot 5PP receives a
disposable filter 60P. Each disposable filter 60P consists of a
plastic rim 3001 and a filter element 3002. Quadrant dividers 61P
provide support for the disposable filters 60P, so they don't get
sucked into the fluid intake chamber 50P. All other components of
the suction 10P are present in the suction/filter 2700. One skilled
in the art could use the FIG. 29 invention technique to apply a
similar design to any know suction device.
[0124] Nominal Dimensional Measurements Are:
1 d1 5.40 inches d2 12.77 inches d3 .25 inches (O.D.) d4 Blank d5
Blank d6 3.50 inches d7 {fraction (6/32)} inches (O.D.) d8
{fraction (11/32)} inches (O.D.) d9 Blank d10 Blank d11 .17 inches
(O.D.) d12 2.27 inches (O.D.) d13 R5.0 inches (Radius) d14
{fraction (4/32)} inches (O.D.) d15 {fraction (9/32)} inches (O.D.)
d16 10.00 inches
[0125] Although the present invention has been described with
reference to disclosed embodiments, numerous modifications and
variations can be made and still the result will come within the
scope of the invention. No limitation with respect to the specific
embodiments disclosed herein is intended or should be inferred.
* * * * *