U.S. patent application number 11/093901 was filed with the patent office on 2005-09-29 for integrated cleaning apparatus and methods.
Invention is credited to Larsson, John A., Lyon, Marvin G., Taylor, Paul H., VanOrden, Scott T..
Application Number | 20050210620 11/093901 |
Document ID | / |
Family ID | 34987975 |
Filed Date | 2005-09-29 |
United States Patent
Application |
20050210620 |
Kind Code |
A1 |
VanOrden, Scott T. ; et
al. |
September 29, 2005 |
Integrated cleaning apparatus and methods
Abstract
Apparatus and method providing efficient cleaning of various
surfaces. The apparatus including a collector and a controller. The
collector having an inlet conduit, a vacuum pump, a first valve, a
second valve, a tank, and a separator. The inlet conduit connects
to an inlet aperture of the separator, the vacuum pump connects to
an outlet aperture of the separator, the first valve regulates flow
between a drain aperture of the separator and an inlet aperture of
the tank, and the second valve regulates flow through a drain
aperture of the tank. One or more filters may filter flow between
the separator and the vacuum pump. The controller may be programmed
to, upon sensing a full tank, selectively close the first valve and
open the second valve and, after the passage of a selected period
of time, selectively close the second valve and open the first
valve. The collector and controller may provide an integrated,
compact cleaning system that supports continuous operation.
Inventors: |
VanOrden, Scott T.; (Plain
City, UT) ; Larsson, John A.; (Plain City, UT)
; Lyon, Marvin G.; (North Ogden, UT) ; Taylor,
Paul H.; (West Weber, UT) |
Correspondence
Address: |
PATE PIERCE & BAIRD
215 SOUTH STATE STREET, SUITE 550
PARKSIDE TOWER
SALT LAKE CITY
UT
84111
US
|
Family ID: |
34987975 |
Appl. No.: |
11/093901 |
Filed: |
March 29, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60557211 |
Mar 29, 2004 |
|
|
|
Current U.S.
Class: |
15/319 ;
15/320 |
Current CPC
Class: |
A47L 7/0009 20130101;
B60S 3/008 20130101; A47L 9/2805 20130101; A47L 9/2889 20130101;
A47L 9/2857 20130101; A47L 7/0038 20130101; A47L 7/0028
20130101 |
Class at
Publication: |
015/319 ;
015/320 |
International
Class: |
A47L 011/30 |
Claims
What is claimed and desired to be secured by United States Letters
Patent is:
1. A cleaning system, comprising: a collector comprising an inlet
conduit, a vacuum pump, a first valve, a second valve, a tank, and
a separator; the separator having an inlet aperture, an outlet
aperture, and a drain aperture; the tank having an inlet aperture
and a drain aperture; the inlet conduit configured to connect to
the inlet aperture of the separator; the vacuum pump configured to
connect to the outlet aperture of the separator; the first valve
positioned to regulate flow between the drain aperture of the
separator and the inlet aperture of the tank; the second valve
positioned to regulate flow through the drain aperture of the tank;
and a controller programmed to, upon sensing a first tank
condition, selectively close the first valve and open the second
valve.
2. The cleaning system as defined in claim 1, wherein the
controller is further programmed to selectively close the second
valve and open the first valve upon sensing a second tank
condition.
3. The cleaning system as defined in claim 2, wherein the first
tank condition occurs when fluid within the tank rises above a
first level and the second tank condition occurs when fluid within
the tank falls below a second level, distinct from the first
level.
4. The cleaning system as defined in claim 2, wherein the second
tank condition occurs at the expiration of a selected period of
time measured from an event selected from the group consisting of
when the first tank condition was detected, when the first valve
was closed, and when the second valve was opened.
5. The cleaning system as defined in claim 1, wherein the separator
comprises an upper cylinder.
6. The cleaning system as defined in claim 5, wherein the inlet
aperture of the separator introduces flow into the upper cylinder
in a substantially tangential direction.
7. The cleaning system as defined in claim 1, wherein the collector
further comprises an outlet conduit configured to provide a
connection between the outlet aperture of the separator and the
vacuum pump.
8. The cleaning system as defined in claim 7, wherein the outlet
conduit comprises a first filter.
9. The cleaning system as defined in claim 8, wherein the outlet
conduit further comprises a second filter positioned between the
first filter and the vacuum pump.
10. The cleaning system as defined in claim 9, wherein the first
filter is configured to be removed, cleaned, and reused
substantially indefinitely without significant degradation in
filtering ability.
11. The cleaning system as defined in claim 1, wherein the
collector further comprises at least one delivery wand, the inlet
conduit connecting the delivery wand to the inlet aperture of the
separator.
12. The cleaning system as defined in claim 11, further comprising
a carrier subsystem comprising a water source, a heater, and at
least one carrier conduit, the carrier conduit delivering water
from the water source to the heater and from the heater to the
delivery wand of the collector.
13. The cleaning system as defined in claim 11, wherein the carrier
subsystem continuously delivers water to the delivery wand of the
collector at temperature in the range of between about 48.degree.
C. and about 121.degree. C.
14. The cleaning system as defined in claim 12, wherein the carrier
subsystem further comprises a pump to increase the pressure of the
water within the carrier conduit.
15. The cleaning system as defined in claim 14, wherein the carrier
conduit forms a recirculation path through the heater.
16. The cleaning system as defined in claim 15, wherein the carrier
subsystem further comprises a storage tank to store heated
water.
17. The cleaning system as defined in claim 11, further comprising
a detergent subsystem comprising a detergent source, a mixer, and
at least one detergent conduit, the mixer educing detergent from
the detergent source and into the detergent conduit.
18. The cleaning system as defined in claim 17, wherein the mixer
selectively mixes detergent from the detergent source with heated
water from the carrier subsystem.
19. The cleaning system as defined in claim 1, wherein the
controller comprises a processor coupled to a memory device, at
least one sensor connected to the tank of the collector, and at
least one actuator connected to each of the first and second valves
of the collector.
20. The cleaning system as defined in claim 1, wherein the
collector further comprises a balancing conduit and a balance
valve, the balancing conduit connecting the tank to the vacuum
pump, the balance valve positioned to regulate flow through the
balancing conduit.
21. A cleaning system, comprising: a separator having an inlet
aperture, an outlet aperture, and a drain aperture; a tank having
an inlet aperture and a drain aperture; a first valve positioned to
regulate flow between the drain aperture of the separator and the
inlet aperture of the tank; a second valve positioned to regulate
flow through the drain aperture of the tank; and a controller
programmed to selectively close the first valve and open the second
valve upon sensing a first condition and selectively close the
second valve and open the first valve upon sensing a second
condition.
22. The cleaning system as defined in claim 21, further comprising:
a vacuum pump providing positive displacement of air; an outlet
conduit configured to provide a connection between the outlet
aperture of the separator and the vacuum pump; a first filter
positioned within the outlet conduit and configured to be removed,
cleaned, and reused without significant degradation in filtering
ability; and a second filter positioned within the outlet conduit
between the first filter and the vacuum pump.
23. A method for cleaning a surface, the method comprising the
steps of: selecting a collector comprising a vacuum pump, a
separator, and a tank; employing the collector to collect a mixture
of liquid and gas; employing the collector to separate the liquid
from the gas and store the liquid in the tank; emptying the tank,
while continuing to employ the collector to collect the mixture, by
isolating the separator from the tank and opening the drain on the
tank; and returning the tank to storage duty, while continuing to
employ the collector to collect the mixture, by closing the drain
on the tank and reestablishing fluid communication between the
separator and the tank.
24. The method for cleaning a surface as defined in claim 23,
wherein the vacuum pump is a positive displacement pump providing a
vacuum of at least 25.4 cm Hg.
25. The method for cleaning a surface as defined in claim 24,
wherein the step of employing the collector to separate the liquid
from the gas further comprises the step of applying an acceleration
greater than gravitational acceleration to the mixture.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 60/557,211, filed on Mar. 29, 2004 for
CYCLONE EXTRACTOR SYSTEM AND METHOD, which is incorporated herein
by reference.
BACKGROUND
[0002] 1. The Field of the Invention
[0003] This invention relates to cleaning systems and, more
particularly, to novel systems and methods for cleaning carpets and
upholstery using high vacuum, high temperature, continuously
operating cleaning systems.
[0004] 2. The Background Art
[0005] Currently, in the automotive detailing industry, dirty
carpets and upholstery are treated with chemicals (e.g.
surfactants) or chemical and water combinations to help lift grime
and debris from the surface. The resulting mixture may then removed
by a vacuum from the treated carpet or upholstery, which is then
left to dry. Doors of the automobile are often left open to aid in
drying. On occasion, heaters may be used to speed the drying
process. However, even with these aids, several hours may be
required for cleaning the treated carpet or upholstery.
Additionally, prior art cleaning processes have a tendency to
create an odor of mildew. Chemicals left within the carpet or
upholstery attract dirt, whereby the treated carpet or upholstery
may soon need to be re-cleaned.
[0006] In the self-serve carwash industry, current interior
cleaning options are limited to wet-dry vacuums or vacuum and
shampoo systems. Vacuums acting alone are only able to remove
debris that is already loose and easily accessible from the surface
of the carpet or upholstery. Accordingly, a vacuum acting alone is
unable to provide a deep clean or remove adhered materials (e.g.,
grime trapped in soft drink spills, etc.).
[0007] In the vacuum and shampoo systems of the prior art, shampoo
is usually introduced and worked into the dirty carpet or
upholstery. A wet-dry vacuum may then be used to remove the dirty
shampoo. In such situations, there is no rinse cycle. A large
amount of dirty shampoo remains in the carpet or upholstery. This
residual shampoo may leave a strong chemical smell and quickly
attract new dirt.
[0008] Regardless of the industry were they are used, known carpet
and upholstery cleaning systems are not generally optimized for
deep cleaning and fast drying. For example, some current cleaning
systems use large gravity settling tanks that are not easily
included within an integrated package. Additionally, some current
cleaning systems use residential water heaters. Such heaters are
typically limited to a maximum of 60.degree. C. Moreover, they lack
the structures to maintain this temperature throughout the cleaning
process. As appreciated, the water used in such systems cools
significantly before it is ever applied to the carpet or
upholstery, thereby reducing its cleaning potential and increasing
drying time.
[0009] Cleaning systems of the prior art typically use vacuum pumps
that are incapable of producing sufficient suction. Furthermore,
known systems lack the structure necessary to implement more
effective vacuum pumps. Current cleaning systems do not provide
continuous operation. That is, they must be shut down before any
tanks (e.g., settling tanks) can be emptied. In operations
utilizing multiple cleaning stations, this downtime may be a
significant nuisance and thereby reduce the overall efficiency of
the cleaning operation.
[0010] In view of the forgoing failings of the current carpet and
upholstery cleaning systems, what is needed is an integrated,
compact cleaning system that supports continuous operation, enables
water to be applied at near optimal temperatures, produces
sufficient vacuum to remove more grime and reduce drying time, and
eliminates or greatly reduces the need for chemicals.
BRIEF SUMMARY OF THE INVENTION
[0011] In view of the foregoing, in accordance with the invention
as embodied and broadly described herein, a method and apparatus
are disclosed in one embodiment of the present invention as
including an integrated cleaning system comprising a cleanser,
collector, and controller. The cleanser may condition and
distribute cleaning fluids such as detergents and heated water for
dissolving, trapping in solution, or otherwise lifting grime (e.g.
dirt, debris, oil, etc.) from the surface being cleaned. The
collector may extract (e.g. vacuum) the soiled cleaning fluids from
the surface. The controller may monitor and control the operation
of the cleanser and collector.
[0012] In selected embodiments, a cleaner may include a heater for
heating one or more cleaning fluids before they are transported to
a wand for application to the surface being cleaned. Suitable
heaters may include heat exchangers, electric heaters, gas heaters,
and the like. In some embodiments, the cleanser may heat the
cleaning fluids (e.g. water) under pressure to increase their
boiling temperature. This may permit the cleaning fluids to have
greater thermal energy when applied to the surface.
[0013] In general, the hotter the cleaning fluids, the better and
faster the cleaning. For example, the hotter the water used, the
less chemical detergents are needed. Certain embodiments in
accordance with the present invention may apply water at
temperatures range from about 48.degree. C. and about 121.degree.
C., or even greater. To maintain the cleaning fluids at the desired
temperature at distant locations, the cleaner may recirculate
cleaning fluid through the heater. Moreover recirculation conduits
and wand conduits may be insulated to reduce heat loss.
[0014] A collector in accordance with the present invention may
utilize deep vacuum pumps. In general, deeper vacuums extract the
cleaning fluids and dirt better than lower vacuums. As a result, a
deeper vacuum generally shortens drying times. Additionally,
cleaning fluids will evaporate at a lower temperature under vacuum.
Selected collectors in accordance with the present invention may
pull a vacuum of 25.4 cm Hg or greater.
[0015] In certain embodiments, a separator may remove the large
majority of the liquid from the flow before it reaches the vacuum
pump. In some embodiments, the separator may enforce a centrifugal
acceleration greater than gravitational acceleration to effect the
separation.
[0016] Deep vacuum pumps typically have close tolerances that must
be protected from the debris and moisture picked up during the
cleaning process. In certain embodiments, one or more filters may
be positioned in the flow between the separator and the vacuum pump
in order to mitigate the debris and moisture.
[0017] After being separated from the flow of air, waste (e.g.,
water, trash, dirt, foam, chemicals, and the like) may be stored in
a storage tank. In certain embodiments, such storage may be
contained within the separator itself. In other embodiments, an
additional tank or tanks may be employed to store the waste as
needed.
[0018] The novel systems in accordance with the present invention
may further include a discharge system allowing for continuous
operation. That is, removal of the waste liquids without shutting
down the collector. By operating selected valves (manually,
mechanically, or under computer control), one volume may be taken
off-line and emptied while another continues to collect
liquids.
[0019] Integrated cleaning systems in accordance with the present
invention may be operated manually, mechanically, or by computer.
In selected embodiments, a controller may facilitate computer
control of the system. For example, a controller may include a
programmable logic controller (PLC) programmed to facilitate the
various valve openings and closings that may be needed to
accomplish continuous operation of a collector. Swapping collection
volumes may be programed or arranged to occur automatically when
certain liquids levels are achieved. Moreover, various sensors and
actuators may inform an operator of maintenance needs, low levels,
low temperatures, high temperatures, low vacuum, high vacuum, and
other system issues that may require attention.
[0020] In selected embodiments of the present invention, multiple
cleaning stations (e.g. multiple wands) may be run with one
integrated cleaning system in accordance with the novel concept of
the present invention. Cleaning systems of the present invention
may be applied to large and small detail shops, car dealers,
semi-truck detail shops, gas stations, self-serve car washes, bus
washes, rental car agencies, and large companies with an automobile
fleet. Moreover, the present invention may be applied to cleaning
applications unrelated to automobiles. For example, an integrated
cleaning system may be used in furniture refurbishing, commercial
carpet cleaning, and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The foregoing features of the present invention will become
more fully apparent from the following description and appended
claims, taken in conjunction with the accompanying drawings.
Understanding that these drawings depict only typical embodiments
of the invention and are, therefore, not to be considered limiting
of its scope, the invention will be described with additional
specificity and detail through use of the accompanying drawings in
which:
[0022] FIG. 1 is a schematic, block diagram of an integrated
cleaning system in accordance with one presently preferred
embodiment of the present invention;
[0023] FIG. 2 is a schematic diagram of one presently preferred
embodiment of a cleanser in accordance with the present
invention;
[0024] FIG. 3 is a schematic diagram of an alternative presently
preferred embodiment of a cleanser in accordance with the present
invention;
[0025] FIG. 4 is a schematic diagram of another alternative
presently preferred embodiment of a cleanser in accordance with the
present invention;
[0026] FIG. 5 is a schematic diagram of one presently preferred
embodiment of a collector in accordance with the present
invention;
[0027] FIG. 6 is a block diagram of one presently preferred
embodiment of a method for operating the collector as shown in FIG.
5;
[0028] FIG. 7 is a top, cross-sectional view of one presently
preferred embodiment of a separator in accordance with the present
invention;
[0029] FIG. 8 is a side, cross-sectional elevation view of the
separator as shown in FIG. 7;
[0030] FIG. 9 is a schematic diagram of an alternative presently
preferred embodiment of a collector providing continuous operation
in accordance with the present invention;
[0031] FIG. 10 is a block diagram of one presently preferred
embodiment of a method of the present invention for operating the
collector as shown in FIG. 9;
[0032] FIG. 11 is a schematic diagram of another alternative
presently preferred embodiment of a collector providing continuous
operation in accordance with the present invention;
[0033] FIG. 12 is a block diagram of one presently preferred
embodiment of a method of the present invention for operating the
collector as shown in FIG. 11;
[0034] FIG. 13 is a side elevation of one presently preferred
embodiment of an integrated cleaning system secured to a skid in
accordance with the present invention;
[0035] FIG. 14 is a schematic, block diagram of one presently
preferred embodiment of a controller in accordance with the present
invention;
[0036] FIG. 15 is a schematic, block diagram of one presently
preferred embodiment of a sensor suite in accordance with the
present invention;
[0037] FIG. 16 is a block diagram of one presently preferred
embodiment of a method of the present invention for monitoring an
integrated cleaning system in accordance with the present
invention; and
[0038] FIG. 17 is a schematic, block diagram of one presently
preferred embodiment of an actuator suite in accordance with the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] It will be readily understood that the components of the
present invention, as generally described and illustrated in the
drawings herein, could be arranged and designed in a wide variety
of different configurations. Thus, the following more detailed
description of the presently preferred embodiments of the system
and method of the present invention, as represented in the
drawings, is not intended to limit the scope of the invention, as
claimed, but is merely representative of various embodiments of the
invention. The presently preferred embodiments of the invention
will be best understood by reference to the drawings, wherein like
parts are designated by like numerals throughout.
[0040] Referring to FIG. 1, an integrated cleaning system 10 in
accordance with one presently preferred embodiment of the present
invention may include a cleanser 12, a collector 14, and a
controller 16. The cleanser 12 may condition and distribute
cleaning fluids for dissolving, trapping in solution, or otherwise
lifting grime (e.g., dirt, debris, oil, etc.) from the surface
being cleaned. The collector 14 may extract the cleaning fluids and
thereby dislodge grime from the surface and properly dispose of the
same. The controller 16 may monitor and control the operation of
the cleanser 12 and the collector 14 to promote safe, efficient
operation of the overall cleaning system 10.
[0041] Referring now to FIGS. 1 and 2, in selected embodiments, a
cleanser 12a in accordance with the present invention may include a
carrier subsystem 18a. A carrier subsystem 18a may prepare and
deliver a primary cleaning fluid. Due to cost, safety, and
availability, the primary cleaning fluid of choice is often water.
However, other fluids or combinations of fluids may be used. For
example, and not by way of limitation, alcohol, dry cleaning
chemicals, and the like may be used as the primary cleaning
fluid.
[0042] In selected embodiments, a carrier subsystem 18a may include
a heater 20 to increase the temperature of the primary cleaning
fluid as it passes through various conduits 21 directing it from a
source 22 to the surface 24 being cleaned. In general, the higher
the temperature of the cleaning fluid, the greater its ability to
lift grime from the treated surface 24. Additionally, in general,
the hotter the cleaning fluid, the more rapidly it will evaporate
from the surface 24 once the treatment or cleaning process is
completed.
[0043] A source valve 26 may be positioned between the source 22
and the heater 20 to control the flow of the primary cleaning fluid
into the carrier subsystem 18a. In certain presently preferred
embodiments, the source valve 26 may be actuated by a solenoid 28.
Accordingly, an operator of the cleaning system 10 desiring
delivery of the cleaning fluid to the surface 24 may close an
electrical circuit and thereby activate the solenoid 28. The
solenoid 28, in turn, may open the source valve 26 permitting
cleaning fluid to pass from the source 22, through the heater 20,
to the point of application on the targeted surface 24, as selected
by the operator.
[0044] A heater 20 in accordance with one presently preferred
embodiment of the present invention, may be found in any suitable
configuration or principal of operation. For example, the heater
may use electric current passing through a heating element to
generate the desired thermal energy to increase the temperature of
the cleaning fluid passing through it. Alternatively, the heater
may burn a combustible material to generate the desired thermal
energy. In alternate other embodiments, a heat exchanger may be
used which is contemplated herein.
[0045] In certain embodiments, a heater 20 may include an insulated
tank. In such embodiments, the heater 20 may heat the primary
cleaning fluid and store the same within the tank for future use.
Such an arrangement may provide a quantity of heated cleaning fluid
when desired. The size of the insulated tank and the heater's
thermal energy generating capacity may be selected to match demand.
Accordingly, the quantity may be sufficiently large to avoid excess
depletion when considering the rate at which heated cleaning fluid
is exiting and unheated cleaning fluid is entering.
[0046] In other embodiments, a heater 20 may adjust according to
flow patterns of the primary cleaning fluid. For example, when the
source valve 26 is closed, the heater 20 may cease operation. When
the source valve 26 is opened and flow of the primary cleaning
fluid resumes, the heater 20 may inject thermal energy into the
flow. In such an embodiment, the source 22, the source valve 26,
and the heater 20 may combine to create an "on demand" system
delivering potentially unlimited quantities of primary cleaning
fluid heated to a temperature selected for optimal or near optimal
cleaning performance (i.e., grime lifting).
[0047] In selected embodiments, the primary cleaning fluid may be
delivered to the surface 24 at or near the pressure of the source
22. For example, if the source 22 is a municipal water system, the
primary cleaning fluid may be delivered to the surface 24 at or
near the local pressure provided by the system supplying the source
22. Alternative, any arrangement of one or more pumps may increase
(i.e., boost) the pressure within the cleanser 12 above that of the
source 22. In still other embodiments, the source 22 may comprise a
pump for extracting fluid from a reservoir. For example, the source
22 may comprise a pump that extracts water from an on-site well. In
such situations, the pressure of the primary cleaning fluid within
the carrier subsystem 18a may be substantially equal to the
pressure generated by the pump, taking into consideration
frictional losses.
[0048] A cleanser 12a, in accordance with one presently preferred
embodiment of the present invention may also include a detergent
subsystem 30a facilitating application of one or more detergents to
the surface 24 being cleaned. Suitable detergents may include any
suitable cleaning agents in either solid of liquid form. For
example, a suitable detergent may be any water-soluble or liquid
preparation that is able to emulsify oils and hold dirt in
suspension.
[0049] The concentration of the ingredients with the detergent may
be controlled in any suitable manner. For example, liquid detergent
manufactured in a high concentration may be appropriately diluted.
Similarly, detergent manufactured as a solid may be dissolved in an
selected amount of an appropriate solvent. In certain embodiments,
detergent may be dissolved in or diluted with a selected amount of
the primary cleaning fluid.
[0050] Still referring to FIG. 2, in one presently preferred
embodiment of the present invention, a detergent subsystem 20 may
include a pump 32 for extracting detergent from a reservoir 34 and
delivering the extracted detergent to the surface 24 being
cleaning. In selected embodiments, the pump 32 may be manually
operated. In one example, the pump 32 and reservoir 34 may be
embodied as a hand-operated spray bottle. Alternatively, the
reservoir 34 may be located some distance from the target treatment
surface 24. In such embodiments, a pump 34 may transport detergent
from the reservoir 34 to the surface 24 through appropriate
conduits 35. If desired, at the point of application, a detergent
subsystem 30 may include a nozzle generating a distributed flow
pattern and producing an efficient application of the detergent to
the surface 24.
[0051] Referring now to FIG. 3, a detergent subsystem 30b are
suitable in accordance with one presently preferred embodiment of
the present invention, may be formed having any suitable
configuration or principles of operation to deliver detergent to
the surface 24 being cleaned. In selected embodiments, the
detergent and primary cleaning fluid may be mixed and
simultaneously applied to the surface 24. For example, in certain
embodiments, a carrier subsystem 18b may deliver the primary
cleaning fluid to one or more delivery wands 36 (i.e., Wand A, Wand
B, Wand C). Accordingly, a mixer 38, positioned along the length of
a conduit 21 of the carrier subsystem 18b, may add detergent to the
primary cleaning fluid before it reaches a corresponding delivery
wand 36.
[0052] In selected embodiments, a mixer 38 may operate as a
venturi, educing detergent from the reservoir 34 at a rate
proportional to the flow of the primary cleaning fluid. In such an
embodiment, a pump 32 may be unnecessary. In other embodiments, a
mixer 38 may act as a pump 32. For example, a mixer 38 may include
a paddle wheel extending into the flow of the primary cleaning
fluid. So arranged, the paddle wheel may rotate with a speed
proportional to the flow of the primary cleaning fluid. The
rotation of the paddle wheel may be used to educe detergent from
the reservoir 34 and meter the same into the flow of the primary
cleaning fluid.
[0053] In one presently preferred embodiment of the present
invention, a single meter 38 may be positioned "upstream" from all
delivery wands 36. For example, in one embodiment, a single meter
38 may distribute detergent after the primary cleaning fluid has
been heated, but before it is divided to service the one or more
delivery wands 36. Alternatively, one meter 38 may distribute
detergent at a location just after the source valve 26. In other
embodiments, more than one meter 38 may be used. For example, a
different meter 38 may be positioned "upstream" of each delivery
wand 36. In such an embodiment, the various meters 38 may draw
detergent from one reservoir 34 or any combination of multiple
reservoirs 34, as desired.
[0054] A carrier subsystem 18, in accordance with one presently
preferred embodiment of the present invention may include any
components or arrangements for simplifying the operation, improving
the efficiency, improving the safety, and reducing the initial and
operating costs thereof. For example, in selected embodiments of
the present invention, a source valve 26 may be a differential
pressure regulator. In such an arrangement, the source valve 26 may
permit fluid to enter the carrier subsystem 18b any time the
pressure of the source 22 exceeds the pressure within the carrier
subsystem 18b by a pre-determined selected amount. In other
embodiments, a source valve 26 may a manually operated gate valve.
If desired, a carrier subsystem 18b of the present invention may
include a pressure relief valve 40 to avoid over pressurization of
the system.
[0055] One presently preferred embodiment of the present invention,
a tank 42 may be included within the carrier subsystem 18b. The
tank 42 may be incorporated as part of the heater 20, as discussed
hereinabove. In other embodiments, the tank 42 may be an
independent component. If desired, the tank 42 may be insulated and
form a buffer between the demand for heated cleaning fluid and the
ability of the heater 20 to provide the same.
[0056] As shown in FIG. 4, in selected embodiments, it may be
desirable to reduce the loss of thermal energy from the cleaning
fluid as it travels in conduits 21 from the heater 20 to the
appropriate delivery wand 36. For example, in certain embodiments,
selected conduits 21 through which the heated cleaning fluid
travels may be insulated, thereby reducing the rate at which
thermal energy is lost to the surrounding environment. According to
such design, the drop in temperature of the cleaning fluid between
the heater 20 and the delivery wand 36 may be reduced.
[0057] Alternatively, or in combination with insulation, selected
conduits 21 of the carrier subsystem 18c may be connected to form a
recirculation loop 44. In such an embodiment, a pump 46 may
recirculate unused cleaning fluid through the heater 20.
Accordingly, the temperature of the cleaning fluid at the extremes
of the carrier subsystem 18 may be maintained very near that of the
cleaning fluid leaving the heater 20. The length 48 of the conduit
21 which extends between the recirculation loop 44 and the delivery
wand 36 may be minimized, or even eliminated, to limit the drop in
temperature of the cleaning fluid as it travels from the
continuously heated recirculation loop 44 to the delivery wand
36.
[0058] In selected embodiments of the present invention, a pump 46
may be used to increase the pressure of the cleaning fluid within
the carrier subsystem 18c. This increase in pressure may be in
addition to that provided by the source 22, booster pump, reservoir
pump, etc. The pump 46 responsible for pressurization may be the
same pump 46 responsible for recirculation. Alternatively, multiple
pumps 46 may be used to the perform the different functions. If
desired or necessary, a throttling valve 50 may be incorporated
with the carrier subsystem 18c to facilitate pressurization.
[0059] The primary cleaning fluid may be heated under pressure to
increase the boiling temperature. For example, in some embodiments
employing water as the primary cleaning fluid, the water may be
heated to temperatures ranging from between about 48.degree. C. and
about 121.degree. C., or even greater. By heating the water above
the boiling temperature of water at the ambient pressure, part of
the water may vaporize as it discharges from the delivery wand 36
into the relatively low pressure environment. This process may
introduce the water deeper into the targeted surface 24,
facilitating a deeper cleaning. Additionally, the extra heat from
the vapor may speed the rate at which grime is dissolved and lifted
from the surface 24 being treated. A portion of the extra heat from
the vapor may also be transferred to the targeted surface 24 and
thereby increase the rate of evaporation (drying) once the cleaning
has been completed.
[0060] In general, the cleaning process may be visualized as a pie
chart divided into three sections. The first section may represent
the temperature of the primary cleaning fluid. The second section
may represent the amount of detergent needed. The final section may
represent the amount of agitation needed. An increase in one area
of the pie chart will generally result in a reduction in one or
both of the other two areas of the pie chart. Similarly, by
increasing the thermal energy carried within the primary cleaning
fluid, the amount of detergent and agitation needed may be
significantly reduced. Such a configuration as contemplated and
taught herein may provide fast cleaning (i.e., less agitation
needed) and limit the use of detergents that attract dirt and leave
unpleasant odors.
[0061] Other components may be incorporated within the carrier
subsystem 18 as necessary. For example, as discussed hereinabove, a
storage tank 42, which may or may not be insulated, may be
employed. Additionally, sensors 52 may be incorporated into the
overall cleaning system to monitor the carrier subsystem 18c and
collect information regarding temperature, pressure, flow rate,
detergent concentration, and the like.
[0062] Referring now generally to FIGS. 5-8, in selected
embodiments, a delivery wand 36 in accordance with one presently
preferred embodiment of the present invention may include a suction
nozzle and a manually triggered spray jet. The suction nozzle may
be connected to a collector 14a. The spray jet may be connected to
a cleanser 12. Accordingly, cleaning fluids and detergents may be
applied to the target surface 24 through the spray jet and be
removed from the surface 24, together with the entrapped grime and
debris, through the suction nozzle. Delivery wands 36 manufactured
by HyDry.RTM. and others have been found to be suitable.
[0063] In operation, a delivery wand 36 may be moved across the
treatable surface 24 while depressing the trigger on the spray jet.
As the delivery wand 36 travels, cleaning fluid (e.g., primary
cleaning fluid, detergent, or combinations thereof) may be injected
into the surface 24 and then removed, with the dissolved grime and
debris, by the suction nozzle. The flow of the cleaning fluid may
be stopped by releasing the trigger. This process may be repeated
as necessary. To extract even more cleaning fluid, grime and debris
from the treated surface 24, an operator may again move the
delivery wand 36 over the surface 24, but without depressing the
trigger on the spray jet.
[0064] Novel cleaning systems 10 in accordance with the
contemplated breadth and scope of the present invention may include
one or more delivery wands 36 of various types. In one presently
preferred embodiment, the delivery wands 36, and the conduits 21
delivering cleaning fluids thereto, may be arranged in such a
manner so as to maintain temperature and pressure of the cleaning
fluids. For example, the conduits 21 leading to one or more
delivery wands 36 may be insulated, configured to recirculate, or
both.
[0065] In certain embodiments, a collector 14a in accordance with
the present invention may include a pump 54, a filter 56, a
separator 58, and various conduits 60. A pump 54 may have or use
any suitable configuration or principle of operation. For example,
but not by way of limitation, suitable pumps 54 may include
positive displacement blowers, a multi-stage centrifugal pumps,
regenerative blowers, and the like. In general, the greater the
vacuum produced by the pump 54, the greater the ability of the
collector 14a to remove additional waste, including cleaning
fluids, from the treated surface 24. Greater removal capabilities,
in turn, improve the cleanliness of the surface 24 and reduce the
drying time. Selected pumps 54, in accordance with one presently
preferred embodiment of the present invention, may pull a vacuum of
25.4 cm Hg or greater.
[0066] In one presently preferred operation of the present
invention, a collector 14a may collect a mixture of liquid and gas.
The liquid may include the cleaning fluid, foam or suds, as well as
the entrapped grime and debris. The gas may include air drawn into
the delivery wand 36 from an ambient reservoir 62. A separator 58
may separate the liquid from the gas. The liquid may then be
properly discarded and the gas may continue on its path to the pump
54.
[0067] A separator 58 may have or use any suitable configuration or
principle of operation. In some embodiments, a separator 58 may use
the acceleration of gravity to separate the heavier liquid from the
lighter gas. In other embodiments, a separator 58 may use
centrifugal force to effect the separation. If desired, a separator
58 system may be sized and shaped to apply a centrifugal
acceleration greater than gravitational acceleration. Such design
may facilitate a compact device producing a rapid separation.
[0068] For example, in certain embodiments, one or more delivery
wands 36 may connect to an inlet conduit 60a extending from an
inlet aperture 64 of the separator 58. In one presently preferred
embodiment of the present invention, the separator 58 may have a
generally cylindrical shape. The inlet aperture 64 may introduce
flow into the separator 58 in a substantially tangential direction
66 with respect to the cylindrical shape. An outlet conduit 60b may
extend from an outlet aperture 68 of the separator 58 to the pump
54. The outlet aperture 68 may be centrally located. With such an
arrangement, the heavy liquid may be forced to a wall 70 of the
separator 58, where it may fall down 72, collect, and drain out a
drain aperture 74. In contrast, the gas may be forced to the center
of the separator 58, where it may be evacuated out the outlet
aperture 68 by the pump 54.
[0069] The pump 54 designed to pull high vacuums may have close
tolerances. To increase the life of such pumps 54, these tolerances
must be protected from the debris and moisture picked up during the
cleaning operation. In certain embodiments, one or more filters 56
may be positioned between a separator 58 and a pump 54 to protect
the pump 54 from trash, waste, grim, grease oil, sand, moisture,
and the like. For example, a filter 56 may be positioned along an
outlet conduit 60b to remove debris from the flow before it reaches
the pump 54.
[0070] In selected embodiments as shown more specifically in FIGS.
5 and 6, a separator 58 may include, or be coupled with, a volume
76 where, during operation, liquid may collect. For example, a
separator 58 may have an internal volume 76 sized to contain a
selected quantity of liquid. Alternatively, an external volume 76
(e.g., external tank) may be coupled to the separator 58 to contain
the liquid. When this volume 76 is filled, it may be emptied,
thereby permitting the collector 14a to continue its normal
operation.
[0071] In one presently preferred embodiment of the present
invention, various steps of procedures may be followed to empty a
volume 76, as illustrated in FIG. 6. These procedures may depend
upon the characteristics of the collector 14a. For example, in
embodiments like that shown in FIG. 5, the first step may be to
detect 78 that the volume is full. The collector 14a may then be
deactivated 80. Once the collector 80 has ceased operation, a drain
valve 82 regulating the flow between the volume 76 and a drain 84
may be opened 86 and remain so until the volume 76 has completely
drained 88. The drain valve 82 may then be closed 90 and the
collector 14a activated 92.
[0072] Referring now to FIGS. 9 and 10, in selected embodiments, a
collector 14b may provide continuous operation. To provide such
functionality, a collector 14b may include a first tank 94a and a
second tank 94b (i.e., external volumes 76a, 76b), both connected
to the drain aperture 74 of the separator 58. By alternating
between the first and second tanks 94a, 94b, continuous operation
of the collector 14b may be achieved.
[0073] In certain embodiments, various valves may be used to
alternately fill and drain the first and second tanks 94a, 94b. For
example, a first separator valve 96a may regulate flow into the
first tank 94 while a first drain valve 82a regulates flow out of
the first tank 94a. Similarly, a second separator valve 96b may
regulate flow into the second tank 94b while a second drain valve
82b regulates flow out of the second tank 94b. If desired or
necessary, balancing conduits 98 with first and second balance
valves 100a, 100b may connect the first and second tanks 94a, 94b,
respectively, to the outlet conduit 60b.
[0074] Operation of a collector 14b providing continuous operation
may begin with the activation 102 of the cleaning system 10. In one
presently preferred embodiment of the present invention, steps may
be taken to close 104 the first drain valve 82a, close 106 the
second drain valve 82b, open 108 the first separator valve 96a, and
close 110 the second separator valve 96b. In such a configuration,
the first tank 94a may receive liquid from the separator 58 while
the second tank 94b does not. However, the second tank 94b may be
ready to take over when needed. The operation of the collector 14b
may then be monitored 112 to determine when a change in the tanks
94a, 94b is needed.
[0075] When a full tank 94a, 94b is detected 114, the corresponding
balance valve 100a, 100b may be closed 116. That is, if a full
first tank 94a is detected 114, then the first balance valve 100a
may be closed 116. Alternatively, if a full second tank 94b is
detected 114, then the second balance valve 100b may be closed 116.
Next, the non-corresponding separator valve 96b, 96a may be opened
118 and the corresponding separator valve 96a, 96b closed 120.
Accordingly, liquid from the separator 58 may stop entering the
full tank 94a, 94b and begin entering the other tank 94b, 94a.
[0076] At this stage, the full tank 94a, 94b is closed off from the
rest of the collector 14b. Accordingly, the corresponding drain
valve 82a, 82b may be opened 122, and remain so until the full tank
94a, 94b has drained 124. Various methods may be used to determine
when the tank 94a, 94b has completely drained 124. In selected
embodiments, the time required for a complete drain may be
determined. Accordingly, by opening 122 the corresponding drain
valve 82a, 82b and waiting the required time (plus, perhaps, a
safety factor), it may reasonably be assured that the tank 94a, 94b
has completely drained 124. Alternatively, one or more sensors 52
(e.g., float sensors) may be used to determine the fluid level
within the tank 94a, 94b.
[0077] Once the tank 94a, 94b has drained 124, the corresponding
drain valve 82a, 82b may be closed 126 and the corresponding
balance valve 100a, 100b opened 128. The pump 54 may then pump down
130 the now empty tank 94a, 94b until its internal pressure matches
that of the separator 58, thus ensuring a smooth transition of the
tank 94a, 94b back into operation. In selected embodiments, the
size (e.g., inner diameter) of the balance conduits 98 may be
selected to limit how fast the empty tank 94a, 94b may be pumped
down 130. In general, the smaller the conduit 98, the longer the
tank pump down 130 process.
[0078] Again, the operation of the collector 14b may be monitored
112 to determine when a change in the tanks 94a, 94b is needed.
When that need arises, the empty tank 94a, 94b may be returned to
duty while the other 94b, 94a is taken off-line and emptied. This
process may continue until the collector 14b is no longer needed.
At that point, the system 10 may be deactivated 132.
[0079] As discussed hereinabove, a collector 14b, in accordance
with one presently preferred embodiment of the present invention
may include one or more filters 56. In selected embodiments, a
collector 14b may have two filters 56a. If desired, the filters
56a, 56b may be identical. Alternatively, each filter 56a, 56b may
perform a different function. For example, in one embodiment, a
first filter 56a may provide an easily cleaned, reusable
pre-filter, which protects the second filter 56. Additionally, the
first filter 56a may act as a demister, pulling additional moisture
from the flow. The second filter 56b may then be a less expensive
filter than would otherwise be suitable in a collector 14b with
just one filter 56. Such a design may increase the ruggedness of
the cleaning system 10 and decrease maintenance frequency and
cost.
[0080] Referring now to FIGS. 11 and 12, in selected previously
preferred embodiments, a collector 14c may provide continuous
operation in a more compact design. For example, certain collectors
14c providing continuous operation in accordance with the present
invention may include one tank 94 connected to a separator 58. To
provide such functionality, a separator 58 may include a volume 76
of selected size therewithin. Accordingly, liquid may be collected
within this volume 76 while the connected, external tank 94 is
being empty. By alternating between the volume 76 located within
the separator 58 and the external tank 94, continuous operation of
the collector 14c may be achieved.
[0081] In one presently preferred embodiment of the present
invention, operation of such a collector 14c may begin with the
activation 112 of the cleaning system 10. Steps may be taken to
close 104 the drain valve 82, open 108 the separator valve 96, and
close 116 the balance valve 100. So configured, all liquid
extracted from the flow will pass out of the separator 58 and into
the tank 94. The operation of the collector 14c may then be
monitored 112 to determine when a change in the tank 94 is
full.
[0082] When a full tank 94 is detected 114, the separator valve 96
may be closed 120. Accordingly, liquid may stop entering the full
tank 94 and begin to collected within the drain conduit 60c and the
volume 76 within the separator 58. At this stage, the full tank 94
is closed off from the rest of the collector 14c. Accordingly, the
drain valve 82 may be opened 122, and remain so until the tank 94
has drained 124. The drain valve 82 may then be closed 126 and the
balance valve 100 opened 128. The pump 54 may pump down 130 the now
empty tank 94 until its internal pressure matches that of the
separator 58.
[0083] Finally, the separator valve 96 may again be opened 108. As
a result, any liquids that have collected within the drain conduit
60c and the volume 76 of the separator 58 may pass into the tank
94. In that the time required to empty the tank 94 may be
relatively short, the amount of liquid collected within the
separator 58 may be limited. However, the volume 76 within the
separator 58 may be sized to match any anticipated liquid
collection rate.
[0084] Once in normal operation, the collector 14c may again be
monitored 112 to determine when the tank 94 full. When that occurs,
the tank 94 may again be taken off-line and emptied. This process
may continue until the collector 14c is no longer needed. At that
point, the cleaning system 10 may be deactivated 132.
[0085] Referring now to FIG. 13, in selected presently preferred
embodiments, a selected component of a cleaning system 10, in
accordance with the present invention may be applied to a skid 134
or other portable or modular device. This may significantly reduce
the size or footprint of the system 10 as well as reduce the time
required for installation, relocation, and the like.
[0086] In certain embodiments, various components may be
incorporated into the skid 134. For example, railings 136 on the
skid 134 may be used to secure various components. Additionally, in
selected embodiments, the base 138 of the skid 134 may be formed as
one or more closed containers. These closed containers may then
function as tanks 94, as discussed hereinabove. The bottom of the
base 138 may be slopped as necessary to facilitate draining
124.
[0087] Referring to FIG. 14, in selected presently preferred
embodiments, a controller 16a in accordance with the present
invention may include a computer 140. The computer 140 may include
a processor 142 coupled to a memory device 144. In some presently
preferred embodiments, the computer may constitute a PLC. The
computer 140 may receive information from a sensor suite 146.
Various logic contained within the computer 140 may direct it how
to respond to this information. Responses may manifest themselves
in commands issued to an actuator suite 148. Accordingly, through
the sensor suite 146, the computer learns what is transpiring with
the cleaning system 10 and through the actuator suite 148, various
operations, corrections, adjustments, warnings, and the like may be
implemented.
[0088] Referring now to FIGS. 15 and 16, in certain embodiments, a
sensor suite 146 may include any combination of fluid level sensors
52a, valve position sensors 52b, pressure sensors 52c, temperature
sensors 52d, flow sensors 52e, filter sensors 52f, concentration
sensors 52g, current sensors 52h, RPM sensors 52i, as well as any
other sensors 52j that may collect desired or necessary
information. These sensors 52 may collect information from the
cleanser 12, the collector 14, or even the controller 16, itself.
For example, the sensors 52 may alert the computer 140 when a tank
94 is full, a pump 32, 46, 54 is working too hard, a detergent
reservoir 34 is low, a valve 26, 40, 82, 96, 100 is not functioning
properly, a pressure is too high, a temperature is too low, and the
like.
[0089] In a monitoring mode 112, a computer 140 may search
information received from the sensor suite 142 in an effort to
identify any error conditions. When an error is detected 150, the
computer 140 may determine 152 whether the error is critical. If
the error is not critical, the computer 140 may simply inform 154
the operator of the condition. This communication may be made
through the use of any appropriate display message, light, sound,
combination thereof, or the like. If the error is critical, the
computer 140 may inform 154 the operator and take 156 appropriate
measures. For example, if a senor 52f senses an excessively dirty
filter 56, the computer 140 may send a command to deactivate the
collector 14. Such precautionary action is intended to prevent
valuable equipment (e.g., the pump 54) from being damaged or
harmed.
[0090] Referring to FIG. 17, in selected presently preferred
embodiments of the present invention, an actuator suite 148 may
provide the mechanisms through which commands issued by a computer
are implemented. In certain embodiments, an actuator suite 148 may
include any combination of valve actuators 158a, and pump actuators
158b, power actuators 158c, as well as any other actuators 158d
that may be desired or necessary. Actuators 158, in accordance with
one presently preferred embodiment of the present invention, may
have or use any suitable configuration or principle of operation.
For example, valve actuators 158a may be solenoids, while pump
actuators 158b may be electrically operated switches.
[0091] Consistent with the foregoing, the present invention
provides an integrated cleaning system comprising a cleanser, a
collector, and a controller. The cleanser may condition and
distribute cleaning fluids such as detergents and heated water for
dissolving, trapping in solution, or otherwise lifting grime (e.g.
,dirt, debris, oil, etc.) from the surface being cleaned. A
cleanser may apply heated water to the surface being cleaned at a
temperature of between about 48.degree. C. and about 121.degree. C.
The collector may extract (e.g., vacuum) the soiled cleaning fluids
from the treated surface. A collector may include one or more
filters positioned to protect the close tolerances of a high
vacuum, positive displacement pump. The controller may selectively
monitor and control the operation of the cleanser and
collector.
[0092] Unlike the prior art, the present invention provides an
integrated, compact cleaning system that supports continuous
operation, enables water to be applied at near optimal
temperatures, produces sufficient vacuum to remove more grime and
reduce drying time, and eliminates or greatly reduces the need for
chemicals.
[0093] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative, and not restrictive. The scope
of the invention is, therefore, indicated by the appended claims,
rather than by the foregoing description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *