U.S. patent application number 13/156337 was filed with the patent office on 2012-12-13 for wet/dry vacuum appliance, dust filtration attachment therefore, and methods of use.
This patent application is currently assigned to EMERSON ELECTRIC CO.. Invention is credited to Robert R. Hollis, Mark J. Tomasiak, Matthew A. Williams.
Application Number | 20120311811 13/156337 |
Document ID | / |
Family ID | 47291889 |
Filed Date | 2012-12-13 |
United States Patent
Application |
20120311811 |
Kind Code |
A1 |
Hollis; Robert R. ; et
al. |
December 13, 2012 |
WET/DRY VACUUM APPLIANCE, DUST FILTRATION ATTACHMENT THEREFORE, AND
METHODS OF USE
Abstract
A wet/dry vacuum assembly is described which includes a
powerhead assembly capable of removable attachment to the open
upper end of a container, the powerhead assembly including a
housing, a motor, a fan, and air inlet, and an air exhaust port;
and, a container having an open upper end, a closed lower end, and
at least one sidewall there between, the container including a
continuous handle member for carrying the container in a suspended
position. Also described are water filter attachments having
particle diffusing means formed therein, for use with the wet/dry
to vacuum assembly for use in dust control when the vacuum assembly
is used for vacuuming up fine particulate dust, such as dust
generated from sanding drywall joint compound.
Inventors: |
Hollis; Robert R.; (St.
Peters, MO) ; Williams; Matthew A.; (Bridgeton,
MO) ; Tomasiak; Mark J.; (St. Peters, MO) |
Assignee: |
EMERSON ELECTRIC CO.
St. Louis
MO
|
Family ID: |
47291889 |
Appl. No.: |
13/156337 |
Filed: |
June 9, 2011 |
Current U.S.
Class: |
15/327.1 ;
15/347 |
Current CPC
Class: |
A47L 9/181 20130101;
B08B 5/04 20130101; A47L 7/0023 20130101; A47L 9/185 20130101 |
Class at
Publication: |
15/327.1 ;
15/347 |
International
Class: |
A47L 5/00 20060101
A47L005/00; A47L 9/10 20060101 A47L009/10 |
Claims
1. A vacuum assembly comprising: a container having an open upper
end, a closed lower end, and at least one sidewall there between,
the container including a continuous handle member for carrying the
container in a suspended position; a power head assembly capable of
removable attachment to the open upper end of the container, the
power head assembly including a to housing, a motor, a fan, an air
inlet and an air outlet; and two oppositely spaced handle-latching
assemblies, having V- or U-shaped notches formed by two latching
ears, wherein the latching members are spaced on opposite sides of
the lower outer rim of the power head assembly.
2. A wet/dry vacuum assembly comprising: a container having an open
upper end, a closed lower end, and at least one sidewall there
between, the container including a continuous handle member for
carrying the container in a suspended position; a power head
assembly capable of removable attachment to the open upper end of
the container, the power head assembly including a housing, a
motor, a fan, an air inlet and an air outlet; and two oppositely
spaced handle-latching assemblies having V- or U-shaped notches
formed by two latching ears, wherein the latching members are
spaced on opposite sides of the lower outer rim of the power head
assembly.
3. A wet/dry vacuum power head assembly capable of being removably
attached to a container/receptacle having a handle for carrying the
receptacle portion in a suspended position, the handle being a
single, continuous member, wherein the power head assembly
comprises: a motor; an air inlet port; an air outlet exhaust port
oriented substantially 180-degrees from the air inlet port; and two
oppositely spaced handle-latching assemblies, having V- or U-shaped
notches formed by two latching ears, wherein the latching members
are spaced on opposite sides of the lower outer rim of the power
head assembly.
4. The wet/dry vacuum powerhead assembly of claim 3, wherein the
assembly is sized to be removably attached to a container having a
cylindrical configuration.
5. A water filter kit for a wet/dry vacuum assembly for dust
control so as to capture and control dust generated from a
construction-related process, the kit comprising, in combination: a
container having an open upper end, a closed lower end opposite the
upper end, and at least one side wall extending therebetween, the
container being capable of holding a predetermined quantity of
water therein; a wet/dry vacuum assembly comprising a power head
assembly capable of removable attachment to the open upper end of
the container, the power head assembly including a housing, a
motor, a fan, an air inlet, an air outlet, and a filter cage; and a
filtering assembly, the filtering assembly comprising: a filtering
tube having an open proximal end and an oppositely spaced distal
end, the proximal end being capable of securedly engaging the lower
face of the power head assembly in an air-tight manner such that
the distal end extends downwardly towards the interior of the
container; and a diffusion plate securable to the distal end of the
filtering tube, the diffusion plate extending substantially
parallel to the lower end of the container.
6. The water filter kit of claim 5, wherein the container has a
cylindrical configuration and a cylindrical side wall extending
between the upper end and the lower end.
7. A method of filtering vacuum air streams comprising sub-micron
particulate contaminants from a contaminated vacuum air stream, the
method comprising: a wet/dry vacuum assembly of claim 2; and a
water filter kit for use with the wet/dry vacuum assembly.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional patent application Ser. No.
61/352,818, filed Jun. 8, 2010, which is incorporated herein by
reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO APPENDIX
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The inventions disclosed and taught herein relate generally
to vacuum appliances, and more specifically are related to portable
wet/dry utility vacuum cleaners having improved convenience and
performance, and methods of use of such vacuum cleaners for debris
collection and dust control applications, such as for controlling
dust generated from sanding drywall joint compound and the
like.
[0006] 2. Description of the Related Art
[0007] Utility vacuum cleaners, also referred to as wet/dry vacuum
cleaners, are commonly used in basements, garages, workshops, on
construction job-sites, and the like, for a variety of heavy duty
cleaning tasks which are beyond the capabilities of the standard
vacuum used to clean carpets and floors. While generally speaking
these known wet/dry vacuums work for their intended purpose, such
as cleaning up solid and liquid debris, there are a few drawbacks
with the typical configuration.
[0008] One such drawback concerns the size and portability of many
of the known wet/dry vacuum cleaners. Some vacuums are of such a
size that their use in smaller areas or elevated areas, such as in
attics, closets, and crawl spaces, is not readily possible due to
size or weight issues, or is limited.
[0009] Another drawback concerns the collection drum used in
containing the dirt, debris, and/or liquid material which is
vacuumed up by the wet/dry vacuum appliance. In the typical wet/dry
vacuum configuration, the vacuum includes a debris collection drum
and a power head. During typical operation, solid and/or liquid
debris are drawn up through a collection hose and into the
collection drum via vacuum generated by a motor assembly within the
power head, the solid and/or liquid debris being deposited within
the collection drum. Thereafter, the user must empty the full
collection drum. In some instances, such as when cleaning up
certain types of particulate or liquid debris, e.g., drywall
compound dust, fine sanding dust, or other fine particulate matter,
the dust can be dangerous to the user, and due to the fine nature
of the particulate matter being drawn into the vacuum, can in part
make its way through the filters and re-enter the environment
through the vacuum exhaust, thus reducing efficiency and subjecting
the user to additional airborne particles. Further, when using a
vacuum appliance to clean up select fine particulate matter, it can
be difficult to fully remove all of the particulates from the
collection drum after cleaning, due to static or other adherence to
the inside walls of the collection drum. Thus, it would be
preferable in situations like this to be able to simply dispose of
the container itself, once full, while retaining the vacuum power
head assembly for continued use.
[0010] Several approaches to solving this problem have been
suggested to date. U.S. Pat. No. 6,083,307 describes a water
filtration kit for drywall dust control for use in capturing and
controlling dust generated from sanding drywall joint compound. The
invention device includes a container. A lid portion secures to the
open upper end of the container. The lid has a pair of apertures
therethrough. A filtering tube is secured to one of the apertures
of the lid and extends interiorly of the container.
[0011] In a further example, U.S. Pat. No. 6,616,733 describes a
method and apparatus for filtering an air stream with an aqueous
froth. According to the disclosure, the process includes passing a
contaminated air stream through a diffusing sieve, into an aqueous
solution in an expansion chamber; generating, maintaining, and
containing an aqueous froth between the liquid-bath reservoir and a
saturated fiber element; and continually saturating a coarse-fiber
element with liquid from the aqueous solution. The froth is
generated and maintained, and the fiber element is saturated, by
controlling the dynamic interface between the contaminated air
stream and the liquid-bath reservoir. The apparatus for filtering
an air stream includes: an air filter device that incorporates a
liquid-bath filter initial stage; an aqueous-froth filter second
stage; a constantly saturated, coarse-fiber filter as a combined
third stage and froth-limiter; and a moist, fine-fiber filter as
the final stage.
[0012] In U.S. Pat. No. 7,297,188, a dust collecting apparatus is
described that provides a vacuum system with a liquid filtering
medium to collect dust produced during screening. A dust collection
unit is also disclosed to collect and separate sawdust produced by
sanding which can cause foaming of a liquid filter medium.
[0013] While all of these approaches seek to address the problems
associated with vacuuming selected fine particulate materials, they
suffer from being cumbersome to handle and move from area to area,
as well as expense and similar related issues.
[0014] The inventions disclosed and taught herein are directed to
an improved utility vacuum cleaner, particularly a wet/dry vacuum
system, with improved portability while retaining the vacuum
suction power, the vacuum system including a disposable debris
collection container. Also disclosed herein are methods of use of
such vacuum appliances in conjunction with a water filter kit,
acting as vacuum-based dust removal units for fine particulate dust
control which acts to capture and control dust generated from
sanding drywall joint compound, fine sawdust, and the like within
the disposable collection container.
BRIEF SUMMARY OF THE INVENTION
[0015] Wet/dry vacuum appliances for use with disposable containers
as debris collection drums are described, as well as methods and
assemblies for the use of such vacuum appliances in both typical
vacuum operations, and in the vacuum collection of fine particulate
material, such as fine sawdust or gypsum dust.
[0016] In accordance with a first aspect of the present disclosure,
a vacuum assembly is described, the vacuum assembly comprising a
container having an open upper end, a closed lower end, and at
least one sidewall there between, the container including a
continuous handle member for carrying the container in a suspended
position; a power head assembly capable of removable attachment to
the open upper end of the container, the power head assembly
including a housing, a motor, a fan, an air inlet and an air
outlet; and two oppositely spaced handle-latching assemblies, V- or
U-shaped wherein the latching members are spaced on opposite sides
of the lower outer rim of the power head assembly.
[0017] In accordance with a further aspect of the present
disclosure, a water filter kit for a wet/dry vacuum assembly for
dust control so as to capture and control dust generated from a
construction-related process is described, wherein the kit
comprises, in combination, a container having an open upper end, a
closed lower end opposite the upper end, and at least one side wall
extending therebetween, the container being capable of holding a
predetermined quantity of water therein; a wet/dry vacuum assembly
comprising a power head assembly capable of removable attachment to
the open upper end of the container, the power head assembly
including a housing, a motor, a fan, an air inlet, an air outlet,
and a filter cage; and a filtering assembly, the filtering assembly
comprising: a filtering tube having an open proximal end and an
oppositely spaced distal end, the proximal end being capable of
securedly engaging the lower face of the power head assembly in an
air-tight manner such that the distal end extends downwardly
towards the interior of the container; and a mixer plate securable
to the distal end of the filtering tube, the mixer plate extending
substantially parallel to the lower end of the container. In
further accordance with this aspect of the present disclosure, the
container has a cylindrical configuration and a cylindrical side
wall extending between the upper end and the lower end.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0018] The following figures form part of the present specification
and are included to further demonstrate certain aspects of the
present invention. The invention may be better understood by
reference to one or more of these figures in combination with the
detailed description of specific embodiments presented herein.
[0019] FIG. 1 illustrates a perspective view of an exemplary vacuum
appliance in accordance with the present disclosure.
[0020] FIG. 2 illustrates a front view of the vacuum appliance of
FIG. 1.
[0021] FIG. 3 illustrates a side view of the vacuum appliance of
FIG. 1.
[0022] FIG. 4 illustrates a top view of the vacuum appliance of
FIG. 1.
[0023] FIG. 5 illustrates a cross-sectional view of the vacuum
appliance of FIG. 1, showing an exemplary dust filtration assembly
in accordance with the disclosure.
[0024] FIG. 6 illustrates a bottom view of the motor head assembly
of the vacuum appliance disclosed herein.
[0025] FIG. 7A illustrates a top view of the proximal end of an
exemplary downspout assembly.
[0026] FIG. 7B illustrates a partial bottom view of the motor head
assembly with the downspout assembly attached.
[0027] FIG. 8 illustrates a side view of the assembly of FIG.
7B.
[0028] FIG. 8A illustrates an expanded view of the cage engagement
interface shown in FIG. 8.
[0029] FIG. 8B illustrates a detailed view of the cage engagement
interface.
[0030] FIG. 9 illustrates a bottom view of an exemplary mixer plate
assembly in accordance with aspects of the disclosure.
[0031] FIG. 9A illustrates a partial top view of the mixer plate
assembly of FIG. 9.
[0032] FIG. 9B illustrates a detailed bottom view of the mixer
plate assembly of FIG. 9.
[0033] FIG. 10 illustrates a further exemplary mixer plate assembly
in accordance with aspects of the disclosure.
[0034] FIG. 11 illustrates a cross-sectional view of an exemplary
fine particle filtration system according to the present disclosure
in use as a dust removal unit, with portions of the vacuum system
broken away for purpose of clarity.
[0035] FIG. 12 illustrates a side-view of a further exemplary
filtration system in accordance with the disclosure.
[0036] FIG. 13 illustrates a more detailed side-view of the
filtration system of FIG. 12.
[0037] FIG. 14 illustrates a bottom view of the filtration system
of FIG. 12.
[0038] FIG. 15 illustrates a perspective bottom view of the
filtration system of FIG. 12.
[0039] While the inventions disclosed herein are susceptible to
various modifications and alternative forms, only a few specific
embodiments have been shown by way of example in the drawings and
are described in detail below. The figures and detailed
descriptions of these specific embodiments are not intended to
limit the breadth or scope of the inventive concepts or the
appended claims in any manner. Rather, the figures and detailed
written descriptions are provided to illustrate the inventive
concepts to a person of ordinary skill in the art and to enable
such person to make and use the inventive concepts.
DETAILED DESCRIPTION
[0040] The Figures described above and the written description of
specific structures and functions below are not presented to limit
the scope of what Applicants have invented or the scope of the
appended claims. Rather, the Figures and written description are
provided to teach any person skilled in the art to make and use the
inventions for which patent protection is sought. Those skilled in
the art will appreciate that not all features of a commercial
embodiment of the inventions are described or shown for the sake of
clarity and understanding. Persons of skill in this art will also
appreciate that the development of an actual commercial embodiment
incorporating aspects of the present inventions will require
numerous implementation-specific decisions to achieve the
developer's ultimate goal for the commercial embodiment. Such
implementation-specific decisions may include, and likely are not
limited to, compliance with system-related, business-related,
government-related and other constraints, which may vary by
specific implementation, location and from time to time. While a
developer's efforts might be complex and time-consuming in an
absolute sense, such efforts would be, nevertheless, a routine
undertaking for those of skill in this art having benefit of this
disclosure. It must be understood that the inventions disclosed and
taught herein are susceptible to numerous and various modifications
and alternative forms. Lastly, the use of a singular term, such as,
but not limited to, "a," is not intended as limiting of the number
of items. Also, the use of relational terms, such as, but not
limited to, "top," "bottom," "left," "right," "upper," "lower,"
"down," "up," "side," and the like are used in the written
description for clarity in specific reference to the Figures and
are not intended to limit the scope of the invention or the
appended claims.
[0041] Applicants have created a wet/dry vacuum assembly which
includes a power head capable of sealingly engaging a separate,
disposable collection container. This vacuum assembly may be used
in typical wet/dry vacuum operations, or may be used in conjunction
with a dust filter attachment for use as a dust removal unit.
[0042] Turning now to the figures, FIG. 1-FIG. 4 are illustrations
of various views of an exemplary wet/dry vacuum assembly 10 in
accordance with the present disclosure. FIG. 1 illustrates a
perspective view of an exemplary, non-limiting vacuum assembly 10
in accordance with the present disclosure. FIG. 2 illustrates a
front view of the vacuum assembly 10 of FIG. 1, showing the air
inlet port 20. FIG. 3 illustrates a side view of the vacuum
assembly 10 of FIG. 1, illustrating the latching of the power head
assembly 12 to a container 14 by way of at least a handle on the
container. FIG. 4 illustrates a top view of the vacuum assembly 10
of FIG. 1. These Figures will now be discussed in combination.
[0043] Vacuum assembly 10 is shown in FIG. 1 in a perspective view
as a completed unit with a power head assembly 12 attached to a
collection container 14. The power head 12 typically comprises an
upper motor cover and opposite, lower lid 11 having a plurality of
reinforcing ribs 31, 33 and 35, and includes a motor, a fan (not
shown), and a filter assembly, and a mounting flange or plate 17 to
which the motor, impeller or fan, and filter assembly are coupled.
The lower lid 11 also includes an outer, annular ring 13 (see, FIG.
6) sized and configured to the appropriate diameter to seal the
open top of the collection container 14, thus joining vacuum
assembly 10 in a sealing engagement with container 14. The
attachment of the motor cover of the power head assembly 12 to the
lower lid 11 may be accomplished by a plurality of fasteners,
including, but not limited to, a set of screws. Power head assembly
12 releasably attaches to a collection container 14 by latches 18a,
18b, the collection container 14 housing any fluid or debris (wet
or dry) introduced by the vacuum assembly 10 into the container
during normal suction operations. The lower lid 11 on the power
head isolates the vacuum motor and associated impellers from the
container 14 so as to prevent contamination or damage to the motor
from liquid and debris entering the vacuum during normal
operation.
[0044] With continued reference to the Figures, and in particular
FIG. 4, a top view of vacuum assembly 10 is shown. According to
embodiments of the present disclosure, vacuum assembly 10 includes
a power head 12 with a motor cover, lid, power cord (not shown for
purposes of clarity), suction inlet port 20, air outlet port 22,
and a power actuating switch 24. Other features of the power head
assembly not shown in the figures may include exhaust doors, motor
exhaust ports (26), noise dampening means, and the like, as
appropriate. During typical operation, a flexible vacuum collection
hose (not shown) is connected to the suction inlet port 20, via a
locking attachment, twist attachment, friction-fit attachment,
threaded attachment, or the like, and allows the user to vacuum up
debris while leaving the vacuum assembly 10 in a stationary
position.
[0045] With reference to the cross-sectional view of FIG. 5,
Included with vacuum assembly 10 and collection container 14 may be
one or more of a float, filter cage 40, filter, and muffling
device, each of which may be installed by the consumer, or during
the manufacturing process. Filter cage 40 may be connected to the
bottom face of the power head 12, specifically to the bottom face
of the plate 17 on the lower lid 11, by a plurality of
fasteners--for example notches on the collector plate may connect
with mating tabs or the equivalent on filter cage 40. Filter cage
40 preferably includes a plurality of rings 42 oriented
horizontally about (and substantially perpendicular to) a central,
longitudinal axis of the filter cage, and two or more vertical ribs
(longitudinal supports) 44 which are substantially parallel to the
central axis of filter cage 40, and which are coupled to the
plurality of rings 42, so as to form a plurality of open spaces
between the rings and the supports. A filter (not shown) may be
optionally placed snugly over the outside of filter cage 40, as
appropriate and depending on the material to be cleaned with the
vacuum assembly 10. Filters suitable for use with the present
disclosure include paper filters, bag filters, pleated filters,
HEPA-type filters, and filters made of either paper or non-natural
fiber, such as polymers or polymer/paper mixtures or other
appropriate synthetic materials suitable for such application.
[0046] With continued reference to FIGS. 1-5, the assembly 10
further includes a separate debris collection container 14, the
container having an open upper end, an opposite closed lower end
15, and at least one sidewall there between, the container
preferably (but not necessarily) including a continuous handle
member 16 for carrying the container in a suspended position. The
handle member 16 may be of a generally curved shape, as shown, or
may have a specific shape, such as a V-shape formed in the middle
portion (not shown), to allow the vacuum assembly 10 to be hung
from an elevated position, e.g., from a ladder hook while the user
works atop a ladder. In non-limiting example, the container 14 may
be a cylindrical container having a cylindrical configuration and a
cylindrical side wall extending between the substantially
circular-shaped upper end and the lower ends. Alternatively and
equally acceptable, the container 14 may be square, rectangular,
ovoid, or any other appropriate shape, the only restriction being
that the container must be capable of sealingly engaging the power
head 12 of the vacuum assembly 10. The container 14 is preferably a
bucket, pail, or similar container being capable of holding a
predetermined quantity of water therein, such as a 5-gallon or
10-gallon plastic bucket.
[0047] In a typical manner of operation, power head 12 is sealingly
attached to the open end of container 14 via latches 18 positioned
on the lower, circumferential edge of the power head, and which are
preferably spaced about 180-degrees apart as illustrated in FIG. 1
and FIG. 4. Each of the latches 18 has an upper hinged portion 29
which is capable of biasing the latches 18a, 18b upward and
downward, and two ears 28a, 28b which are oriented substantially
perpendicular to the body of the latch, the latter of which is
generally perpendicular to the central axis of the vacuum assembly
10, or the wall(s) of the container 14. Ears 28a, 28b of latches 18
in combination form a V- or U-shaped groove 27 therebetween, the
groove 27 being capable of receiving handle 16 associated with
container 14. In typical operation, the user orients the power head
12 over container 14 having the handle 16 in a lowered (not
vertical position), such that latches 18a, 18b are substantially
aligned with the direction of the handle 16 when it is raised to a
90-degree angle (parallel with the central axis of the container
14), biases the latches 18 upward toward the top of the power head
12, and then pushes the power head down over the upper lip 19 of
the open end of the container 14. The handle 16 of the container is
then raised from the lowered position to an upright vertical
position (as shown in FIGS. 1-3), and is fit into the groove 27
formed between ears 28a, 28b of each latch. Latches 18a and 18b are
then biased downward via hingeable rotation about hinged portion 29
until the latches are tight against the outer wall of the container
14. At this point, the vacuum appliance 10 is ready to for
operation by the user.
[0048] While the vacuum assembly 10 described above may be used for
carrying out both wet and dry cleaning operations of various debris
types in a variety of areas, particularly hard-to reach or areas of
limited confinement (e.g., attics or crawlspaces), due to the fact
that the assembly uses a disposable and easily replaceable
container 14 (such as a 5-gallon bucket) as the collection drum, it
can also be used to vacuum up fine particulate dust and similar
materials, using the particle diffusion assemblies shown in FIGS.
5-15. As used herein, the term fine particulate dust material
refers to material of fine particle size, including but not limited
to sawdust from sanding operations (typically on the order from
about 50 .mu.m to about 1000 .mu.m), and dust particles from
drywall installation, particularly those gypsum dust particles
which result from sanding the joint compound on the drywall between
the seams (typically on the order of less than about 0.1 .mu.m to
about 5 .mu.m), and which can contain dust particles that are known
to cause respiratory health hazards, such as calcite, gypsum, talc,
silica, asbestos, fiberglass, and mica dust particles. As shown in
FIG. 5, the power head 12 of a vacuum assembly 10 may be further
modified to include an air-filter assembly 60 insertable into the
container 14 and which may be lockably mounted to the bottom face
11 of the power head, the assembly 60 being in fluid communication
with inlet 20, and so as to be free of rotation. The air-filtration
assembly 60 comprises at least an inlet pipe or downspout 50 and a
diffusion assembly, such as diffusion plate 70, 80, or 100, which
will be described in more detail herein, and which is spaced apart
from the inlet 20. Downspout 50 is a shaped, hollow tube of any
appropriate cross-sectional geometry (circular, square, or the
line) and material, such as blow-molded plastic or the like, having
a proximal end 52 and an oppositely-spaced distal end 54. Proximal
end 52 has a shaped region sized to mate tightly with the opening
20' of inlet 20 in the bottom face 11 of the lid portion of power
head 12, via either friction or threaded attachment means.
Downspout 50 extends from the inlet aperture 20' on the bottom face
lid 11 in a substantially downward direction (toward the bottom 15
of the container), where it terminates above the bottom of the
container in a deflector portion 56 at its distal end. Deflector
portion 56 may be curved, such as will be described in accordance
with the embodiment illustrated in FIGS. 12-15, or it may include
radially inward curving side walls, as illustrated generally in
FIG. 9B and FIG. 10. As a result of the curvilinear, angled or
tapered shape of deflector 56, a fluid stream directed in through
inlet aperture 20 (as illustrated by the fluid flow arrows A in
FIGS. 5 and 9) is deflected in a direction dictated by the shape of
the deflector 56, preferably across the bottom face of a diffusion
plate 70, 80 or 100.
[0049] Attachment and securement of the downspout 50 (and the rest
of assembly 60) to the vacuum assembly 10 is by a combination of
base insert 32 and cage attachment means 62, both of which will be
described in more detail herein, and as shown in FIGS. 7-8.
[0050] As shown in FIG. 7A, a base insert 32 is fit over the
proximal end 52 of downspout 50, via an orifice 34 in the insert 32
sized to receive downspout 50. Base insert 32 is substantially
planer is shape, having sides 36, 38 shaped so as to allow the base
insert 32 to substantially match the shape found on the underside
of the lid 11 at the inlet exit area 20', such shape being defined
by at least the outer wall/annular flange 13 of the bottom face of
lid 12, the outer wall of cover 17, and reinforcing ribs 31 and 31'
extending downward from the bottom face of the lid 11 and outwardly
from bottom cover 17, the combination thereof penning in the inlet
exit area 20'. This is shown most clearly in FIG. 6. The shape of
the sized base insert 32 at the proximal end of pipe 50 is so as to
prevent the attachment from rotating or slipping free by a twisting
motion during operation of the assembly. This can be seen in FIG.
7B, illustrating the downspout 50 and associated base plate 32
attached to the lower face of the lid 11 and extending downwardly,
away from the vacuum powerhead 12.
[0051] Downspout 50, and associated air filtration assembly 60, is
also secured by way of a filter cage attachment means, 62, as
illustrated in FIGS. 8-8B. FIG. 8 illustrates this attachment in a
side view. FIG. 8A illustrates detail of the section "A" within
FIG. 8. FIG. 8B illustrates a detailed view of attachment means 62
engaging the filter cage 40 from a front perspective. These figures
will be discussed in combination. The filter cage attachment means
62 acts to secure the downspout 50 into position proximate the
filter cage 40, thereby preventing accidental disassembly during
operation of the system. Filter cage attachment means 62 includes a
first, upper securement arm 61 and a second, lower securement arm
63, both securement arms extending substantially perpendicular to
the central axis of downspout 50, and being spaced apart both
vertically, and horizontally by a distance d.sub.1, as shown in
FIG. 8B. The vertical and horizontal spacing between arms 61 and 63
is such that they fit around a vertical rib 44 of the filter cage
40, and between either two rings 42 of the filter cage, or between
a ring 42 and the bottom face 46 of the filter cage 40. Preferably,
at least a portion of the lower edge 65 of both arms extends past
the inner plane of the interior of the rigs and rings, as shown in
FIG. 8B. Lower securement arm 63 may further include a ramped
portion 67 along its bottom edge 65', so as to aid the attachment
means 62 in slidably engaging a rib 44 and rings 42 of the filter
cage 40. This attachment feature forces the assembly 60 up and into
the bottom face of the vacuum power head/lid, thus creating an
air-tight seal between the base plate 32 and proximal end 52 of the
downspout and the air inlet 20'. Additionally, this attachment
feature acts to prevent the assembly 60 from being pulled
side-to-side during operation, and allows for the accessory to be
assembled in an easy, no-tool fashion.
[0052] As shown in FIG. 9, particle diffusion plate 70 is installed
at the distal end 54 of downspout 50, and the two pieces connect
via a twist-lock engagement, as shown in detail in FIG. 9A, wherein
the plate 70 includes an opening 79 formed therethrough which is
sized to accommodate downspout 50, the plate 70 further including a
twist-lock engagement means 69 formed in the top face 75 of the
diffusion plate 70. Diffusion plate 70 may have a variety of
designs in order to maximize extraction of dust particles from the
air stream during operation. For example, in FIGS. 9 and 9B, the
diffusion plate 70 includes a plurality of semi-circular walls 73,
75 extending between the arcuate outer wall 74 of the plate 70, and
oriented generally perpendicular to the deflector 56 at the distal
end 54 of downspout 50, the walls 73, 75 being of increasingly
shorter height as the walls extend outward away from the downspout
50 toward the front edge 76 of the diffusion plate 70. This
arrangement of stepped walls of differing heights forces the air
entering the container 14 via downspout 50 to cascade over the
walls, thus allowing for increased particle extraction from the air
stream as it flows.
[0053] Alternatively, as shown in FIG. 10, the shaped diffusion
plate 80 may include a plurality of flow channels "C" formed on the
bottom face of the diffusion plate 80 by a series of radiating
walls 81, 83 and 85 extending from the back wall 84 of the
diffusion plate 80 toward the front edge 82 of the diffusion plate,
preferably in a tapered manner as they extend radially outward
toward the front edge. For example, as shown in FIG. 10, a channel
"C" is formed between radiating walls 81 and 83, and between walls
83 and 85. These radiating walls may be formed and used alone, or
in combination with a plurality of openings 88 of varying sizes
formed in and through the top of the diffusion plate, which act to
provide an even volume of bubbles across the bottom surface of
diffusion plate 80, thereby improving the particle extraction by
the water during operation.
[0054] An example method of operation is now described,
illustrating use of the systems of the present disclosure with
diffusion plate 80, although it will be understood that any of the
diffusion plate assemblies described herein may be used. Once the
air-filtration assembly 60 has been positioned within the vacuum
assembly 10 such that the downspout 50 of assembly 60 is in an
in-line orientation with the vacuum air stream, extends downward
into the debris collection container 14 as described above, and the
operator has filled the container with liquid to a predetermined
level above the diffusion plate but below the filter cage 40,
thereby forming a liquid reservoir 90 as shown in FIG. 11, the
vacuum assembly 10 can be powered on such that the vacuum power can
be used to clean up particulate dust and debris and decontaminate
the vacuum stream simultaneously during operation. During the
typical use, the vacuum brings contaminated air (that is, air
containing fine, particulate dust particles) into the inlet 20 of
the power head 12, and this air stream is then introduced below the
surface of the liquid reservoir 90 through the mixer
plate/diffusion means 80 attached at the distal end of the
downspout 50. The contaminated air stream, containing fine
particulate matter or the like, is then exposed to the water
surface during the initial interface with the water, directed
across the bottom face of the diffusion plate 80 by deflector 56 at
the distal end of downspout 50, and a plurality of air bubbles are
diffused through the upper reservoir via orifices 88 in the plate
80. The majority of the fine particulate contaminants are thus
removed from the air stream during this filtration process. The
lower portion of the liquid reservoir 90 remains relatively calm,
thereby allowing most of the heavier contaminants (the dust
particles) to settle out into a sludge layer 92 on the bottom of
the container 14. The turbulence created by the air stream
considerably increases the surface area available to remove the
contaminants from the air stream, and allows the now clean air
stream to be drawn through the filter cage 40 and up and out
through the exhaust port 22 in the power head assembly.
[0055] FIGS. 12-15 are illustrations of various views of a further
particle filtration assembly 100 for use with wet/dry vacuum
assembly 10 in accordance with the present disclosure. FIG. 12
illustrates a side view of an exemplary, non-limiting particle
diffusion assembly 100 in accordance with the present disclosure,
in association with a wet/dry vacuum assembly 10. FIG. 13
illustrates a side view of the diffusion assembly 100 alone. FIG.
14 illustrates a bottom view of the diffusion assembly 100 of FIG.
13, illustrating the details of the scroll design. FIG. 15
illustrates a bottom perspective view of the assembly 10 of FIG.
12. These Figures will now be discussed in combination.
[0056] As illustrated in FIGS. 12 and 13, the diffusion assembly
100 attaches in generally the same manner as the
previously-described embodiments of the disclosure, and the
base-plate 101 of the assembly attaches to the downspout 50 in a
similar manner, e.g., via an attachment means 32 at the proximal
end of the downspout, and via a cage engagement assembly 62,
allowing stabilization of the assembly by providing a means for
securement to filter cage 40. The diffusion assembly 100 is
generally circular or ovoid in shape, and includes a
downwardly-extending skirt region 106 which circumscribes
substantially all of, or alternatively the entire circumference of
the base-plate 101. Base-plate 101 further includes an opening 109
formed in and extending through the top face 104 of the base-plate,
the opening being optionally circumscribed by a raised collar 102.
The opening 109 is oriented in the base-plate such that when the
assembly 100 is attached to the vacuum appliance 10, the opening
109 is positioned substantially directly below the filter cage 40.
In this manner, any liquid splash through the opening 109 that may
be generated during operation of the system is reflected back to
the water reservoir within the container 14, rather than being
sucked into the motor intake of the vacuum appliance. In accordance
with further aspects of this embodiment, a mesh or similar cover
(not shown) could be included to cover opening 109 so as to further
reduce liquid splash and/or any foaming of the liquid within the
container 14, the only requirement for such a cover being that it
is permeable to air.
[0057] FIG. 14 illustrates a bottom view of the underside of
particle diffusion assembly 100, showing a centrifugal
force-generating means, such as a general scroll shape as formed on
the underside of the base-plate 101. As may be seen therein, the
downspout 50 terminates at its distal end 54' at a deflection angle
of approximately 90.degree., relative to the central axis of the
downspout itself. This angled distal end acts to direct the
airstream during use of the system into the scroll-shaped diffusion
area of the assembly 100, the diffusion area having at least one
diffusion wall 110 extending downward from the bottom face 108 of
the base-plate 101, substantially perpendicular to the bottom face
108. Diffusion wall 110 may be separate from, or a continuation of,
outer skirt 106. During operation, particles enter the diffusion
assembly 100 via downspout 50, and are driven into the walls 106
and 110 of the scroll by centrifugal force, while clean air escapes
through the provided opening 109. This "cyclonic-cleaning" using
centrifugal force is further enhanced by the presence of water
within the container 14, as described above in accordance with the
other embodiments of this disclosure, as the water will both serve
to capture and contain the fine particulate material, and also
clean the surfaces of the interior walls of the container 14 during
operation of the unit. FIG. 15 illustrates a bottom perspective
view of the particle diffusion assembly 100 in association with the
vacuum assembly 10.
[0058] The size, shape and geometry of the scroll within the bottom
face of the assembly 100 is limited only by physical factors, and
as such variations on wall placement (e.g., placement of diffusion
wall 110, or the addition of further diffusion walls) may be
included without detracting from the present disclosure. The size
of the plate 100 is limited by the bucket diameter at that area.
The scroll may be defined by first picking a circular path that
allows the air flow from the downspout 50 sufficient room (that is,
small enough that the air flow didn't intersect the downspout, but
not so small it left insufficient clearance to the exit hole 109).
Diffusion wall 110 may then be defined by an arc of the same
diameter and made tangent to the inner and outer circles at the
defined areas. In this way, the air flow into the base-plate 101 is
forced into the walls at all points within the scroll, so as to aid
in the particle separation. Alternatively, the diffusion walls of
the assembly may be arranged in a logarithmic or non-logarithmic
spiral, as appropriate.
[0059] Other and further embodiments utilizing one or more aspects
of the inventions described above can be devised without departing
from the spirit of Applicant's invention. For example, the mixer
plates associated with the filter attachment may include a
combination of increasingly shorter deflection walls and air
channels of varying sizes, or alternatively may include a coarse,
fine, or coarse and fine filter element associated with the lower
face of the mixer plate to act as a pre-filter. Further, the
various methods and embodiments of the present disclosure can be
included in combination with each other to produce variations of
the disclosed methods and embodiments. Discussion of singular
elements can include plural elements and vice-versa.
[0060] The order of steps can occur in a variety of sequences
unless otherwise specifically limited. The various steps described
herein can be combined with other steps, interlineated with the
stated steps, and/or split into multiple steps. Similarly, elements
have been described functionally and can be embodied as separate
components or can be combined into components having multiple
functions.
[0061] The inventions have been described in the context of
preferred and other embodiments and not every embodiment of the
invention has been described. Obvious modifications and alterations
to the described embodiments are available to those of ordinary
skill in the art. The disclosed and undisclosed embodiments are not
intended to limit or restrict the scope or applicability of the
invention conceived of by the Applicants, but rather, in conformity
with the patent laws, Applicants intend to fully protect all such
modifications and improvements that come within the scope or range
of equivalent of the following claims.
* * * * *