Abstract:
The present patent document provides embodiments of a filter and a system for use with the filter for separating dirt and other contaminates from wash liquids. In a preferred embodiment the filter comprises: a plurality of passages all oriented parallel to each other wherein the passages have a circular top with a first diameter and a circular bottom with a second smaller diameter and a portion in between the top and the bottom that is funnel shaped; a body that couples each of the plurality of passages together; wherein the passages are arranged in concentric circles radiating out from the center of the body.

Description:
The present patent document relates to particle traps and filters and systems related thereto. More particularly, the present patent document relates to particle traps and filters for use in containers of fluid used for washing objects. 
     BACKGROUND 
     It has been appreciated by those skilled in the art that particles of dirt or other contaminates may cause scratches during the cleaning process. For example, if one were to clean a car with a sponge or pad, the dirt trapped between the sponge and the surface of the car may cause scratches in the paint when the sponge is moved over the surface. Accordingly, it is beneficial to try and remove as much of the dirt or other contaminants from the sponge as possible as frequently as possible. By keeping the sponge or pad clean, there is less risk of scratching the surface of the car or other object being cleaned. 
     Traditionally, someone cleaning a car repeatedly dunks the sponge or pad in a bucket of soapy water to remove the dirt and other particles from the sponge or pad. While this method of cleaning does help remove some of the contaminants from the cleaning object, it is not efficient in doing so. To this end, dirt or other particles may remain on the sponge or cleaning pad and cause scratches on the surface of the object being cleaned or at a minimum, prevent the maximum cleanliness from being achieved. 
     To this end, people have tried to come up with ways to better remove the dirt and other contaminants from the cleaning apparatus during the process of cleaning an object. Traditional strainers are not effective and filtering systems rely on pads, sponges or filters that require replacing and simply do not function well. 
     One proposed method is provided in U.S. Pat. No. 7,025,880, titled Fluid Receptacle and Filter System (hereinafter “&#39;880 patent”) The &#39;880 patent provides a system for separating particles from fluid which includes a receptacle for containing fluid and a filter assembly which includes a filter component shaped to fit the receptacle, an O-ring encircling the perimeter of the filter component for securing the filter assembly in the receptacle, and at least two baffles attached to the bottom of the filter component for reducing the motion of the fluid around and through the filter assembly. While the system disclosed in the &#39;880 patent may be more effective than traditional filters, it still does not provide the maximum effectiveness at filtering and removing dirt and contaminates from a sponge, pad or other washing device during the washing process. To this end, a more effective and efficient particle trap/filter is desirable. It would be particularly beneficial if the particle trap/filter could be used in the process of washing cars and other objects. It would also be beneficial if the particle trap/filter could be used with the traditional method of using a bucket of soapy water or other cleaning liquid. 
     SUMMARY OF THE EMBODIMENTS 
     In view of the foregoing, an object according to one aspect of the present patent document is to provide filters and systems for use with the filters for separating dirt and other contaminants from wash liquids. Preferably the methods and apparatuses address, or at least ameliorate one or more of the problems described above. To this end, a filter is provided. In one embodiment the filter comprises: a main body with a planar top surface and planer bottom surface; and, a plurality of passages that pass through the body wherein the passages have a larger diameter section that extends above the top surface and a smaller diameter section that extends below the bottom surface. 
     In preferred embodiments, at least a portion of the passages is funnel shaped. In yet other embodiments, the entire passage may be funnel shaped. In still yet other embodiments, the top of each passage is a straight round section that transitions into the funnel shape. 
     In some embodiments, the passages are arranged in concentric circles radiating out from a center of the filter. Although circular patterns of the passages is preferred, other concentric shapes may be used. For example, the passages may be patterned in concentric hexagons, octagons, decagons, or other geometric shape with multiple sides. The more sides used the closer to a circle and the more preferred. 
     The body of the filter includes a plurality of supports to form a gap under the bottom of the passages when the filter is installed in a container such as the bottom of a bucket. In preferred embodiments, the filter is supported by a plurality of legs that extend from the body down below the bottom of the passages. In other embodiments, other support structures may be used. If legs are used, the legs may also be funnel shaped. In some embodiments, at least a subset of the plurality of legs further include holes in their sidewalls below the body. 
     In some embodiments, the filter further comprises a plurality of holes through the body and located in between the passages. In some embodiments, those holes may also be funnel shaped. 
     Although many different manufacturing techniques may be used, the filters are preferably made from injection molded plastic. However, molding or other manufacturing techniques may be used. 
     In some embodiments of the filter, the filter comprises: a plurality of passages all oriented parallel to each other wherein the passages have a circular top with a first diameter and a circular bottom with a second smaller diameter and a portion in between the top and the bottom that is funnel shaped; a body that couples each of the plurality of passages together; wherein the passages are arranged in concentric circles radiating out from the center of the body. In some of these embodiments, the top extends above a top of the body and the bottom extends below a bottom of the body. 
     In another aspect of the embodiments described herein, a system for separating dirt from a cleaning liquid is provided. In some embodiments of the system, the system comprises: a filter as described herein; and, a bucket with an inner diameter designed to receive the outer diameter of the filter. In preferred embodiments of the system, the system further comprises a seal designed to seal the filter to the bucket. 
     Further aspects, objects, desirable features, and advantages of the apparatus and methods disclosed herein will be better understood from the detailed description and drawings that follow in which various embodiments are illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration only and are not intended as a definition of the limits of the claimed embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an exploded view of one embodiment of a system for providing clean wash water. 
         FIG. 2  illustrates an isometric view of a system for separating dirt and other contaminants from a wash liquid with a filter as described herein located on the bottom of a container. 
         FIG. 3  illustrates an isometric view of one embodiment of a filter according to the teachings of the present patent document. 
         FIG. 4  illustrates a cross sectional view of one design of a passage for use with the filter embodiments described herein. 
         FIG. 5  illustrates a cross-sectional view of another embodiment of a passage for use in a filter. 
         FIG. 6  illustrates a cross-sectional view of another embodiment of a passage for use in a filter. 
         FIG. 7  illustrates a top view of the embodiment of the filter in  FIG. 3 . 
         FIG. 8  illustrates a close up view of an edge portion of the filter of  FIG. 3 . 
         FIG. 9  illustrates an isometric view of the bottom of the filter of  FIG. 3 . 
         FIG. 10  illustrates a side view of the filter of  FIG. 3 . 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     The present patent document discloses systems, apparatus and methods to deliver clean wash water without replacing filters.  FIG. 1  illustrates an exploded view of one embodiment of a system for providing clean wash water. The embodiment shown in  FIG. 1  comprises a container  12 , a filter  14  and a seal  16 .  FIG. 2  illustrates an assembled version of the embodiment of  FIG. 1  with the filter  14  placed in the bottom of the container  12 . 
     Container  12  may be any type of container including a bucket, bin, cup, tub or any other type of container that can hold a fluid. Moreover, container  12  may be made of various different materials including metal, glass or plastic to name a few. In a preferred embodiment, container  12  is a bucket and may further include a handle and/or lid (not shown). In an even more preferred embodiment, container  12  is a standard size bucket such as a 1 gallon, 2 gallon or 5 gallon bucket. Although container  12  may be any shape, it is preferably cylindrical. 
     In a preferred embodiment, filter  14  is shaped and sized to fig snuggly inside of container  12 . As used herein, a snug fit means that the diameter of the filter  14  is slightly smaller than the inner diameter of container  12 . For example, filter  14  may have a diameter of approximately 1 millimeter less than the inside diameter of container  12  where the filter sits when assembled. In some embodiments, a seal  16  is placed in the space between the outside of the filter  14  and the inside of the container  16 . The seal acts to provide a complete or partial fluid seal between the filter  14  and the container  12 . In preferred embodiments, the seal is made from rubber, silicone or another soft deformable material. In some embodiments, seal  16  may be an O-ring. In some embodiments, no seal  16  is used. In some embodiments the diameter of the outside of the filter may be sized such that when it is pushed into a container with a reducing inside diameter, it may be pushed down until an interference fit occurs. To this end, a correctly shaped and sized container  12  and filter  14  may be provided such that the filter  14  is self-positioning at the correct depth within the container. 
     While in some embodiments a seal  16  may be used, in other embodiments no seal  16  is used. In embodiments without a seal  16 , whatever gap exists between the outside of the filter  14  an the inside of the container  12  may serve as an air release. 
     In some embodiments, the diameter of the outside of the filter  14  may vary in order for the filter  14  to match a changing diameter in the inside of a container  12 . For example, the top of the filter  14  may have a slightly larger diameter than the bottom of the filter  14  such that the filter  14  wedges inside a container  12  with a reducing inner diameter. 
     The filter  14  may be made out of various different kinds of materials but is preferably made from plastic. Filter  14  may be created using molding, injections molding, 3D printing such as Selective Laser Sintering (SLS) or other rapid prototype manufacturing, or other manufacturing methods. 
     In some embodiments, the filter  14  is designed to be less buoyant than the liquid it will be submerged in and particularly, less buoyant that water. This allows the filter  14  to stay down under the surface of the wash liquid. In some embodiments, this is achieved by the way the passages are positioned and their shape. The shape of the passages may also help keep the filter submerged in the wash water. For example, where the passages have a bigger diameter at a top and the smaller diameter is at the bottom. Finally, a planar body  21 , as shown in  FIG. 3  also helps the filter  14  stay at the bottom of a container  12  filled with a wash liquid. 
     As may be seen in  FIG. 2 , the container may be filled or partially filled with a cleaning fluid. The cleaning fluid may be any type of cleaning fluid including but not limited to water, soapy water, water with a soap additive, chemical solutions, cleaning agents or any other type of cleaner or cleaning fluid. 
       FIG. 3  illustrates an isometric view of one embodiment of a filter  14  according to the teachings of the present patent document. In the embodiment of the filter  14  shown in  FIG. 3 , the filter  14  includes a plurality of passages  20  that pass through the filter from the top to the bottom. The passages are all connected together by a body  21 . The body  21  connects each of the outer walls of the passages  20  together to form a continuous filter  14 . In a preferred embodiment, the body  21  is generally planar located with a thickness such that a top portion of the passage projects above the top surface of the body  21  and a lower portion of the passage projects below the bottom surface of the body  21 . To this end, the body  21  is much thinner than the thickness of the filter  14 . A thinner body  21  reduces weight and manufacturing costs. As will be discussed below, allowing the passages to extend above and below the body  21  also has additional benefits. 
     In some embodiments, body  21  can have a slanted angle from the outer to the center of the body, creating a funnel-like feature where any dirt not trap by the passages  20  can fall to the center. This creates one big funnel out of the entire body. In other embodiments, the slope may be in the opposite direction such that any dirt not trap by the passages  20  would fall to the outer diameter of body  21 . 
     In the embodiment shown, the passages  20  are small half inch diameter plastic cone that point down into the container  12  when the filter  14  is inserted. As may be seen in this embodiment, the passages  20  may be a tapering, cone-shaped piece of plastic with small holes in the top that gradually get smaller towards the bottom. As explained in more detail below, the shape and orientation of these passages are important to creating an effective filter. 
     In the embodiments described herein, the passages  20  on the filter  14  are configured to utilize the natural centrifuge that is created during the wash process. As a user inserts their hand in and out of the water and soap filled container  12 , a natural rotation of the liquid inside the container  12  is created. This rotation moves the wash liquid around and into the passages  20  where it can be filtered. The rotations created in the container  12  combined with gravity create the ideal environment for spinning water to filter through the system—delivering the most effective way to separate the grit out of the water or other liquid. 
     In the embodiments disclosed herein, the passages  20  and filter  14  are configured to promote this centrifuge effect to clean the water and trap dirt at the bottom of the container  12  allowing clean water to flow back to the top above the filter  14 . 
       FIG. 4  illustrates a cross section of one design of a passage  20  for use with the filter  14  embodiments described herein. As may be seen in  FIG. 4 , the passage  20  is preferably cone shaped and has a funnel portion  22 . In preferred embodiments, the passage  20  has a larger diameter hole  26  at the top and a smaller diameter hole  28  at the bottom with a funnel shaped wall  22  connecting the larger diameter hole  26  to the smaller diameter hole  28 . The larger diameter hole  26  at the top makes it easy for the particulates in the cleaning fluid to enter the passage  20  from the top while making it difficult for them to enter the passage from the bottom. This helps trap the particulates in the wash fluid under the filter  14 . Moreover, the funnel shape  22  helps promote the natural centrifuge effect created in the wash fluid when a user pushes their hand in and out of the container  12 . 
     In preferred embodiments, the passage includes a portion  24  that extends above the body  21  of the filter  14 . The portion  24  of the passage that extends above the top surface  31  of the body  21  of the filter  14  may also be referred to as a “lip”  24 . The lip  24  provides a better cyclone design as well as making it the ideal surface for cleaning wash pads, mash mitts, sponges, buffing pads or any other type of washing device. By lifting the passages  20  such that they extend above the body of the filter  14  they work better and clean items rubbed against them, therefore making them an ideal wash board. In preferred embodiments, the lip  24  may be a small portion of the passage  20 . In some embodiments, 10% of the passage  20  extends above the top surface  31  of the body  21  of the filter  14  while in other embodiments only 5% or 3% extends above the body  21  of the filter  14 . A subtle lift assures that no dirt or grime can stay trapped between the passages  20 . 
     As may be seen in the cross section of the passage  20  shown in  FIG. 4 , in some embodiments, the entire passage is not required to be a funnel  22 . As may be seen, the passage  20  may be made up of portions like the lip  24  that are not part of the funnel  22 . However, in the preferred embodiments disclosed herein, at least a portion of the passage  20  is funnel shaped  22 . In the embodiment shown in  FIG. 4 , the passage  20  comprises a funnel shaped portion  22  that extends up from the smaller diameter hole  28  with a steadily increasing diameter. In some embodiments, the funnel shaped portion  22  may extend all the way to the top of the larger diameter hole  26 . However, in some embodiments, the funnel shaped portion  22  may terminate at an upper portion that is comprised of a vertical wall. The vertical wall may form the lip  24 . In yet other embodiments, the passage  20  may also include a vertical wall portion at the bottom of the funnel shaped portion  22 . In still yet other embodiments, the passage  20  may be made of combinations of vertical wall portions and funnel portions. In embodiments with cross section of varying designs, the funnel portions may have walls with varying slope or identical slopes or a mix of both. 
       FIG. 5  illustrates a cross-sectional view of another embodiment of a passage  20  for use in a filter  14 . In the embodiment shown in  FIG. 5 , the entire passage  20  is constructed of a funnel  22 . In preferred embodiments, the top of the funnel  22  may be pushed up above the body  21  of the filter  14  as shown. 
       FIG. 6  illustrates a cross-sectional view of another embodiment of a passage  20  for use in a filter  14 . The embodiment shown in  FIG. 6  includes a plurality of varying sections. The top of the passage  20  consists of a vertical section  23 . The vertical section  23  transitions into a funnel section  22 . Finally, the funnel section  22  transitions into another vertical section  27 . As may be seen, the top portion  24  of the passage  20  forms a lip  24  my rising above the body  21  of the filter  14 . 
     In operation, the filter  14  is placed in a container full of a washing liquid. The passages  20  within the filter  14  work with the natural centrifugal force created in the wash liquid within the container  12  to trap dirt and other contaminants below the filter  14 . The dirt particles floating in the water are drawn through the passages  20 , spin around, drops down, and collect in the bottom of the container  12  where they are prevented from coming into contact with the sponge cloth or other washing device being used. 
       FIG. 7  is a top down view of a filter  14 . As may be seen, filter  14  includes a plurality of passages  20 . In a preferred embodiment, the passages  20  are spaced such that they cover as much of the top of the body  21  of the filter  14  as possible. 
     In  FIG. 7 , filter  14  is illustrated as round but filter  14  may be any shape. Filter  14  is preferably shaped to match the interior shape of container  12 . Round is preferable for both because round promotes the spinning of the wash fluid and the centrifugal effects created thereby. 
     In some embodiments, the passages  20  may be placed randomly within the body  21  of the filter  14 . In yet other embodiments, the passages  20  may be patterned. By maximizing the spread of the passages  20  along with systematically and geometrically placing the passages  20  over the surface of the filter  14 , a more efficient method of filtering water during a wash may be provided. In a preferred embodiment, the passages are patterned in circles that start in the center and extend to the outer edge of the filter  14 . As may be seen in the embodiment in  FIG. 7 , the passages  20  are patterned in 9 concentric circles across the radius of the filter  14 . Depending on the size of the passages  20  and the size of the filter  14 , any number of concentric circles may be used such the filter  14  is covered with passages  20 . Patterning the passages  20  in concentric circles helps further promote the rotation of the wash liquid and increases the centrifugal forces created thereby. Although concentric circles are preferred, the passages may be oriented or patterned in other ways. 
     In some embodiments, the space between the passages  20  is preferably minimized. To this end, the concentric circles of passages  20  may be rotated with respect to each other such that the diameters of the passages  20  in one concentric circle falls between the diameters of two passages  20  in a neighboring concentric circle. In this way, the concentric circles can be pushed closer together and the space between the passages  20  minimized. 
       FIG. 8  illustrates a close up view of a portion of one embodiment of a filter  14 . As may be seen in  FIG. 8 , in some embodiments, the filter  14  may include holes  15  in the spaces between the passages  20 . The holes  15  may help trapped air be released when the filter  14  is first pushed into the wash liquid. The holes may further act as filters for particles that fall between passages  20 . Any number of holes  15  may be used and a single filter  14  may have only a few holes  15  or may have a hole  15  in every space between the passages  20 . 
     The holes  15  may be any shape or size. In most embodiments, the holes  15  will be significantly smaller than the passages  20 . In some embodiments, the holes  15  may also have a funnel shape. In other embodiments, the holes may simply pass straight through. In yet other embodiments, no holes  15  exist in the spaces between the passages  20 . 
     Instead of or in addition to holes  15 , filter  14  may have holes  17  in the side walls of some of the passages. It is important that hole  17  in the side wall of passage  20  is located under the plane of the filter  14  such that dirt falling through the hole is trapped under filter  14 . Any number of holes  17  may be used. Preferably, only a select number of passages  20  include holes  17 . In preferred embodiments, 10-20% of the passages include holes  17 . In yet other embodiments, less than 10% of the passages  20  include holes  17  and in some embodiments, holes  17  in the side walls of the passages  20  may not be used at all. If holes  17  are used, they may be made large enough to allow the tip of a human finger fit into the hole such that it may be used to better grasp the filter  14 . 
     In yet other embodiments, one or more larger passages  20  may be created within the plane of the body that can accommodate a human finger. These passages  20  may be bunched such that a human hand can easily pick up the filter. In a preferred embodiment, four large passages  20  may be located in the center of body. 
       FIG. 9  illustrates an isometric view of the bottom of one embodiment of a filter  14 . As may be seen in  FIG. 9 , the filter  14  may include a plurality of legs or stands  25 . Legs  25  are extrusions from the bottom of the filter  14  that extend down past the bottom of the passages  20  such that the entire filter  14  is suspended off the bottom of the container  12  by the legs  25  when the filter  14  is placed in the container  12 . Thus, when the filter  14  is placed in a container  12 , the distance from the bottom of the legs  25  to the bottom of the passages  20  is a gap that is used to trap the dirt and particulates in the washing fluid. 
     In a preferred embodiment, the legs/stands  25  may simply be longer versions of passages  20 . As may be seen in  FIG. 9 , the legs  25  have the same shape and design as the other passages  20  except the legs  25  have a longer, extended funnel section  22 . In preferred embodiments, a set of legs  25  are positioned around the outer diameter. Additional legs  25  may also be used more towards the center of the filter. As may be seen in  FIG. 9 , a single leg  25  was added in the very center of the filter  14 . 
       FIG. 10  illustrates a side view of one embodiment of a filter  14 . As may be seen in  FIG. 10 , the legs  25  extend down past the bottom of the passages  20  forming a gap under the filter  14  when the filter  14  is placed in the container  12 . As may also be seen, the passages  20  extend above and below the body  21  of the filter  14 . 
     Depending on the application, any number of passages  20  may be used on a filter  14 . In some embodiments, a single filter  14  may contain tens, hundreds, or even thousands of passages  20 . Passages  20  may be any size. 
     The passages  20  of the filter  14  are preferably sized to reduce the volume of grit, dust and dirt particles floating through the wash liquid. In some embodiments, the passages  20  have a large diameter of 2.5 centimeters and a small diameter of around 1 mm. However, the passages  20  may have a large diameter larger or smaller depending on the application. In some embodiments the passages have a large diameter of 20 cm. In still yet other embodiments, the large diameter may be 8 cm, 5 cm, or 3 cm. In still yet other embodiments, other sizes may be used. Similarly, the smaller diameter may include a range of sizes. In a preferred embodiment, the smaller diameter of the funnel  22  is smaller than 1 cm. Preferably, the small diameter is 8 mm, 6 mm, 4 mm, 3 mm, 2 mm or 1 mm. Preferably, the smaller diameter is sized to let large dirt particles to pass through from the top to the bottom while making it difficult for any particles to pass in the opposite direction. 
     Preferably the ratio of the larger diameter to the smaller diameter is at least 10 to 1. However, in other embodiments other ration may be used. In some embodiments, a ratio of 100 to 1 may be used. In yet other embodiments 50 to 1, 30 to 1, 5 to 1 or 3 to 1 may be used. In yet other embodiments, still other ratios may be used. 
     Generally, the smaller the passages  20 , the higher the centrifugal forces exerted on the dust particles. To this end, a filter  14  with smaller and more abundant passages  20  is preferable. A filter  14  with a plurality of small funnel shaped passages  20  creates an efficient fluid straining and filtering system allowing separate smaller particles of dust and dirt to separate from wash fluids fast and efficiently. 
     Although embodiments of filters and systems and methods for use have been described with reference to preferred configurations and specific examples, it will readily be appreciated by those skilled in the art that many modifications and adaptations are possible without departure from the spirit and scope of the embodiments as claimed hereinafter. Thus, it is to be clearly understood that this description is made only by way of example and not as a limitation on the scope of the embodiments as claimed below.