Abstract:
An air filter cleaner assembly having a graduated sealing disk, an air conduit having a shut-off valve and a quick connect male fitting on one end, and a cleaning head assembly on the other end. The cleaning head assembly enables air to flow from the interior of the air conduit to the exterior via a rotating sleeve, quick connectors, and nozzles. Various length nozzles can be interchanged on the rotating sleeve using the quick connectors, thereby enabling compressed air to be delivered in close proximity to the interior surface of an air filter being cleaned.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 61/923,429, filed Jan. 3, 2014, said application being hereby fully incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The embodiments of the invention are directed to a filter cleaning assembly for cleaning air filters. Specifically, the embodiments of the invention are directed to a filter cleaning assembly for cleaning cylindrical filters and radial seal air filters using pressurized air and a cleaning head with nozzles mounted on a rotating nozzle. 
       BACKGROUND 
       [0003]    Equipment with internal combustion engines is used in various industries such as farming, mining, construction, transportation, and in dirt and dust producing environments such as welding, powder coating, and fiberglass, wood, and paper industries. The equipment can be stationary or mobile but the common denominator is that air is brought into the engine to mix with the fuel for the combustion process. Ambient air enters the engine through an air filter that is provided to filter out dust, dirt and other contaminants. As the air filter traps the dust, dirt and other contaminants, the pores within the filter become clogged and air does not flow through the filter as freely and “dirty” air is also more likely to be provided to the engine. This results in poor performance of the engine as well as increased consumption of fuel, and if dirt passes through into the engine, increased engine wear and damage. 
         [0004]    In order to increase the air flow, the air filter is often replaced with a brand new clean filter or the dirty filter is cleaned, either using compressed air or even, in some instances, chemicals. An issue with replacement is that many of the filters used in heavy duty equipment are expensive and large. Thus, replacement not only results in higher operating costs due to the cost in replacing the filter, but disposal of the filter is not eco-friendly. Current cleaning systems, using compressed air or chemicals, do not sufficiently clean the filters thus resulting in excessive cleaning activities which can be timely and costly. In addition, more fuel is used as the semi-clean filter is not allowing free air flow to the engine. It is known that during harvest season, a filter installed on a tractor or combine can need to be cleaned and/or replaced at least three times per an eight hour period. Neglecting to properly clean or not cleaning the air filter can result in the use of additional five gallons of fuel per hour. 
         [0005]    It is well known for such filters to be cleaned with a nozzle attached to a source of compressed air, with a blast of air from the nozzle being applied to the inner surface of the filter. Such techniques, however, often result in a damaging rate of air flow being applied to localized areas on the filter, thereby blowing holes in the filter media and compromising the filtering characteristics of the media. 
         [0006]    There have been attempts at producing an air filter cleaner using compressed air and a rotating element so as to reduce the direct impact of air on localized areas of the filter. For example, U.S. Pat. No. 6,588,057 to McMahon discloses an air filter cleaner having a rotating head that directs jets of air outwardly from the rotating head in order to clean a cylindrical air filter. U.S. Pat. No. 7,815,701 to Grieve discloses an apparatus for cleaning an air filter wherein jets of air from a rotating pipe member placed inside an air filter are directed onto the inside surface of the air filter. U.S. Patent Publication No. US2013/0037061 to Grieve discloses an apparatus for cleaning an air filter, wherein a head rotated by a system of internal baffles and orifices directs air onto the interior surface of an air filter through nozzles connected to the rotating head. All of these attempts, however, have various drawbacks, and none have fully addressed the need in the industry for a simple, durable, and effective air filter cleaner that is easy to use in the field. 
       SUMMARY 
       [0007]    An air filter cleaner assembly, according to an embodiment of the present invention, can include a graduated sealing disk to accommodate differing diameters of air filters, an air conduit having a shut-off valve and a quick connect male fitting on one end, and a cleaning head with nozzles coupled to a rotating sleeve on the other end. The cleaning head enables air to flow from the interior of the air conduit to the exterior via the rotating sleeve, connectors, and nozzles. Various length nozzles can be interchanged on the rotating sleeve using quick-connect pneumatic fittings so as to accommodate placing the air filter discharge in relatively close proximity to the interior surface of cylindrical air filters of varying internal diameters. 
         [0008]    In an embodiment, the air filter cleaner assembly safely cleans air filters using pressurized air, without damaging the air filter, thus effectively extending the life of the filter. The air filter cleaner is portable, lightweight, durable, and easy to use. The air filter cleaner is able to be used on multiple sizes and styles of radial seal filters as well as other types and styles of cylindrical filters, including filters for, but not limited to, combustion engines, electrical motors, dust collection units, and vacuums. 
         [0009]    The air filter cleaner system can be used with pressurized air provided from an ordinary shop-style air compressor or portable air compressor. Nozzles can be provided in various lengths and are interchangeable thus allowing the user to alter the configuration on the rotating sleeve to coincide with the size of filter being cleaned. The graduated sealing disk is configured so that the graduating disk layers coincide with the inside diameter of the most common size air filters on the market. 
         [0010]    An air filter cleaner assembly according to an embodiment of the invention includes an elongate air conduit, and a sealing disk adapted to engage with an end of a cylindrical air filter, the sealing disk defining an aperture, with the elongate air conduit being slidingly received in the aperture. The apparatus further includes a cleaning head assembly disposed at a distal end of the elongate air conduit. The cleaning head assembly includes a shaft member having a head portion and a shaft portion, the shaft member defining a longitudinal bore, the shaft portion defining a plurality of air ports extending from the longitudinal bore to an outer surface of the shaft portion. The cleaning head assembly further includes a connecting sleeve coupling the shaft member to the elongate air conduit, and a rotating member rotatably mounted on the shaft portion between the head and the connecting sleeve, the rotating member including a bearing portion defining a plurality of apertures vertically registered with the air ports of the shaft portion, and a first plurality of nozzles, each of the first plurality of nozzles being coupled to a separate one of the apertures in the bearing portion with a separate quick-connect pneumatic fitting such that the nozzles are attachable and detachable from the bearing portion by operation of the quick-connect pneumatic fittings, the nozzles being oriented tangentially relative to the bearing portion and fluidly coupled with the air conduit, such that compressed air supplied through the air conduit, longitudinal bore, air ports, and quick-connect pneumatic fittings causes air to be expelled from the nozzles, thereby causing rotation of the rotating member on the shaft portion. 
         [0011]    In embodiments of the invention, the sealing disk may have a plurality of disk levels, each disk level having a different diameter. In other embodiments, the quick-connect pneumatic fittings are elbows. The elbows may have an elbow angle of 90 degrees or 135 degrees. In other embodiments, the quick-connect pneumatic fittings are straight fittings. 
         [0012]    The rotating member may have three apertures, the apertures equally radially spaced apart by 120 degrees. The shaft member may have four air ports, the air ports equally radially spaced apart by 90 degrees. 
         [0013]    In embodiments of the invention the bearing portion is made from acetal homopolymer resin, and the connecting sleeve and shaft member are made from heat treated stainless steel. 
         [0014]    In other embodiments, the air filter cleaner assembly may further include a second plurality of nozzles, the first plurality of nozzles having a first length dimension, the second plurality of nozzles having a second length dimension greater than the first length dimension, the second plurality of nozzles being interchangeable with the first plurality of nozzles. The assembly may further include a spare nozzle holder operably coupled to the sealing disk, the spare nozzle holder adapted to receive at least one of the first plurality of nozzles or the second plurality of nozzles. 
         [0015]    According to an embodiment of the invention, a cleaning head for an air filter cleaner includes a shaft member having a head portion and a cylindrical shaft portion extending from the head portion, the shaft member defining an internal cavity and a plurality of ports extending from the internal cavity to an outer surface of the shaft portion. A generally cylindrical sleeve is rotatably mounted on the shaft portion. The cleaning head further includes a plurality of straight nozzles, each nozzle operably coupled to the sleeve though a pneumatic quick-connect fitting, the nozzles oriented tangentially relative to the sleeve, the nozzles being in fluid communication with the internal cavity of the shaft member through the plurality of ports and the pneumatic quick-connect fittings. 
         [0016]    The shaft member may have four ports radially spaced apart at 90 degree intervals. The pneumatic quick-connect fittings may be elbows, and the elbows may have an elbow angle of 90 degrees. The sleeve may have a plurality of apertures, each aperture receiving a separate one of the pneumatic quick-connect fittings. The apertures may be radially spaced apart by 120 degrees. 
         [0017]    In an embodiment, an air filter cleaner assembly includes an elongate air conduit, a sealing disk adapted to engage with an end of a cylindrical air filter, the sealing disk defining an aperture, the elongate air conduit being slidingly received in the aperture, and a cleaning head assembly disposed at a distal end of the elongate air conduit. The cleaning head assembly includes a shaft member having a head portion and a cylindrical shaft portion extending from the head portion, the shaft member defining an internal cavity and a plurality of ports extending from the internal cavity to an outer surface of the shaft portion, a generally cylindrical sleeve rotatably mounted on the shaft portion, and a plurality of straight nozzles, each nozzle operably coupled to the sleeve though a pneumatic quick-connect fitting, the nozzles oriented tangentially relative to the sleeve, the nozzles being in fluid communication with the internal cavity of the shaft member through the plurality of ports and the pneumatic quick-connect fittings. 
         [0018]    The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    The embodiments of the invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which: 
           [0020]      FIG. 1  is a perspective view of an air filter cleaner assembly according to an embodiment; 
           [0021]      FIG. 2  is a top perspective view of a graduated sealing disk having an air conduit centrally disposed in the disk; 
           [0022]      FIG. 3  is a side elevation view of a shut-off valve and a quick connect male fitting disposed on one end of the air conduit; 
           [0023]      FIG. 4  is a side perspective view of the cleaning head of the air filter cleaner assembly of  FIG. 1 ; 
           [0024]      FIG. 5  is a bottom plan view of the cleaning head of  FIG. 4  without attached nozzles; 
           [0025]      FIG. 6  is a top plan view of the cleaning head of  FIG. 4 ; 
           [0026]      FIG. 7  is a bottom plan view of the cleaning head of  FIG. 4 ; 
           [0027]      FIG. 8  is a disassembled view of a cleaning head depicting the shaft member, connecting sleeve, and rotating member; 
           [0028]      FIG. 9  is a side plan view of an arm according to an embodiment; 
           [0029]      FIG. 10  is an end view of an arm according to an embodiment; 
           [0030]      FIG. 11  depicts an air filter cleaner according to an embodiment of the invention with an air filter; 
           [0031]      FIG. 12  depicts a partial, inverted, vertical cross-section taken at section  12 - 12  of  FIG. 4 ; 
           [0032]      FIG. 13  depicts a partial, horizontal cross-section taken at section  13 - 13  of  FIG. 4 ; and 
           [0033]      FIG. 14  depicts a partial, horizontal cross-section taken at section  13 - 13  of  FIG. 4  for an alternative embodiment in which the radial arms of the rotating head are disposed directly tangentially to the rotating head of the apparatus. 
       
    
    
       [0034]    While the embodiments of the invention are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION 
       [0035]      FIG. 1  depicts an air filter cleaner assembly  20  according to an embodiment. Air filter cleaner assembly  20  generally includes graduated sealing disk  22 , air conduit  24  with shut-off valve  26 , quick connect male plug  28 , and cleaning head assembly  30 . Graduated sealing disk  22  generally includes various disk levels  32 ,  34 ,  36  disposed on underside  38  of graduated sealing disk  22 . As depicted in  FIG. 11 , disk levels  32 ,  34 ,  36  can be sized to coincide with the inner diameter (d) of a cylindrical air filter  40  so that the appropriately sized disk level  32 ,  34 ,  36  is snugly mated to an end  42  of filter  40 , thus limiting any lateral movement of air filter cleaner assembly  20  relative to the filter  40 . It is understood that while three disk levels  32 ,  34 ,  36  are depicted, there can be more or fewer disk levels provided. In an embodiment, a pyramidal shape can be provided on underside  38  of sealing disk  22  to provide varying sealing circumferences. Sealing disk  22  and disk levels  32 ,  34 ,  36  define centrally located apertures  44 , registered with each other, and that are sized to receive air conduit  24 . Inwardly facing surface (not shown)  46  defining apertures  44  and outer surface  48  of air conduit  24  can be closely mated to enable longitudinal sliding movement of air conduit  24  in apertures  44  while still inhibiting excessive air leakage between air conduit  24  and surface  46 . In an embodiment, a silicone seal or other type of sealing arrangement can be provided between apertures  44  and air conduit  24 . It should be understood, however, that any type of sealing arrangement between air conduit  24  and apertures  44  can be used that is suitable for inhibiting leakage while also enabling air conduit  24  to be freely slid longitudinally relative to sealing disk  22 . 
         [0036]    In the embodiment depicted in  FIGS. 1-3 , proximal end  50  of air conduit  24  is coupled to shut-off valve  26  which is, in turn, coupled to quick connect male plug  28 . Shut-off valve  26  generally includes valve body  52  and valve handle  54 , can be any kind of shut-off valve that is known to those with skill in the art, including, but not limited to, lever, wheel, ball, compression, etc. Quick connect male plug  28  is adapted to matingly attach to a standard quick connect female coupling  56  as is commonly used on air hose  58 . Distal end  60  of air conduit  24  defines external threads  62 . 
         [0037]      FIGS. 4-12  depict an embodiment of cleaning head assembly  30 . Cleaning head assembly  30  generally includes connecting sleeve  64 , shaft member  66 , and rotating member  68 . Connecting sleeve  64  defines bore  70  with internal threads  72  facing proximal end  74 , and internal threads  76  facing distal end  78 . Internal threads  72  receive external threads  62  of air conduit  24  so that connecting sleeve  64  is rotationally and longitudinally fixed to air conduit  24 . In an embodiment, connecting sleeve  64  is made from heat treated stainless steel. In other embodiments, connecting sleeve may be made from other metals such as brass, or polymer materials. 
         [0038]    Shaft member  66  generally includes head portion  80 , and shaft portion  82 . Shaft portion  82  presents proximal end  84  defining external threads  86 . An internal cavity in the form of longitudinal bore  88  extends from proximal end  84  to proximate head portion  80 . Air ports  90  extend from longitudinal bore  88  through to shaft outer surface  92 . As depicted in  FIG. 13 , shaft portion  82  may have four air ports  90 , equally spaced radially at 90 degrees from each other. It will of course be appreciated that more or fewer air ports  90  may be provided within the scope of the invention. Shaft member  66  may be made from heat treated stainless steel or other suitable metal, or from polymer material. External threads  86  engage with internal threads  76  of connecting sleeve  64  so that shaft member  66  is longitudinally and rotationally fixed to connecting sleeve  64  and air conduit  24 . 
         [0039]    Rotating member  68  generally includes bearing portion  94 , elbows  96 , and interchangeable nozzles  98 . Bearing portion  94  defines bore  100  with apertures  102  extending through from bore  100  to outer surface  104 . As depicted in  FIG. 13 , bearing portion  94  may have three apertures  102  equally spaced radially at 120 degrees from each other. It will of course be appreciated that more or fewer apertures  102  may be provided within the scope of the invention. In an embodiment, bearing portion  94  may be formed from acetal homopolymer resin (Delrin®) or other polyoxymethylene (POM) polymer material. In another embodiment, rotating bearing portion  94  can be made from metal such as brass or steel. In another embodiment, bearing portion  94  can be formed from other lubricious and durable plastic materials such as PTFE, other fluoropolymer, or polyurethane blends. The lubricious qualities of acetal homopolymer resin, polyoxymethylene (POM) polymer material, PTFE, other fluoropolymer, or polyurethane blends may help reduce friction between bearing portion  94  and shaft portion  82  and aid in free rotation of rotating member  68 . 
         [0040]    Elbows  96  may be standard quick connect pneumatic fittings with external threads on proximal end  104  and push-in tubing quick-connector  106  at distal end  108 . Proximal end  104  of each elbow  96  is threaded into a separate one of apertures  102 . Each of nozzles  98  is received in a separate one of push-in tubing quick-connectors  106 . Nozzles  98  define air passage  99 . Nozzles  98  may be straight lengths of rigid aluminum tubing, or other rigid metallic or polymer tubing, having an outer diameter at end  107  suitable to be received in push-in tubing quick-connectors  106 . 
         [0041]    It will be appreciated that the length L 1  of nozzles  98  may be selected so as to enable end  110  of nozzles  98  to be located proximate inner surface  112  of filter  40 . Advantageously, as depicted in  FIGS. 6 and 9 , length L 1  of nozzles  98  can be selected such that the diameter d 2  of a circle c 1  circumscribed around the ends  110  of nozzles  98  is just less than the diameter d 3 , d 4 , or d 5 , of a respective one of disk levels  32 ,  34 ,  36 , thus preventing the nozzles  98  from contacting inner surface  112  during rotation of rotating member  68 . It will be appreciated that elbow angle θ as depicted in  FIG. 5 , may be 90 degrees as depicted in the embodiment of  FIGS. 1-13 , or another suitable angle greater than zero and less than 180 degrees, such as 135 degrees. 
         [0042]    As depicted in  FIGS. 4 ,  6 , and  12 - 14 , shaft portion  82  of shaft member  66  is received through bore  100 . The clearance between shaft outer surface  92  and wall  104  defining bore  100  is just sufficient such that rotating member  68  is freely rotatable on shaft portion  82 . In some embodiments, these components may be at least separated by a thin layer of air in operation, thereby achieving a partially aerodynamic lubrication arrangement between the components. Air passages  114  of elbows  96  are vertically registered with air ports  90  of shaft member  66  with bottom wall  116  of bearing portion  94  abutting head portion  80 . Top wall  118  of bearing portion  94  abuts lower surface  120  of connecting sleeve  64  so that rotating member  68  is retained on shaft portion  82  with minimal vertical movement. 
         [0043]    In an embodiment depicted in  FIG. 2 , top side  122  of sealing disk  22  can be provided with spare nozzle retaining device  124 . Nozzles  98  having various lengths may be stored in spare nozzle retaining device  124 , thus providing the benefit of easy access and retention of additional nozzles  124  for easy substitution. As set forth above, nozzles  98  may have lengths L 1  such that the diameter d 2  of a circle circumscribed around the ends  110  of nozzles  98  is just less than the diameter d 3 , d 4 , d 5 , of a respective one of disk levels  32 ,  34 ,  36 . Nozzle sets  126 ,  128 ,  130 , may be assembled with nozzle  98  lengths thus corresponding respectively with disk levels  32 ,  34 ,  36 . 
         [0044]    In operation, as depicted in  FIG. 11 , filter  40  is removed from the engine, or other equipment requiring clean air flow, with end  132  placed on a flat surface such as the ground so that air filter channel  134  is orthogonal to the surface. Nozzles  98  of a suitable length L 1  are chosen based on the air filter channel inner diameter (d) and attached to elbows  96 . It will be appreciated that the length L 1  of nozzles  98  is chosen so that the ends  110  do not contact the inner surface  112  of filter  40 , enabling free rotation of rotating member  68 . Conveniently, one of nozzle sets  126 ,  128 ,  130 , may be selected based on which of disk levels  32 ,  34 ,  36 , is engaged by the filter  40 . Air conduit  24  extends through apertures  44  of sealing disk  22  so that cleaning head assembly  30  is disposed inside air filter channel  134 . Sealing disk  22  is abutted with end  42  of filter  40  so that the appropriate disk level  32 ,  34 ,  36 , matingly engages with end  42 . Air hose  58  is coupled with a source of compressed air, and is coupled to air conduit  24  through quick connect male plug  28  and quick connect female coupling  56 . Compressed air is admitted to air conduit  24  by opening shut-off valve  26 . As compressed air flows through air conduit  24 , the air passes through longitudinal bore  88  of shaft member  66 , through air ports  90  in shaft member  66 , and air passages  114  of elbows  96 , and is expelled from ends  110  of nozzles  98 . Since nozzles  98  are oriented tangentially to bearing portion  94  by virtue of elbow angle θ, the jets of air escaping from ends  110  cause rotating member  68  to rotate on shaft portion  82 . With sufficient air pressure, rotating member  68  will rotate at a high speed. The jets of air impinge upon the inner surface  112  of filter  40  and blow dirt and particles from the outer surface  140  of filter  40 . As the rotating member  68  is rotating, the user manually slides the air conduit  24  up and down, with aperture  44  as a guide, so as to traverse the entire length (L) of air filter channel  134 . Once filter  40  is sufficiently clean, shut-off valve  26  can be closed, air filter cleaner assembly  20  removed from filter  40 , and filter  40  replaced in the equipment. 
         [0045]    It will be appreciated that with air ports  90  radially spaced at 90 degree intervals and air passages  114  radially spaced at 120 degree intervals as depicted in  FIG. 13 , the compressed air is directly connected to only one of nozzles  98  at a time as bearing portion  94  rotates. With a sufficiently high rotational speed, however, a substantially continuous flow of air will escape from the ends  110  of nozzles  98 , if at a somewhat reduced pressure. This reduced pressure may advantageously reduce any tendency of the jets of air to blow holes in the media of filter  40 . 
         [0046]    In an alternative embodiment depicted in  FIG. 14 , straight fittings  142  connected at a tangential angle to bearing portion  94 , and supplied with nozzles  98 , can provide a similar rotating and filter cleaning function. As depicted, straight fittings  142  may be may be standard quick connect pneumatic fittings with external threads on proximal end  144  and push-in tubing quick-connector  146  at distal end  148 . 
         [0047]    Although air filter cleaner assembly  20  is useful to clean air filters for internal combustion engines, it will be appreciated that the device can also be used to clean air filters used for any other purpose as well. 
         [0048]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and described in detail. It is understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.