Abstract:
A filter system especially useful in the treatment of waste material, in particular liquid waste material which may include particulate matter therein. The filter system includes a series of filters of progressively finer porosity in order to selectively eliminate particulate (or semi-particulate) matters from a carrier material, typically but not exclusively, of a fluid or liquid nature. The filters are mounted within a housing which includes an outlet port and a plurality of inlet ports, wherein each inlet port includes a check valve.

Description:
RELATED APPLICATIONS  
       [0001]    This application is a divisional of application Ser. No. 09/860,694, filed May 21, 2001, which is a divisional of application Ser. No. 09/566,491, filed May 8, 2000, now U.S. Pat. No. 6,331,246. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    This invention is directed to a waste filter and manifold system, in general, and, more particularly, to a waste filter and manifold system for removing solids or semi-solids from a fluid or liquid carrier.  
         BACKGROUND OF THE INVENTION  
         [0003]    There are many uses for waste filter and manifold systems and/or devices for removing certain types of materials from a carrier. One such application is the removal of solid or semi-solid detritus such as bone chips, flesh, blood clots, or the like from the waste material generated by a medical procedure or operation. This removal process permits the liquid or fluid carrier to be treated separately from the other debris which is trapped by the filtration process. Of course, filtration processes are not limited to the medical field, per se, but can be used in areas such as clean rooms or other sterile environments.  
         BRIEF SUMMARY OF THE INVENTION  
         [0004]    The invention relates to a waste filter and manifold system which is especially useful in the treatment of waste material, in particular liquid waste material which may include particulate matter therein. The waste filter and manifold system includes filtration means, for example, a series of filter elements of increasingly finer porosity in order to selectively eliminate particulate and/or or semi-particulate matter from a fluid or liquid carrier material passing through the filter elements. The filter elements are mounted within a housing which includes at least one inlet port and at least one outlet port. The waste filter and manifold system includes at least one check valve to establish unidirectional flow to prevent reverse flow of effluent therethrough. The filter elements are intended (but are not required) to be disposable. The housing may also be disposable, if preferred. 
       
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0005]    [0005]FIG. 1 is an oblique view of one embodiment of a housing for a waste filter and manifold system of the instant invention;  
         [0006]    [0006]FIG. 2 is an exploded view of one embodiment of the waste filter and manifold system of the instant invention;  
         [0007]    [0007]FIG. 3 is a partially broken away rear view of a preferred embodiment of the waste filter and manifold system of the instant invention;  
         [0008]    [0008]FIG. 4 is a partially broken away side or oblique view of the waste filter and manifold system shown in FIG. 3;  
         [0009]    [0009]FIG. 5 is a top view of the housing for the waste filter and manifold system shown in FIG. 1 with the lid and the internal components removed;  
         [0010]    [0010]FIG. 6 is an oblique view of a check valve shown in FIG. 2 and used in the waste filter and manifold system of the instant invention;  
         [0011]    [0011]FIG. 7 is an exploded view of the check valve shown in FIG. 6; and  
         [0012]    [0012]FIGS. 8A and 8B show a distal end of the check valve shown in FIG. 6 illustrating closed and open positions, respectively. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0013]    Referring now to FIG. 1, there is shown an oblique, external view of a preferred embodiment of a waste filter and manifold system  100  of the instant invention. The waste filter and manifold system  100  may also be referred to as a filtration unit  100  or simply as the system  100 . The system  100  includes a generally hollow housing  101  and a removable lid  102 . The lid  102  can include one or more ears  102 A, which are useful in removing the lid from the housing.  
         [0014]    A plurality of inlet ports  103 - 106  are shown projecting outwardly from a front surface of the housing  101 . As will be noted infra, the inlet ports  103 - 106  can be integrally formed with the housing  101 . Alternatively, the inlet ports  103 - 106 , the number of which is not a critical part of the invention, per se, can be formed as a separate assembly which is conveniently mounted at the housing  101  (see infra at FIG. 2). The inlet ports  103 - 106  are provided to be connected to a suitable source of material to be filtered by means of a suitable conduit. In a typical application, the conduit comprises conventional “plastic” tubing.  
         [0015]    As shown in this embodiment, an outlet port  107  depends from a bottom of the housing  101  and is adapted to drain and conduct the filtered contents of the housing  101  to a suitable receiver. Again, while not intended to be limitative of the invention, the outlet port  107  is inserted into a conduit such as conventional tubing.  
         [0016]    An optional feature of the system  100  comprises port caps  110 - 113  which fit snugly over outer ends of the inlet ports  103 - 106 , respectively. In this embodiment, the port caps  110 - 113  are attached together via a flexible cap leash  109 . The configuration of the leash  109 , typically a thin plastic strip, can vary as a function of design preference. In this embodiment, the leash  109  includes a cap ring  108  which is adapted to encircle and engage the outlet port  107  for convenience. In addition, the leash  109  includes a leash grommet  114  which is adapted to engage a leash pin  115  which depends from a lower front portion of the housing  101 . In this embodiment, the leash grommet  114  and cap ring  108  are formed as an integral unit.  
         [0017]    In use, the port caps  110 - 113  are used to cover any of the inlet ports  103 - 106  which are not connected to an input source (not shown) as described supra, in order to maintain the integrity of the system  100 , in general, and to prevent leakage through the housing  101 , in particular. The port caps  110 - 113  can, of course, be individually provided (with or without individual leashes) and need not be connected by a common leash  109 .  
         [0018]    Referring now to FIG. 2 there is shown an exploded view of the system  100 . Typically, the lid  102  is formed of polyethylene and includes a peripheral groove  102 B (see infra at FIG. 3) which receives and snugly engages an upper edge  101 A or lip of the housing  101 . In this embodiment, the housing  101  is formed of ABS and is, generally, rectangular in configuration with a slightly arcuate rear surface (which is provided for mounting purposes in one typical application).  
         [0019]    In this embodiment, a plurality of inlet port openings  213 - 216  are provided through the front surface of the housing  101 . That is, as suggested supra, the inlet ports  103 - 106  can be formed on a common support base  202 , and take the form of a separate assembly  201 . In this case, the assembly  201  is placed inside the housing  101  with the proximal ends of the inlet ports  103 - 106  extending outwardly through the ports openings  213 - 216 . The support base  202  is, typically, affixed to an inner surface of the housing  101  in any suitable manner. Of course, in the embodiment wherein the inlet ports  103 - 106  are formed as integral parts of the housing  101 , per se, the separate port openings  213 - 216  are unnecessary.  
         [0020]    The port caps  110 - 113  and the related cap leash  109 , cap ring  108 , and leash grommet  114  are adapted to be mounted to the assembly  201  as suggested in FIG. 1 whether the inlet ports  103 - 106  are separate or integral with the housing  101 . Again, the leash  109  (and the design thereof) is not a critical portion of the invention.  
         [0021]    A plurality of check valves  203 - 206  are adapted to be attached to inner or distal ends of the inlet ports  103 - 106 , respectively. Each of the check valves  203 - 206 , described in greater detail infra, includes a connection portion, for example connector  301 , (generally cylindrical in this embodiment) which is the proximal end of the check valve and is adapted to be snugly joined to the inner (distal) end of the respective inlet port  103 - 106 . A flexible distal end of each of the check valves  203 - 206  permits fluid flow through the check valves  203 - 206  in one direction only as described infra relative to FIGS. 6, 7,  8 A, and  8 B.  
         [0022]    Mounted within the housing  101  is a first filter element  210  which is the least porous filter element in the preferred embodiment. Typically, the first filter element  210  is fabricated of reticulated polyurethane foam and is, in a preferred embodiment, about 0.3 inches thick. In this embodiment, the first filter element  210  has approximately  100  pores per linear inch although this parameter can vary in accordance with the application of the system  100 .  
         [0023]    Mounted within the housing  101  immediately above the first filter element  210  is a filter support gasket  209  which is fabricated of ABS and, thus, provides a rather rigid gasket. Typically, the gasket  209  conforms somewhat snugly to an inner perimeter of the housing  101 . The gasket  209  is, typically, affixed to the inner surface of the housing  101  by any suitable method such as adhesives, bonding, frictional force fit, sonic welding, or the like. Thus, the gasket  209  maintains the first filter element  210  in position and prevents leakage flow to the outlet port  107  around the first filter element  210 .  
         [0024]    Mounted above the first filter element  210  is a second filter element  211  wherein the second filter element  211  is typically more porous than the first filter element  210 . In the preferred embodiment, the second filter element  211  contains about 30 pores per linear inch and is about 0.3 inches thick. The second filter element  211  is, typically, fabricated of reticulated polyurethane foam and extends snugly to the inner surface of the housing  101  to prohibit flow therearound. The second filter element  211  tends to rest loosely upon the support gasket  209  and an upper surface of the first filter element  210 .  
         [0025]    Also, mounted in the housing  101  is a third filter element  212  which is the most porous filter element in this embodiment. Typically, the third filter element  212  is fabricated of reticulated polyurethane foam and has about 5 pores per linear inch. It is noted that the third filter element  212  has a configuration which advantageously substantially surrounds the distal ends of the check valves  203 - 206 . In this embodiment, the configuration of the third filter element  212  is such that wall thicknesses thereof are about 0.5 inch, while a height of a back and sides is about 1.5 inches. The third filter element has the effect of confining any effluent which passes through the check valves  203 - 206  so that the effluent material flow must pass through the filter elements  210 - 212  of the system  100  in order to traverse from the inlet ports  103 - 106  to the outlet port  107 .  
         [0026]    The third filter element  212  may be fabricated in a “sofa” configuration as shown. Alternatively, the third filter element  212  can be fabricated from a flat sheet of material which is cut to shape and folded into the depicted shape.  
         [0027]    It must be understood, of course, that the specific configurations and/or parameters of any of the filter elements  210 - 212  are desirable but can be varied in accordance with a specific filtration process required. In fact, some or all of the filter elements  210 - 212  may be combined or eliminated as a single filter element, if so desired.  
         [0028]    Referring now to FIG. 3, there is shown a partially broken away view of the system  100  taken through a rear of the housing  101 . There is shown an interior of the front surface of the housing  101  with the distal end of check valves  203 - 206  extending inwardly. The lid  102  includes the groove  102 B which is secured to the edge  101 A of the housing  101 . Ribs  310  provide support and rigidity to the lid  102  and can be omitted in some designs.  
         [0029]    As seen, the first filter element  210  is mounted adjacent to the bottom of the housing  101  and above the outlet port  107 . A partial shading suggests a fine porosity of the first filter element  210 .  
         [0030]    The gasket  209  is disposed above the first filter element  210  and, as noted, is secured to the housing  101 . In one embodiment, upright pins  320  extend upwardly from an inner bottom surface of the housing  101 . The pins  320  extend through the first filter element  210  and engage apertures in the gasket  209  to secure the gasket  209  and the first filter element  210  to the housing  101 . This arrangement maintains the first filter element  210  in position and affords a support for the other filter elements  211 , 212 . The pins  320 , if utilized, can be treated to assist in securing the gasket  209  to the housing  101 .  
         [0031]    The second filter element  211  rests upon the gasket  209  and, to some extent, upon the first filter element  210 . The partial shading of second filter element  211  suggests a more porous structure than the first filter element  210 .  
         [0032]    The third filter element  212  is also provided in the housing  101  and is adjacent to the check valves  203 - 206 . As shown, the third filter element  212  rests upon the second filter element  211  and substantially surrounds the distal ends of the check valves  203 - 206 . That is, the third filter element  212  includes side walls  212 A and  212 B which extend upwardly along side walls of the housing  101  into close proximity to an inner surface of the lid  102 . Thus, effluent from the check valves  203 - 206  is contained within the third filter element  212  to insure filtration of all of the effluent. The partial shading of the third filter element  212  suggests a structure which is more porous than the second filter element  211 .  
         [0033]    In FIG. 3, the support base  202  for the inlet ports  103 - 106  is shown although this support base  202  may be eliminated as described supra.  
         [0034]    Referring now to FIG. 4, there is shown a cut away view of the system  100 . The system  100  includes the housing  101 , lid  102  and outlet port  107 . Also, the inlet port  106  is shown complete while the inlet port  105  is partially broken away. The port cap  113  is shown along with the partially broken away port cap  112  together with the optional leash  109  and leash ring  108 .  
         [0035]    A partially cutaway view of the check valve  205  is shown inside the housing  101  and connected to the inlet port  105 . The check valve  205  is described infra.  
         [0036]    Ribs  116  (seen best in FIG. 5) are formed at a lower internal surface of the housing  101  extending toward an opening  107 A in the outlet port  107 . The first filter element  210  rests upon an interior ledge  118  adjacent to the bottom of the housing  101  and, in some cases, upon upper edges of the ribs  116 . The gasket  209  maintains the first filter element  210  in place as described supra. The second filter element  211  is supported by the gasket  209 .  
         [0037]    As seen in FIG. 4, the third filter element  212  rests on the second filter element  211 . The third filter element  212  includes the side wall portions  212 A and  212 B which are joined to the bottom section of the third filter element  212 . As noted supra, the third filter element  212  comprises a sofa-shaped, basket-like filter element which receives and filters all of the effluent from the check valves  203 - 206  before the flow passes through the other filter elements  210 - 211  and out through outlet port  107 . The decreasing porosity of the filter elements  210 - 212  removes smaller sized, fluid borne matter as the fluid passes through the system  100 .  
         [0038]    Referring now to FIG. 5, there is shown a top view of the housing  101  with the lid  102  and the filter elements  210 - 212  removed. In this view, the inlet ports  103 - 106  are shown formed integrally with the housing  101  and with the check valves  203 - 206  removed. The bottom of the housing  101  is shown to incorporate a plurality of the ribs  116  which extend generally radially from the opening  107 A of the outlet port  107  to the inner surface of the housing  101 . The ribs  116  serve to channel the effluent which has passed through the filter elements  210 - 212  into the opening  107 A in the outlet port  107 . The rim  117  adjacent to the opening  107 A may be formed in the interior bottom surface  118  of the housing  101  and is sloped downwardly to enhance outward flow from the housing  101  to the outlet port  107 . The interior bottom surface  118  of housing  101  may also be configured to slope from the perimeter thereof toward the outlet port  107  in order to enhance outward flow of effluent.  
         [0039]    Referring now concurrently to FIGS. 6 and 7, there are shown an assembled view and an exploded view, respectively, of one of the check valves  203 - 206 , for example. The check valve  203  comprises the connector tube  301  which is designed to engage with the respective inlet port  103 . Typically, the tube  301  is a short cylindrical tube which is relatively rigid in order to maintain its shape. However, the tube  301  is able to snugly engage the inlet port  103  and form a secure, leakproof connection therewith.  
         [0040]    The check valve  203  also includes an elongated, flattened tube  304  which is, in this embodiment, formed by flaps  302  and  303  of generally planar, flexible material such as PVC. The flaps  302  and  303  each have one end joined to the connector tube  301  in suitable fashion, as for example by adhesives, RF bonding, sonic welding or the like to form a secure seal. Side edges of the flaps  302  and  303  are also sealed to each other in a suitable fashion as suggested above. Thus, a common end of the flaps  302  and  303  along with the tube  301  forms a generally cylindrical opening which communicates with the space between the flaps which are sealed together at the side edges at seams  305  and  306  to form the flattened tube  304 . The other ends of the flaps  302  and  303  are not sealed together but are independently flexible.  
         [0041]    Thus, as shown in FIG. 8A, by properly selecting the dimensions of the components, the unsealed ends of the flaps  302  and  303  tend to come together snugly and form a closed end to the check valve  203 .  
         [0042]    Conversely, as shown in FIG. 8B, the unsealed ends of the flaps  302  and  303  can be spread apart by application of a modest force applied thereto by fluid passing through the check valve  203 .  
         [0043]    Thus, fluid can flow through the tube  301 , through the channel in the tube  304  defined between the edge-sealed flaps  302  and  303 , and out the unsealed end of the check valve  203 . However, inasmuch as the unsealed ends of the flaps  302  and  303  tend to come together in the absence of a pressurized flow through the check valve  203  unidirectional flow is achieved and reverse flow through the check valve  203  cannot occur.  
         [0044]    It should he understood that the pressurized flow can be provided by supplying a positive pressure at an input side of the connector tube  301  (e.g. via the inlet ports  103 - 106 ) or by supplying a negative pressure (e.g. vacuum) at the unsealed end of the flaps  302  and  303  at the distal end of the check valve  203  (e.g. via the outlet port  107 ). In either case, unidirectional flow through the check valve  203  is achieved.  
         [0045]    Thus, there is shown and described a unique design and concept of a waste filter and manifold system  100 . While this description is directed to a particular embodiment, it is understood that those skilled in the art may conceive modifications and/or variations to the specific embodiments shown and described herein. Any such modifications or variations which fall within the purview of this description are intended to be included therein as well. It is understood that the description herein is intended to be illustrative only and is not intended to be limitative. Rather, the scope of the invention described herein is limited only by the claims appended hereto.