Particle trap/filter and systems related thereto

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.

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 “'880 patent”) The '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 '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.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The present patent document discloses systems, apparatus and methods to deliver clean wash water without replacing filters.FIG. 1illustrates an exploded view of one embodiment of a system for providing clean wash water. The embodiment shown inFIG. 1comprises a container12, a filter14and a seal16.FIG. 2illustrates an assembled version of the embodiment ofFIG. 1with the filter14placed in the bottom of the container12.

Container12may be any type of container including a bucket, bin, cup, tub or any other type of container that can hold a fluid. Moreover, container12may be made of various different materials including metal, glass or plastic to name a few. In a preferred embodiment, container12is a bucket and may further include a handle and/or lid (not shown). In an even more preferred embodiment, container12is a standard size bucket such as a 1 gallon, 2 gallon or 5 gallon bucket. Although container12may be any shape, it is preferably cylindrical.

In a preferred embodiment, filter14is shaped and sized to fig snuggly inside of container12. As used herein, a snug fit means that the diameter of the filter14is slightly smaller than the inner diameter of container12. For example, filter14may have a diameter of approximately 1 millimeter less than the inside diameter of container12where the filter sits when assembled. In some embodiments, a seal16is placed in the space between the outside of the filter14and the inside of the container16. The seal acts to provide a complete or partial fluid seal between the filter14and the container12. In preferred embodiments, the seal is made from rubber, silicone or another soft deformable material. In some embodiments, seal16may be an O-ring. In some embodiments, no seal16is 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 container12and filter14may be provided such that the filter14is self-positioning at the correct depth within the container.

While in some embodiments a seal16may be used, in other embodiments no seal16is used. In embodiments without a seal16, whatever gap exists between the outside of the filter14an the inside of the container12may serve as an air release.

In some embodiments, the diameter of the outside of the filter14may vary in order for the filter14to match a changing diameter in the inside of a container12. For example, the top of the filter14may have a slightly larger diameter than the bottom of the filter14such that the filter14wedges inside a container12with a reducing inner diameter.

The filter14may be made out of various different kinds of materials but is preferably made from plastic. Filter14may 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 filter14is designed to be less buoyant than the liquid it will be submerged in and particularly, less buoyant that water. This allows the filter14to 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 body21, as shown inFIG. 3also helps the filter14stay at the bottom of a container12filled with a wash liquid.

As may be seen inFIG. 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. 3illustrates an isometric view of one embodiment of a filter14according to the teachings of the present patent document. In the embodiment of the filter14shown inFIG. 3, the filter14includes a plurality of passages20that pass through the filter from the top to the bottom. The passages are all connected together by a body21. The body21connects each of the outer walls of the passages20together to form a continuous filter14. In a preferred embodiment, the body21is generally planar located with a thickness such that a top portion of the passage projects above the top surface of the body21and a lower portion of the passage projects below the bottom surface of the body21. To this end, the body21is much thinner than the thickness of the filter14. A thinner body21reduces weight and manufacturing costs. As will be discussed below, allowing the passages to extend above and below the body21also has additional benefits.

In some embodiments, body21can 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 passages20can 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 passages20would fall to the outer diameter of body21.

In the embodiment shown, the passages20are small half inch diameter plastic cone that point down into the container12when the filter14is inserted. As may be seen in this embodiment, the passages20may 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 passages20on the filter14are 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 container12, a natural rotation of the liquid inside the container12is created. This rotation moves the wash liquid around and into the passages20where it can be filtered. The rotations created in the container12combined 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 passages20and filter14are configured to promote this centrifuge effect to clean the water and trap dirt at the bottom of the container12allowing clean water to flow back to the top above the filter14.

FIG. 4illustrates a cross section of one design of a passage20for use with the filter14embodiments described herein. As may be seen inFIG. 4, the passage20is preferably cone shaped and has a funnel portion22. In preferred embodiments, the passage20has a larger diameter hole26at the top and a smaller diameter hole28at the bottom with a funnel shaped wall22connecting the larger diameter hole26to the smaller diameter hole28. The larger diameter hole26at the top makes it easy for the particulates in the cleaning fluid to enter the passage20from 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 filter14. Moreover, the funnel shape22helps promote the natural centrifuge effect created in the wash fluid when a user pushes their hand in and out of the container12.

In preferred embodiments, the passage includes a portion24that extends above the body21of the filter14. The portion24of the passage that extends above the top surface31of the body21of the filter14may also be referred to as a “lip”24. The lip24provides 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 passages20such that they extend above the body of the filter14they work better and clean items rubbed against them, therefore making them an ideal wash board. In preferred embodiments, the lip24may be a small portion of the passage20. In some embodiments, 10% of the passage20extends above the top surface31of the body21of the filter14while in other embodiments only 5% or 3% extends above the body21of the filter14. A subtle lift assures that no dirt or grime can stay trapped between the passages20.

As may be seen in the cross section of the passage20shown inFIG. 4, in some embodiments, the entire passage is not required to be a funnel22. As may be seen, the passage20may be made up of portions like the lip24that are not part of the funnel22. However, in the preferred embodiments disclosed herein, at least a portion of the passage20is funnel shaped22. In the embodiment shown inFIG. 4, the passage20comprises a funnel shaped portion22that extends up from the smaller diameter hole28with a steadily increasing diameter. In some embodiments, the funnel shaped portion22may extend all the way to the top of the larger diameter hole26. However, in some embodiments, the funnel shaped portion22may terminate at an upper portion that is comprised of a vertical wall. The vertical wall may form the lip24. In yet other embodiments, the passage20may also include a vertical wall portion at the bottom of the funnel shaped portion22. In still yet other embodiments, the passage20may 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. 5illustrates a cross-sectional view of another embodiment of a passage20for use in a filter14. In the embodiment shown inFIG. 5, the entire passage20is constructed of a funnel22. In preferred embodiments, the top of the funnel22may be pushed up above the body21of the filter14as shown.

FIG. 6illustrates a cross-sectional view of another embodiment of a passage20for use in a filter14. The embodiment shown inFIG. 6includes a plurality of varying sections. The top of the passage20consists of a vertical section23. The vertical section23transitions into a funnel section22. Finally, the funnel section22transitions into another vertical section27. As may be seen, the top portion24of the passage20forms a lip24my rising above the body21of the filter14.

In operation, the filter14is placed in a container full of a washing liquid. The passages20within the filter14work with the natural centrifugal force created in the wash liquid within the container12to trap dirt and other contaminants below the filter14. The dirt particles floating in the water are drawn through the passages20, spin around, drops down, and collect in the bottom of the container12where they are prevented from coming into contact with the sponge cloth or other washing device being used.

FIG. 7is a top down view of a filter14. As may be seen, filter14includes a plurality of passages20. In a preferred embodiment, the passages20are spaced such that they cover as much of the top of the body21of the filter14as possible.

InFIG. 7, filter14is illustrated as round but filter14may be any shape. Filter14is preferably shaped to match the interior shape of container12. Round is preferable for both because round promotes the spinning of the wash fluid and the centrifugal effects created thereby.

In some embodiments, the passages20may be placed randomly within the body21of the filter14. In yet other embodiments, the passages20may be patterned. By maximizing the spread of the passages20along with systematically and geometrically placing the passages20over the surface of the filter14, 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 filter14. As may be seen in the embodiment inFIG. 7, the passages20are patterned in 9 concentric circles across the radius of the filter14. Depending on the size of the passages20and the size of the filter14, any number of concentric circles may be used such the filter14is covered with passages20. Patterning the passages20in 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 passages20is preferably minimized. To this end, the concentric circles of passages20may be rotated with respect to each other such that the diameters of the passages20in one concentric circle falls between the diameters of two passages20in a neighboring concentric circle. In this way, the concentric circles can be pushed closer together and the space between the passages20minimized.

FIG. 8illustrates a close up view of a portion of one embodiment of a filter14. As may be seen inFIG. 8, in some embodiments, the filter14may include holes15in the spaces between the passages20. The holes15may help trapped air be released when the filter14is first pushed into the wash liquid. The holes may further act as filters for particles that fall between passages20. Any number of holes15may be used and a single filter14may have only a few holes15or may have a hole15in every space between the passages20.

The holes15may be any shape or size. In most embodiments, the holes15will be significantly smaller than the passages20. In some embodiments, the holes15may also have a funnel shape. In other embodiments, the holes may simply pass straight through. In yet other embodiments, no holes15exist in the spaces between the passages20.

Instead of or in addition to holes15, filter14may have holes17in the side walls of some of the passages. It is important that hole17in the side wall of passage20is located under the plane of the filter14such that dirt falling through the hole is trapped under filter14. Any number of holes17may be used. Preferably, only a select number of passages20include holes17. In preferred embodiments, 10-20% of the passages include holes17. In yet other embodiments, less than 10% of the passages20include holes17and in some embodiments, holes17in the side walls of the passages20may not be used at all. If holes17are 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 filter14.

In yet other embodiments, one or more larger passages20may be created within the plane of the body that can accommodate a human finger. These passages20may be bunched such that a human hand can easily pick up the filter. In a preferred embodiment, four large passages20may be located in the center of body.

FIG. 9illustrates an isometric view of the bottom of one embodiment of a filter14. As may be seen inFIG. 9, the filter14may include a plurality of legs or stands25. Legs25are extrusions from the bottom of the filter14that extend down past the bottom of the passages20such that the entire filter14is suspended off the bottom of the container12by the legs25when the filter14is placed in the container12. Thus, when the filter14is placed in a container12, the distance from the bottom of the legs25to the bottom of the passages20is a gap that is used to trap the dirt and particulates in the washing fluid.

In a preferred embodiment, the legs/stands25may simply be longer versions of passages20. As may be seen inFIG. 9, the legs25have the same shape and design as the other passages20except the legs25have a longer, extended funnel section22. In preferred embodiments, a set of legs25are positioned around the outer diameter. Additional legs25may also be used more towards the center of the filter. As may be seen inFIG. 9, a single leg25was added in the very center of the filter14.

FIG. 10illustrates a side view of one embodiment of a filter14. As may be seen inFIG. 10, the legs25extend down past the bottom of the passages20forming a gap under the filter14when the filter14is placed in the container12. As may also be seen, the passages20extend above and below the body21of the filter14.

Depending on the application, any number of passages20may be used on a filter14. In some embodiments, a single filter14may contain tens, hundreds, or even thousands of passages20. Passages20may be any size.

The passages20of the filter14are preferably sized to reduce the volume of grit, dust and dirt particles floating through the wash liquid. In some embodiments, the passages20have a large diameter of 2.5 centimeters and a small diameter of around 1 mm. However, the passages20may 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 funnel22is 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 passages20, the higher the centrifugal forces exerted on the dust particles. To this end, a filter14with smaller and more abundant passages20is preferable. A filter14with a plurality of small funnel shaped passages20creates 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.