Abstract:
A filter assembly with upper and lower filter chambers containing a filter material, preferably activated carbon, and a coalescing filter, respectively. The filter assembly includes a visual indicator for showing when the filter assembly is saturated and requires replacement or maintenance. In a preferred embodiment, the visual indicator is a temperature indicator. In an alternate embodiment, the visual indicator is an air flow indicator. A particularly preferred embodiment, the upper filter chamber includes a removable lid which allows for removal and replacement of the filter material. The filter assembly further includes at least one flashback inhibitor to prevent igniting fumes. The filter assembly connected to a storage drum which accepts residue from pressurized containers and removes contaminants from gas fumes which escape from the storage drum.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 62/158,928, filed May 8, 2015 for “Improved filter for a propellant gas evacuation system”, incorporated by reference herein in its entirety. This application is related to co-pending U.S. patent application Ser. No. 14/676,458, filed Apr. 1, 2015 for “Improved filter for a propellant gas evacuation system”, incorporated by reference herein in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to gaseous-material evacuation systems and more particularly to such systems having filters for cleaning evacuated gases. 
     2. Description of Related Art 
     This invention has uses in the area of waste disposal, such as in devices and systems for evacuating aerosol cans, and other containers of pressurized gases and residue contents. 
     Pressurized aerosol cans, and other pressurized containers, have widespread usage in homes and industry. It has long been recognized that improper disposal of such containers constitutes a safety hazard in that excessive external heat and/or pressure can cause them to explode if they have not been relieved of internal pressure. Similarly, the release of contents, both propellant gases and dangerous residue materials, from such containers often damages the environment. 
     Due to these hazards, the Environmental Protection Agency (EPA), an agency of the U.S. Government, regulates disposal of pressurized containers as well as their contents for industries. These regulations mandate regulated businesses and industries dispose of pressurized containers as hazardous waste. The Resource Conservation and Recovery Act mandates that the pressure within aerosol cans equal atmosphere prior to disposal. Further, these regulations require that certain contents of pressurized containers be captured and disposed of in particular manners. Depending upon the natures of such contents, disposal methods can involve permanent disposal through incineration, landfills or other means; treatment and permanent disposal; treatment and recycling; and treatment and reclamation for a new use. An example of reclamation would be recovering a solvent contained in waste paint for use as a fuel. But, whichever disposal method is used, the EPA requires many industries to relieve the pressure in pressurized containers prior to transporting them for disposal. 
     In addition to the above requirements of the EPA, many states within the United States and countries outside the United States have requirements similar to, or even stricter than, those of the EPA. For example, California closely regulates release of gases into the atmosphere. In this respect, California considers some propellants used in aerosol cans to be contaminants, particularly when they contain small aerosolized particles of materials, such as insecticides, paints and the like, which were in the aerosol cans. 
     Further, while EPA regulations do not apply to individuals and many small businesses, many of these still desire to dispose of hazardous contents of such containers, and the containers themselves, in a manner which provides personal safety and protects the environment, and would do so if a reliable, inexpensive apparatus therefor exists. 
     There have been a number of prior-art devices suggested for piercing pressurized containers such as are described in U.S. Pat. No. 3,303,968 to Compere; U.S. Pat. No. 3,333,735 to Odasso; U.S. Pat. No. 3,828,976 to Sidelinker; U.S. Pat. No. 3,926,340 to Tygenhof; U.S. Pat. No. 4,500,015 to Penney, and U.S. Pat. No. 4,934,055 to Chambers. Some of these devices do not adequately provide for disposal of gases and residual contents of the pressurized containers, such as the devices of Compere, Sidelinker, Odasso, Tygenhof and Penney. 
     The device of Chambers (U.S. Pat. No. 4,934,055) does provide for disposal of contents of pressurized cans, however, this device appears to be somewhat limited in application having an unduly small, custom-built, reservoir and apparently requiring an undue amount of strength and dexterity to operate. Also, the device of this patent does not appear to be sufficiently durable to withstand repeated use. 
     A number of US Patents to Michael Campbell describe systems for evacuating gaseous materials from aerosol containers and other types of containers, see U.S. Pat. Nos. 5,163,585; 5,265,762; and 5,992,475. Most of these systems involve sealing a wall of an aerosol can on a seat, puncturing the can below the seat, and evacuating the contents of the can into a drum. 
     A widely used device for piercing pressurized containers is described in U.S. Pat. No. 5,265,762 to Campbell et al. This Campbell et al. patent describes a puncturing device for aerosol containers which includes an elongated tubular housing having male threads at a second end for being screwed into a first, or large, bung-plug hole (bunghole) of an off-the-shelf drum, such as a 15, 30 or 55 gallon drum. An aerosol can to be disposed of is inserted into a first opening at a first end of the cylindrical housing, nozzle-end-first, until a shoulder of the aerosol can engages a sealing shoulder seat in the elongated tubular housing. A puncturing member, as part of a mechanism mounted to the side of the housing, is driven through the housing to create a puncture opening in the aerosol can below the sealing shoulder seat. Propelling gas and residue material are driven from the aerosol can, by pressure of the propellant gas, through the puncture opening and through the second end opening of the housing into the drum. The sealing shoulder seat prevents the propellant gas and residue from retro-movement toward the first end opening of the housing (which opens to the environment) and ensures that these materials go into the drum. 
     Campbell et al (U.S. Pat. No. 5,265,762) also describes a filter screwed into a second, small, bunghole of the drum for filtering propellant gases escaping from the second bunghole of the drum to the environment for cleaning escaping gaseous vapors of atmosphere-harmful materials. 
     U.S. Pat. No. 5,992,475 to Campbell discloses a spring-activated check valve at the second end of the tubular wall of the housing with a spring-activated valve poppet positioned at the second end for opening and closing in response to pressure. Basically this check valve opens to allow propellant gases to escape from the punctured aerosol cans into the drum and then closes to prevent retrograde movement of the gases from the drum back through the piercing-device housing once the cans are removed. U.S. Pat. No. 5,181,462 to Isaac also describes a similar valve. 
     Other patents which describe devices and systems relating to the system described in Campbell et al (U.S. Pat. No. 5,265,762) include U.S. Pat. No. 3,358,883 to Loe; U.S. Pat. No. 3,828,976 to Sidelinker; U.S. Pat. No. 3,926,340 to Tygenhof; U.S. Pat. No. 4,349,054 to Chipman et al; U.S. Pat. No. 5,114,043 to Collins, Jr.; U.S. Pat. No. 5,181,462 to Isaac; U.S. Pat. No. 5,271,437 to O&#39;Brien et al; U.S. Pat. No. 5,284,997 to Spearman et al; U.S. Pat. No. 5,309,956 to Hajma; U.S. Pat. No. 5,365,982 to O&#39;Neill; U.S. Pat. No. 6,422,273 to Campbell; and U.S. Pat. No. 6,644,515 to Campbell. Additional patent documents disclosing devices for puncturing pressurized cans and/or disposing of their contents include U.S. Pat. No. 5,067,529 to Gonzalez-Miller et al., U.S. Pat. No. 4,459,906 to Cound et al., and U.S. Pat. No. 4,407,341 to Feldt et al. as well as Soviet patent document 821399 and German Offenlegungsschrift 1,607,991. All of these patent documents disclose relatively complicated, expensive, and large machines. 
     Although these prior-art devices prevent retrograde movement of unfiltered gases through the piercing-device housing back to atmosphere, they do not filter gases as they pass through the filter from the small bunghole in a manner which indicates when the filter is saturated and which inhibits flashback. Flow of such gaseous materials through the filter to atmosphere can be dangerous because personnel standing near the drum containing evacuated residue and gases are not aware that dangerous gases are being continually released. For example, one might smoke a cigarette close to a storage drum, thereby possibly igniting gases escaping from the drum through the filter. For this reason, it is desirable that evacuation systems filter residue and/or contaminants from the gaseous materials that escape into the atmosphere and prevent flashback so that the fumes are not ignited. 
     It is an object of the invention to provide a filter assembly for use in conjunction with a storage drum into which the contents of pressurized cans have been emptied. In common use, the filter assembly is used in conjunction with a device for puncturing a pressurized container to relieve the pressure therein and for releasing gases and residual contents thereof into a storage drum. 
     It is further an object to provide a filter assembly which is not unduly complicated, which can be easily transported to a site and installed thereat, which is relatively easy and convenient to use requiring no outside power, which can be used with off-the-shelf receptacles in common use, which is relatively inexpensive to manufacture, which operates in a manner complying with EPA regulations in a safe and efficient manner, and which can accommodate pressurized containers of various sizes. Thus, it is an object of this invention to provide a device for allowing desired easy flow of evacuated gaseous materials through a filter of an evacuation system when the evacuation system is being actively use for evacuation, but for stopping such flow when gaseous materials are not being actively evacuated. 
     Finally, it is an object of the present invention to accomplish the foregoing objectives in a simple and cost effective manner. 
     The above and further objects, details and advantages of the invention will become apparent from the following detailed description, when read in conjunction with the accompanying drawings. 
     SUMMARY OF THE INVENTION 
     The present invention addresses these needs by providing a device for filtering exhaust fumes from a storage container, having an upper filter chamber which has an outer housing and contains filter material, preferably activated carbon, such that exhaust fumes may pass therethrough and residue is filtered from the exhaust fumes. A lower filter chamber has an outer housing and contains a coalescing filter for filtering residue from the exhaust fumes. The upper end of the lower filter chamber is attached to a lower end of the upper filter chamber and the lower end of the lower filter chamber is adapted to attach to a venting hole on the storage container. A visual indicator is attached to the filter assembly which indicates when the filter assembly is saturated with residue and a flashback inhibitor, preferably a stainless steel screen, prevents flashback of the exhaust fumes or residue. The visual indicator is preferably a temperature indicator and/or an airflow indicator. A temperature indicator is attached to the inside or outside of the outer housing of the upper filter chamber. If the temperature indicator is attached to the inside of the outer housing of the upper filter chamber, then the outer housing includes a transparent window such that the temperature indicator may be seen through the outer housing. The temperature indicator provides a temperature reading of the temperature inside of the filter assembly or may indicate whether a sufficient temperature increase has been achieved inside of the filter assembly. An airflow indicator is a transparent chamber located between the upper filter chamber and the lower filter chamber which encloses a lightweight material which reacts to an airflow, preferably at least one spherical floating element. The flashback inhibitor is located either at the lower end of the upper filter chamber below the filter material or at the upper end of the lower filter chamber above the coalescing filter or, preferably at both locations. The upper filter chamber and lower filter chamber are preferably made from aircraft grade aluminum or polyethelene. In the preferred embodiment, the upper filter chamber and said lower filter chamber are connected by an airtight, threaded connection by means of an o-ring. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A more complete description of the subject matter of the present invention and the advantages thereof, can be achieved by reference to the following detailed description by which reference is made to the accompanying drawings in which: 
         FIG. 1  is a perspective view of the invention in use with a storage drum and puncturing device; 
         FIG. 2  is a side view of the first embodiment device of this invention; 
         FIG. 3  is an exploded view of the first embodiment device of this invention; 
         FIG. 4  is a cross sectional view of the second embodiment device of this invention; 
         FIG. 5  is a perspective view of the invention; 
         FIG. 6  is a cross sectional view of the upper filter chamber of the preferred embodiment of the invention; 
         FIG. 7  is a cross sectional view of the upper filter chamber of the preferred embodiment of the invention; 
         FIG. 8  is a perspective view of the upper filter chamber of the preferred embodiment of the invention; 
         FIG. 9  is a perspective view of the upper filter chamber of the preferred embodiment of the invention; 
         FIG. 10  is a top view of the upper filter chamber of the preferred embodiment of the invention; 
         FIG. 11  is a cross sectional view of the upper filter chamber of the preferred embodiment of the invention taken across line X-X of  FIG. 10 ; 
         FIG. 12  is an exploded view of circle C of  FIG. 11 ; 
         FIG. 13  is a perspective view of the upper filter chamber of the preferred embodiment of the invention; and 
         FIG. 14  is a side view of the upper filter chamber of the preferred embodiment of the invention. 
     
    
    
     ELEMENT LISTING 
       10  filter assembly 
       12  upper filter chamber 
       14  flashback inhibitor 
       16  o-ring 
       18  flashback inhibitor 
       20  coalescing filter 
       22  lower filter chamber 
       24  inlet port 
       26  outlet port 
       28  puncturing device 
       30  storage drum 
       32  activated carbon 
       33  activated carbon cartridge 
       34  temperature indicator 
       36  flow indicator 
       38  flow indicator material 
       40  direction of gas flow 
       42  removable lid 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The following detailed description is of the best presently contemplated mode of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The embodiments of the invention and the various features and advantageous details thereof are more fully explained with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and set forth in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and the features of one embodiment may be employed with the other embodiments as the skilled artisan recognizes, even if not explicitly stated herein. Descriptions of well-known components and techniques may be omitted to avoid obscuring the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those skilled in the art to practice the invention. Accordingly, the examples and embodiments set forth herein should not be construed as limiting the scope of the invention, which is defined by the appended claims. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings. 
     A puncturing device  28  for evacuating pressurized cans, punctures a pressurized container (aerosol can) for relieving the pressure therein and for releasing into a storage drum  30  gases and residue contents. The puncturing device  28  generally comprises an elongated housing, a puncturing apparatus, a force applying apparatus, and an auxiliary support member. Exemplary puncturing devices are shown in U.S. Pat. No. 6,422,273; U.S. Pat. No. 5,163,585; U.S. Pat. No. 5,265,762; U.S. Pat. No. 5,992,475 and co-pending U.S. patent application Ser. No. 14/623,996, filed Feb. 17, 2015 for Puncturing Device for Aerosol Containers, all of which are incorporated herein by reference in their entirety. 
     The puncturing device  28  generally works as follows: The elongated housing defines an elongated cavity with openings at either end thereof. The elongated housing member has an intermediate aperture through which a puncture pin extends. The elongated housing further includes a threaded terminus for selectively engaging and disengaging a large female threaded bunghole of a standard storage drum  30 . It should be noted that other containers besides drums could serve as receptacles in similar systems. Further, in other embodiments the threaded terminus can be sized and threaded to fit other collection receptacles. In this regard, standard off-the-shelf drums mentioned above usually have 2 inch filling or spout bungholes with standard threads as well as three quarter inch venting bungholes, also with standard threads. Generally, drums meeting standards of other countries also usually have large and small threaded bungholes. 
     The puncturing device  28  comprises structure for driving the pressurized container onto the puncture pin or the puncture pin into the pressurized container to be emptied. Pressure in the thusly punctured pressurized container forces gases and residue materials from the container through the puncturing device  28  and into the storage drum  30 . 
     A filter assembly  10 , which can be part of a kit including the puncturing device  28 , is mounted in the venting bunghole or outlet port  26  of the receptacle, a storage drum  30 , for filtering escaping propellant gases and collecting gaseous vapors thereof. Propellants and other gases escaping through the filter assembly  10  to atmosphere are thereby filtered and released, with gaseous vapors being coalesced, prior to the release. 
     The filter assembly  10  depicted in the drawings is sometimes referred to as a two-stage capsule filter; it comprising a lower filter chamber  22  with a male pipe-threaded section or inlet port  24  for engaging female threads of the venting bunghole, or outlet port  26 . On top of the lower filter chamber  22  is a detachable upper filter chamber  12  that can be removably attached to the lower filter chamber  22 . The description in U.S. Pat. No. 5,284,997 to Spearman et al. describes such a filter assembly and the teachings of that patent are incorporated herein by reference. 
     Generally, as shown in  FIGS. 1-5 , the invention is an improved filter assembly  10  includes upper and lower filter chambers  12 ,  22 , each of which has a housing, which is made from any material appropriate for this type of industrial device, preferably polypropylene or aircraft grade aluminum, with an inlet port  24  through which a propellant gas enters. The propellant gas then proceeds into a coalescing filter  20  which acts to remove up to 99.9% of the liquid particulate from the propellant gas. Once the propellant gas, now free from liquid particulates, exits the coalescing filter  20 , it is preferably forced through a first flashback inhibitor  18 . The flashback inhibitor  18  is preferably a stainless steel screen which is sufficiently porous to allow uninhibited flow of the propellant gas but prevents the flow of an indicator material into the lower filter chamber  22  of the filter assembly  10 . The flashback inhibitor  18  additionally minimizes the ability of an ignited propellant to path or return to the storage drum  30  should the propellant gas accidentally become ignited by an outside source during the filtration process. The propellant gas then enters the upper filter chamber  12  which preferably contains activated carbon  32 . In this chamber, activated carbon  32  adsorbs hydrocarbons from the propellant gas. A second flashback inhibitor  14 , preferably a stainless steel screen, is preferably included within the upper filter chamber  12  to provide additional safety. 
     This filter assembly  10  includes a method for determining when it has ceased to function as intended and requires replacement. A visual indicator may be in the form of a temperature indicator  34  attached to the upper filter chamber  12  of the filter assembly  10 . During proper functioning of the upper filter chamber  12 , adsorption of hydrocarbons by the activated carbon  32  causes an increase in temperature of the housing around the upper filter chamber  12  of the filter assembly  10 , preferably by having the temperature indicator  34  in direct contact with the upper filter chamber  12 . A temperature indicator  34 , preferably a liquid crystal indicator, is attached to the outer or inner surface of the outer housing of the upper filter chamber  12 . If the temperature indicator  34  is attached to the inner surface of the outer housing, the housing includes a transparent window such that the indicator may be seen through the outer housing of the upper filter chamber  12 . This temperature indicator  34  shows the appropriate temperature increase so long as the filter assembly  10  is functioning properly. Once the filter assembly  10  fails to function properly, either because the coalescing filter  20  is saturated or because the activated carbon  32  in the upper filter chamber  12  is incapable of adsorbing additional hydrocarbons from the propellant, the temperature indicator  34  displays a temperature below the normal functioning temperature. This temperature indicator  34  may display either the ambient temperature, in degrees, during operation or may simply indicate that the required temperature increase has been achieved. 
     Alternatively, a visual indicator in the nature of a flow indicator  36  can be located in the filter assembly  10 , preferably, between the lower filter chamber  22  and the upper filter chamber  12 , above the flashback inhibitor  18 . This flow indicator  36  is preferably a translucent section in the housing into which at least one lightweight object is placed, preferably a plurality of lightweight beads, to act as flow indicator material  38 . As the propellant gas flows  40  through the flashback inhibitor  18  and enters the translucent section of the flow indicator  36 , the beads, acting as a flow indicator material  38 , are agitated to indicate gas continues to flow. The translucent portion of the flow indicator  36  allows the operator to see the beads, acting as a flow indicator material  38 , and appreciate when they are agitated or still. The coalescing filter  20  in this device eventually becomes saturated with liquid particulates as they are removed from the propellant gas. Once the coalescing filter  20  is saturated, flow of the propellant gas is impeded such that the beads, acting as a flow indicator material  38 , are no longer agitated. Once this occurs, the filter assembly  10  must be replaced. 
     The propellant gas then enters the upper filter chamber  12  of the filter assembly  10 . In this portion, activated carbon  32  adsorbs hydrocarbons from the propellant gas. 
     In construction, the coalescing filter  20  is inserted into the housing of the lower filter chamber  22  and rests upon a protrusion on the floor of the housing. The first flashback inhibitor  18  includes a central hole which fits over a protrusion on the top of the coalescing filter  20 . The O-ring  16  rests on a lip located near the upper end of the housing of the lower filter chamber  22 . The lower end of the upper filter chamber  12 , which includes activated carbon  32 , then screws onto threads in the upper end of the housing of the lower filter chamber  22  with a sealed connection via the O-ring  16 . This design allows for replacement of the coalescing filter  20  and/or the activated carbon  32 , as needed. 
     In a particularly preferred embodiment as shown in  FIGS. 6-14 , the upper filter chamber  12  is designed with a removable lid  42 . In this embodiment, rather than removing and replacing the entire upper filter chamber  12  via the screw threads as described above, the removable lid  42  may be removed to expose the activated carbon  32  in the upper filter chamber  12 . When the activated carbon  32  is saturated, the removable lid  42  is removed, the spent activated carbon  32  is removed and replaced with fresh activated carbon  32 . The removable lid  42  is friction or press fit onto the upper end of the upper filter chamber  12  such that it stays in place during use. It is critical that the removable lid  42  allow the escaping propellant gas to pass over the activated carbon  32  and escape through the upper filter chamber  12  and into the environment. 
     The activated carbon  32  may be in the form of granular carbon in a mesh bag or a carbon cartridge  33  as shown in  FIGS. 11 and 12 . The carbon cartridge is preferably generally cylindrical in shape and open at the top and bottom to allow the escaping gases to flow through with residue and contaminants being adsorbed onto the activated carbon  32 . 
     This preferred embodiment allows the upper filter chamber  12  to be reused rather than discarded. In addition, because the activated carbon is removed independently, it can be recharged and reused rather than discarded with the upper filter chamber  12 . 
     It can be appreciated by those of ordinary skill in the art that neither the filter assembly  10  of this invention does not require a power source and can be located indoors or outdoors with no consideration for access to electricity or other power sources. 
     Also, the filter assembly  10  of this invention can be directly attached to existing off-the-shelf collection containers or receptacles for collection of residual contents. That is, since the threaded terminus or inlet port  24  of the filter assembly  10  is sized to engage bung threads of typical storage drums, the invention can be easily transported without consideration for transporting large containers and can be inexpensively manufactured. It should be understood that although the device has been described herein to be mounted on drums standard in the United States, it could be sized to drum standards in any country. 
     This invention is portable, lightweight and inexpensive, all features which facilitate compliance with regulations within a manufacturing plant. That is, the invention can be located at each “work center” at the convenience of workers, rather than in one centralized location which is where a large expensive machine would typically be located. That is, if a facility employs expensive machines, it is not economical to have many such machines spread out through the facility. However, manufacturing facilities have, in addition to their normal production line, maintenance shops where many aerosol cans are used, such as pump shops, machine shops, electrical shops, HVAC shops, maintenance shops etc. 
     This invention facilitates the filtering of gases released from aerosol cans since filters can be relatively easily mounted to vent bung ports of standard drums. 
     Further, the filter assembly  10  of this invention can be easily disassembled for required maintenance such as replacing the coalescing filter  20  or the activated carbon  32 . 
     Obviously, many modifications may be made without departing from the basic spirit of the present invention. Accordingly, it will be appreciated by those skilled in the art that within the scope of the appended claims, the invention may be practiced other than has been specifically described herein. Many improvements, modifications, and additions will be apparent to the skilled artisan without departing from the spirit and scope of the present invention as described herein and defined in the following claims.