Abstract:
A large scale vapor dispersion apparatus for dispersing a vapor of essential oil without the use of water by forcing an air stream through and/or over a volume of the essential oil, vaporizing a portion of the essential oil, controlling the vaporization rate by increasing or decreasing the amount of heated air passing through the essential oil, and distributing the air and vapor mixture over a large scale space. The apparatus includes a blower, an evaporator assembly, piping joining the blower to the evaporator assembly, and a tray containing an essential oil. Other aspects in accordance with the present invention include a damper directing a portion of the air above and/or below the tray, and a vapor dispersing device for dispersing the air and vapor exhausted from the apparatus into a large space.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to an apparatus for deodorizing a stream of gas (also interchangeably referred to herein as “air”) and for large-scale dispersion of vaporized essential oils into large open spaces or volumes without the use of water. 
         [0003]    2. Background of the Technology 
         [0004]    Dispersion of vaporized essential oils into a large space without the use of water is known in the art, for example, by U.S. Pat. No. 6,142,383 issued to Timothy W. Planker and U.S. patent application Ser. No. 11/301,250 filed Dec. 12, 2005, by Timothy W. Planker, the contents of both of which are hereby incorporated by reference in their entirety. Additionally, U.S. Pat. No. 6,423,274, also issued to Timothy W. Planker, which is hereby incorporated by reference in its entirety, relates to an apparatus for deodorizing gas by passing the gas over a surface of a deodorizing liquid. 
         [0005]    Although devices are known for dispersing essential oils, the devices vaporize oil by forcing a volume of air over a surface of the oil in order to vaporize or otherwise entrain the oil in the gas for subsequent dispersal or by atomizing the oil into a stream of air. While effective in some applications, there exists a need to deodorize and/or disperse essential oils at varying rates or in varying concentrations with a single device. There is also a need to more easily clean the apparatus and more easily change the mixture or type of essential oils. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention solves these problems, as well as other, by forcing warm air over and/or below a removable tray containing a volume of essential oil in order to vaporize or entrain a desired concentration of the essential oil in the air. The present invention provides for the vaporization and widespread dispersion of essential oils without necessarily using water. Further, the present invention provides the ability to easily remove and/or replace the essential oil. 
         [0007]    According to a first aspect of the present invention, the apparatus of the present invention disperses essential oil by vaporizing a super concentrated liquid essential oil in one of three modes. 
         [0008]    The first mode, the maximum strength setting, involves convective vaporization by forcing heated air over a surface of the liquid essential oil contained in a tray, which is located inside an evaporation chamber. The air vaporizes a portion of the liquid essential oil, wherein the resulting mixture of air and essential oil vapor is exhausted from the evaporation chamber through an outlet and possibly dispersed by a vapor dispersing device, such as a perforated hose or nozzle. The second mode, the minimum strength setting, involves conductive vaporization by forcing air below a tray containing the liquid essential oil and thereby heating the tray to heat the oil. The third mode, the medium strength setting, involves convective and conductive vaporization by forcing air both above and below the tray containing the liquid essential oil. All three modes may be initiated by adjusting a damper at the heated air inlet portion, for example, or adjusting a position of the tray inside the evaporation chamber. The resulting mixture of air and essential oil vapor is then exhausted through the outlet of the evaporation chamber and possibly dispersed by the vapor dispersing device. The present invention increases vaporization efficiency by directing the entire volume of air within the apparatus through the evaporation chamber containing the essential oil regardless of the position of the damper, or the position of the tray, as opposed to bypassing a portion of the air outside the evaporation chamber. 
         [0009]    According to a second aspect of the present invention, the apparatus of the present invention deodorizes a flow of air used for dispersing the essential oils. The airflow passes above and/or below an essential oil, causing a portion of the essential oil to be vaporized in the air. The deodorized airflow then exits the apparatus through an exhaust pipe and possible muffler. The apparatus is useful in deodorizing air emanating, for example, from inside a pumping station of a wastewater treatment plant or air flow generated during the transport of sewage, such as when sewage is removed from a septic tank. 
         [0010]    Additional advantages of the present invention include a low capital cost, ease of maintenance, and technological simplicity so as not to require a sophisticated electronic controller. Further, because no water is used in dispersing the essential oil and the freezing point of essential oil is well below −100° F., the apparatus of the present invention allows winter operation. 
         [0011]    Additional aspects, advantages, and novel features of the invention will be better understood as set forth in the following description and accompanying drawings and will also become apparent to those skilled in the art upon examination of the following or upon learning by practice of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0012]    The features of the invention will be more readily understood with reference to the following description and the attached drawings, wherein: 
           [0013]      FIG. 1  shows a side cutaway view of an odor control apparatus, in accordance with aspects of the present invention; 
           [0014]      FIG. 2  shows a front view of an evaporator tray mounted in an evaporator cylinder of an odor control apparatus, in accordance with aspects of the present invention; 
           [0015]      FIG. 3  shows a perspective view of an evaporator cylinder of an odor control apparatus, in accordance with aspects of the present invention; 
           [0016]      FIG. 4  shows a side view of the odor control unit of  FIG. 1  with the damper set to direct air flow below the tray, in accordance with aspects of the present invention; 
           [0017]      FIG. 5  shows a side view of the odor control unit of  FIG. 1  with the damper set to direct air flow above the tray, in accordance with aspects of the present invention; 
           [0018]      FIG. 6  shows a side view of the odor control unit of  FIG. 1  with the damper set to direct air flow over and under the tray, in accordance with aspects of the present invention; 
           [0019]      FIG. 7  shows an overhead view of the odor control unit of  FIG. 1 , in accordance with aspects of the present invention; and 
           [0020]      FIGS. 8A-8C  show side views of an odor control unit, in accordance with aspects of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The detailed description may include specific details for illustrating various aspects of an odor control unit and related systems and methods. However, it will be apparent to those skilled in the art that aspects of the invention may be practiced without these specific details. In some instances, previously described or well known related elements may be shown in block diagram form, or omitted, to avoid obscuring the inventive concepts presented throughout this disclosure. 
         [0022]    Various aspects of an odor control system, for example, may be illustrated by describing components that are coupled together. As used herein, the term “coupled” is used to indicate either a direct connection between two components or, where appropriate, an indirect connection to one another through intervening or intermediate components. In contrast, when a component is referred to as being “directly coupled” to another component, there are no intervening elements present. 
         [0023]    Relative terms such as “lower” or “bottom” and “upper” or “top” may be used herein to describe one element&#39;s relationship to another element from the perspective illustrated in the drawings. It will be understood that relative terms are intended to encompass different orientations of an apparatus in addition to the orientation depicted in the drawings. By way of example, if an apparatus in the drawings is turned over, elements described as being on the “bottom” side of the other elements would then be oriented on the “top” side of the other elements. The term “bottom” can therefore encompass both an orientation of “bottom” and “top” depending on the particular orientation of the apparatus. 
         [0024]      FIG. 1  provides a cutaway view of an odor control apparatus  1  for the vaporization and widespread dispersion of essential oils without the use of water, in accordance with aspects of the present invention. As shown in  FIG. 1 , the apparatus  1  may include an air filter assembly  5 , an air blower  10 , and an evaporator assembly  20 . 
         [0025]    The air filter assembly  5  may contain, for example, a replaceable, pleated paper filter cartridge that is enclosed at a top of the air filter  5  by a standard air filter cover. An air inlet pipe  6  couples the air filter assembly  5  to an inlet side of the air blower  10 . The air blower  10  may be a regenerative air blower, for example, in which the air entering the air blower  10  from the air inlet pipe  6  is warmed by the heat of compression. The warm air exits an outlet side of the air blower  10  through an outlet pipe  7  that couples the air blower  10  to the evaporator assembly  20 . A control panel  25 , such as an electronic controller or an on/off switch, for example, may be provided to control the air blower  10 . Although  FIG. 1  illustrates the control panel  50  as being separate from the air blower  10 , it is within the scope of the present invention that the control panel  50  could be directly attached to the air blower  10 . 
         [0026]    The evaporator assembly  20  may include an evaporator cylinder  25  having an air inlet portal  26  provided on an end wall  27  and an air outlet portal  28  provided on a second end wall  29 . The evaporator cylinder  25  entirely encloses a volume of air, creating an evaporation chamber  30  inside the evaporator cylinder  25 . Although described herein as having a cylindrical shape, the evaporator cylinder  25  may be any suitable shape, such as a rectangular box, a cylinder, a cube, or any other shape. The evaporator cylinder  25  can be made of any stable non-reactive or low reactive material such as, for example, stainless steel, tin, aluminum, titanium, plastic, glass, etc. 
         [0027]    An evaporator tray  40  is located within the evaporation chamber  30 . The evaporator tray  40  may be removeably positioned in the evaporation chamber  30  such that air traveling through the evaporation chamber  30  can pass both above and below the tray  40 . The tray  40  has an open top and fits side to side within the evaporator cylinder  25 . The tray  40  is configured to receive and hold a volume of essential oil (referred to hereinafter as “oil  42 ”), such as a biodegradable essential plant oil blend, for example. As shown in  FIG. 1 , an optional filling inlet  24 , may be provided on the evaporator cylinder  25  to provide easy access for refilling the oil  42  without having to remove the tray  40  from the evaporation chamber  30 . The tray  40  may be made of any suitable material that is non-reactive or low reactive. For example, the tray  40  may be made from stainless steel, tin, aluminum, titanium, plastic, etc. The material should be very heat conductive. The tray  40  may be removed from the evaporation chamber  30  by means of an access door  45 , for example. The access door  45  may be attached to the evaporator cylinder  25  by any suitable fastening fixtures, including bolts and wingnuts, hinges, and/or clasp locks, for example. Other features in accordance with aspects of the present invention may include seals or sealing material provided in connection with the access door  45 , for example, to enable or enhance an airtight environment in the evaporation chamber  30 , providing increased internal pressure and temperature control. 
         [0028]    As shown in  FIGS. 2 and 3 , tray tracks  46 , such as angle irons, for example, may be welded or otherwise attached to the evaporator cylinder  25  to cradle, or otherwise support, the evaporator tray  40  in the evaporation chamber  30 . Furthermore, another feature in accordance with aspects of the present invention may be inclusion of tray stoppers  48  provided, for example, on the inlet side and/or outlet side of the evaporator cylinder  25  to work in combination with the tray tracks  46  to ensure proper positioning of the tray  40  within the evaporation chamber  30 . Thus, the tray  40  can be easily replaced, drained, filled and/or cleaned. 
         [0029]    Referring again to  FIG. 1 , warm air is received into the evaporation chamber  30  from the air blower  10  through the inlet portal  26  and flows over and/or under the evaporator tray  40 . Odor neutralizing waterless vapor flows from the evaporation chamber  30  by way of the outlet portal  28  and into an exhaust pipe  55  coupled to the outlet portal  28 . A vapor dispersing device for dispersing vaporized oil in a fog-like manner may be coupled to the exhaust pipe  55 . Alternatively, the vapor dispersing device may attach directly to the outlet portal  28 , for example. The vapor dispersing device can be for example a nozzle, such as those manufactured by Bete Fog Nozzle Co. The nozzle includes, for example, a ¼ inch nozzle orifice and is made of polypropylene, for example. However, it is within the scope of the present invention to include any device capable of dispersing a vaporized liquid. 
         [0030]    As shown in  FIG. 1 , a pivoting damper  21  extends from the end wall  27  of the evaporator cylinder  25 .  FIG. 4  shows the damper  21  in a downwardly extending position from a point on the end wall  27  above the inlet portal  26  to a bottom edge of the tray  40 . When the damper  21  is arranged in such a manner, the flow of air entering the evaporator cylinder  25  is blocked from traveling above the tray  40 . Rather, the air flow is routed below the tray  40 . Forcing the air flow below the tray  40  allows for a conductive heating of the tray and thus, a certain minimum amount of oil  42  to evaporate into the evaporation chamber  30 . Thus a mixture of air and oil  42  is produced (interchangeably referred to hereinafter as “mixture”). The combined stream of oil and air is free to flow through the outlet portal  28 . 
         [0031]    Regarding  FIG. 5 , a second position is shown wherein the damper  21  is positioned so that the air flow is forced to flow above the tray  40 . In this position, the damper  21  extends from the end wall  27  at a point below the inlet portal  26  to the upper edge of the tray  40 . By being positioned in such a manner, the path below the tray  40  is blocked and the air is forced to flow above the tray  40 . When passing over the top of the tray  40 , the oil  42  is in direct contact with the air and thus a certain maximum amount of oil  42  is evaporated into the air stream. The combined stream of oil and air is free to flow through the outlet portal  28 . The minimum and maximum amounts of oil evaporated depend upon the temperature of the air flowing through, the temperature of the oil, and the materials of construction, the volume of air flow, and the particular mixture of oils. 
         [0032]    Regarding  FIG. 6 , a third position is shown wherein the damper  21  is positioned so that the air is free to flow both above and below the tray  40 . As shown in  FIG. 6 , the damper  21  is positioned such that it extends parallel to the end wall  27 . When in this position, neither path is totally blocked by the damper  21  and the air is free to flow both above and below the tray  40 . By passing both above and below the tray  40 , the oil  42  is evaporated both directly and, indirectly. Thus, a medium concentration of oil  42  is evaporated into the air stream. The combined stream of air and vaporized oil  42  is free to flow through the outlet portal  28 . 
         [0033]    It is also within the scope of the invention that the damper  21  can be positioned at any point in between the three positions described above. In these intermediate positions the ratio of air flow above the tray to the air flow below the tray will vary between the extremes described. Thus, a range of oil vapor concentrations may be achieved by adjusting the position of the damper  21 . In order to maintain the damper  21  in the desired intermediate position, any known means that prohibit movement of the damper  21  can be used. For example, a locking mechanism that prevents rotation of an actuation arm may be used. 
         [0034]    In accordance with aspects of the present invention, the air blower  10  includes a motor (not shown), such as a TEFC (Totally Enclosed, Fan Cooled) motor, having a stock size, such as a ½ horsepower (HP), ¾ HP, 1 HP, 3 HP, or 5 HP motor, for example. The motor may include permanently sealed ball bearings, for example. An air blower  10  having a motor with a more powerful motor is capable of dispersing a greater volume of vaporized oil  42  during a given time period, whereas an air blower  10  having a motor with a less powerful motor disperses a lower volume of oil  42  during the same period of time. Additionally, the inlet and outlet of the air blower  10  may be muffled so as to meet or exceed OSHA noise standards, for example. 
         [0035]    In operation, the air blower  10  may be switched on via the control panel  50  and draws outside air through the air filter assembly  5  and air inlet pipe  6 . The ambient air, heated by the compressive action of the air blower  10 , may then be forced through the outlet pipe  7 . 
         [0036]    Heated air entering through the inlet portal  26  passes into the evaporation chamber  30  of the evaporator cylinder  25  and, depending on the position of the damper  21 , will travel over, below, or simultaneously over and below the tray  40 , causing a portion of the oil  42  to vaporize. Consequently, the capability to redirect a portion of the heated air over the tray  40 , under the tray  40 , or simultaneously over and under the tray  40 , thereby allows for a desired concentration of the vaporized oil  42  to be exhausted from the apparatus. 
         [0037]      FIG. 7  shows an overhead view of the apparatus  1 . By adjusting the position of the damper  21  by means of an actuating arm  22 , for example, the operator can select between the three positions described above. Thus, at least three levels of oil concentration can be produced through the operation of a single apparatus. Furthermore, as discussed above, the operator can set the damper  21  at any position intermediate to the three described positions by pivoting the damper  21  in order to achieve a desired concentration of oil in air. Whenever the operator of the device wishes to change the concentration of the oil  42  in the air, the actuating arm  22  is rotated on a central axle/axis to move the damper  21  into the desired position. It is to be understood that the actuating arm is simply one example of a means for adjusting the damper position. Any other device that allows the damper  21  to rotate about a pivot axis can be used. For example, a wheel, a motor, a crank, etc., can be used. 
         [0038]    In accordance with yet other aspects of the present invention, alternative configurations may be used to achieve the same results as having a damper  21  direct air flow from a single pipe. For example, dual pipes may be used to initially separate the air flow into two streams prior to entering the evaporator cylinder  25 . The air outlet pipe  7  could first split into two pipes rather than a single central pipe, as currently shown in  FIG. 1 . Each of the dual pipes may have valves to control the respective flow rates of air exiting the pipes into the evaporator cylinder  25 . The first pipe would open into the evaporator cylinder  25  at a point above the tray  40  and the second pipe would open into the evaporator cylinder  25  at a point below the tray  40 . In this alternative, the damper  21  would not be necessary or could be set in either the maximum or minimum flow setting as described above in order to prevent the flow of air from the first pipe and the second pipe from combining before the passing over and/or below the tray  40 . A single actuating device may be used to synchronously open and close the valves in order to adjust the respective flow rates from the dual pipes. When the actuating device is at one extreme, the valve in the pipe above the tray would be completely open and the valve in the pipe below the tray would be completely closed. This will cause the air to flow only above the tray because the damper has blocked the path below the tray. This setting corresponds to the maximum strength setting of the single pipe method described above. As the actuating device is adjusted, the valve in the top pipe will begin to open and the valve in the bottom pipe will begin to close. Each one of these points would decrease the concentration of oil in the air stream because less air will flow from the top pipe and more will flow from the bottom pipe. When the actuating device is in the middle setting, both valves are opened half-way, so half the gas will flow out top pipe and half will flow out the bottom pipe. This setting replicates the medium setting of the single pipe method described above. Finally, when the actuating device is set at the other extreme, the valve in the top pipe may be completely closed and the valve in the bottom pipe will be completely open. This will cause the air to only flow out the bottom pipe and below the tray. This setting corresponds to the minimum setting in the single pipe method. 
         [0039]      FIGS. 8A-8C  illustrate aspects of yet another configuration of the apparatus in which the tray  40  may be configured to slide within the evaporator cylinder  25  to control the air flow above and below the tray  40 . For example, as shown in  FIG. 8A , the tray  40  may be extended longitudinally into the evaporator cylinder  25  through the access door  45  so that an end surface  44  of the tray abuts an interior surface of the end wall  27  of the evaporator cylinder  25 . The tray  40  may be formed to have a lateral dimension equal to or slightly smaller than an interior lateral dimension of the evaporator cylinder  25 . Thus, insertion of the tray  40  into the evaporator cylinder  25  substantially or wholly prevents air flow leakage along the longitudinal length of the sides of the tray  40  and along the end surface  44 . Sealing structures, including rubber lubricant seals, for example, in combination with the tray tracks, for example, may be used to further enhance the air flow properties of the apparatus, in accordance with aspects of the present invention. 
         [0040]    As shown in  FIG. 8A , with the end surface  44  of the tray  40  abutting the interior surface of end wall  27  of the evaporator cylinder  25 , warm air from the air inlet portal  26  may be directed below the tray  40  upon entering the evaporator chamber  30 . Accordingly, air flow is routed substantially below the tray  40 . Forcing the air flow below the tray  40  allows for a conductive heating of the tray and thus, a certain minimum amount of oil  42  to evaporate into the air stream. Thus a odor neutralizing mixture of air and vaporized oil  42  is produced (interchangeably referred to hereinafter as “mixture”). The odor neutralizing waterless mixture is free to exit the evaporation chamber  30  by flowing through the outlet portal  28 . 
         [0041]    Regarding  FIG. 8B , a second position is shown wherein the tray  40  is positioned to allow a gap between the end surface  44  of the tray  40  and the interior surface of the end wall  27 . Accordingly, the tray is in a position so that the air is free to flow both above and below the tray  40 . When the tray  40  is placed in this position, air is permitted to flow through the gap, as well as below the tray  40 , creating an air flow both above and below the tray  40 . By passing both above and below the tray  40 , the oil  42  is evaporated both directly and indirectly. Thus, a medium concentration of oil  42  may be evaporated into the air stream. The combined streams of air and vaporized oil  42  are then free to flow through the outlet portal  28 . 
         [0042]      FIG. 8C  illustrates a third position in which the tray  40  is positioned so that a second end  43  abuts an interior surface of the second end wall  29  and/or an interior surface of the access door  45 . In this manner, the warm air flow is forced to flow above the tray  40 . With the tray  40  positioned in such a manner, the path below the tray  40  is blocked and the air below the tray  40  is prevented from exiting the evaporator chamber  30  through the exit portal  28 . Rather, the air is forced to flow above the tray  40 . Thus, when passing over the top of the tray  40 , the oil  42  is in direct contact with the air and a certain maximum amount of oil  42  may be evaporated into the air stream. The combined stream of oil and air is then free to exit the evaporation chamber  30  by flowing through the outlet portal  28 . The minimum and maximum amounts of oil evaporated depend upon the temperature of the air flowing through, the temperature of the oil, and the materials of construction, the volume of air flow, and the particular mixture of oils. 
         [0043]    In accordance with other aspects of the present invention, various sensors and indicators may be provided, which may also be connected to the controller  50 , for example, to provide important data for control of the system. For example, a concentration indicator may be included. The concentration indicator would display either a number or another visual indicator to show how much oil will be in the air stream upon exiting the evaporation chamber  30 . A looking glass or a level float, for example, may be provided to manually or mechanically provide a means for determining the level of oil  42  in the tray  40 . Pressure and temperature gauges may be provided that indicate or communicate to the controller  50 , for example, the internal pressure and/or temperature of the evaporation chamber  30 . Adjustments and/or maintenance, such as filter replacement, may be performed based on the readings of the various gauges. For example, a low system temperature and/or pressure reading may indicate that the system is not operating efficiently. The filter may be clogged and/or, if the unit is enclosed in a cabinet, for example, the cabinet vents may be checked for obstructions. A high temperature or pressure reading may indicate an obstruction in the outlet section of the evaporator assembly, or a problem with the vapor distribution system, for example. 
         [0044]    Example uses of the present invention include deodorizing an air flow generated by pumping waste material from a septic tank or other waste facility to a tank, such as a tank mounted on a truck. Additionally, the present invention is useable to deodorize an air flow emitted from a pump house of a wastewater treatment plant. Accordingly, it is within the scope of the present invention that the apparatus be portable, such as transportable by truck, to a preferred location or permanently mounted at a particular location. 
         [0045]    While there has been described what are at present considered to be preferred embodiments of the present invention, it will be understood that various modifications may be made thereto, and it is intended that the appended claims cover all such modifications as fall within the true spirit and scope of the invention. Other modifications will be apparent to those skilled in the art.