Patent Publication Number: US-8535452-B1

Title: Automated pipe clearing apparatus

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to pipe clearing devices. More specifically, it relates to an automated device for prophylactically clearing a pipe at predetermined times. 
     2. Brief Description of the Related Art 
     In almost every technological application, periodic preventive maintenance reduces the need for repairs and extends the life of equipment. This axiom holds true for the preventive maintenance of the fluid-carrying pipe systems. Specifically, a very prevalent problem associated with the central air conditioning and commercial refrigeration units is due to clogged drain pipes. The clogs are often caused by accumulation of dust, sludge, mold, algae, fungus, or a combination thereof within a drain line. A clogged pipe that is not detected in due time may overflow, causing extensive water damage to drywall and wooden beams. Overflowing drain pipes may also create health hazards by facilitating mold growth and producing foul odors inside the building. 
     Air handlers are commonly positioned in attics, where overflowing drain pipes may go unnoticed for a prolonged period of time. Often, the problem visually manifests itself only after the insulation and the ceiling are thoroughly soaked with the overflowing water, at which point, the damage may be substantial. Even upon detection of problems caused by a clogged overflowing drain pipe, the solution is not always simple or even apparent to many homeowners. A service call to a professional technician is one way of resolving the issue, but it may come at a fairly steep price. Moreover, the damage already caused by the overflowing water prior to detection of the problem may necessitate costly repairs. 
     Many expert technicians advise that periodic preventive maintenance is the most effective method for preventing the drain pipe from becoming clogged. Several techniques and devices are known in the art for prophylactically clearing out a pipe. Manually attaching an electric or mechanical vacuum pump to the outlet of the pipe and utilizing the suction to dislodge and remove debris is perhaps the most common technique of clearing a pipe. Some currently available technologies, such as the rod-and-piston device disclosed in U.S. Pat. No. 6,427,458, require a fair amount of manual labor. Moreover, to be fully effective, preventive pipe clearing must be performed on a regular basis. Clearly, such preventive maintenance may be a time-consuming, dreadful, and burdensome task. Accordingly, what is needed is an automatic pipe clearing apparatus that prophylactically clears the pipe without interfering with the pipe&#39;s normal drainage. 
     SUMMARY OF THE INVENTION 
     The long-standing but heretofore unfulfilled need for an automatic pipe clearing apparatus for prophylactically clearing a pipe without disrupting its normal operation is now met by a new, useful, and nonobvious invention. 
     In one embodiment, the automatic pipe clearing apparatus has a housing with an open bottom. The apparatus is adapted to connect to an existing drain pipe outlet, specifically condensate drain pipes of air conditioning and refrigeration systems. The housing optionally includes an integrated fitting adapted for this purpose. A door is rotationally, pivotally, or slidingly attached within the housing. Possible means of rotational attachment include circular channels disposed on the inner surface of the housing receiving annular ends of the rotating door. A hinge may be used to pivotally dispose the door within the housing. While grooves or channels may be utilized to allow the door to slide within the housing. 
     The door transitions between two positions: an open position and a closed position. The length and width of the door are essentially the same as the length and width of the open bottom. When the door is in the open position, the pipe drains as it normally would. However, when the door is in the closed position, the pipe is sealingly enclosed within the housing. 
     An electrical power source, a switch module, and a vacuum pump are contained within the housing. The air intake of the vacuum pump is within the housing, while the air outlet is outside the housing. The electrical power source supplies electrical current to the switch module and the vacuum pump. The switch module is adapted to actuate the vacuum pump at predetermined times for a predetermined duration. 
     When the door is in the closed position, the housing is essentially sealed, and the only source of air intake is the outlet of the pipe to which the apparatus is attached. Gaskets may optionally be disposed on the door or the inner surface of the housing to improve the seal between the door and the housing. Accordingly, when the vacuum pump is operating while the door is closed, the suction produced by the vacuum pump essentially creates a vacuum within the housing dislodging and extracting debris, mold, algae, and other buildup from the pipe. 
     In an embodiment, the door has a first annular end, a second annular end, a semi-cylindrical hollow body, and a center axis. The door rotates about the center axis to transition between the open and the closed positions. 
     In an embodiment, an electric motor is placed within the housing and is also powered by the electrical power supply. The electric motor is in mechanical communication with the door, whereby the electric motor may transition the door between the open and closed positions. 
     In an embodiment, the switch module may be adapted to automatically control the electric motor to synchronize the operation of the vacuum pump with the door, so that the vacuum pump operates when the door is in the closed position. 
     In an embodiment, the door in controlled using vacuum pressure. In this embodiment, the vacuum pump has two air intakes. The second air intake is fluidly coupled to a tube, in which a piston is slidingly disposed. When the second air intake is operating, a vacuum is created inside the tube causing the piston to move up within the tube. The piston is in mechanical communication with the door, wherein the door closes as the piston rises. When the door is in its closed position, the suction of the first air intake clears the pipe. 
     In an embodiment, the door may be urged toward the open position by a biasing element, such as a coil spring. 
     In an embodiment, the door may be hingedly connected to the housing. When the door is in the open position, the drain flow exits the housing through the bottom opening thereof. When the vacuum pump is actuated, the suction produced by the vacuum pump causes the door to pivot upwards until the lower member engages a bottom edge of the housing, thus enclosing the pipe outlet within the housing. Since the housing is sealed, the only air intake available is through the outlet of the pipe, which enables the vacuum pump to remove the buildup from the pipe. 
     The electrical power source utilized by the pipe clearing apparatus may be a battery, an alternating electrical current source, and a capacitor. A solar panel may be used to charge the battery. 
     In an embodiment, the pipe clearing device may include a temperature sensor that would prevent the device from actuating when the outside temperature is below freezing. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which: 
         FIG. 1A  depicts the automatic pipe clearing apparatus attached to an exterior wall of a building; 
         FIG. 1B  depicts an embodiment of the automatic pipe clearing apparatus with a solar panel attached to an exterior wall of a building; 
         FIG. 2A  is a perspective view of the bottom opening of the pipe clearing device with the rotating door in an open position; 
         FIG. 2B  is a perspective view of the bottom opening of the pipe clearing device with the rotating door in a closed position; 
         FIG. 2C  is a perspective view of the door; 
         FIG. 3  is a perspective side view of the housing depicting the outlet of the vacuum pump; 
         FIG. 4  is a cross-sectional view of an embodiment using an electric motor; 
         FIG. 5A  is a cross-sectional view of an embodiment involving the vacuum pump having two air intakes with the door in an open position; 
         FIG. 5B  is a cross-sectional view of the embodiment involving the vacuum pump having two air intakes with the door in a closed position; 
         FIG. 6A  is a perspective cross-sectional view of an embodiment involving a v-shaped door where the door is in an open position; 
         FIG. 6B  is a cross-sectional view of the embodiment involving a v-shaped door where the door is in a closed position. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the following detailed description of the preferred embodiment, reference is made to the accompanying drawings, which form a part hereof, and within which specific embodiments are shown by way of illustration by which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the invention. 
     Referring to  FIGS. 1A and 1B , a pipe clearing apparatus  10  is shown in an attachment to an exterior wall of a house. The exemplary embodiment depicted in  FIGS. 1A and 1B  is intended for clearing out condensation drain pipes of central air conditioning (hereinafter “AC”) units and refrigeration systems. However, pipe clearing apparatus  10  may also be adapted for clearing out other types of draining, venting, and exhaust systems. 
     As depicted in  FIGS. 1A and 1B , pipe clearing apparatus  10  fixedly attaches to an exterior wall of a building. The attachment may be accomplished via any means commonly used in the art, including fasteners and adhesive. Housing  12  of pipe clearing apparatus  10  contains a discharge conduit  14  adapted to fluidly couple with a condensation drain pipe  16  of an AC unit. In most buildings equipped with central AC units, condensation drain pipe  16  protrudes from a lower part of an exterior wall allowing the condensate to drain outside the building. Accordingly, pipe clearing apparatus  10  may be easily retrofitted into an existing system without any major modifications to the system itself. 
     Referring to FIGS.  2  and  4 - 6 , housing  12  has a top surface and a lateral surface, and it is open on the bottom. Housing  12  is preferably of a water impermeable and noncorrosive material, such as plastics. Some examples include polyethylene, polypropylene, polyethylene terephthalate, polyvinylchloride, polyvinylidenechloride, polycarbonate, polyurethane, polyamide, polytetrafluoroethylene, and polyvinylacetate. Noncorrosive metals such as titanium, stainless steel, and alloys thereof may also be used. However, plastics are preferred due to low cost, low weight, and easy of manufacturing. 
     Referring to  FIGS. 1A-B  and  2 A-B, outlet of drain pipe  16  is fluidly coupled to discharge conduit  14 , which is fluidly coupled housing  12 . Discharge conduit  14  may optionally include an extension  18  with an outlet  19  to divert the flow of condensate away from the walls of housing  12  helping to prevent possible water damage to the components contained within housing  12 . 
     In one embodiment, a door  20  is rotationally disposed within housing  12  as shown in  FIGS. 2A-B . Door  20  is depicted in greater detail in  FIG. 2C . Door  20  comprises a semi-cylindrical hollow body  22 , a first annular end  24 , and a second annular end  26 . Gear teeth  25  are disposed around the circumference of first annular end  24 . In an alternative embodiment, gear teeth  25  may be disposed on the inner or lateral surface of first annular end  24  to reduce exposure of gear teeth to dust, debris, moisture, and other environmental elements that may form a buildup between gear teeth  25 . Moreover, it is preferred that housing  12  includes an internal panel that would sealingly cover first annular end  24 . Housing  12  contains circular grooves  27  adapted to engage inner surfaces of first and second annular ends  24  and  26 , whereby door  20  may rotate about its central axis within housing  12 . 
     Door  20  is capable of rotating between an open position depicted in  FIG. 2A  and a closed position depicted in  FIG. 2B . Referring to  FIG. 2A , in its open position, door  20  does not discharge conduit  14 , therefore, allowing normal drainage of the condensate. When pipe clearing device  10  is not operating, door  20  is always open allowing condensate to freely drain from discharge conduit due to gravity as it normally would. 
     To transition from the open position shown in  FIG. 2A  to the closed position shown in  FIG. 2B , door  20  rotates by essentially 180 about its central axis. In the closed position, door  20  closes the bottom opening of housing  12  forming essentially a sealed interior space within housing  12 , wherein the only significant air inlet is discharge conduit  14 . 
     The width and length of door  20  are essentially the same as the inner width and length of the bottom opening of hosing  12 . Accordingly, in both closed and open positions, semi-cylindrical hollow body  22  of door  20  essentially seals the inner space of housing  12 , preventing moisture, debris, and pests from entering housing  12 . Housing  12  may further contain interior panels sealingly enclosing components housed within housing  12  to further protect them from exposure to the environmental elements. 
     In all embodiments of pipe clearing device  10  depicted in  FIGS. 3-6 , an electric vacuum pump  30  is disposed within housing  12 . Referring to  FIG. 3 , housing  12  contains an opening adapted to allow outlet  31  of vacuum pump  30  to be in fluid communication with the exterior of housing  12 . Outlet  31  allows the air pumped by vacuum pump  30  to exit housing  12 . 
     Vacuum pump  30  is actuated at predetermined times to clear out pipe  16 . While pipe  16  is being cleared, door  20  is in its closed position depicted in  FIG. 2B , sealingly enclosing discharge conduit  14  within housing  12 . Accordingly, the only source of air intake inside housing  12  is through discharge conduit  14 . When vacuum pump  30  is operating, the vacuum created within the housing extracts debris, sludge, fungus, and other buildup from pipe  16  through discharge conduit  14 , thus clearing the pipe to prevent clogging. 
     The debris that is removed by vacuum pump  30  is retained within semi-cylindrical hollow body  22  of closed door  20 . After vacuum pump  30  has been operating for a predetermined duration, vacuum pump  30  turns off, and door  20  rotates back into its open position. As door  20  completes its rotation, the debris extracted from drain pipe  16  that was retained within semi-cylindrical hollow body  22  is ejected by the gravitational force. Pipe clearing device  10  remains in this configuration with door  20  in the open position until the next scheduled operation. The condensate continues to drain normally through discharge conduit  14 . 
     It is envisioned that in some climates pipe clearing apparatus  10  may not be operational in freezing temperatures due to a possibility of door  20  being frozen. Accordingly, to prevent damage to the door-actuating mechanism, pipe clearing apparatus  10  may further include a temperature sensor in electrical communication with switch module  38 , preventing switch module  38  from actuating pipe clearing apparatus  10  when the outside temperature is below the freezing point. 
     A wide array of mechanisms may be used to actuate door  20 . Some possible mechanisms are illustrated in  FIGS. 4-6 . In these embodiments of pipe clearing apparatus  10 , a gear wheel  32  is rotationally attached to the inner surface of housing  12 . The teeth of gear wheel  32  engage gear teeth  25  of annular end  24  of door  20 . Gear wheel  32  is adapted to drive annular end  24  causing door  20  to rotate about its center axis. Alternative embodiments may utilize cable-pulley or other mechanical systems instead of the gear system. A person of ordinary skill in the art will appreciate that various known methods of translating mechanical work are known in the art and fall within the scope of the present invention. 
     Alternatively, an electric magnet may be used to operate door  20 . In such embodiment, door  20  would contain one or more pieces of a magnetically-attractive material causing the door to open when an electric magnet housed within housing  12  is actuated. A combination of a magnetic and mechanical actuation mechanism is also within the scope of the invention. 
     EXAMPLE 1 
     The embodiment depicted in  FIG. 4  involves an electrical power source  34 , an electric motor  36 , and a switch module  38 . Electrical power source  34  is used to provide electric energy to switch module  38 , electric motor  36 , and vacuum pump  30 . Electrical power source  34  may be a battery, a source of an alternating current (such as a household electrical outlet), or a capacitor. 
     In an embodiment depicted in  FIG. 1B , a solar panel  40  may be used to charge the electrical power source  34 . This embodiment of pipe clearing device  10  is virtually maintenance free since the battery will not have to be replaced. Where necessary or practicable, solar panel  40  may be placed on the roof of a building to increase its exposure to sunlight. Since electrical outlets are not always readily available outside a building, the embodiment utilizing a battery is preferable to facilitate easy and convenient installation of pipe clearing device  10 . 
     Continuing reference to  FIG. 4 , electric motor  36  is connected to gear wheel  32  by means of translating rotational energy, such as a belt  33 . Switch module  38  may include a CPU programmed to automatically actuate electric motor  36  and vacuum pump  30  at predetermined times and for predetermined duration. Switch module  38  may be programmed to bring pipe clearing device  10  into operation at scheduled times—for example, once a month, once every other month, etc. In an alternative embodiment, switch module  38  may be actuated manually. 
     Switch module  38  is preferably programmed to first bring electric motor  36  into operation until door  20  is fully closed. At that point, switch module  38  turns off electric motor  36  and actuates vacuum pump  30  for a predetermined duration to extract buildup from pipe  16 . Then, switch module  38  turns off vacuum pump  30  and actuates electric motor  36  to bring door  20  back to its open position. 
     In an embodiment where gear teeth  25  are disposed along the entire circumference of annular end  24 , electric motor  36  may rotate in the same direction to both close and open door  20 . However, if gear teeth  25  are disposed on less than entire circumference of annular end  24 , electric motor  36  must rotate in one direction to close door  20  and in the opposite direction to open it. 
     EXAMPLE 2 
     Another embodiment of pipe clearing apparatus  10  is shown in  FIGS. 5A-B . In this embodiment electric motor  36  is eliminated. Instead, vacuum pump  30  includes a first air intake  42  and a second air intake  44 . First air intake  42  is sealingly attached to a tube  46 . A piston  48  is slidingly disposed within tube  46 , whereby vacuum produced within the tube by first air intake  42  causes piston  48  to rise. Piston  48  is connected to gear wheel  32  via a pulley-cable system  50 , whereby as piston  48  rises, gear wheel  32  rotates, causing door  20  to close as shown in  FIG. 5B . In this embodiment, door  20  is biased toward an open position by a biasing element, such as a coil spring. Accordingly, when vacuum pump  30  is turned off, the biasing element returns door  20  to its open position shown in  FIG. 5A . In alternative embodiments, gear wheel  32  and gear teeth  25  may be eliminated, and a cable-pulley or another mechanical system may be used instead. 
     In a variation of the embodiment depicted in  FIGS. 5A-B , switch module  38  actuates first air intake  42  to close door  20 . After door  20  is closed, switch module  38  actuates second air intake to clear pipe  16 . 
     In an alternative embodiment, both air intakes  42  and  44  are actuated simultaneously. This embodiment may lose some efficiency due air intake  44  operating while door  20  is not fully closed, thus intaking air from the bottom opening of housing  12  and not creating a vacuum within the housing due to absence of a sealed enclosure. However, a major advantage of this embodiment is that vacuum pump  30  may be simplified because air intakes  42  and  44  are not required to operate independently of each other. 
     In yet another embodiment, second air intake  44  may be turned on by an actuator positioned inside tube  46 . The actuator may be adapted to be triggered by piston  48  when piston  48  rises to a position within tube  46  corresponding to door  20  being fully closed. 
     EXAMPLE 3 
     Another embodiment of pipe clearing apparatus  10  is showed in  FIG. 6 . This embodiment does not have a semi-cylindrical hollow door  20 . Instead, a v-shaped door  50  is pivotally disposed within housing  12 , whereby v-shaped door  50  pivots about pivot axis  52 . V-shaped door  50  comprises an upper member  54  and a lower member  56 , wherein lower member  56  is wider than the bottom opening of housing  12 , so that when v-shaped door  50  pivots up, lower member  56  engages an edge of housing  12  closing the bottom opening. Upper member  54  serves functions of facilitating pivoting of door  50  into the closed position and covering the components housed inside housing  12 . 
     In an alternative embodiment, door  50  may comprise only lower member  56 . In yet another embodiment (not shown), door  50  may comprise two parts, each hingedly attached to an opposite side of the housing. The vacuum pressure causes the two parts to pivot up into position where they sealingly mate with each other, forming a sealed enclosure within housing  12 . 
     Analogously to the embodiments shown in FIGS.  2  and  4 - 5 , v-shaped door  50  has an open position and a closed position. In  FIG. 6A , door  50  is depicted in its open position where upper member  54  is substantially horizontally positioned above discharge conduit  14  and lower member  56  leaves the bottom opening of housing  12  partially opened, so that condensate may drain normally form discharge conduit  14 . In its open position upper member  54  may rest on pipe extension  18 . 
     The embodiment involving v-shaped door  50  also utilizes vacuum pump  30 , electrical power source  34 , and switch module  38 . Analogously to other embodiments, switch module  38  is programmed to periodically automatically actuate vacuum pump  30  at a predetermined time and for a predetermined duration. When vacuum pump  30  is operating, the air suction causes v-shaped door  50  to pivot upwards into the closed position. In the closed position, lower member  56  engages a bottom edge of housing  12 , thus closing the bottom opening of housing  12 , as shown in  FIG. 6B . In this configuration, discharge conduit  14  is sealingly enclosed within housing  12 . 
     The continuous air suction produced by vacuum pump  30  retains v-shaped door  50  in the closed position. Once the v-shaped door sealingly closes the bottom opening of housing  12 , the only source of air intake for vacuum pump  30  is through discharge conduit  14 . Accordingly, the vacuum created within the housing by vacuum pump  30  extracts the buildup from pipe  16 , which is fluidly coupled to discharge conduit  14 . 
     After vacuum pump  30  has operated for a predefined duration sufficient to extract buildup from pipe  16 , switch module  38  turns vacuum pump  30  off. After the suction is discontinued, v-shaped door  50  pivots down to its open position due to its own weight. Pipe  16  continues to drain normally with condensate exiting the pipe through discharge conduit  14  and leaving housing  12  through the bottom opening. 
     The embodiment shown in  FIGS. 6A-B  contains fewer electrical components and moving parts than embodiments depicted in  FIGS. 4-5 . Furthermore, the programming of switch module  38  is also significantly simplified because the only function that switch module  38  must perform is actuating vacuum pump  30  and turning it off at scheduled times. Accordingly, the embodiment of pipe clearing apparatus  10  depicted in  FIGS. 6A-B  may lead to decreased manufacturing and operational costs, increased reliability, and longer life. 
     The advantages set forth above, and those made apparent from the foregoing description, are efficiently attained. Since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 
     GLOSSARY OF TERMS 
     Automatic—working by itself with no direct human control other than initial programming of a set of instructions. 
     Switch module—a component that actuates other components. 
     Center axis—an imaginary line passing through centers of annular ends. 
     Conduit—a tube for conveying a fluid. 
     Buildup—accumulation of debris, fungus, algae, dust, sludge, mold or other substance capable of clogging a pipe. 
     Discharge conduit—a tube through which a fluid is discharged. 
     Door—a hinged, sliding, or revolving barrier that encloses an interior space. 
     Electric motor—an electric machine that convers electricity to mechanical work. 
     Electrical communication—an electrical connection between at least two components where the electrons may flow between the components. 
     Electrical power source—an element capable of storing and releasing electricity. 
     Face—a side of a structure. 
     Fluid coupling—a connection between two components whereby fluid may flow between the components, but does not escape at the point of connection. 
     Housing—a structure at least partially inclosing an amount of space adapted to contain components of a device. 
     Mechanical communication—a relationship between two or more components that transfers mechanical energy from one component to the other. 
     Open face—an uncovered side of a structure that exposes the interior of the structure. 
     Piston—a member fitting closely within a tube in which it moves along. 
     Sealingly—not permitting fluids to enter or exit. 
     Semi-cylindrical hollow body—a member whose shape may be described by a hollow cylinder that was cut longitudinally along a diameter. 
     Suction—the production of partial vacuum by the removal of air in order to force fluid into a vacant space. 
     Tube—an elongated hollow member for holding or transporting a piston. 
     Vacuum pump—a pump used for creating a vacuum