Patent Publication Number: US-2021162467-A1

Title: Directed flow pressure washer system, method and apparatus

Description:
TECHNICAL FIELD 
     The present disclosure relates to the field of precision cleaning, and more particularly, to a directed flow pressure washer system, method and apparatus for the precision cleaning of parts in bulk for various industries. 
     BACKGROUND 
     Conventional precision cleaning systems, methods and apparatuses for the cleaning of parts, particularly small parts in bulk, present many challenges. In particular, ultrasonic cleaning, tumbling and pressure washing with detergent, deionized water, solvents or other chemicals have limited ability to penetrate a large mass of components evenly and quickly. Precision cleaning systems from various companies in the industry use trays, racks and baskets to hold the parts. Self-contained cleaning systems do the same. Parts placed in a basket for bulk cleaning expose the outermost parts to the best cleaning. Sprayers and tumblers rely on repetition to cover all areas effectively leaving results uneven. Parts that are tumbled do not have the rinse flow rate for the best particle removal. Conveyor systems also rely on baskets to secure the parts with the same deficiency. Ultrasonic cleaning does not penetrate the entire depth of parts to be cleaned. Parts that are pressure washed are exposed to the most intense pressure near the nozzle and pressure is quickly dissipated by distance and deflection. The mass of parts can hold particulate like a filter. Small parts must be contained, but bulk containment usually sacrifices consistency. Smaller batches for cleaning increase the cost. 
     It would thus be desirable to have an improved precision cleaning system, method and apparatus, among other desirable features as described herein, which avoid the disadvantages of conventional precision cleaning systems, methods and apparatuses. 
     SUMMARY 
     In a first aspect, there is provided herein a directed flow pressure washer system for precision cleaning of parts. The system includes a plurality of inlets connected to an elongated pipe tubing at a proximal end thereof via an inlet tee fitting. The plurality of inlets are configured to receive at least a gas, a detergent or surfactant, and a solvent, intermittently or simultaneously therethrough. A gas source supplies the gas configured to be connected to one of the plurality of inlets configured to receive the gas via a first tubing. A detergent or surfactant source supplies the detergent or surfactant configured to be connected to one of the plurality of inlets configured to receive the detergent or surfactant via a second tubing. A solvent source supplies the solvent configured to be connected to one of the plurality of inlets configured to receive the solvent via a third tubing. A component retainer is removably attached to the elongated pipe tubing at a distal end thereof. The elongated pipe tubing is configured to contain the parts therein such that the parts are exposed to a directed variable pressure and flow rate of the gas, the detergent or surfactant, and the solvent. The component retainer includes openings at an outlet thereof to allow particles therethrough while retaining the parts therein the elongated pipe tubing during cleaning. 
     In certain embodiments, the gas, the detergent or surfactant, and the solvent are configured to be filtered to a predetermined micron level before passing therethrough the inlet tee fitting for cleaning of the parts in the elongated pipe tubing. 
     In certain embodiments, the plurality of inlets are controllable via a shut-off valve for each inlet such that the gas, the detergent or surfactant, and the solvent flow intermittently or simultaneously therethrough and into the inlet tee fitting. 
     In certain embodiments, the gas accelerates the solvent and forms pockets of gas that compress and push through the parts contained therein the elongated pipe tubing and triggers a repeating pulse of energy during cleaning. 
     In certain embodiments, turbulence and change from liquid to gas push particles in one direction by pulsing from start to finish during cleaning. 
     In certain embodiments, change from gas to liquid and back provides energy to dislodge particles and moves liberated particles through a mass of the parts and in turn through the component retainer outlet. 
     In certain embodiments, the plurality of inlets are configured with at least one optional valve or orifice to regulate back pressure during cleaning. 
     In certain embodiments, the plurality of inlets are configured to receive process aids during cleaning. 
     In certain embodiments, the gas source includes at least one of nitrogen, compressed air, argon, carbon dioxide, or other product compatible pressurized gas. 
     In certain embodiments, the detergent or surfactant source includes at least one of any compatible detergent solution. 
     In certain embodiments, the solvent source includes at least one of ultra-pure de-ionized water, distilled water, hydrogen peroxide, mineral spirits, rust inhibitor or industrial cleaning solvent. 
     In a second aspect, there is provided herein a directed flow pressure washer method for precision cleaning of parts. The method includes the following steps: connecting a plurality of inlets to an elongated pipe tubing at a proximal end thereof via an inlet tee fitting; configuring the plurality of inlets for receiving at least a gas, a detergent or surfactant, and a solvent, intermittently or simultaneously therethrough; providing a gas source for supplying the gas configured to be connected to one of the plurality of inlets configured to receive the gas via a first tubing; providing a detergent or surfactant source for supplying the detergent or surfactant configured to be connected to one of the plurality of inlets configured to receive the detergent or surfactant via a second tubing; providing a solvent source for supplying the solvent configured to be connected to one of the plurality of inlets configured to receive the solvent via a third tubing; placing the parts for cleaning inside the elongated pipe tubing at a distal end thereof; attaching a component retainer configured with openings at an outlet thereof to the elongated pipe tubing at the distal end thereof for containing the parts therein and allowing particles therethrough during cleaning; exposing the parts to a directed variable pressure and flow rate of the gas, the detergent or surfactant, and the solvent, intermittently or simultaneously; removing the attached component retainer from the distal end of the elongated pipe tubing after cleaning is completed; and removing the cleaned parts from the elongated pipe tubing. 
     In certain embodiments, the step of configuring the plurality of inlets for receiving at least the gas, the detergent or surfactant, and the solvent, intermittently or simultaneously therethrough further includes: filtering the gas, the detergent or surfactant, and the solvent to a predetermined micron level before passing therethrough the inlet tee fitting for cleaning of the parts in the elongated pipe tubing. 
     In certain embodiments, the step of configuring the plurality of inlets for receiving at least the gas, the detergent or surfactant, and the solvent, intermittently or simultaneously therethrough further includes: configuring the plurality of inlets with at least one optional valve or orifice to regulate back pressure during cleaning. 
     In certain embodiments, the step of configuring the plurality of inlets for receiving at least the gas, the detergent or surfactant, and the solvent, intermittently or simultaneously therethrough further includes: feeding at least one of the detergent or surfactant and the solvent at a predetermined pressure and flow rate into the inlet tee fitting with the gas fed at one of the plurality of inlets, thereby forming a pressure washing chamber. 
     In certain embodiments, the step of exposing the parts to the directed variable pressure and flow rate of the gas, the detergent or surfactant, and the solvent, intermittently or simultaneously, further includes: feeding the detergent or surfactant followed by the solvent pushed with the gas at a predetermined pressure and flow rate into the inlet tee fitting, the gas triggering surges in the solvent forming turbulence for distribution of the detergent or surfactant, particle liberation and flow over the parts during cleaning. 
     In certain embodiments, the step of exposing the parts to the directed variable pressure and flow rate of the gas, the detergent or surfactant, and the solvent, intermittently or simultaneously, further includes: configuring the plurality of inlets to be switched from detergent to rinse to purge for an integrated cleaning method that washes, rinses, pressure washes and dries. 
     In certain embodiments, the step of removing the cleaned parts from the elongated pipe tubing further includes: storing or packaging the cleaned parts until next use. 
     In a third aspect, there is provided herein a directed flow pressure washer apparatus for precision cleaning of parts. The apparatus includes a plurality of inlets connected to an elongated pipe tubing at a proximal end thereof via an inlet tee fitting. The plurality of inlets are configured to receive at least a gas, a detergent or surfactant, and a solvent, intermittently or simultaneously therethrough. A component retainer is removably attached to the elongated pipe tubing at a distal end thereof. The elongated pipe tubing is configured for containing the parts therein and for exposing the parts to a directed variable pressure and flow rate of the gas, the detergent or surfactant, and the solvent. The component retainer includes openings at an outlet thereof for allowing particles therethrough while retaining the parts therein the elongated pipe tubing during cleaning. 
     In certain embodiments, the plurality of inlets are controllable via a shut-off valve for each inlet for controlling the flow and pressure of the gas, the detergent or surfactant, and the solvent, intermittently or simultaneously therethrough and into the inlet tee fitting. 
     Various advantages of this disclosure will become apparent to those skilled in the art from the following detailed description, when read in light of the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a setup of the directed flow pressure washer system and apparatus for precision cleaning of parts in accordance with an example embodiment of the present disclosure. 
         FIG. 2  is an enlarged sectional view of the directed flow pressure washer system and apparatus shown with parts to be precision cleaned placed in an elongated pipe tubing in accordance with an example embodiment of the present disclosure. 
         FIG. 3  is an enlarged sectional view of the directed flow pressure washer system and apparatus shown with parts in process of being precision cleaned in the elongated pipe tubing in accordance with an example embodiment of the present disclosure. 
         FIG. 4  is an enlarged sectional view of the directed flow pressure washer system and apparatus shown with the cleaned parts retained by the component retainer in accordance with an example embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     This disclosure is not limited to the particular apparatus, systems, methodologies or protocols described, as these may vary. The terminology used in this description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope. 
     As used in this document, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. All sizes recited in this document are by way of example only, and the disclosure is not limited to structures having the specific sizes or dimensions recited below. As used herein, the term “comprising” means “including, but not limited to.” 
     In consideration of the figures, it is to be understood for purposes of clarity that certain details of construction and/or operation are not provided in view of such details being conventional and well within the skill of the art upon disclosure of the document described herein. 
     The present disclosure pertains to a directed flow pressure washer system, method and apparatus for the precision cleaning of parts in bulk for various industries. The restriction of overspray directed within the confined space of the tubing allows positive contact with each part to be cleaned. The use of gas, such as nitrogen, to accelerate the solvent creates pockets of gas that compress and push through the parts to be cleaned. This turbulence and change from liquid to gas push particulate in one direction by pulsing from beginning to end. This system and method requires all parts to be exposed to the pressure and flow rate of the cleaning source. When sized appropriately, the parts are exposed to an intense flow rate not available otherwise. The inlet can be switched from detergent to rinse to purge for an integrated cleaning method that washes, rinses, pressure washes and dries. This can also establish a packaging method by not removing the cleaned parts and instead of bagging or weighing for counting, instead sealing the vessel and rotating parts from manufacturing, to cleaning, to storage, to assembly, and back again. This may also allow the vessel to be a type of magazine for manual or robotic assembly, which could eliminate sources of contamination from handling. 
     Referring now to the drawings, the directed flow pressure washer system  10  and apparatus  12  of the present disclosure will be described in more detail.  FIG. 1  is a perspective view of a setup of the directed flow pressure washer system  10  and apparatus  12  for precision cleaning of parts  14  ( FIGS. 2-4 ) according to the present disclosure.  FIG. 2  is an enlarged sectional view of the directed flow pressure washer system  10  and apparatus  12  shown with parts  14  to be precision cleaned placed in an elongated pipe tubing  16 . The system  10  generally includes a plurality of inlets  18  connected to an elongated pipe tubing  16  at a proximal end  20  thereof via an inlet tee fitting  22 . The plurality of inlets  18  are configured to receive at least a gas  24 , a detergent or surfactant  26 , and a solvent  28 , intermittently or simultaneously therethrough. A gas source  24 ′ supplies the gas  24  configured to be connected to one of the plurality of inlets  18  configured to receive the gas  24  via a first tubing  30 . A detergent or surfactant source  26 ′ supplies the detergent or surfactant  26  configured to be connected to one of the plurality of inlets  18  configured to receive the detergent or surfactant  26  via a second tubing  32 . A solvent source  28 ′ supplies the solvent  28  configured to be connected to one of the plurality of inlets  18  configured to receive the solvent  28  via a third tubing  34 . A component retainer  36  is removably attached to the elongated pipe tubing  16  at a distal end  38  thereof. The elongated pipe tubing  16  is configured to contain the parts  14  therein such that the parts  14  are exposed to a directed variable pressure and flow rate of the gas  24 , the detergent or surfactant  26 , and the solvent  28 . The component retainer  36  includes openings  40  at an outlet  42  thereof to allow particles  44  therethrough while retaining the parts  14  therein the elongated pipe tubing  16  during cleaning. 
     In accordance with the present disclosure, the gas  24 , the detergent or surfactant  26 , and the solvent  28  are configured to be filtered  46  to a predetermined micron level before passing therethrough the inlet tee fitting  22  for cleaning of the parts  14  in the elongated pipe tubing  16 . 
     In the illustrated embodiments, the plurality of inlets  18  are controllable via a shut-off valve  48  for each inlet  18  such that the gas  24 , the detergent or surfactant  26 , and the solvent  28  flow intermittently or simultaneously therethrough and into the inlet tee fitting  22 . 
       FIG. 3  is an enlarged sectional view of the directed flow pressure washer system  10  and apparatus  12  shown with parts  14  in process of being precision cleaned in the elongated pipe tubing  16  according to the present disclosure. In some embodiments, the gas  24  accelerates the solvent  28  and forms pockets of gas  24 ″ that compress and push through the parts  14  contained therein the elongated pipe tubing  16  and triggers a repeating pulse of energy during cleaning. 
     In other embodiments, turbulence and change from liquid to gas  24  push particles  44  in one direction by pulsing from start to finish during cleaning. It is to be understood that the liquid is in the form of the detergent or surfactant  26  and/or solvent  28  used with the directed flow pressure washer system  10  and apparatus  12  disclosed herein. 
       FIG. 4  is an enlarged sectional view of the directed flow pressure washer system  10  and apparatus  12  shown with the cleaned parts  14  retained by the component retainer  36  according to the present disclosure. The removed particles exit the component retainer  16  through the openings  40  at the outlet  42  after cleaning is completed. 
     In the illustrated embodiments, change from gas  24  to liquid and back provides energy to dislodge particles  44  and moves liberated particles  44  through a mass of the parts  14  and in turn through the component retainer outlet  42 . 
     In some embodiments, the plurality of inlets  18  are configured with at least one optional valve or orifice (cleaning valve)  50  to regulate back pressure during cleaning. 
     It is to be understood that the three-way valves of the inlet tee fitting  22  shown in the figures are customized to the particular cleaning process and can be configured to toggle between detergent and water during the cleaning process. In addition, it is to be understood that the cleaning may be performed without the detergent as a minimum such that just gas and water is used in the cleaning process. However, most parts  14  would benefit from the addition of the detergent or surfactant in the cleaning process as disclosed herein. 
     In other embodiments, the plurality of inlets  18  are configured to receive process aids (not shown) during cleaning. In particular, chlorinated water, isopropyl alcohol (IPA), and hydrogen peroxide can be used to sterilize the parts  14  and silicon oil or another lubricant may need to be applied to a surface of the parts  14  in a pure state. For example, a secondary solvent or gas can be used to sterilize or condition the parts  14  and oxygen or ozone can be used to finish the surface of parts  14 . 
     In some embodiments, the gas source  24 ′ includes at least one of nitrogen, compressed air, argon, carbon dioxide, or any other suitable product compatible pressurized gas. The gas  24  accelerates solvent  28  flow in pulses compressing between surges of solvent  28 . 
     In some embodiments, the detergent or surfactant source  26 ′ includes at least one of any suitable compatible detergent solution. The detergent or surfactant  26  is selected for material compatibility and specification compliance. Non-limiting examples of suitable detergents that can be used in the system  10  include ALCONOX, LIQUINOX, Triton X-100, Sodium Hydroxide, CITRISURF, Optical Cleaning Solution, Brulin, and other commercial cleaning solutions. 
     In certain embodiments, the solvent source  28 ′ includes at least one of ultra-pure de-ionized water, distilled water, hydrogen peroxide, mineral spirits, rust inhibitor or industrial cleaning solvent. It is to be understood that the solvent source  28 ′ can be any suitable solvent and is not limited to those disclosed herein for use in the directed flow pressure washer system  10  of the present disclosure. The solvent  28  is selected per material compatibility. 
     In accordance with the present disclosure, the additional parameters of temperature and sonic cavitation can be included in the directed flow pressure washer system  10 . Increasing temperature can remove soluble residues such as hydrocarbon and paraffin, and sonication can supplement particle liberation if transducers (not shown) are mounted to the cleaning chamber. 
     It is to be understood that the various components (i.e., inlet tee fitting  22 , elongated pipe tubing  16 , and component retainer  36 ) of the apparatus  12  disclosed herein can be fabricated of metals, metal alloys, stainless steel, plastic or any suitable sturdy material. It is to be further understood that the various components of the apparatus  12  can be of any suitable size and shape to accommodate the parts  14  to be precision cleaned via the directed flow pressure washer system  10  and method of the present disclosure. 
     In accordance with the present disclosure, the various components of the apparatus  12  disclosed herein can be manufactured via  3 D printing, injection molding, roll forming, extrusion, welding or any suitable manufacturing process. 
     The present disclosure further contemplates a method for a directed flow pressure washer method for precision cleaning of parts using the system  10  and apparatus  12  disclosed herein. The method generally includes the following steps: 
     connecting a plurality of inlets  18  to an elongated pipe tubing  16  at a proximal end  20  thereof via an inlet tee fitting  22 ; 
     configuring the plurality of inlets  18  for receiving at least a gas  24 , a detergent or surfactant  26 , and a solvent  28 , intermittently or simultaneously therethrough; 
     providing a gas source  24 ′ for supplying the gas  24  configured to be connected to one of the plurality of inlets  18  configured to receive the gas  24  via a first tubing  30 ; 
     providing a detergent or surfactant source  26 ′ for supplying the detergent or surfactant  26  configured to be connected to one of the plurality of inlets  18  configured to receive the detergent or surfactant  26  via a second tubing  32 ; 
     providing a solvent source  28 ′ for supplying the solvent  28  configured to be connected to one of the plurality of inlets  18  configured to receive the solvent  28  via a third tubing  34 ; 
     placing the parts  14  for cleaning inside the elongated pipe tubing  16  at a distal end  38  thereof; 
     attaching a component retainer  36  configured with openings  40  at an outlet  42  thereof to the elongated pipe tubing  16  at the distal end  38  thereof for containing the parts  14  therein and allowing particles  44  therethrough during cleaning; 
     exposing the parts  14  to a directed variable pressure and flow rate of the gas  24 , the detergent or surfactant  26 , and the solvent  28 , intermittently or simultaneously; 
     removing the attached component retainer  36  from the distal end  38  of the elongated pipe tubing  16  after cleaning is completed; and 
     removing the cleaned parts  14  from the elongated pipe tubing  16 . 
     In some embodiments, the step of configuring the plurality of inlets  18  for receiving at least the gas  24 , the detergent or surfactant  26 , and the solvent  28 , intermittently or simultaneously therethrough further includes: filtering the gas  24 , the detergent or surfactant  26 , and the solvent  28  to a predetermined micron level via a filter  46  before passing therethrough the inlet tee fitting  22  for cleaning of the parts  14  in the elongated pipe tubing  16 . 
     In other embodiments, the step of configuring the plurality of inlets  18  for receiving at least the gas  24 , the detergent or surfactant  26 , and the solvent  28 , intermittently or simultaneously therethrough further includes: configuring the plurality of inlets  18  with at least one optional valve or orifice (cleaning valve)  50  to regulate back pressure during cleaning. 
     In other embodiments, the step of configuring the plurality of inlets  18  for receiving at least the gas  24 , the detergent or surfactant  26 , and the solvent  28 , intermittently or simultaneously therethrough further includes: feeding at least one of the detergent or surfactant  26  and the solvent  28  at a predetermined pressure and flow rate into the inlet tee fitting  22  with the gas  24  fed at one of the plurality of inlets  18  (see directional flow indicated by arrows in  FIG. 3 ), thereby forming a pressure washing chamber  52 . 
     In some embodiments, the step of exposing the parts  14  to the directed variable pressure and flow rate of the gas  24 , the detergent or surfactant  26 , and the solvent  28 , intermittently or simultaneously, further includes: feeding the detergent or surfactant  26  followed by the solvent  28  pushed with the gas  24  at a predetermined pressure and flow rate into the inlet tee fitting  22  (see directional flow indicated by arrows in  FIG. 3 ), the gas  24  triggering surges in the solvent  28  forming turbulence for distribution of the detergent or surfactant  26 , particle liberation and flow over the parts  14  during cleaning. 
     In other embodiments, the step of exposing the parts  14  to the directed variable pressure and flow rate of the gas  24 , the detergent or surfactant  26 , and the solvent  28 , intermittently or simultaneously, further includes: configuring the plurality of inlets  18  to be switched from detergent to rinse to purge for an integrated cleaning method that washes, rinses, pressure washes and dries. 
     In further embodiments, the step of removing the cleaned parts  14  from the elongated pipe tubing  16  further includes: storing or packaging the cleaned parts  14  until next use. 
     It is to be understood that filtration, pressure, flow, elongated tubing size and the component retainer will vary with process control parameters. The diameter of the chamber in the elongated pipe tubing  16  should allow the voids between the parts  14  to be cleaned sufficient flow so as to not inhibit the pulsing action while cleaning. Excessive space would not equally clean parts because pulses would not be produced and insufficient space would result in a significantly reduced flow rate, which would fail to propel fine particulate. Detergents provide increased wetting at poorly accessible surfaces due to contact. When cleaning with a proper flow rate, the detergent assists in the expulsion of particulate. 
     These and other advantages of the present disclosure will be apparent to those skilled in the art. Accordingly, it will be recognized by those skilled in the art that changes or modifications may be made to the above-described embodiments without departing from the broad inventive concepts of the present disclosure. It should therefore be understood that the present disclosure is not limited to the particular embodiments described herein, but is intended to include all changes and modifications that are within the scope and spirit of the disclosure as encompassed by the disclosure and figures herein and the following claims.