Patent Publication Number: US-7896939-B2

Title: Debris receiver

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a divisional of application Ser. No. 11/500,213, filed Aug. 7, 2006 now U.S. Pat. No. 7,686,860, entitled Debris Receiver. This application claims subject matter disclosed in U.S. provisional patent application Ser. No. 60/744,599 filed Apr. 11, 2006 titled Central Vacuum System With Integrated Countertop Debris Collector and U.S. provisional patent application Ser. No. 60/743,631 filed Mar. 22, 2006 titled Central Vacuum System With Integrated Countertop Debris Collector. 
    
    
     BACKGROUND 
     Central vacuum systems, used increasingly in homes and businesses, provide centralized debris collection and eliminate the need to move around a heavy motor and collector bag or canister while cleaning. These systems are adapted to provide suction to many different areas in homes, offices and other facilities. In a typical conventional central vacuum system, suction ports located in walls and other concealed locations are accessed through long portable hoses that plug into the ports. Debris is collected through the hoses in much the same way that debris is collected with a portable vacuum except, of course, without the need to move around the motor and the collector bag or canister. Embodiments of the present invention were developed in an effort to facilitate removing debris from countertops, desktops, work benches, and similar types of work surfaces utilizing components of a central vacuum system. 
    
    
     
       DRAWINGS 
         FIG. 1  illustrates a cabinet according to an embodiment of the invention. 
         FIG. 2  illustrates a countertop debris collection system according to an embodiment of the invention. 
         FIGS. 3-6  are perspective views of a debris receiver assembly according to an embodiment of the invention. 
         FIG. 7  is a detailed exploded view of the drawer receptacle and cover in the assembly of  FIGS. 3-6 . 
         FIG. 8  is a detailed exploded view of the drawer in the assembly of  FIGS. 3-6 . 
         FIG. 9  is another embodiment of a drawer that may be used in the assembly of  FIGS. 3-6 . 
         FIGS. 10 and 11  are section views that illustrate collecting debris off a countertop using an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     As used in this document: “drawer” means a sliding receptacle opened by pulling or pushing and closed by pushing or pulling; “port” means an opening for the intake or exhaust of air; “seal” means a device that prevents the passage of air into a passage or container; “suction” means reduced air pressure or the act or process of exerting a force upon a solid, liquid, or gaseous body by reason of reduced air pressure; and “valve” means a device by which the flow of liquid, gas, or loose material may be started, stopped, or regulated by a movable part that opens, shuts, or partially obstructs a port or passage. 
       FIG. 1  illustrates a cabinet  10  such as might be utilized at various locations in a home or business. Referring to  FIG. 1 , cabinet  10  includes a base  12 , a countertop  14  on base  12 , and a debris receiver assembly  16  mounted in base  12  just below countertop  14 . Receiver assembly  16  includes a drawer receptacle  18  fixed in base  12  and a debris receiving drawer  20  that slides in receptacle  18 . A duct  22  runs from a suction port  24  at the back of receptacle  18  to a central vacuum (not shown in  FIG. 1 ). Suction port  24  represents generally any suitable opening in receptacle  18  that allows suction supplied by the central vacuum through duct  22  to reach drawer  20  when drawer  20  is open. A seal  26  is positioned in the floor of drawer  20  to close suction port  24  when drawer  20  is closed and seal port  24  when suction is supplied to port  24 . Hence, when drawer  20  is closed, the central vacuum can suck air in through other suction ports, if any, in the central vacuum system. A switch  28  may be used to automatically turn on the central vacuum when drawer  20  is opened and to automatically turn off the central vacuum when drawer  20  is closed. Switch  28  represents generally any suitable electrical, electronic, optical, or other switching device and circuitry operable to turn on the central vacuum when drawer  20  is opened and to turn off the central vacuum when drawer  20  is closed. If the central vacuum system includes other suction ports, switch  28  is configured to allow the central vacuum to run when drawer  20  is closed. 
     Seal  26  in drawer  20  functions as a valve that starts and stops the flow of air through drawer  20  into duct  22 . If drawer  20  is closed, seal  26  closes and, when suction is supplied to port  24 , seals suction port  24  so that air will not flow through drawer  20  into duct  22  when suction is supplied to port  24 . If drawer  20  is open, suction port  24  is also open so that air will flow through drawer  20  into duct  22  when suction is supplied to port  24 . The speed of air flowing through drawer  20  into duct  22  may be increased by minimizing the entry of air into receptacle  18  and duct  22  other than through the open drawer  20 . Air will also flow faster through drawer  20  when drawer  20  is more closed and slower when drawer  20  is more open. Hence, as drawer  20  closes the rate of air flow increases to help draw debris in drawer  20  back into duct  22 . As shown in  FIG. 1 , the sides of drawer  20  may be tapered towards the rear, behind the debris entry area, to help make the air flow faster and to direct debris toward suction port  24 . Drawer  20  might also be tapered between the top and bottom toward the rear to help make the air flow faster behind the debris entry area. 
       FIG. 2  is a block diagram illustrating a countertop debris vacuum collection system  30  utilizing, for example, a cabinet  32  such as the one shown in  FIG. 1 . Referring to  FIG. 2 , system  30  includes a motor  34 , a vacuum pump  36 , a collector  38 , and ducting  40  typically used in conventional central vacuum systems. System  30  also includes a debris receiver assembly  42  mounted in cabinet  32 . Receiver assembly  42  in  FIG. 2  includes a drawer receptacle  44  fixed in cabinet  32  and a debris receiving drawer  46  that slides in receptacle  44 . Ducting  40  in system  30  will usually include multiple ducts  40   a - 40   e  to multiple suction ports  48   a - 48   e  in addition to duct  50  to suction port  52  in cabinet  32 . A seal  54  operatively connected to drawer  46  seals suction port  52  when drawer  46  is closed and suction is supplied to port  52 . A switch  56  operatively connected to drawer  46  automatically turns on pump  36  with the use of power supply  58  when drawer  46  is opened and automatically turns off pump  36  when drawer  46  is closed. 
     In operation, opening drawer  46  opens suction port  52  and “activates” switch  56  to the on position to start vacuum pump  36 . Pump  36  supplies suction to port  52  at the back of receptacle  44  through duct  50 . Any debris swept off the top of cabinet  32  or otherwise dumped into the open drawer  46  is sucked through the rear of drawer  46 , into receptacle  44 , and then into duct  50  through suction port  52  and on to collector  38 . Closing drawer  46  closes suction port  52  and “deactivates” switch  56  to turn off vacuum pump  36 . 
       FIGS. 3-6  are perspective views of a debris receiver assembly  60  such as might be used in cabinets  10  and  32  of  FIGS. 1 and 2 .  FIG. 7  is a detailed exploded view showing the drawer receptacle and cover from the assembly of  FIGS. 3-6 .  FIG. 8  is a detailed exploded view of the drawer from the assembly of  FIGS. 3-6 . Referring to  FIGS. 3-8 , receiver assembly  60  includes a drawer receptacle  62 , a debris receiving drawer  64  that slides in receptacle  62  and a cover  66  attached to receptacle  62 . Receptacle  62  forms a generally Y-shaped bay  68  defined by a floor  70 , cover/ceiling  66 , sidewalls  71  and  72 , and a rear end wall  73 . An opening  74  in floor  70  at the rear of bay  68  forms a suction port  76  (see  FIG. 4 ) that may be connected to ducting in a vacuum system. In the embodiment shown, as best seen in  FIGS. 4 and 7 , suction port  76  is configured as a stepped cylinder projecting down from floor  70  for connection to round tubular ducting. Of course, other configurations for suction port  70  are possible. 
     As also seen in  FIGS. 4 and 7 , cover  66  conforms to the uppermost planar shape of receptacle  62 . Cover  66  is attached to a flange  78  along sidewalls  72  of receptacle  62  with screws  80 . A groove  82  may be formed along flange  78  as shown in  FIG. 7  to contain a gasket, including a ridge on the underside of cover  66  (not shown), to help seal cover  66  to receptacle  62 . Other suitable fasteners or attachment techniques and seals may be used. Cover  66  could also be formed as an integral part of receptacle  62  rather than using the two discrete parts shown in the figures. As best seen in  FIGS. 4 and 7 , an electrical on-off switch  83  is located at the rear of receptacle  62  near the front of suction port  76 . Switch  83  is mounted into a small forward facing wall  85  formed at the rear of receptacle  62 . Other locations for switch  83  are, of course, also possible. 
     Referring now to  FIGS. 6 and 8 , drawer  64  forms a generally Y-shaped chamber  84  defined by a floor  86 , sidewalls  87  and  88 , and a front end wall  90  that extends across the front of drawer  64  between sidewalls  87  and  88 . As best seen in  FIG. 6 , the outer shape of drawer  64  conforms closely to the inner shape of receptacle  62  so that drawer  64  nests inside receptacle  62  fully under cover  66  when drawer  64  is closed. In the embodiment shown, outer perimeter sidewalls  91  and  92 , which extend parallel to chamber sidewalls  87  and  88  along the stem of the Y, form the outer perimeter of drawer  64  along this rear portion. Short rear end walls  93 ,  94  extend between sidewalls  87 ,  91  and  88 ,  92  at the rear of drawer  64 . Outer perimeter sidewalls  91  and  92  strengthen chamber sidewalls  87  and  88  and rear end walls  93  and  94 . One of the rear end walls  93  or  94  is used as a stop at the back of drawer  64  to activate switch  83  (see  FIG. 7 ) to the off position when drawer  64  is closed. For switch  83  located at the rear right of receptacle  62 , as shown in  FIG. 7 , rear end wall  94  is used as the stop. 
     Referring again to  FIG. 8 , the more broad forward part of drawer chamber  84  forms a basin  96  into which debris is swept when drawer  64  is open. The more narrow rearward part of chamber  84  forms a channel  98  through which debris is channeled from basin  96  to an outlet  100  at the rear of drawer  64 . Air flowing through chamber  84  accelerates as it moves from the broad forward part through the gradually constricting sidewalls  87 ,  88  into the narrow channel  98  to help move debris toward suction port  76  (see  FIG. 4 ). The tapered sidewalls  87 ,  88  of the Y-shaped chamber  84  also eliminate deep corners to help debris along the sidewalls move more easily from basin  96  into channel  98 . In addition, as drawer  64  closes and suction is applied to an ever diminishing supply of air, the vacuum effect in chamber  84  is greatly increased, making it virtually impossible for any debris to remain in drawer  64  after it is closed. 
     Referring still to  FIG. 8 , a pair of rails  102  formed along the floor  86  of drawer  64  slide in tracks  104  formed in the floor  70  of receptacle  62  (see  FIG. 7 ) to help keep drawer  64  properly aligned in receptacle  62 . A rubber sleeve  106  fitted onto a tongue  108  extending from the rear of drawer  64  closes suction port  76  (see  FIG. 4 ) when drawer  64  is closed. Sleeve  106  functions as a valve that starts and stops the flow of air through chamber  84 . When drawer  64  is closed, sleeve  106  closes port  76  and, when suction is supplied to port  76 , seals suction port  76  so that air will not flow through chamber  84 . A pair of blocks  110  positioned on either side of channel  98  may be used in drawer  64  as necessary or desirable to reduce air volume in basin  96  and thereby accelerate the speed of air passing through basin  96 . 
       FIG. 9  illustrates another embodiment of a drawer  112  that might be used in a receiver assembly such as the one shown in  FIGS. 3-6 . Referring to  FIG. 9 , drawer  112  is substantially the same as drawer  64  shown in  FIG. 8  except that drawer  112  includes a ramp  114  providing a sloped transition from front end wall  90  down to floor  86 , with a hollowed-out area on the underside (not shown) for use as a finger catch to open the drawer, and a single block  116  positioned in front of channel  98  to reduce air volume and accelerate the speed of air passing through basin  96 . The front and rear of block  116  are tapered to help direct debris around block  116  and then in to channel  98 . 
       FIGS. 10 and 11  are section views that illustrate collecting debris off a countertop using an embodiment of the invention. Referring to  FIGS. 10 and 11 , a debris receiver assembly  118  is installed in a cabinet  120  having a countertop  122 . Assembly  118  is positioned just below countertop  122 . Receiver assembly  118  includes a drawer receptacle  124  and a debris receiving drawer  126  that slides in receptacle  124 . A suction port  128  at the rear of receptacle  124  allows air to flow into vacuum duct  130 . In this embodiment, a seal  132  is embedded in the floor of receptacle  124  surrounding suction port  128 . When drawer  126  is closed (see  FIG. 10 ) and suction is supplied to suction port  128 , the floor of drawer  126  seals against seal  132  to prevent the flow of air through port  128  into duct  130 . When drawer  126  is open (see  FIG. 11 ), debris  134  falling into drawer  126  is immediately sucked back through suction port  128  into duct  130  and on to the collector in the central vacuum system. 
     Suction acting on particles of debris  134  as they fall into drawer  126  and before the particles hit the floor of drawer  126  helps minimize the drag that must be overcome to move particles toward suction port  128 . Also, after debris  134  is swept into drawer  126  and drawer  126  starts to close, the suction applied to the particles of debris  134  greatly increases to help ensure all debris  134  in drawer  126  is sucked into duct  130 . While air flow rates may vary depending on the suction produced by the vacuum pump, the size of the duct/suction port relative to the size of the drawer, and the “efficiency” of the receiver assembly, it is expected that a typical residential vacuum pump producing 350-1,000 airwatts at the pump will generate adequate flow through the debris receiver drawer if the ratio between the exposed area of the open drawer and the area of the duct/suction port is in the range of 14:1-92:1. For example, in a drawer  126  that is nominally 1 inch deep, 11 inches across chamber basin  96  tapering to a 1 inch wide channel  98  (basin  96  and channel  98  are shown in  FIGS. 8 and 9 ), and opening a maximum of 6 inches along parallel sidewalls, the ratio between the exposed area of the fully open drawer  126  and a 1 inch diameter suction port  128  is 84:1. At this ratio, the suction from a typical residential vacuum pump is expected to suck air into the 1 inch diameter suction port  128  through drawer basin  96  at the rate of at least 1,000 feet per minute. This flow rate increases as the ratio between the area of the open drawer and the area of the suction port decreases (for the same drawer depth). As drawer  126  nears full closure, air is sucked through basin  96  at more than 10,000 feet per minute. Even if these flow rates are reduced by 30% to account for air leaking into drawer  126  (reflecting a 70% air leak “efficiency” for receiver assembly  118 ), the actual flow rates are still expected to be adequate to suck debris through drawer  126  and into suction port  128 . 
     The present invention has been shown and described with reference to the foregoing exemplary embodiments. It is to be understood, however, that other forms, details, and embodiments may be made without departing from the spirit and scope of the invention which is defined in the following claims.