Patent Publication Number: US-9897377-B2

Title: Exhaust safety system

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATION 
     This patent application relates to U.S. Provisional Patent Application Ser. No. 61/604,420 filed on Feb. 28, 2012 entitled IMPROVED LINT COLLECTOR SYSTEM which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to an exhaust safety system and in particular a dryer exhaust safety system that may be used with or without a filter cleaner, lint collector or booster fan and may be used in association with clothes dryers in single and multiple dwellings. 
     BACKGROUND OF THE INVENTION 
     It has long been recognized that lint poses a fire hazard in homes and in multi-unit dwellings whether they be high rises or low rises. Many systems have been suggested to address the lint problem but there are still many serious problems with the systems that have been previously proposed. 
     SUMMARY OF THE INVENTION 
     An exhaust system includes a filter; and a fan downstream for the filter whereby activating the fan clears the filter. The exhaust system may form part of a lint collection system that is for attachment to a dryer. Alternatively the exhaust system may be part of the dryer, either retrofit into the dryer or manufactured as part of the dryer. 
     The exhaust system may further include a flow meter and the fan may be activated responsive to a measurement from the flow meter being below a predetermined level. 
     The exhaust system may further include a pressure sensor and the fan may be activated responsive to a measurement from the pressure sensor being below a predetermined level. 
     The fan is manually activatable. The fan may be activated at predetermined times. 
     The exhaust system may further include a display. The display may include one of light indicators, and audio indicator and display screen and a combination thereof. 
     The exhaust system may further include sensors and the sensors may be chosen from a group consisting of flow meters, pressure sensors, temperatures sensors and water level sensors and a combination thereof. 
     The exhaust system may be operably connected to a dryer whereby if the sensors are outside of predetermined levels power to the dryer is interrupted. 
     The exhaust system may form part of a lint collection system. The lint collection system may include an upper and lower housing, the upper housing having and inlet and an outlet includes the exhaust system. The lower housing may be primed with water. A disposable liner may be used in the lower housing. 
     A receptacle may be provided proximate to the filter for receiving lint from the filter after the fan has been activated. The receptacle may be provided with water. The receptacle may be provided with a disposable liner. 
     The exhaust system may be located in an exhaust pipe insert. The exhaust pipe insert may include an elbow extending out from a general flow of the exhaust pipe insert and the exhaust system is located in the elbow. 
     Further features of the invention will be described or will become apparent in the course of the following detailed description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described by way of example only, with reference to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of an embodiment of the improved lint collector system; 
         FIG. 2  is a perspective view of an alternate embodiment of the improved lint collector system, similar to that shown in  FIG. 1  but showing the lint screen on an alternate side; 
         FIG. 3  is perspective view of lower housing used in lint collector system of  FIGS. 1 and 2 ; 
         FIG. 4  is an end view of the lower housing of lint collector system shown in  FIG. 3 ; 
         FIG. 5  is a perspective view of upper housing and bracket of lint collector system of  FIGS. 1 and 2 ; 
         FIG. 6  is a top view of upper housing of  FIG. 1 ; 
         FIG. 7  is a bottom view of upper housing of  FIG. 6 ; 
         FIG. 8  is a perspective view of filter used in lint collector system of  FIGS. 1 and 2 ; 
         FIG. 9  is a top view of the filter shown in  FIG. 8 ; 
         FIG. 10  is a perspective view of the lint collector system of  FIG. 1  attached to a dryer with a low voltage plug enabling the lint collector system; 
         FIG. 11  is a perspective view of the lint collector system of  FIG. 1  attached to a dryer similar to that shown in  FIG. 10  but showing the lint collector system attached to a regular voltage plug; 
         FIG. 12  is a perspective view of a plug system wherein the lint collector system uses a low voltage plug; 
         FIG. 13  is a perspective view of a plug system wherein the lint collector system uses a regular voltage plug; 
         FIG. 14  is a perspective view of a plug system similar to that shown in  FIG. 12  but configured differently and wherein the lint collector system uses a low voltage plug; 
         FIG. 15  is a perspective view of a conventional plug system wherein the lint collector system uses a low voltage jack; 
         FIG. 16  is a perspective view of a conventional plug system wherein the lint collector system uses a regular voltage plug; 
         FIG. 17  is a blown apart perspective view of an alternate embodiment of the lint collector system including a disposable liner; 
         FIG. 18  is a side view of an alternate embodiment of the lint collector system; 
         FIG. 19  is a side view of an alternate embodiment of the lint collector system, similar to that shown in  FIG. 18  but showing liquid in the lint collector portion; 
         FIG. 20  is a side view of an alternate embodiment of the lint collector system, similar to that shown in  FIG. 18  but showing the fan connected to a regular voltage plug; 
         FIG. 21  is a side view of an alternate embodiment of the lint collector system, similar to that shown in  FIG. 20  but showing a display screen; 
         FIG. 22  is a side view of an alternate embodiment of the lint collector system, similar to that shown in  FIG. 19  but showing a disposable liner for the lint collector portion; 
         FIG. 23  is a side view of the filter and fan assembly with a display including audio and light indicators; 
         FIG. 24  is a side view showing a display including audio and a display screen; 
         FIG. 25  is a side view showing a display including audio, light indicators and a display screen; 
         FIG. 26  is a side view showing a display including an audio indicator; 
         FIG. 27  is a side view showing a filter and fan assembly and an on and off switch; 
         FIG. 28  is a side view showing a filter and fan assembly and a push button; 
         FIG. 29   a ) to  f ) show perspective views of filter and fan assembly with a variety of different sensors therein; 
         FIG. 30   a ) to  c ) shows perspective views of alternate embodiments of an exhaust pipe insert that is connected to a dryer and connected to a plug adaptor a), a conventional plug through a remote display b) and conventional plug; 
         FIG. 31  is a perspective view of a dryer showing an exhaust insert as part of the dryer; 
         FIG. 32  is a perspective view of an alternate embodiment of exhaust pipe insert; 
         FIG. 33  is a perspective view of the exhaust pipe insert of  FIG. 32  installed external to a dryer; and 
         FIG. 34  is a perspective view of the exhaust pipe insert of  FIG. 32  installed in a dyer. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIGS. 1 and 2  a lint collector system is shown generally at  10 . The lint collector system  10  includes a lower housing  12 , an upper housing  14  and a back bracket  16 . Lower housing  12  is detachable and removable from upper housing  14 . 
     Upper housing  14  has an inlet  18  and an outlet  20 . The inlet can be arranged such that it is on the left hand side as shown in  FIG. 1  or the right hand side as shown in  FIG. 2 . The diameter of each of inlet  18  and outlet  20  may be varied, but is most preferably of the same diameter as exhaust ducting passing from a clothes dryer  22  (shown in  FIG. 10 ). In particular, each of inlet  18  and outlet  20  is of a diameter consistent with the flexible corrugated hose that is used with many clothes dryers. However, it will be understood that the diameter may be varied to accommodate a lint collector system  1  into an existing exhaust system from a clothes dryer. 
     Back bracket  16  is attachable to a wall and typically would be attached above, behind or beside a clothes dryer  22  as shown in  FIG. 10 . Bracket  16  includes a shelf  24  which is spaced below the lower housing  12  where it is in position. 
     Lower housing  12  is separable from upper housing  14 , and in normal use is attached to upper housing  14  by means of closure  26 . It is understood that closure  26  may be of any type suitable for attachment of lower housing  12  to upper housing  14 , while permitting separation of lower housing  12  from upper housing  14 . Closures  26  may be provided on opposed ends of upper housing  14 , such that lower housing  12  may be detached and lowered from upper housing  14  for the purpose of emptying. Upper housing  14  is provided with a foam tape  28  so that when lower housing  12  is attached thereto there is a good seal and the moisture from the lint from the dryer  22  generally remains therein. 
     Outlet  20  has a filter  30  positioned therein. Filter  30  is preferably made from a fine mesh so that it can trap as much lint as possible. In use typically the bulk of the lint will be “caught” in the lower housing  12  but in the event that some lint gets by the lower housing  12  it will be caught by the filter  30 . Filter may be made of different materials such as nylon, steel, aluminium or polyester by way of example. Preferably filter  30  is removable so that it is easy to inspect and easy to replace. 
     Outlet  20  is also provided with fan  32  which is downstream from the filter  30 . Fan  32  is for providing back pressure so that lint that has accumulated on the underside of filter  30  can be pushed off the filter and into lower housing  12  and thus clean the screen. Thus the fan allows the filter  30  to be essentially self-cleaning. Fan  32  may be activated in a number of ways. For example fan  32  may be active periodically through the drying cycle at predetermined times. Alternatively outlet  20  may have an airflow sensor and the fan  32  may be activated when the air flow drops below a predetermined amount. As further alternative it may be manually activated such that a user may activate the fan to produce back pressure at the end or beginning of each drying cycle. 
     Fan  32  may be a reversible fan such that it can be used to measure air flow when rotating in one direction and then used to clear filter  30  when activated in the other direction. Alternatively fan  32  may be used to increase air flow of the outgoing air in the outlet downstream of the filter  30 . 
     Preferably, lint collector system  10  includes a display  34 . Display  34  may include light indicators  36  operably connected to different sensors. Light indicators  36  by way of example may be LED or LCD. As well, display  34  may include an audio indicator  38 . Referring to  FIGS. 23 to 26  a variety of different configurations of the display  34  are shown which include different combinations of one or more light indicators  36 , audio indicators  38  or a display screen  40 . 
     The display  34  may be connected to one or more sensor. Some examples of sensors are shown in  FIGS. 29   a ) through  f ) but these sensors are by way of example only. Some sensors may be air flow sensors such a flapper type flow meter  42 , vane type flow meter  44  or propeller type flow meter  46 . Sensors may also be a pressure sensor  48  for measuring pressure in the outlet pipe  50 . Sensors may also include a temperature sensor  52  or a sensor  54  to determine if the filter  30  is damaged. As well, lower housing  12  may include a water sensor  56  shown in  FIG. 3 . It will be appreciated that the use of sensors is optional and that if used some or all of these sensors may be used. Typically the sensors will be operably connected to the display  34 . 
     Preferably the dryer  22  is configured such that if the sensors are outside a predetermined value or range the electrical power to the clothes dryer will be shut down. This may be achieved by way of original equipment manufacturer (OEM) of the dryer including such electronics. Alternatively a plug adaptor  62  may be provided into which the dryer plug  60  is plugged and into which the lint collector system  10  is plugged such that power to the dryer is interrupted in response to a signal from the lint collector system  10 . Plug adaptor  62  is adapted to be plugged into a conventional dryer plug receptacle  58 . Alternatives of which are shown in  FIGS. 12, 13 and 14 . Alternatively, regular wall plug receptacle  67  or jack type receptacle may be installed proximate to the conventional dryer plug receptacle  58 . Lint collector system  10  and fan  32  may run on a low voltage and be connected using a jack type plug  64  as shown in  FIGS. 10 and 12 . Alternatively lint collector system  10  and fan  32  may use a regular voltage and be connected by way of a regular plug  66  and shown in  FIGS. 11 and 13 . 
     A variation of lint collector system  10  is shown in  FIG. 17  wherein lint collector system  10  further includes a disposable liner  68  which fits into lower housing  12 . Disposable liner  68  is somewhat similar to a disposable coffee filter. Disposable liner  68  provides user with an easy way of removing and disposing of lint. 
       FIGS. 18 to 22  show alternate embodiments wherein the filter  30  and fan  32  are housed in an exhaust pipe insert  70 . Preferably exhaust pipe insert  70  includes filter  30 , fan  32  and display  34 . Exhaust pipe insert  70  may be operably connected to sensors as described above and as shown in figures. Exhaust pipe insert  70  may connect to dryer plug as shown in  FIGS. 18 and 19  or plugged in as shown in  FIGS. 20 and 21 . A receptacle  72  is provided proximate to the exhaust pipe insert such that when the fan  32  is activated to create back pressure lint or other debris that has collected on the filter  30  will be blown into receptacle  72 . Receptacle  72  may have water  73  therein as shown in  FIG. 19 or 21  or no water as shown in  FIGS. 18 and 20 . As well receptacle  72  may include a liner  74  as shown in  FIG. 22 . Receptacle  72  is removable so that it can be cleaned out when needed. Exhaust pipe insert  70  may be positioned anywhere in the exhaust pipe or alternatively close to the dryer  22  as shown in  FIGS. 20 and 21 . 
     Alternate versions of outlet  20  and exhaust insert are shown in  FIGS. 23 to 29 . As shown in  FIGS. 27 and 28  outlet  20  or exhaust pipe insert  70  may be provided with an on/off switch  76  or a push button  78  either of which will allow the user to manually turn on the fan to clear the filter  30 . The exhaust pipe insert  70  may be installed in an external exhaust pipe  71  as shown in  FIGS. 30   a ) to  c ) or installed in a dryer  22  as shown in  FIG. 31 . The exhaust pipe insert  70  is operably connected to a display  34  and may be powered as described above. 
     An alternative version of pipe insert  80  is shown in  FIG. 32  and shown in an external exhaust pipe  71  and in a dryer  22 . Pipe insert  80  has an elbow  82  extending out from the general flow of the exhaust pipe. In this embodiment the fan  32  and the filter  32  are located in the elbow  82  and are operably connected to the display  34 . Note this embodiment may be installed in an external exhaust pipe  71  as shown in  FIG. 33  or located in a dryer  22  wherein the display  34  is proximate to the other controls on the dryer as shown in  FIG. 34 . 
     Preferably a small amount of water is used in the lower housing  12  to “prime” the lint collection. It has been observed that only a small amount of water is needed to prime the lint collection and that once there is a small amount of lint “caught” by the water that the new lint will tend to attach to the base of moist lint. Further it has been observed that this continues to be the case when the lint in the lower housing  12  appears to be moist. Further it has been observed that the lint over time will form a somewhat felt-like appearance and very surprisingly it has been observed that this felt-like mass is difficult to ignite and was shown to be self-extinguishing during some experiments. This is very surprising when contrasted to lint when collected on a filter or screen often forms a fire hazard. 
     It has been observed that while it is preferred that the lower housing  12  is primed with a small amount of water it will also work without any water since the lint in the dryer typically has some moisture therein. 
     It will be appreciated that this system may be considered a self-cleaning lint collection system or exhaust system. In at least one embodiment the system is configured such that if a measurement from flow meter in the outlet or exhaust pipe is below a predetermined level the fan is automatically active to clear the lint from the filter  30 . Accordingly the fan is activated responsive to a measurement from the flow meter being below a predetermined level. Alternatively the fan may be activated responsive to a measurement from a pressure sensor being below a predetermined level. Alternatively or in addition the fan is manually activatable. Alternatively the fan is activated at predetermined times. 
     It will be appreciated that the lint collection system  10  may be retrofit into an existing dryer system or it may be manufactured by an OEM as part of their dryer system. Further the lint collection system may be the primary lint collection system or a secondary lint collection system which is used in addition to the internal lint screen in a dryer. 
     Generally speaking, the systems described herein are directed to lint collector systems. As required, embodiments of the present invention are disclosed herein. However, the disclosed embodiments are merely exemplary, and it should be understood that the invention may be embodied in many various and alternative forms. The Figures are not to scale and some features may be exaggerated or minimized to show details of particular elements while related elements may have been eliminated to prevent obscuring novel aspects. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. For purposes of teaching and not limitation, the illustrated embodiments are directed to lint collector systems. 
     As used herein, the terms “comprises” and “comprising” are to construed as being inclusive and opened rather than exclusive. Specifically, when used in this specification including the claims, the terms “comprises” and “comprising” and variations thereof mean that the specified features, steps or components are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.