Patent Document

This application is a continuation of Ser. No. 09/097,439 filed Jun. 15, 1998. U.S. Pat. No. 6,095,163 which is a continuation of Ser. No. 08/315,902 filed Sep. 30, 1994 abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to the field of cleaning and more particularly to the field of parts washers. 
     Parts washers are well known and are often employed in the cleaning of parts that are contaminated with organic waste products such as, for example and not limitation, hydrocarbons, oils, and greases. For background and understanding, the type of parts normally being discussed as washed in a parts washer are, for example, automotive parts such as valves, pistons, transmission parts, covers, and so forth. Most conventional parts washers include a basin mounted to the top of a tank. The tank is partially filled with a mineral spirits solvent that is pumped from the tank through a conduit that discharges into the basin where the parts are washed. The mineral spirits solvent drains from the basin back to the tank for reuse. A filter is sometimes interposed in the solvent flowpath to collect organic waste products and particulates washed from the parts. 
     While mineral spirits are an effective cleaning solvent, there are many drawbacks to the employment of parts washers that utilize mineral spirits. For example, some mineral spirit solvents are presently classified by government regulatory agencies as hazardous materials because of their low flash point and potential health concerns Because of this classification, mineral spirits must be used, handled, and disposed of in compliance with extensive governmental regulations. Further, mineral spirits that are not properly contained can have a negative impact on the environment, and it is not uncommon for workers to have dermatitis and respiratory problems exacerbated by unprotected use of mineral spirits. Additionally, many users of mineral spirits find it necessary to dispose of used mineral spirits by having a waste disposal company pick up the used mineral spirits so that the used mineral spirits can be disposed of in compliance with the various governmental guidelines and regulations; such disposal can be expensive. 
     Filters are often incorporated into conventional parts washers to remove the organic waste products and particulates from the solvent. Thus, the filters eventually become saturated with tile organic waste products and particulates and therefore need to be replaced. The filters are often difficult to access and replace. Furthermore, the filters, once they have absorbed the organic waste products, are often considered a hazardous material and are therefore difficult to dispose of 
     There is, therefore, a need in the industry for a system and method which addresses these and other related, and unrelated, problems. 
     SUMMARY OF THE INVENTION 
     Briefly described, the present invention comprises a parts washing system characterized by a cooperative interaction among a mechanical component, fluid component, and biological component. The parts washer apparatus (herein also referred to as the “parts washer”) of the parts washing system includes, in the preferred embodiment, a holding tank, cleaning fluid retained within the tank, microorganisms living with the cleaning fluid, a wash basin, a fluid delivery system and an in-line filter. 
     In accordance with the preferred embodiment of the present invention, the wash basin is a multi-tiered basin including a sink member defining a bottom panel and a false bottom disposed above the bottom panel. The multi-tiered basin further includes a support grid and filter interposed between the false bottom and the sink member; and the false bottom, support grid, and filter are readily removable from the sink member. The tank is partially filled with the cleaning fluid and a pump and conduit assembly direct a flow of the cleaning fluid to the basin. The cleaning fluid discharged into the basin flows through a drain hole in the false bottom, through the filter and support grid, and then through a drain hole defined through the bottom panel of the sink member and cleaning fluid is then returned to the tank for reuse. 
     In accordance with the preferred embodiment of the present invention, the cleaning fluid includes, at least, a surfactant that functions to remove organic waste from the parts being washed. The biological component includes microorganisms that digest the organic waste. The cleaning fluid is not toxic to the microorganisms such that the microorganisms survive and reproduce within the cleaning fluid environment. The pump and conduit assembly, in addition to aiding in the removal or organic waste, functions to aerate the cleaning fluid to maintain a proper environment for the sustainment of the microorganisms. A heater, thermostat, and level control assembly function to maintain the cleaning fluid within a certain temperature range so as to aid in the removal of organic waste and maintain a proper environment for the sustainment of the microorganisms. Tile microorganisms are preferably introduced into the cleaning fluid as spores (i.e., in a dominant state). The microorganisms in spore form are preferably adhered to the filter prior to use, and released from the filter when tile cleaning fluid flows through the filter. 
     While the present invention is presented, for the most part, in the context of a system, the multi-tiered basin, in isolation, and the combination of the fluid component and biological component, in isolation, are each considered inventive. 
     It is therefore an object of the present invention to provide a new method, and apparatus for washing parts. 
     Another object of the present invention is to provide an “environmentally friendly” parts washing system. 
     Yet another object of the present invention is to decrease the production of hazardous waste materials. 
     Still another object of the present invention is to provide a parts washer that does not require frequent fluid replacement. 
     Still another object of the present invention is to provide a parts washer that breaks down organic waste into its non-contaminating components. 
     Still another object of the present invention is to sustain a biological component within a parts washer. 
     Still another object of the present invention is to provide a parts washer with a multi-tiered sink structure. 
     Still another object of the present invention is to provide a parts washer with a readily accessible and replaceable filter. 
     Still another object of the present invention is to greatly reduce (or eliminate) the need for disposal of organic waste washed from parts. 
     Still another object of the present invention is to wash parts and recycle resultant organic waste in a closed, self contained environment. 
     Still another object of the present invention is to provide a cleaning system that does not have a toxic effect on users. 
     Still another object of the present invention is to provide a parts washing system that does not employ a volatile and flammable cleaning fluid; whereby, contrary to that which is required for most, if not all, conventional parts washers, an automatically closing lid is not required on the parts washer of the present invention to isolate the cleaning fluid in the case of a shop fire. 
     Other objects, features and advantages of the present invention will become apparent upon reading and understanding this specification, taken in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exterior perspective view of a parts washer in accordance with the preferred embodiment of the present invention. 
     FIG. 2 is a cut-away, perspective, exploded view of isolated components of the parts washer of FIG.  1 . 
     FIG. 3 is a front, vertical cross-sectional, cut-away view of the parts washer of FIG. 1, wherein certain portions of the parts washer are not cross-sectioned or cut-away. 
     FIG. 4 is a perspective, cut-away view of a filter pad portion of the parts washer in accordance with the preferred embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     referring now in greater detail to the drawings, in which like numerals represent like components throughout the several views, FIG. 1 is an exterior, perspective view of a parts washer apparatus (the “parts washer”)  10 , in accordance with the preferred embodiment of the present invention. The parts washer  10  includes a tank  12  and a basin  14 . The basin  14  includes a sink member  16  that defines a basin cavity  18 . The sink member includes a sink ledge  20  around the periphery of the inlet to the basin cavity  18 . A back-splash  22  extends upward from a rear portion of the sink ledge  20 , and a flexible faucet  24  penetrates the rear portion of the sink ledge  20  and terminates in the form of a nozzle  26 . An optional work light (not shown) extends upward from the basin and illuminates the basin cavity  18 . The tank  12  preferably includes a level indicator  28  and a control panel  30 . The level indicator  28  is depicted as comprising a temperature sensitive, liquid crystal display. Tile control panel  30  includes an off/on switch  32 , a power indicator light  34 , a low fluid warning light  36 , and a timer switch  38 . 
     FIG. 2 is a cut-away, perspective, exploded view of certain components (mentioned below) of the parts washer  10 , in accordance with the preferred embodiment of the present invention. A lower portion of the tank  12  is cut-away, and the faucet  24  and components associated with tile lower portion of the tank  12  are not shown in FIG.  2 . The tank  12  includes tank walls  42  that define a tank cavity  44  therebetween. The tank  12  further includes a tank lip  46  that extends around the periphery of the inlet to the tank cavity  44 . The sink member  16  includes sink walls  48  extending downward from the sink ledge  20  to a bottom panel  50  that defines a drain hole  52  therethrough. The sink walls  48  and bottom panel  50  define the basin cavity  18 . The sink walls  48  further define an upper ledge  54  and a lower ledge  56 . Each of the ledges  54 , 56  encircle the basin cavity  18  and include four segments that together define a rectangular shape. Each edge of a planar, rectangular support grid  58  rest upon a segment of the lower ledge  56  such that the support grid  58  partitions the basin cavity. A rectangular filter pad  60  rests upon and covers (lie support grid  58 . Each edge of a generally planar, rectangular false bottom member  62  rests upon a segment of tile upper ledge  54  such that the false bottom member  62  also partitions the basin cavity  18  and is disposed above the support grid  58 . The false bottom member  62  is preferably unitary, defines a drain hole  64  therethrough and includes an upwardly protruding lip  66  around the periphery thereof A strainer (not shown) is defined within the drain hole  64 . A pair of supplemental drain holes  70  are defined through the rear sink wall  48  just above the filter pad  60 . 
     FIG. 3 is a front, vertical cross-sectional, cut-away view of the parts washer  10 , wherein certain portions of the parts washer are, for explanatory purposes, not cross-sectioned or cut-away. FIG. 3 represents each of the mechanical component (i.e., the hardware, or “parts washer”  10 , as herein described), the fluid component (represented by a cleaning fluid  72 ), and the biological component (not seen) living within the cleaning fluid  72 . As depicted in FIG. 3, the periphery of the false bottom member  62  preferably snugly contacts the sink walls  48 . The tank cavity  44  is preferably partially filled with a cleaning fluid  72 . A submersible pump  73  is disposed within the tank cavity  44 . When the pump  73  is operating, it draws the cleaning fluid  72  from the bottom region of the tank cavity  44  and discharges the cleaning fluid  72  into a conduit  74 . The conduit  74  is connected to and discharges into a base (not shown) of the faucet  24 , whereby the fluid discharges from the nozzle  26 . The parts washer  10  is preferably further equipped with optional cleaning accessories (not shown) such as a fountain brush (not shown) that is in fluid communication with the conduit  74 . A heater  76 , that is controlled by a thermostat  75 , selectively heats the cleaning fluid  72 , and tile heater  76  is acceptably in the form of an electric heating element that extends from the control panel  30  into the depths of the tank cavity  44 . A level probe monitors the depth of the cleaning fluid  72 , and the level probe is acceptably in the form of a float actuated electric switch  78  that includes a magnet equipped float  80 . A lip  82  extends around the periphery of the sink ledge  20  forward of the back-splash  22 . The lip  82  and back-splash  22  seek to keep cleaning fluid  72  from dripping over the edges of the sink ledge  20 . In accordance with the presently preferred construction of the present invention, much of the parts washer  10  is acceptably constructed from high density polyethylene. In addition, the sink walls  48 , bottom panel  50 , upper ledge  54 , lower ledge  56 , sink ledge  20 , and backsplash  22 , are, in accordance with the presently preferred construction, formed as a single, molded, unitary piece. 
     The biological component is preferably in the form of microorganisms that biodegrade organic compounds such as, for example and not limitation, hydrocarbons, oils, greases, petroleum by-products, creolates, polychlorinated biphenols, and other carbon based compositions. For example, the microorganisms convert hydrocarbon compounds into elements of water, carbon dioxide, and other digestion products. The microorganisms employed preferably not only, have the capability of biodegrading organic waste, but further are resistant to environmental shock and have metabolic versatility. Additionally, the microorganisms are preferably nonpathogenic. Acceptable microorganisms, for example and not limitation, are those from the genera Bacillus, Pseudomonas, and Flavobacterium. Suitable species are well known and reported in the art. The microorganisms preferably range in size from approximately three to five microns, whereby they readily pass through the filter pad  60 . The microorganisms are preferably employed in combination with nitrifying or denitrifying bacteria, phosphate solubilizing strains of microorganisms, bio-emulsifer producing strains of microorganisms, and strains of microorganisms which produce growth factors such as, for example and not limitation, B-vitamins. 
     The microorganisms are preferably subjected to a preservation technique in an effort to ensure their viability in the field, their viability while remaining in spore form for extended periods, and their resistance to environmental shock. For example, nutrient and buffer components such as, for example and not limitation, agar, and water soluble adhesives such as, for example and not limitation, gum, are preferably mixed with the microorganisms to promote stability of the microorganisms prior to mixing the microorganisms with a carrier. The carrier is, for example and not limitation, acceptably an inert and nutrient organic material such as, but not limited to, heat treated, expanded, cellulose material. The carrier preferably preserves and protects the microorganisms in spore form during storage and transportation. In accordance with the preferred embodiment of tile present invention, an acceptable example of tile microorganisms is available from the Louisiana Remediation Company, located in Motaire, La., as part number LRC-1. 
     In accordance with the preferred embodiment of tile present invention, the filter pad  60  functions as a vehicle for bringing the microorganisms in spore form into contact with the cleaning fluid  72 . The filter pad  60  is acceptably constructed, for example and not limitation, from cotton, cellulose, polyolefin fibers, polyester fibers, fiberglass, or the like. Additionally, the filter pad  60  is acceptably constructed from combinations of such components. Further, the filter pad  60  is acceptably a ten micron filter or larger. In accordance with the preferred embodiment of the present invention, microorganisms in spore form are attached to the filter pad  60  with an adhering agent  84  (FIG. 4) that is water soluble and releases the microorganisms when the cleaning fluid  72  is introduced to tile filter pad  60 , as discussed below. Referring to FIG. 4, which is a perspective, cut-away view of the filter pad  60  in accordance with the preferred embodiment of the present invention, the filter pad  60  includes a layer  86  of inert material that is disposed below a layer  88  of micron-rated media. The inert material is acceptably fiberglass. The micron-rated media is preferably a material that does not have an affinity for hydrocarbons such as, for example and not limitation, polyester. The microorganisms in spore form, the components mixed therewith as discussed above, and the adhering agent  84  are preferably sandwiched between the layers  86 , 88  of the filter pad  60 . A portion of the layer  88  is cut-away for explanatory purposes in FIG. 4 such that the adhering agent  84  is seen. In accordance with the preferred embodiment of the present invention, an acceptable adhering agent  84  is “Super  77  Spray Adhesive”, which is available from the 3M Corporation of St. Paul, Minn. Once the microorganisms in spore form are attached to the filter pad  60 , the filter pad  60  is acceptably stored until its usage within the parts washer  10  is desired. In accordance with an alternate embodiment of the present invention, the microorganisms are added directly to the cleaning fluid  72  without being initially attached to the filter pad  60 . Thus, the filter pad  60  functions, in accordance with the preferred embodiment, as both a mechanical filter (i.e., straining particulate matter from the fluid  72 ) and as an initial transport medium for the microorganisms and in an alternate embodiment, the filter pad  60  functions solely as a mechanical filter. 
     In accordance with the preferred embodiment of the present invention, the cleaning fluid  72  is compatible with (i.e., is non-toxic to) the microorganisms such that the microorganisms are capable of living within the cleaning fluid  72 . Additionally, the cleaning fluid  72  tends to remove organic waste from parts washed in the basin  14 , as will be discussed in greater detail below. An acceptable cleaning fluid  72 , for example and not limitation, is a mixture of pH neutral emulsifiers and surfactants containing no volatile organic compounds, phosphates, formaldehyde, biocides, or other toxic materials. T he emulsifier and surfactants are blended in liquid form to produce a biodegradable, non-toxic, non-caustic, non-flammable oil dispersant cleaner and degreaser. Further, and for example and not limitation, the exemplary acceptable cleaning fluid  72  contains no known carcinogens, no OSHA (Occupational Health and Safety Act) or DOT (United States Department of Transportation) regulated chemicals, no ingredients requiring SARA (Superfund Amendments and Reauthorization Act) Title III reporting, no RCRA (Solid Waste Disposal Act as amended by the Resources and Conservation Recovery Act of 1976 as amended),hazardous waste chemicals, and no items on the CERCLA (Comprehensive Environmental Response, Compensation and Liability Act) hazardous substance list (based upon the relevant regulations at the time this application was filed). Additionally, and for example and not limitation, the exemplary cleaning fluid  72  is a freely flowing liquid with a specific gravity of 1.083, a slight pleasant odor, no flash point, a boiling point of 210° Fahrenheit, a pH of approximately seven, and which is infinitely soluble in water. In accordance with the preferred embodiment of the present invention, an acceptable example of the cleaning fluid  72  is available from Warren Chemical Corporation of Robert, La., as part number Sea Wash 7. 
     Referring further to FIG. 3, in operation, the pump  73 , conduit  74 , and faucet  24  circulate cleaning fluid  72  from the depths of the tank cavity  44  to the basin cavity  18  where parts cleaning takes place. The false bottom member  62  is preferably sufficiently sturdy and well supported such that a variety of parts are capable of being placed thereon for cleaning. In accordance with one method of the present invention, cleaning fluid  72  flows out of the nozzle  26  and the part being washed is oriented within the stream of cleaning fluid  72  exiting the nozzle  26 . The cleaning fluid  72  removes organic waste from the part being washed, and then the cleaning fluid  72 , along with the organic waste and any small particulate washed from the part, flows by gravity through the drain hole  64  and the strainer (not shown) associated therewith. The strainer will, of course, keep certain objects from passing through the drain hole  64 . The cleaning fluid  72 , organic waste, and remaining particulate matter then encounter the filter pad  60 . Subsequently, the fluid  72  and organic contaminants pass through the support grid  58 , and drain hole  52  to deposit into the tank cavity  44 . Should flow through the filter pad  60  become obstructed, flow will divert through the pair of supplemental drain holes  70  defined through the rear sink wall  48  just above the filter pad  60 . The filter pad  60  preferably functions to trap the particulate matter and allow the organic contaminants and cleaning fluid  72  to pass therethrough. Because the filter pad  60  does not collect tile organic contaminant, it is capable of being disposed of as a solid waste. 
     If the filter pad  60  is new or relatively new such that all of the microorganisms in spore form have not been previously released therefrom, the cleaning fluid  72  releases dormant microorganisms attached to the filter pad  60 , and the released microorganisms flow with the cleaning fluid  72  and organic contaminants through the drain hole  52  into the tank cavity  44 . Within the tank cavity  44 , a large percentage of the microorganisms and organic contaminants will tend to accumulate proximate to the surface of the cleaning fluid  72  such that a large portion of the biodegradation takes place proximate to the surface of the cleaning fluid  72 . In theory, this forms a sort of vapor barrier that tends to minimize the evaporation of the cleaning fluid  72 . If living microorganisms are not present in the parts washer  10 , increasing amounts of organic waste will accumulate toward the surface of the cleaning fluid  72  in the tank cavity  44 , and this condition is indicative of tile need to replenish the microorganisms. In theory, however, if the parts washer  10  is used for normal parts cleaning, new microorganisms should never need to be added to the cleaning fluid  72  of the parts washer  10 . Nonetheless, by virtue of the fact that the filter pad  60  is the vehicle for adding the microorganisms to the cleaning fluid  72 , as discussed above, microorganisms are added to tile cleaning fluid  72  each time a new filter pad  60  is added to the parts washer  10 , as discussed in greater detail below. By virtue of the microorganisms digesting the organic waste within the tank  12 , the cleaning fluid  72  is “recycled” within the parts washer  10 , whereby the cleaning fluid  72  has the potential to last for extended periods of time. It is likely, however, that some cleaning fluid  72  replenishment will be required, however, to make up for evaporative and “drag-out” losses incurred as parts are removed from the basin cavity  18  in wet condition. Furthermore, by virtue of the cooperative effect of the filter pad  60  (removing particulate matter) and the microorganisms (digesting organic waste), the tank is, potentially, seldom in need of “dredging” to remove waste. The pump  73  is preferably proximate to the bottom of the tank  12  such that any sludge that might tend to accumulate at the bottom of the tank cavity  44  is circulated through the filter pad  60 . 
     Referring back to FIGS. 1 and 3, when the off/on switch  32  is in the “on” position electricity is supplied to circuitry (not shown) which is housed within the control panel  30  by way of a conventional power cord (not shown), and the indicator light  34  is illuminated. In accordance with the preferred embodiment of the present invention, once the off/on switch  32  is in the “on” position, the circuitry, in combination with the thermostat  75 , will activate and deactivate the heater  76 . While the thermostat  75  senses that the temperature of the cleaning fluid  72  within the tank cavity  44  is below a desired temperature, the heater  76  is on, and while the thermostat  75  senses that the temperature of the cleaning fluid  72  is at or above the desired temperature, the heater  76  is off, The cleaning fluid  72  is preferably maintained in a temperature range which supports the lives of the particular microorganisms employed within the parts washer  10 . In accordance with the preferred embodiment of the present invention, the temperature is acceptably maintained in the range of approximately 110° to 115° degrees Fahrenheit. The float actuated electric switch  78  also controls the operation of heater  76 . When the magnet equipped float  80  drops downward due to a low level of cleaning fluid  72 , the switch  78  is actuated which, in combination with the circuitry, disables the heater  76  and causes the low level warning light  36  to illuminate. Operation of the pump  73  is controlled by the timer switch  38 . A user can manually actuate the timer switch  38  which, in combination with the circuitry, causes the pump  73  to operate and automatically cut off after a certain period of time. In accordance with an alternate embodiment of the present invention, an additional switch (not shown) is provided that overrides the timer switch  38  such that the pump  73  will remain running as long as the additional switch is “on” 
     Referring back to FIGS. 2 and 3, the parts washer  10  is designed to provide easy access to the filter pad  60 . Access is obtained by simply lifting the false bottom member  62  out of the basin cavity  18 . In accordance with the preferred embodiment of the present invention there is no restrictive engagement between any of the components that are depicted as exploded away from each other in FIG. 2, whereby the components of the parts washer  10  are readily accessible. 
     While certain of the preferred and alternate embodiments of the present invention have been disclosed herein, other embodiments of the apparatus and methods of tile present invention will suggest themselves to persons skilled in the art in view of this disclosure. Therefore, it will be understood that variations and modifications can be effected within the spirit and scope of the invention and that the scope of the present invention should only be limited by the claims below. Additionally, while it is intended that the scope of the present invention also include various alternate embodiments, it should be understood that each of the embodiments disclosed herein, including the preferred embodiment, includes features and characteristics which are considered independently inventive. Accordingly the disclosure of variations and alterations expressed in alternate embodiments is intended only to reflect on the breadth of the scope of the present invention without suggesting that any of the specific features and characteristics of the preferred embodiment are in any way obvious or unimportant.

Technology Category: 8