Ambient Air Dryer with Improvements in Performance, Safety, Ease of Use and Cost of Manufacture

Abstract

The already energy saving ambient air dryer is improved in methods of manufacture, performance, increased safety devices, and storage options which include in part: construction in pieces of different manufacture for assembly to lower cost, added inhibitors to extend life and durability, extrusions on the drum functioning as scoops to cause additional ambient air to be passed through the clothes, light and reflector system so moving drum may be visible at night or in partial light, non-defeating GFCI system, specific designed energy efficient motor, programmed functions such as stopping the drum in “access” or “park” position and sounding alarm for pre-determined operational issues, remote control as well as control box on dryer frame, a system for capturing lint and particulates, motion/heat detectors which eliminate need for safety guard surrounding moving drum, sound emitters to keep animals away, security codes for operation, and collapsible drum and frame for compact storage.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

Hastings U.S. Pat. No. 4,236,322, discloses an apparatus for drying articles of clothing and the like in the open, ambient air. As shown therein, a drum of a convenient size having screen-like sides is rotatably supported on a frame. A motor mounted on the support frame is coupled to the drum by a belt and rotates the drum so that the objects therein are tumbled.

It has been found that a dryer constructed as shown therein performs well and has numerous advantages over conventional enclosed clothes dryers which use heat produced, usually, by electricity or gas. The most obvious advantage, of course, is the great saving in energy since only a small part of the power consumed by a conventional dryer is needed to turn the drum of the dryer disclosed in the above-mentioned patent.

It has been found, however, that the apparatus shown in U.S. Pat. No. 4,236,322 could be more suitable for use under some circumstances and could be manufactured in a simpler and less expensive manner. The rotating drum is exposed, presenting the hazard that a person, particularly a child, might be injured by inserting a hand, for example, between the drum and frame, coming into contact with the moving drum or being caught between the belt and drum or pulley.

Accordingly Hastings U.S. Pat. No. 4,702,018, provided an improved drying apparatus having a rotatable drum enclosed within a housing functioning as a guard which provides safety but does not significantly impede air flow and access to the dryer.

A further object of the above mentioned patent provided such a dryer which can be produced in large quantity at reasonable cost and which is safe and effective to use.

The dryer with a guard as shown in the above mentioned patent can still pose safety risks. Persons can still approach the dryer while the drum is rotating within the guard and, since the guard must be an open mesh construction, thrust a small item through an opening of the guard. There remains the possibility that persons, children in particular, could pick up small sticks, wire, a nail, screwdriver or other small object and stick it through the openings on the guard causing not only damage to the dryer, but perhaps causing considerable injury to such persons if one of the aforesaid objects were thrown back at them or caught their fingers or clothing. The guard adds significant additional weight to the appliance, making it more cumbersome and difficult to maneuver, while also greatly increasing the cost of the dryer in terms of materials used, time of manufacture and assembly as well as increased shipping costs.

Perque U.S. Pat. No. 5,809,663 advances a portable solar powered clothes dryer. The Ambient Air Clothes Dryer of U.S. Pat. No. 4,702,018 already depicted the dryer in a portability state with a frame and wheels and made no reference to a specific size. U.S. Pat. No. 5,809,663 further advances the claim that the “perforated hamper” be black to maximize the heat energy from the sun by the dark color of the hamper. While this may enhance the drying capabilities in some way of the aforementioned patent, it is not applicable to this ambient air dryer. The principle of this ambient air dryer is the use of solar heated ambient air entering a perforated rotating drum and expelling moisture laden air, not a device which further collects or heats the air. In the testing of the present embodiment of both a black and a yellow ambient air dryer, there has been no significant noticeable difference in the efficiency of the dryer. The exposed surface area of the present embodiment of the dryer drum contains large numbers of holes, making it difficult to collect any demonstrable amount of heat from the rays of the sun, the dryer drum in motion constantly changes its attitude to the sun's rays and continually expels the moisture laden air within the drum through the perimeter of the drum thereby actually cooling the surface of the drum no matter what the color.

Ford U.S. Pat. No. 7,178,265 uses a fan to provide axial airflow through the drum. This drum is comprised of an impervious cylindrical wall defining a diameter. The present embodiment in this application of the dryer drum has perforations both on the sides and perimeter of the drum and air is drawn in the sides and expelled out the perimeter by the rotating motion of the drum itself and not with any cumbersome external power consumptive source which blows air through the drum.

One of the principal benefits of the ambient air clothes dryer is energy savings. Increased energy savings not only with operation, but manufacture, and ease of use coupled with appropriate and additional safety measures are to be desired.

BRIEF SUMMARY OF THE INVENTION

Accordingly, the object of the present invention is to improve the already energy saving ambient air dryer with more energy and ecologically friendly savings in operation as well as manufacture coupled with appropriate and additional safety features, not impeding, but increasing, the performance and effectiveness of the ambient air dryer. In addition the present improvements make the dryer less cumbersome and easier to operate.

The preferred embodiment of the drum in the two prior Pat. Nos. 4,236,322 and 4,702,018, was in a shape of a cylinder and in the most recent patent, of injected molded plastic. By definition, a device formed of injected molded plastic must be formed in a mold in which molten plastic resin is injected under pressure. A steel mold of the size needed for this device would be necessarily large and expensive. Parts made with this procedure are cost effective, but only when made in very large quantities. With advances of recent years and broadened experience in manufacturing allowing for lower cost options in the plastic molding industry, this drum can now also be made in different and multiple ways. For ease in description, the two vertical planes of the drum will be referred to as the “sides” of the drum and the cylindrical portion of the drum joining these two sides will be referred to as the “perimeter” of the drum. The preferred embodiment as shown in this patent utilizes more than one process of manufacturing to form separate pieces to be attached and/or fitted together to form the rotatable drum. The frame for the drum is formed of blow molded plastic, roto molded plastic or other suitable material with shaped forms of injected molded plastic, metal mesh and/or other appropriate material attached to the drum frame. This type of manufacture allows the dryer to be made with much smaller, less energy consuming injectors (injectors which initially also cost far less than the huge injectors needed for injecting a large plastic part) or with a combination of plastic and other suitable materials. If the configuration of the drum is cylindrical, it can be driven by rollers or a belt. However, it is not necessary that the sides of the drum be circular in shape so long as there is provision for a carrier for a drive belt included on one location of the drum so a belt can rotate the drum.

The resin used for the preferred embodiment of the dryer drum provides for the use of re-cycled or partially re-cycled resin, cutting the cost of the resin needed for the manufacture of the parts and dramatically cutting the energy costs of the initial resin production.

A major factor in any plastic device being used outdoors is the life and durability of the resin. The use of carbon black, the most efficient UV inhibitor in addition to being the most cost effective, substantially extends the life and durability of the resin when this device is used outdoors. Non static electricity additive is also added to the resin primarily as a safety precaution. Leaving clothes in the rotating drum long after they have dried does not damage clothing, but items made of fabrics such as nylon can become full of static electricity if the resin is not treated with an additive to prevent the static electricity.

To enhance the airflow into the dryer drum, extrusions shaped like scoops are molded into or attached to the frame of the drum to gather and force additional air into the dryer drum as it rotates, to further the efficiency of the drying process by forcing additional dry solar heated ambient air through the tumbling clothes which in turn is expelled when laden with moisture from the wet clothes through the perimeter of the drum as the clothes strike the inside perimeter surface of the drum where they fall.

The purpose-designed motor used for rotating the drum is high efficiency, equipped with variable speed and a demand sensor. Said motor will not run if the dryer is over-loaded with too much weight. The variable speed makes it possible to control the speed of rotation, thereby making it possible to control the point at which the clothes within the drum free fall. This optimizes the drying process by having the clothes falling and fluttering the greatest distance possible within the drum. It also serves to expel the greatest amount of moisture laden air. Clothes push air out of the openings of the drum when they compress as they land against the inside perimeter of the dryer drum and free falling clothes will push out more air than clothes which are rolling within the drum. The more moisture laden air that is pushed out by the clothes, the more solar heated air is sucked into the dryer drum. The demand sensor on the motor automatically lowers the amount of energy used as the clothes become lighter as they dry, requiring less energy to rotate the dryer drum.

The frame supporting the rotating drum in the preferred embodiment of this patent is fabricated of hollow metal tubing, but can be fabricated of blow, roto or injected molded plastic or other suitable material.

The ambient air dryer is used primarily outdoors so safety is essential. In this embodiment there are exposed moving parts that without safety devices could pose a threat of injury to persons or animals. To alleviate this danger of moving parts, the frame on which the dryer drum rotates has motion and/or heat sensors located on each side of the dryer. Each sensor is multi-directional, detecting motion/heat from every direction for a pre-determined distance considered safe. Any motion or heat detection within that distance, whether it be from an adult, child, or animal will immediately stop the motor, rotating drum and any other moving part of the dryer. In addition a sound emitter at frequencies not detectable to human ears will operate to repel small animals and birds from the immediate area of the dryer. Re-starting the dryer will require the operator to enter a start-up code. After entering the start-up code, the dryer will remain motionless until the operator is beyond the range of the motion/heat detectors. Inclusion of a ground fault circuit interrupter (GFCI) in the control panel will insure that protection to the user who may or may not have available use of such a protected circuit.

The preferred embodiment of this present patent has wheels on the base of the frame supporting the dryer drum, at least two of which have locking capability to keep the dryer from moving.

An upset switch will immediately stop all the moving parts of the dryer if the dryer moves or tips over. The dryer may not be restarted until in the upright position, operator enters start up code and moves a pre-determined distance away.

Dust and lint particles drop through the mesh on the dryer drum at the point where the free falling clothes hit the inside perimeter of the drum. A screen type of lint filter is positioned under the drum at this position to catch these particles. In addition a soft brush sweeps the exterior of the drum to brush off any particles as the drum rotates. A fan under the filter draws air through the filter to further enhance the gathering and containment of any particles exiting the rotating dryer drum. A sensor on the filter indicates on the control panel and remote control when the filter requires service.

Lights are affixed to the frame supporting the dryer drum at the point of the bearing or other suitable location. These lights are directed to shine toward reflectors mounted along the edge of the sides of the dryer drum. When the dryer drum is rotating in the dark these lights and reflectors make the rotating drum visible.

A control panel is suitably located on the dryer frame with a numeral key pad, messaging display screen, audio alarm, lighted alarm, sound emitter, and menu, functions of said menu which include instructions for operation, humidity reading at dryer location, elapsed time the current load has been in the dryer, programmable settings such as delayed start up, plus time and date. The control panel also includes a ground fault circuit interrupter.

A typical wireless remote control programmed for the specific needs of the dryer can also operate the dryer, permitting the operator to control the dryer from a distance out of the direct sun and including the same functions as the control panel on the dryer frame.

Further improvements include portability functions. For ease in storage, the dryer drum can be made of materials allowing it to collapse or shaped in two pieces which fit inside one another. Especially for smaller models, extendable legs for the wheels raise the dryer for ease in use. The dryer frame can be made to fold to a smaller configuration when the dryer drum has been removed.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1, item 1, shows the ambient air dryer in the rotatable configuration of an octagon.

FIG. 1, item 2, shows an affixed circular carrier for a belt driven application.

FIG. 1, item 3, shows the perimeter entry door in the open, “access” position.

FIG. 1, item 4, shows this dryer application rotated on a central bearing.

FIG. 2, item 5, shows the ambient air dryer in the rotatable configuration of a circle.

FIG. 2, item 6, shows the perimeter entry door in the open, “access” position.

FIG. 3, item 7, shows the perimeter view of the dryer rotated on a central bearing on each side.

FIG. 3, item 8, shows a perimeter door in the closed position.

FIG. 3, item 8A, indicates a frame member.

FIG. 4, item 9, shows the perimeter door of the dryer in the open, “access” position.

FIG. 4, item 10, shows the interior of dryer drum through the open door.

FIG. 5, item 11, shows the ambient air dryer in the rotatable configuration of a circle in a roller driven application.

FIG. 5, item 12, shows a centrally located entry door in the closed position.

FIG. 6, item 13, shows the centrally located entry door in an open position.

FIG. 7, item 14, shows an entry door on the side of the drum in a belt driven application.

FIG. 7, item 15, shows a configuration of the frame for an entry door located on the side of the drum in a belt driven application.

FIG. 8, item 16, shows the framework for the side of the dryer drum in an octagon configuration.

FIG. 9, item 17, shows an attachable panel for the perimeter of the dryer drum.

FIG. 9, item 18, shows the open mesh that is attached or molded within the frame.

FIG. 10, item 19, shows frame for attachable piece for side of drum.

FIG. 10, item 20, shows attachable or molded mesh.

FIG. 10, item 21, shows this application attached by screws to frame.

FIG. 11, item 22, shows the frame with mesh of FIG. 10 attached to rigid frame of dryer side.

FIG. 12, item 23, shows some suggested points for attaching extrusions for forcing additional air into the drum.

FIG. 13, item 24, indicates shape of extruded parts for forcing air into the dryer drum.

FIG. 13, item 25, shows closed end of extruded part.

FIG. 13, item 26, shows open space leading into dryer drum.

FIG. 13, item 27, shows two attached parts with open mesh allowing air to freely pass through into dryer drum.

FIG. 14, item 28, shows side view of extruded shape for forcing air into the dryer drum.

FIG. 14 shows side view of attached open mesh parts for allowing air to pass through, item 29, indicating direction of air flowing into the dryer drum.

FIG. 14, item 30, indicates passage of air through open mesh into dryer drum.

FIG. 15, item 31, shows the component with an extruded shape with an open front to allow for free passage of air into the openings of the dryer drum.

FIG. 16 indicates by use of multiple directional arrows from the motion/heat sensors which are located to detect any motion or heat within a pre-determined range of the dryer.

FIG. 17, item 32, is an above view of the dryer with directional arrows indicating the field of detection by the sensors.

FIG. 18, item 33, indicates direction of rotation of dryer drum.

FIG. 18 item 34 indicates edge of dryer drum.

FIG. 18, item 35, indicates direction of freefalling clothes within dryer drum.

FIG. 18, item 36, indicates motor.

FIG. 18, item 37, indicates soft brush along the edge of filter shroud.

FIG. 18, item 38, indicates filter within shroud.

FIG. 18, item 39, indicates shroud for filter.

FIG. 18, item 40, indicates duct from shroud to fan.

FIG. 18, item 41, indicates supporting frame for shroud.

FIG. 19, item 42, shows view from perimeter of drum of the filter shroud.

FIG. 19, item 43, shows exhaust fan.

FIG. 19, item 44, shows motor with shaft on each side, one end of which shaft operating exhaust fan.

FIG. 20 shows a portion of the dryer drum, item 45 indicating one of the lights attached to the motor mount on the side of dryer drum frame.

FIG. 20, item 46, indicates directional arrows of illumination from light attached to dryer frame as well as directional arrows of illumination from a light source other than the light on the dryer.

FIG. 20, item 47, indicates reflector positioned to reflect illumination from light attached to frame.

FIG. 20, item 48, indicates a reflector positioned to reflect illumination from sources other than the light attached to the frame.

FIG. 21 indicates the remote control for the ambient air dryer.

FIG. 21, item 49, indicates a button for turning power on and off.

FIG. 21, item 50, indicates keypad for entering codes and operation of menu options.

FIG. 21, item 51, indicates the menu button.

FIG. 21, item 52, indicates a display screen for messaging, said screen in drawing indicating an “error, plugged filter” message.

FIG. 21, item 53, is flashing alarm button.

FIG. 21, item 54, indicates speaker for alarm sound and other audio alerts.

FIG. 22 indicates control box located on dryer frame.

FIG. 22, item 55, indicates key receptacle for locking cover down on control box.

FIG. 22, item 56, indicates cover for control box.

FIG. 22, item 57, indicates one of the keys of the keypad.

FIG. 22, item 58, indicates power button for turning power on or off.

FIG. 22, item 59, indicates speaker for sound alarm and other audio alerts.

FIG. 22, item 60, indicates menu button.

FIG. 22, item 61, shows display screen for messaging.

FIG. 22, item 62, indicates flashing alarm button.

FIG. 22, item 63, indicates sound emitter button.

FIG. 23, item 64, indicates brake on stationary or swivel wheel of dryer.

FIG. 24, item 65, indicates rear support member for dryer drum which rotates on rollers.

FIG. 24, item 66, shows dryer wheels on extendable legs.

FIG. 25, item 67, shows back support member in a partial fold down position.

FIG. 25, item 68, shows dryer wheels in the folded up position.

FIG. 25, item 69, shows frame support in a folded down position to facilitate rolling dryer drum off frame.

FIG. 26, item 70, indicates rigid frame members of collapsible dryer drum.

FIG. 26, item 71, indicates attached perforated member between rigid frame members of dryer drum.

FIG. 26, item 72, indicates by dotted lines the collapsible feature of the perforated material attached to frame members of the dryer drum.

FIG. 27, item 73, shows collapsible drum, side view, showing the rigid frame members configured in such a way that they fit within each other when drum is collapsed.

FIG. 28, item 74, shows a perimeter view of half of a dryer drum constructed in such a configuration that it will fit within the other half of the dryer drum.

FIG. 28, item 75, indicates a locking type mechanism to secure together the two halves of the dryer drum.

FIG. 29 indicates a portion of the central rigid member of the dryer drum and driving roller, which, when in contact with each other, serve to rotate the dryer drum.

FIG. 29, item 76, indicates a suitable surface material such as that used for serpentine belts on the drum to provide proper traction.

FIG. 29, item 77, indicates shape of drum in contact with driving roller.

FIG. 29, item 78, indicates shape of the driving roller.

FIG. 29, item 79, indicates surface material such as that used for serpentine belts on driving roller to provide proper traction with the dryer drum member.

FIG. 29, item 80, indicates how a surface material such as that used for serpentine belts on the drum and driving roller fits together when in contact due to shaping of surface material.

FIG. 30 shows collapsible frame for dryer.

FIG. 30, item 81, indicates frame member in partial fold down position.

FIG. 30, item 82, indicates wheels folded up position.

FIG. 30, item 83, shows drum support in partial folded down position.

FIG. 30, item 84, shows frame and handle folded down position.

FIG. 31, item 85, shows side view of collapsible drum configuration with door suitable for frame with center bearings on each side of dryer drum.

FIG. 32, item 86, shows frame with vertical member in a belt driven configuration that still allows for a door opening on the side of the dryer drum.

FIG. 33, item 87, shows a center opening door on collapsible drum configuration for the drum driven by rollers.

FIG. 34 is a view of a belt driven circular drum embodiment of the ambient air dryer with many of the features, which have been shown individually in other drawings, included in one drawing.

FIG. 34, item 88, indicates the telescoping handle.

FIG. 34, item 89, indicates one of the fasteners for side pieces of drum.

FIG. 34, item 90, indicates one of the lights mounted on bearing.

FIG. 34, item 91, indicates one of the set of reflectors on side of drum.

FIG. 34, item 92, indicates one of the air flow extrusions.

FIG. 34, item 93, indicates placement of a swivel wheel, placed so wheel may swivel without interfering with frame member.

FIG. 34, item 94, indicates a one of several heat/motion detectors.

FIG. 34, item 95, indicates shroud/duct/filter system for the containment of lint and particulates.

FIG. 34, item 95, indicates shroud/duct/filter system for the containment of lint and particulates.

FIG. 34, item 96, indicates wheel brake.

FIG. 35 is identical to FIG. 34 without intrusive markings in order to be used for the view drawing for the patent.

DETAILED DESCRIPTION OF THE INVENTION

The object of the present invention is to enhance the efficiency and ease of use, increase safety, allow wider application and lower cost of the already energy saving ambient air dryer by utilizing improved manufacturing technology and present availability of materials; and providing cost effectiveness. Use of motion/heat sensors and eliminating the guard as shown in a previous patent makes the dryer lighter in weight and easier to move. In addition, the elimination of the guard makes for easier access to put items in and take items out of the dryer, increases the air flow through the dryer drum reducing drying time, and increases the visibility of items in the dryer when running. Elimination of the guard also lowers the cost of manufacture and shipping, which in turn lowers the retail price to the consumer.

Previous patents explained in detail a rotatable drum driven by a belt and a rotatable drum driven by rollers. Both of these methods function suitably. Manufacturers in recent years in the plastic molding industry have become more experienced in larger consumer plastic products, making it possible to fabricate the rotating drum utilizing a combination of components. The exact shape of the drum is of no consequence, so long as it is conveniently rotatable either by a belt or rollers, as shown in several different drawings.

FIG. 1 shows a rotatable drum configuration shaped like an octagon, item 1, with a centrally located bearing, item 4, and with an affixed circular carrier, item 2, for a belt driven application. This particular embodiment shows a door placed on the perimeter of the drum in the open, “access” position, item 3, said open position allowing for easy access for loading and unloading items. FIG. 2 shows a rotatable drum configuration in a circular shape, item 5, with a door placed on the perimeter shown in the open, access position, item 6. This circular shaped configuration of the dryer drum can be either belt or roller driven. FIG. 3 indicates a perimeter view of the drum with a centrally located bearing mounted on each side of the drum, item 7, with a door located on the perimeter of the drum, item 8, shown closed in access position. FIG. 4 indicates a perimeter view of the dryer drum with a perimeter door shown in the open, access position, item 9. Item 10 shows the interior of the drum as seen through the open door. FIG. 5 shows the rotatable drum in the circular shaped configuration driven by rollers, item 11. The door in this embodiment which is driven by rollers can be placed on the side of the drum, item 12, and is shown in the closed position. FIG. 6 shows the embodiment of FIG. 5 with the door in the open position, item 13. FIG. 7 shows yet another embodiment for the dryer drum with a centrally located bearing mounted on each side of the drum. The frame, item 15, is constructed in such a way, as to permit a door on side of the drum, item 14.

When the dryer is switched off, the rotation of the drum slows, then stops at the access position for easy loading and unloading of the drum. FIG. 1, item 3 and FIG. 2, item 6, show two different embodiments of doors located on the perimeter of the drum and indicate the access position shown with open doors. FIG. 3, item 8 shows the access position of a closed door located on the perimeter of the drum and FIG. 4, item 9 shows this same embodiment with an open door. FIG. 5, item 12 shows the access position with a centrally located side door in closed position and FIG. 6, item 13 shows the access position with a centrally located side door in open position. FIG. 7, item 14 shows yet another embodiment of the access location of a door located on the side on the dryer drum.

The dryer drum may also be stopped at “park” which positions the door opposite a frame member of the apparatus frame to interfere with the opening of the door. In “park” position the closed door of FIG. 3, item 8, would be positioned with frame member, item 8A, or any other frame member, opposite the door, thus interfering with the opening of said door. In FIG. 7, the door, item 14, is shown in the closed “access” position. The closed door in “park” would be positioned opposite either or both frame members such as the frame member, item 15, to interfere with the opening of said door.

The dryer drum must be strong and stable, yet have ample openings for the free exchange of air in order to function properly. The inside of the drum must be free of any protrusions or rough surfaces which could snag or damage clothing as the drum rotates, in addition to having the openings for the free exchange of air small enough so buttons, fasteners and small items do not catch on or fall through the openings. FIG. 8, using the octagon shaped drum embodiment, shows a rigid, blow molded frame or other suitable material for the side of the dryer drum, item 16, designed with ample strength, stability and durability for this application. The component part, FIG. 10, is fabricated to be attached to the ribs and outer edge of the side frame of the dryer. The frame for this component, item 19, can be plastic, metal or other suitable material; the mesh insert, item 20, can be plastic, metal or other suitable perforated material; or the entire part can be formed of molded plastic. The pieces for the eight components shown on this particular embodiment, FIG. 10, can be securely held in place by screws, item 21, rivets, welded or glued into receptacles molded into the frame, FIG. 8. With blow molded construction, the molded receptacles for receiving screws or rivets are imbedded within the frame so no sharp edge is exposed inside or outside the dryer drum. FIG. 11, item 22, shows one such component attached to the side frame of this embodiment.

FIG. 9, the component pieces for the perimeter of the drum, each consisting of a rigid frame, item 17, with a mesh insert, item 18, are also attached into receptacles molded into the outer edges of the blow molded side frame, again into receptacles imbedded within the molded dryer drum frame. These components can be fabricated entirely with molded plastic or the frame can be a separate piece with an attached mesh. Both frame and mesh can be formed of plastic, metal or other suitable material or formed entirely of molded plastic.

The tumbling clothes within the present embodiment of this clothes dryer are dried by the dry air flowing through the clothes and moisture laden air expelled from the dryer drum. The component part, FIG. 10, can be designed to incorporate extrusions that by design force additional air into the dryer drum as the drum rotates, which necessarily facilitates the efficiency of the drying process. FIG. 12, item 23, shows an embodiment with eight typical locations along one edge of each part, such as the FIG. 10 part, for such increased air flow extrusions on the side of the dryer drum designed to force air into the rotating dryer drum.

FIG. 13 shows a portion of this air flow extrusion. The component part is fabricated with a mesh to the front, item 27, said mesh perpendicular to the side of the dryer drum. The component part is shaped, item 24, to function as a scoop with closed ends, item 25, to force additional air into the dryer drum as the drum rotates. The air enters the open mesh openings in the front, two of which are shown, item 27, and is forced into the opening to the dryer drum, item 26. The open mesh is attached along the entire front of the component for maximum efficiency. This component part can be fabricated from plastic or other suitable material with attached mesh inserts; said inserts which can be fabricated from plastic, metal or other suitable perforated material. This component part can be fabricated as a separate part to be attached to the dryer drum or can be directly molded as part of one of the side pieces of the drum. FIG. 14 shows a cut-a-way side view of this component, item 28, shaped to force air as shown by directional arrow, item 29, through the mesh openings, item 30, into the dryer drum. The embodiment of this component part is designed to be used with an opening in the drum under the part. FIG. 15 shows a partial embodiment of this component part indicating one of the closed ends, but the front of the part left open and placed over the mesh, item 31, on the side of the dryer drum. Either embodiment will function to force air into the dryer drum.

When this dryer is in operation, safety devices initiate to keep persons and/or animals from harm. FIG. 16 indicates by the multi-directional arrows from motion/heat sensors, such as the type manufactured by Optex and Honeywell, placed on multiple sides of the dryer frame to detect any motion or heat within a pre-determined range of the dryer. These sensors detect motion/heat from every side, above, and below the dryer apparatus. Any motion or heat detected by the sensors will immediately interrupt power to the motor. The dryer will start again only with the use of the start-up code.

In addition to the heat/motion sensors are sound emitters, inaudible to humans but audible to animals, to keep animals and birds away from the dryer. The sound emitters will automatically function when the dryer is in operation and may be manually set to emit sound with either battery power or an external power source even when the dryer is not in operation, again to keep animals and birds away from the dryer.

FIG. 17, item 32, is a view from above the dryer apparatus with directional arrows indicating a pre-determined field of detection by the sensors located on the dryer's frame. Any motion/heat detected within this pre-determined field of detection will interrupt the power supply to the motor and require the start-up code to re-start the dryer.

FIG. 18 shows the mechanism for the containment of lint and other particles exiting the drum from the tumbling clothes and items within the dryer drum. As the dryer drum rotates in the direction indicated by item 33, the free falling items within the drum land in the area designated by the directional arrow, item 35. As items inside the dryer drum fall against the open mesh they release lint and other particulates, which fall through the openings into the lint filter, item 38, encased by the shroud, item 39. Soft brushes, item 37, are on both sides and across lower edge of the shroud, item 39, thereby sweeping both edges of the perimeter of the rotating dryer drum to keep lint and particulates from floating or exiting off to the side as well as sweeping across the perimeter of the drum, item 34, to further aid in the capture of lint and other particulates by sweeping them into the filter. The purpose-designed motor , item 36, used for rotating the drum is high efficiency, equipped with variable speed and a demand sensor. Said motor will not run if the dryer is over-loaded with too much weight. Start up speed of the motor is slow, then increases to operational speed over a sufficient period of time to prevent loss of traction due to the possible high moment of inertia at start up. The variable speed makes it possible to control the speed of rotation, thereby making it possible to control the point at which the clothes within the drum free fall. This optimizes the drying process by having the clothes falling and fluttering the greatest distance possible within the drum. It also serves to expel the greatest amount of moisture laden air. Clothes push air out of the openings of the drum as they land and compress against the inside perimeter of the dryer drum and free falling clothes will push out more air than clothes which are rolling within the drum. The more moisture laden air that is pushed out by the clothes, the more solar heated air is sucked into the dryer drum. The demand sensor on the motor automatically lowers the amount of energy used as the clothes become lighter as they dry, requiring less energy to rotate the dryer drum.

In addition to the soft brushes, a motor, item 36, operated fan, FIG. 19, item 43, is positioned to draw additional air through the filter to assist in capturing lint and particulates. This lint containment assembly is supported by a frame, FIG. 18, item 41, which is in turn attached to the dryer frame. The shroud is molded plastic or other suitable material and the flat lint filter, item 38, can be easily removed to clean. A duct, item 40, is connected to the shroud and leads to the motor driven fan.

FIG. 19 shows the lint containment assembly from the perimeter view of the dryer. Item 42 indicates the shroud with the duct leading to the fan, item 43. Item 44 indicates the shaft of the motor which operates the fan as well as the mechanism to rotate the dryer drum.

This dryer which uses open, ambient air may be used in the dark as well as daylight. As an added safety feature, lights, such as LED lights, are affixed to the frame of the dryer. FIG. 20 shows a partial section of the dryer drum assembly. A light, item 45, is affixed to the bearing cover of the frame of the dryer. Reflectors are positioned along the edge of the dryer drum side. One reflector, item 47, is positioned to reflect illumination from the light source on the dryer. The other reflector is positioned to reflect illumination from sources other than on the dryer. The directional arrows, item 46, indicate the reflected light both from the light affixed to the dryer frame as well as from a light source other than on the dryer assembly. These lights and reflectors make the rotating drum visible in the dark or in partial light.

FIG. 21 indicates a typical wireless remote control programmed for the specific needs of the clothes dryer and permitting the operator to control the dryer from a distance. Item 49 is an on/off switch. The “off” position slows, then stops the drum in access position. “Access position” stops the dryer drum in a convenient position for the loading and unloading of the drum. A menu option allows the drum to be stopped in “park position” as well to interfere with the opening of said door, particularly useful when dryer is not in use. The “on” position will not start the dryer until the start-up code is entered and the operator has moved away to a pre-determined distance as detected by the motion/heat sensors. The “on” position also activates a sound emitted at a frequency inaudible to humans but audible to animals to keep animals away from the dryer when in operation. Item 50 indicates several pads of the keypad control, said keypad control used for the start-up code and menu functions.

Item 51 indicates the “menu” button and displays a list of functions on the messaging display screen, item 52. The menu list includes instructions for general use (ie. on”, “off”, entering secure start up code, manually setting sound emitter to continue to function when dryer is off, setting delayed start, setting on again off again cycle for rotation of drum for pre-drying hard to dry items); information (humidity at dryer location, elapsed time since load put into dryer, estimated dry time, programmable settings such as delayed start up, plus time and date); and error messages (plugged filter, overloaded, heavy point weight, water on dryer, fire, dryer moved or tipped). The display screen, item 52, automatically displays error/general messages and remedies.

Item 54 is the alarm light which lights up or flashes for pre-determined issues, such as the dryer stopping. Item 55 is a speaker for the alarm which sounds when the alarm light is on. This alarm will sound for several pre-determined issues such as the dryer stopping or error messages such as “dryer tipped”, “fire” or “water on dryer”. Said speaker sounds a lesser sound for pre-determined less critical error messages such as plugged filter, overloaded, and heavy point weight. This speaker can also give audio messaging for all functions on the menu. The alarm functions operate even when the dryer is not in use by using battery power as well as an external power source in order to prevent unauthorized tampering with the dryer when unattended and not in use in an unsecured area.

FIG. 22 indicates the control box suitably located on the dryer frame. Item 55 indicates the receptacle for a key for locking the closed cover. Item 56 indicates the cover, shown in a partially open position, which fits over the controls for protection from the elements or tampering. Item 57 indicates one of the pads for the keypad control, said keypad control used for the start-up code as well as menu functions. Item 58 indicates the on/off button. The “on” function engages power to the dryer. To initiate the tumbling motion of the drum, a start-up code must be entered and operator must move away from the dryer for a pre-determined distance before the dryer drum will actually begin to rotate. The “on” function also engages the sound emitter. The “off” cuts off power to the dryer. The dryer drum will automatically stop as operator moves toward the operating dryer, but the power source remains engaged until dryer is actually turned off or until not in use for a pre-determined length of time. Item 59 in the speaker for audio alerts. An alarm will sound for several pre-determined issues such as the dryer stopping or error messages such as “dryer tipped”, “fire” or “water on dryer”. The speaker sounds a lesser sound for pre-determined, less critical error messages such as plugged filter, overloaded, and heavy point weight. This speaker can also give audio messaging for all functions on the menu. The alarm functions operate even when the dryer is not in use by using battery power as well as an external power source in order to prevent unauthorized tampering with the dryer when unattended and not in use in an unsecured area.

Item 60 is the menu button and displays a list of functions of the messaging display screen, item 61. The menu list includes instructions for general use (ie. on”, “off”, entering secure start up code, manually setting sound emitter to continue to function when dryer is off, setting delayed start, setting on again off again cycle for rotation of drum for pre-drying hard to dry items); information (humidity at dryer location, elapsed time since load put into dryer, estimated dry time, programmable settings such as delayed start up, plus time and date); and error messages (plugged filter, overloaded, heavy point weight, water on dryer, fire, dryer moved or tipped).

Item 61 is the messaging display screen which automatically displays error/general messages such as the “error plugged filter” as shown, remedies for error messages, plus the menu options. Item 62 is the alarm light which lights up or flashes for all the alarm functions associated with the speaker. The alarm functions, including this alarm light, operate even when the dryer is not in use by using battery power as well as an external power source in order to prevent unauthorized tampering with the dryer when unattended and not in use in an unsecured area. Item 63 is the sound emitter button which when engaged continually emits sound even when the dryer is in “off” mode. Inclusion of a ground fault circuit interrupter (GFCI) in the control panel insures that protection to the user who may or may not have available use of such a protected circuit.

FIG. 23 shows one typical wheel of the type attached to the dryer frame. Item 64 indicates a standard type of lock for the wheel which can be operated by foot or hand. These locking wheels are on a minimum of two wheels to keep the dryer from moving when positioned and when drum is in motion. These wheels may or may not swivel or may be used in combination.

FIG. 24 shows a side view embodiment of the clothes dryer with a belt driven drum. Item 65 shows the rear support member for the dryer drum. Item 66 shows wheels with extendable legs in the extended position in order to raise the dryer assembly for more ease in use. The wheels have two positions. The extension leg can swing out as indicated by the curved arrow and slide into a slotted bracket as shown in FIG. 25.

It is not necessary that the ambient air dryer be portable. However, all the embodiments of the ambient air dryer in the drawings have been shown in a portable configuration with wheels. In addition to wheels, the ambient air dryer can be further configured to aid in portability and storage. FIG. 25 indicates portability/storage functions of the clothes dryer assembly which is driven with rollers and supported by a rear support member. Item 67 indicates the disengaged rear support member for the dryer drum in a partially folded down position. Item 68A and 68B show the wheels with extendable legs. Item 68A is already slid into position along the frame; item 68B to be slid into position along the frame. Item 69 indicates a frame member tipped forward to facilitate rolling the dryer drum off the frame.

FIG. 26 shows the perimeter view of a collapsible drum with silicon or other suitable flexible perforated material affixed to rigid frame members, said drum designed for portability and ease in storage. Item 70 indicates the rigid members of the drum. Item 71 indicates one of the several perforated flexible parts of the dryer drum and item 72 indicates how the flexible parts of the dryer drum fold in order to collapse.

FIG. 27 shows the side view of the collapsible dryer drum. Item 73 indicates how the rigid members of the drum are configured to allow each part of the collapsible drum to fit inside one another when the dryer drum is collapsed, thus allowing for more convenient and space saving storage.

FIG. 28 shows the perimeter view of a dryer drum that is configured to come apart at the mid perimeter point, said drum designed for portability and ease in storage. The two halves of the dryer drum are shaped with the outside circumference of the drum smaller than the circumference at the point of attachment to the other half, item 74, so the two halves of the drum fit inside one another when the dryer drum is disassembled. Item 75 indicates a locking mechanism so the two halves of the dryer drum can be securely fitted together when assembled for use. As shown, the extended portions on the edge of each dryer half are configured so the drum parts are fitted together, then turned to lock together securely. As an added safety precaution, these drum halves are also fitted with a pin or screw to lock and prevent the two halves from rotating separately and coming apart.

FIG. 29 indicates a portion of the rigid center member on the collapsible dryer drum, such as the drum of FIG. 26, which, when in operation, is in contact with the driving roller which rotates the drum. Item 76 indicates a surface material attached to the rigid center member on the collapsible dryer drum, this material being suitable for traction, durability and shape, such as the material used for serpentine automotive belts, to adhere to the surface material on the driving roller. Item 77 indicates the shape of a small portion of the flexible material of the dryer drum that is affixed to the rigid frame. Item 78 indicates the shaped driving roller designed to help keep the drum in the proper position while rotating. Item 79 indicates a surface material attached to the drive roller, this material being suitable for traction, durability and shape, such as the material used for serpentine automotive belts, to adhere to the surface material on the rigid center member on the collapsible dryer drum. Item 80 indicates the shape of the surface materials on both the rigid center member on the collapsible dryer drum and the driving roller which, when in contact with each other, fit together in addition to the traction from the material adhered to both parts to provide stability when dryer drum is in motion.

FIG. 30 indicates a collapsible frame for the dryer drum in a partially collapsed position. Item 81 shows a portion of the frame which can fold outward to help in rolling drum off frame or fold inward as shown for more compact storage of the frame. Item 82 shows the extendable wheels still operational in their folded up position. Item 83 shows the drum support member in a partially folded down position. This member folds down to a horizontal position for more compact storage. Item 84 indicates the portion of the frame which includes the controls telescoped in the “down” position for more compact storage.

FIG. 31 shows the side view of a collapsible drum configuration with a door configuration, item 85, suitable for a supporting frame with a center bearing and support on both sides. It is also suitable for a configuration with a back support center bearing only.

FIG. 32 indicates a frame support consisting of a center bearing on each side of the dryer drum which is rotated by a circular belt that allows for a door opening on the side of the drum with no impediment from the frame.

FIG. 33 shows the collapsible dryer drum configuration driven by rollers with a center door, item 87, located on the side of the dryer drum.

FIG. 34 shows an embodiment of the ambient air clothes dryer with multiple improvements shown on a single drawing. All of these particular improvements have been shown and explained individually in other drawings. Item 88 is the telescoping handle. Item 89 indicates one of the fasteners for attaching drum side pieces to the drum frame. Item 90 indicates one of the lights mounted on the center bearing cover that shines toward the reflectors, one of which is item 91. Item 92 indicates one of the air flow extrusions on the side of the dryer drum. Item 93 indicates a positioning of one of the wheels on the end of a portion of the frame of the dryer to accommodate a swivel. Item 94 indicates one of several heat/motion sensors. Item 95 indicates the support frame, shroud, duct, filter and brushes for capturing lint and particulates when the dryer drum is in motion. Item 96 indicates a wheel locking mechanism.

FIG. 35 is identical to FIG. 34 except without intruding item numbers and may be used as the view drawing for the patent.

Claims

1. An improved apparatus for drying clothes in open, ambient air which includes the following:

a drum using a combination of components for ease and savings in manufacture, construction and shipping costs such as:

a blow molded drum frame;

appropriately designed, framed or unframed molded plastic, metal mesh or other appropriate perforated material attached to drum frame;

drum formed in any rotatable configuration such as circular or octagon and driven by belt or rollers; and

drum constructed in pieces for assembly.

2. Said drum of claim 1, wherein extrusions are attached or formed within the construction of the drum members;

said extrusions functioning as scoops to cause an additional amount of ambient air to be passed through the clothes with corresponding moisture laden air expelled through the openings of the drum.

3. Said drum of claim 2, whereby re-cycled resins may be used in part or used completely for manufacture to reduce the cost of making the drum or parts of the drum and dramatically reducing the energy required for the manufacture of the resin used.

4. Said drum of claim 3, whereby a UV inhibitor is used in manufacture, such as carbon black (the most efficient UV inhibitor in addition to being the most cost effective) to extend the life and durability of the resin when apparatus is used outdoors in the sunlight.

5. Said drum of claim 4, further comprising a cover on bearing mount with lights such as LED lights so moving dryer drum can be seen at night or in partial light;

said drum including reflectors situated along outside edge of dryer;

lights on bearing mount of said drum positioned to shine toward reflectors to further illuminate moving dryer in the dark or in partial light; and

said reflectors situated to reflect the light produced by lights on the dryer frame as well as light from other sources.

6. Said drum of claim 5 mounted on an appropriate frame with a suitably mounted purpose-designed motor to rotate said drum; said motor with following features:

slow start up speed increasing to operational speed over a sufficient period of time to prevent loss of traction due to the possible high moment of inertia at start up;

high energy efficiency;

over-heating shut down designed to stop if over-loaded;

equipped with a demand sensor which utilizes less energy as the clothes become lighter weight as they dry;

designed to slow speed of revolution before stopping at pre-programmed point of rotation for access position for easy access for loading and unloading;

designed to slow speed of revolution before stopping at an additional pre-programmed point of rotation for park position to position door by frame members of the dryer so door cannot be opened; and

equipped with a variable speed making it possible to control the point at which the clothes free fall within the dryer.

7. Said apparatus of claim 6, whereby is used an electronically programmed sequence which cycles the motor on and off to pre-dry hard to dry fabrics to provide greater efficiency.

8. Said apparatus of claim 7, further including devices, many commonly available but used in a new application, to enhance safety and ease of use which include:

motion and/or heat sensors which will immediately stop dryer if anyone approaches operating dryer at a preset unsafe distance from any direction;

a sound emitter at frequencies not detectable to human ears to repel small animals and birds from immediate area of the dryer;

a system for turning on the dryer which requires a code to start;

a requirement for the operator to move back to a pre-determined safe distance as detected by motion/heat sensors after turning on the dryer before dryer actually begins to operate;

an upset switch which will immediately stop the dryer in case it is tipped over;

a “park position” which stops the dryer drum in such a position that the door of the dryer drum cannot be opened when dryer is not in use;

a double insulated electrical design where no parts subject to electrical current are accessible;

electrical grounding provided through all parts to the wheels; and a

Ground Fault Circuit Interrupter to halt power supply to the unit if proper ground is lost.

9. Said apparatus of claim 8 further comprising a system for capturing lint which includes:

a lint screen type filter located under the drum at the point where lint and particles from drying clothes exit the drum;

a soft brush attached to the filter housing touching the dryer drum along perimeter of the drum at point where lint and particles from drying clothes exits the drum to further sweep lint into the filter;

a small fan under lint filter drawing air through the filter; and

a sensor attached to filter which indicates by sound and/or message on messaging screen on the control or remote control when the filter is plugged.

10. Said apparatus of claim 9 further comprising a control panel including a GFCI (ground fault circuit interrupter) with an on/off switch, typical wireless key pad, messaging display screen, menu button, sound emitter button, alarm light, and speaker for audio messaging and alarms positioned on frame of dryer specifically programmed with the following functions:

keypad for entering start-up code and moving through and responding to menu options;

“on” function requiring code to start and operator to move away to pre-determined safe distance before initiating rotating drum operation;

“off” function which ceases power to dryer;

menu with messaging on display screen for functions available on dryer which include:

instructions for general use (ie. “on”, “off”, entering secure start up code, manually setting sound emitter to continue to function when dryer is off, setting delayed start, setting on/off rotation of drum for pre-drying hard to dry items); information (humidity at dryer location, elapsed time since load put into dryer, estimated dry time, time and date); error messages (plugged filter, overloaded, heavy point weight, water on dryer, fire, dryer moved or tipped);

speaker which sounds an alarm for pre-determined critical error messages (water on dryer, fire, dryer tipped over);

said speaker which sounds a repeating lesser sound for pre-determined error messages (plugged filter, overloaded, heavy point weight);

said speaker for audio messaging for all functions on the menu; and

Ground Fault Circuit Interrupter which halts power supply to the unit if proper ground is lost.

11. Said apparatus of claim 10 including a typical wireless remote control with an on/off switch, key pad, messaging display screen, menu button, alarm light, and speaker for audio messaging and alarms specifically programmed with the following functions:

keypad for entering start-up code and moving through and responding to menu options;

“on” function requiring code to start and operator to move away to pre-determined safe distance before initiating rotating drum operation;

“off” function which slows, then stops dryer drum at “access” or “park” position;

said “off” function which can halt the power supply to the unit;

menu with messaging on display screen for functions available on dryer which include: instructions for general use (ie. “on”, “off”, entering secure start up code, manually setting sound emitter to continue to function when dryer is off, setting delayed start, setting on/off rotation of drum for pre-drying hard to dry items); information (humidity at dryer location, elapsed time since load put into dryer, estimated dry time, time and date); error messages (plugged filter, overloaded, heavy point weight, water on dryer, fire, dryer moved or tipped);

speaker which sounds an alarm for pre-determined critical error messages (water on dryer, fire, dryer tipped over);

said speaker which sounds a repeating lesser sound for pre-determined error messages (plugged filter, overloaded, heavy point weight); and

said speaker which gives verbal messages for all functions on the menu.

12. Said drum of the apparatus of claim 11 wherein is added a non static electricity additive to resin to help prevent any sparking from dried items in dryer.

13. Said frame of apparatus of claim 12 whereby extensions on the frame are able to lift the apparatus for ease in use.

14. The apparatus for drying clothes, further comprising optional drum and framework designs to increase portability and storage options such as:

the bracket holding the dryer drum designed to be disengaged so the drum may be lifted or rolled out of the frame;

support members of frame specifically designed to facilitate rolling disengaged drum out of frame;

drum of apparatus made in two halves designed to be disassembled to fit one inside the other for storage;

a foldable frame to allow frame to be folded flat for storage when drum removed;

silicon inserts or other appropriate flexible perforated material attached to a framework making it possible to flatten the drum for storage; and

framework for attached flexible inserts comprised of gradated sized shapes making it possible for each shape to fit within the next larger shape when the drum is flattened.