VALVE SYSTEM AND METHOD

Abstract

Embodiments of the invention provide a vacuum system including a housing and at least one filter disposed within the housing. A valve assembly can be at least partially disposed within the housing and can be in fluid communication with the filter. The valve assembly can include a manifold and a support member coupled to a plurality of dampers. The plurality of dampers can include a first damper and a second damper that include unequal sizes. The support member and the dampers can be configured and arranged to move between a first position and a second position.

Description

BACKGROUND

Some conventional vacuum systems can exhibit decreased performance over the life of the system. At least some of the decrease in performance can be attributed to filter clogging. For example, at least a portion of the debris passing through the filters can be retained, clogging the filters over time and reducing air flow through the vacuum and reducing suction provided by the vacuum's motor, which leads to decreases in performance.

The manufacturers of some conventional vacuum systems attempt to address filter clogging by altering configurations of the vacuum system. For example, some manufacturers have removed filters and rely on precipitation of larger debris particulate within a receptacle. However, exhausted air, including smaller debris and particulate, must be exhausted outside of the structure in which the system is installed, which may require disposing one or more exhaust holes through walls of the structure.

SUMMARY

Some embodiments of the invention provide a vacuum system comprising a housing and at least one filter that can be disposed within the housing. In some embodiments, a valve assembly can be at least partially disposed within the housing and can be in fluid communication with the filter. In some embodiments, the valve assembly can include a manifold and a support member coupled to a plurality of dampers. In some embodiments, the plurality of dampers can include a first damper and a second damper comprising unequal sizes. In some embodiments, the support member and the plurality of dampers can be configured and arranged to move between a first position and a second position.

Some embodiments of the invention provide a vacuum system comprising a housing including a motor enclosure and a filter enclosure. In some embodiments, a filter can be at least partially disposed in the filter enclosure and a manifold can be at least partially disposed within the motor enclosure. The manifold can include a support member coupled to a first damper and a second damper. In some embodiments, the first damper and the second damper can be configured and arranged to function as a relief valve for a motor. In some embodiments, a movement device can be coupled to at least a portion of the manifold. In some embodiments, the movement device can be configured and arranged to move the support member and the first and the second dampers from a first position to a second position.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vacuum system according to one embodiment of the invention.

FIG. 2 is an isometric cross-sectional view of a valve assembly according to one embodiment of the invention.

FIG. 3 is a cross-sectional view of a valve assembly according to one embodiment of the invention.

FIG. 4 is a cross-sectional view of a valve assembly according to one embodiment of the invention.

FIGS. 5A and 5B are partial cross-sectional views of a valve assemblies according to some embodiments of the invention.

FIG. 6 is a graph depicting results of experiments conducted on some embodiments of invention.

FIG. 7 is a cross-sectional view of a filter according to one embodiment of the invention.

FIG. 8 is an isometric view of a mechanical actuation device and a filter according to one embodiment of the invention.

FIG. 9 is an isometric view of a portion of a filter according to one embodiment of the invention.

FIG. 10 is an isometric view of a portion of a filter according to one embodiment of the invention.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives that fall within the scope of embodiments of the invention.

FIG. 1 illustrates a vacuum system 10 according to one embodiment of the invention. The vacuum system 10 can include a housing 12, one or more inlets 14 and one or more outlets 16 defined through the housing 12, and a motor 18 at least partially disposed within the housing 12. In some embodiments, the vacuum system 10 can be configured to function as a stationary vacuum system 10 that is in fluid communication with a duct system (not shown). For example, the vacuum system 10 can comprise a central vacuum system 10 for a structure (e.g., a house or other dwelling, a commercial property, or any other building or structure). The structure can include the duct system disposed within and/or coupled to walls, beams, or other support elements of the structure so that a user of the vacuum system 10 can access the duct system for removing debris from the structure. In other embodiments, the vacuum system 10 can comprise a mobile configuration. For example, the housing 12 can comprise one or more wheels or other movable elements (not shown) and a handle (not shown) so that a user can transport the vacuum system 10 to a location for debris removal. Although future references to the vacuum system 10 allude to a stationary configuration of the vacuum system 10, this exemplary discussion is not intended to limit the vacuum system 10 to stationary configurations.

In some embodiments, the motor 18 can be at least partially disposed within the housing 12 and in fluid communication with at least one of the inlet 14 and the outlet 16. For example, the motor 18 can be disposed within the housing 12 and the inlet 14 can be coupled to the duct system. As a result, upon an activation signal (e.g., a user connecting an adaptor to the duct system, the user actuating a switch to close a circuit connected to the motor 18, etc.), the motor 18 can be activated to move air, effluent, or other fluids through the duct system and into the housing 12 via the inlet 14 and out of the housing 12 via the outlet 16.

In some embodiments, the motor 18 can draw air, including any debris and/or particulate carried by the air, or other fluids from the structure into the housing 12 where at least a portion of the air can pass through one or more filters 20 or other particulate-removing media 20 (e.g., filter bags, permanent filters, mesh filters, etc.). In some embodiments, the filter 20 can comprise a disposable filter 20 and in other embodiments, the filter 20 can comprise a removable and/or a reusable filter 20. In some embodiments the vacuum system 10 can comprise filters 20 of multiple configurations (e.g., one or more reusable filters 20 and one or more disposable filters 20). In some embodiments, activation of the motor 18 can draw air or other fluids into housing 12 via the inlet 14 where some or all of the debris and/or particulate can be removed from the air after passing through the filter 20. After passing through the filter 20, at least a portion of the air can be exhausted from the housing 12 via the outlet 16.

In some embodiments, the vacuum system 10 can comprise a valve assembly 22. The valve assembly 22 can be in fluid communication with the filter 20, the motor 18, and the outlet 16 so that at least a portion of the air or other fluid that enters the housing 12, flows through the valve assembly 22. In some embodiments, the valve assembly 22 can comprise a manifold 24 that can include a filter aperture 26, a motor aperture 28, and one or more intake apertures 30, and one or more exhaust apertures 32. In some embodiments, the housing 12 can comprise a motor enclosure 34 into which at least a portion of the valve assembly 22 and the motor 18 can be disposed, as shown in FIGS. 2-5.

Moreover, as shown in FIG. 3, in some embodiments, the housing 12 can comprise a filter enclosure 35 into which at least a portion of one or more of the filters 20 can be disposed. In some embodiments, the filter enclosure 35 can be in fluid communication with the inlet 14 and/or the duct system. For example, as shown in FIG. 3, in some embodiments, the filter 20 can be at least partially disposed within the filter enclosure 35 and the valve assembly 22 can be disposed substantially adjacent to an interface between the motor enclosure 34 and the filter enclosure 35. As a result, at least a portion of the air or other fluids entering the motor enclosure 34 can pass from the filter enclosure 35 to the motor enclosure 34 via the valve assembly 22 (e.g., apertures disposed through the valve assembly 22 and the motor 18).

In some embodiments, the valve assembly 22 can be in fluid communication with other elements of the vacuum system 10. For example, as shown in FIGS. 2-4, the filter aperture 26 can be in fluid communication with the filter 20, the motor aperture 28 can be in fluid communication with the motor 18, and at least one of the intake apertures 30 can be in fluid communication with the motor enclosure 34. In some embodiments, some or all of the apertures 26, 28, and 30 can extend from the manifold 24, as shown in FIGS. 2-4, and in other embodiments, some or all of the apertures 26, 28, and 30 can be substantially flush (i.e., the apertures do not extend from the manifold 24) with the manifold 24.

Referring to FIGS. 2-5, in some embodiments, the manifold 24 can comprise a support member 36 coupled to a plurality of dampers. For example, the plurality of dampers can include a first damper 38 and a second damper 40. In some embodiments, the dampers 38, 40 can be integral with the support member 36 and in other embodiments, the dampers 38, 40 can be coupled to the support member 36 at a point after fabrication of the support member 36. Further, as shown in FIGS. 2-5, the manifold 24 can comprise a substantially hollow configuration so that fluids, such as air, can flow through at least some portions of the manifold 24 (e.g., fluids can flow from one aperture to another aperture) and the support member 36 and dampers 38, 40 can be at least partially disposed within the manifold 24. In some embodiments, the manifold 24 can comprise one or more seating regions 42 that are configured and arranged to aid in positioning the support member 36 and the dampers 38, 40. For example, as shown in FIGS. 2-5, the support member 36 and the dampers 38, 40 can be disposed within the manifold 24 and the seating regions 42 can extend from walls of the manifold 24 to engage one or both of the dampers 38, 40 to retain the support member 36 and dampers 38, 40 in position. Moreover, in some embodiments, the dampers 38, 40 can be engaged with an interior surface of the manifold 24 to substantially seal at least some portions of the manifold 24 relative to other portions of the manifold 24, as discussed in greater detail below.

In some embodiments, the manifold 24 can comprise one or more biasing members 44 (e.g., springs) that can be configured and arranged to bias the support member 36 and dampers 38, 40 in a first position 46, as shown in FIG. 3. As shown in FIGS. 2-4, in some embodiments, a first seating region 42a can extend from the manifold 24 walls at a point substantially adjacent to the motor aperture 28 and a second seating region 42b can extend inward from the manifold 24 walls at a point substantially adjacent to the filter aperture 26. Moreover, the biasing member 44 can be disposed around at least a portion of the support member 36 between the second damper 40 and a third seating region 42c disposed substantially adjacent to an exhaust aperture 32 at a first end 48 of the manifold 24. As a result of the positioning of the biasing member 44, the support member 36 and dampers 38, 40 can be at least partially disposed in the first position 46 during some operations of the vacuum system 10. For example, the biasing member 44 positioned against the second damper 40 and can exert a biasing force against the second damper 40 leading to the first damper 38 being positioned substantially adjacent to the first seating region 42a and the second damper 40 being positioned substantially adjacent to the second seating region 42b (i.e., the support member 36 and the dampers 38, 40 can be in the first position 46).

In some embodiments, when the support member 36 and the dampers 38, 40 are disposed in the first position 46, at least a portion of the air or other fluids within the vacuum system 10 can move along a first fluid path, as reflected by the arrows in FIG. 3. In some embodiments, the first fluid path can comprise the flow of air or other fluids when the vacuum system 10 is operating in a normal mode of operation (e.g., removing debris and/or particulates from the structure). Moreover, as reflected by the arrows in FIG. 3, when the support member 36 and the dampers 38, 40 comprise the first position 46, the filter aperture 26 can be in fluid communication with the motor aperture 28 and the second damper 40 can substantially or completely seal the filter aperture 26 relative to at least one of the exhaust apertures 32.

For example, when the support member 36 and dampers 38, 40 are disposed in the first position 46 and the motor 18 is active, movement of a fan (not shown) within the motor 18 can generate a vacuum within the motor aperture 28 and manifold 24. As a result of the vacuum generated by the motor 18, air and other fluids can be drawn through the duct system and enter the housing 12 via the inlet 14 and pass through the filter 20. As the air or other fluids pass through the filter 20, at least a portion of the debris and/or particulates carried by the air can be removed by filter 20. For example, the filter 20 can comprise a material including a plurality of pores (not shown) configured and arranged to enable air flow through the filter 20, but the pores can be sized to retain at least a portion of the airborne particulate.

As reflected by the arrows in FIG. 3, after passing through the filter 20, at least a portion of the air or other fluids can enter the valve assembly 22 via the filter aperture 26. Once within the manifold 24, at least a portion of the air can pass through the manifold 24 and between the two dampers 38, 40 and move toward the motor 18. The air can continue to move toward the motor 18 because the remainder of manifold 24 can be substantially sealed relative to the first flow path by the dampers 38, 40 being positioned substantially adjacent to the seating regions 42a, 42b, respectively, when the support member 36 and dampers 38, 40 are in the first position 46. In some embodiments, after passing through the motor aperture 28, at least a portion of the air can pass through the motor 18 and enter the motor enclosure 34. At least some of the air can be guided from the enclosure 34 to one or more of the intake apertures 30 by the positive pressure created by the motor 18 moving air into the motor enclosure 34. After re-entering the manifold 24 via the intake aperture 30, at least a portion of the air can be guided to the outlet 16 of the housing 12 via the exhaust aperture 32 at the first end 48 of the manifold 24. After exiting the manifold 24 and the housing 12, the air can enter a ventilation system (not shown) of the structure (e.g., an HVAC system) or it can be exhausted to the local environment surrounding the vacuum system 10.

As previously mentioned, when the support member 36 and the dampers 38, 40 are disposed in the first position 46, the vacuum system 10 can operate under substantially normal conditions. For example, the user can activate the vacuum system 10 to remove debris and/or particulate from the structure by passing air or other fluids containing debris and/or particulate through the filter 20. However, after repeated use of the system 10, the debris and/or particulate can clog the filter 20, leading to reduced system efficiency (e.g., reduced airflow through the first flow path and reduced ability to generate air movement through the filter 20 and the duct system). In addition to reduced system efficiency, portions of some conventional vacuum systems 10 (e.g., the inlet 14, the outlet 16, any other apertures, the filter 20, the duct system, etc.) can become partially or completely blocked (e.g., the conventional system becomes partially or completely impermeable to material volumes of fluids passing through the filter 20 and/or housing 12). When the motor 18 is in an active state, the motor 18 can be damaged or destroyed as a result of the lack of air flow through these conventional systems 10 (e.g., the motor 18 can overheat because of the lack of air or other fluids passing through the motor 18).

Some manufacturers of conventional vacuum systems 10 can prevent and/or reduce the risk of motor 18 damage by including preventative structures. For example, some manufacturers can include a conventional relief valve (e.g., a spring-loaded relief valve) that will enable the motor 18 to draw a volume of air sufficient enough to reduce and/or prevent damage to the motor 18 in the event of significant blockage of the conventional vacuum system 10. Additionally, some manufacturers may include one or more thermal sensors that can detect when the motor 18 temperature exceeds a predetermined threshold and can further deactivate the motor 18 when the sensors detect the over-temperature condition to prevent motor 18 damage or destruction.

In some embodiments, some portions of the vacuum system 10 can comprise a self-cleaning mode. The vacuum system 10 can be configured and arranged to reduce and/or eliminate some of the problems associated with debris and/or particulate clogging the filter 20 and complete or near-complete blockage of the system 10. For example, the support member 36 and dampers 38, 40 can be moved into a second position 50 that can allow for air or other fluids to enter the manifold 24 and pass through the filter 20 to dislodge at least a portion of the debris clogging the filter 20 to reduce and/or eliminate the reduced efficiency associated with filter 20 clogging.

In some embodiments, the support member 36 and the dampers 38, 40 can be moved from the first position 46 to the second position 50 by a movement device 52. As shown in FIG. 5, in some embodiments, the movement device 52 can comprise a damper motor 52 and the support member 36 can comprise one or more flanges 54 extending from the support member 36. In some embodiments, the damper motor 52 can be operatively coupled to the flange 54. As a result, the damper motor 52, upon activation, can move the flange 54 (e.g., push, pull, or otherwise move the flanges 54), which can lead to movement of the support member 36 from the first position 46 to the second position 50. In some embodiments, the support member 36 can function without flanges 54 and the movement device 52 can be operatively coupled to the support member 36 in any other suitable manner.

In other embodiments, the movement device 52 can comprise a solenoid or other form of electromagnetic movement apparatus, gear boxes and motors, a servo motor, or any other device, apparatus, or structure that can move the support member 36. Moreover, although FIG. 5 illustrates the movement device 52 and the support member 36 moving in a substantially linear direction, other embodiments, can include the movement device 52 rotating the support member 36 or otherwise moving the support member 36 in substantially or completely non-linear directions. For example, by configuring the support member 36 to rotate in lieu of, or in addition to, moving in a substantially linear direction, the manufacturing process may be eased, costs may be reduced, and it may be more simple to facilitate movement of the support member 36.

As shown in FIG. 5, the movement device 52 can be at least partially activated and deactivated by one or more switches 56 (e.g., a limit switch). For example, the switch 56 can be operatively coupled to the movement device 52 and the switch 56 can be opened and closed to control operations of the movement device 52. In some embodiments, the switch 56 and/or the movement device 52 can be controlled in multiple ways. For example, the switch 56 and/or the movement device 52 can be coupled to another switch (not shown) or other device that a user can actuate or activate to transmit a signal that the support member 36 should be moved to the second position 50. In other embodiments, the switch 56 and/or the movement device 52 can be configured and arranged to automatically activate at a predetermined interval (e.g., every day, every week, every month, at the beginning of activation of the system 10, after deactivation of the system 10, etc.).

In some embodiments, the switch 56 and/or the movement device 52 can be coupled to one or more sensors (not shown) to control movement of the support member 36. For example, in some embodiments, at least a portion of the sensors can comprise pressure sensors (not shown) that are configured and arranged to sense a pressure differential on both sides of the filter 20 (e.g., clogging of the filter 20 can create an increase in pressure levels within the motor enclosure 34, relative to a pressure level within the filter enclosure 35, which can be sensed by the pressure sensors). As a result of detecting an increased pressure differential from the pressure sensors, the movement device 52 can move the support member 36 to enable at least partial cleaning of the filter 20, as discussed below. In other embodiments, other configurations can be used to control movement of the support member 36, such as, but not limited to a processor (not shown) coupled to a printed circuit board coupled to the system 10 and/or a mechanical timing device (e.g., a clock).

In some embodiments, the movement device 52 can move the support member 36 to the second position 50 to enable air or other fluids to pass through the filter 20 to reduce and/or eliminate clogging. For example, as shown in FIG. 4, by moving the support member 36 and dampers 38, 40 toward the first end 48 of the manifold 24, the second damper 40 can be disposed substantially adjacent (e.g., at least partially engage) to a fourth seating region 42d and the biasing member 44 can become at least partially compressed. The second damper 40 can at least partially seal the exhaust aperture 32 at the first end 48 and movement of the first damper 38 away from the first seating region 48a can at least partially create a secondary intake aperture 58. Furthermore, by moving the second damper 40 substantially adjacent to the fourth seating region 42d, the intake aperture 30 and the filter aperture 26 can be in fluid communication with each other, as shown in FIG. 4. Moreover, when in the second position 50, the first damper 38 can be substantially adjacent to the filter aperture 26 to substantially or completely seal a remainder of the manifold 24 from the intake and filter apertures 30, 26 (e.g., the secondary intake aperture 58, the motor aperture 28, etc.). In some embodiments, when the movement device 52 is inactivated (e.g., via a signal or after a predetermined time of activation), the compressed biasing member 44 can expand and return the support member 36 and the dampers 38, 40 to the first position 46 (i.e., the first damper 38 substantially adjacent to the first seating region 42a).

In some embodiments, as a result of motor 18 being activated, air or other fluids can enter the manifold 24. For example, as reflected by the arrows in FIG. 4, a second end 60 of the manifold 24 can be in fluid communication with the local environment and the motor 18 can move air or other fluids into the manifold 24 at the second end 60 and pass at least a portion of the air through the secondary intake aperture 58. In some embodiments, as shown by the arrows in FIG. 4, after passing through the secondary intake aperture 58, the motor 18 can move at least a portion of the air through the motor aperture 28 and into the motor enclosure 34. After entering the motor enclosure 34, at least a portion of the air can enter the intake aperture 30. As previously mentioned, when the valve assembly 22 comprises the support member 36 and the dampers 38, 40 in the second position 50, the second damper 40 can be substantially adjacent to the fourth seating region 42d so that the intake aperture 30 and filter aperture 26 are in fluid communication. As a result, the flow generated by the motor 18 can move at least a portion of the air or other fluids from the motor enclosure 34 and through the filter 20 via the intake and filter apertures 30, 26, as reflected by the arrows in FIG. 4.

In some embodiments, the valve assembly 22 can comprise one or more alternative configurations, as shown in FIGS. 5A and 5B. In some embodiments, the manifold 24 can comprise a first auxiliary aperture 51 and a second auxiliary aperture 53. For example, the auxiliary apertures 51, 53 can be configured and arranged to enable air or other fluids to pass through the vacuum system 10 in alternative pathways. As shown in FIG. 5A, in some embodiments, during normal operations (i.e., the support member 36 and the dampers 38, 40 being disposed in the first position 46), air or other fluids can pass through the first auxiliary aperture 51 after passing through the motor 18. and entering the motor enclosure 34. After re-entering the manifold 24, at least a portion of the air can exit the manifold 24 via the intake aperture 30 that is in fluid communication with the outlet 16, as reflected by arrow in FIG. 5A. The support member 36 can be configured and arranged so that when the support member 36 and the dampers 38, 40 are in the first position 46, the first auxiliary aperture 51 is in fluid communication with the intake aperture 30, as shown in FIG. 5A. Moreover, when the support member 36 and the dampers 38, 40 are in the first position 46, at least one of the dampers 38, 40 can at least partially obstruct an air flow path leading from the second auxiliary aperture 53 so that little or no air or other fluids enter the manifold 24 via the second auxiliary aperture 53.

Additionally, in some embodiments, as reflected by the arrow in FIG. 5B, when portions of the valve assembly 22 are in the second position 50, air from the local environment can pass through the second end 60 of the manifold 24 and enter the motor enclosure 34 after passing through the motor 18, as previously discussed. In some embodiments, the air from the local environment can re-enter the manifold 24 via the second auxiliary aperture 53 and pass into the filter 20 via the filter aperture 26 to dislodge and/or disrupt any debris potentially clogging the filter 20. Moreover, when the support member 36 and the dampers 38, 40 are in the second position 50, at least one of the dampers 38, 40 can at least partially obstruct an air flow path leading from the first auxiliary aperture 51 so that little or no air or other fluids enter the manifold 24 via the first auxiliary aperture 51.

In some embodiments, regardless of configuration, as a result of the dampers 38, 40 and the support member 36 moving from the first position 48 to the second position 50, air flow direction through the vacuum system 10 can change. In some embodiments, the change in air flow direction can rapidly occur. For example, soon after the system 10 receives a signal to change the valve assembly 22 configuration from the first to the second position 46, 50, the support member 36 and dampers 38, 40 can move and the direction of the air path can rapidly change (e.g., change from air entering the manifold 24 from the filter 20 to air entering the filter 20 from the manifold 24).

In some embodiments, as a result of the rapid change in direction of the air flow, at least a portion of the debris and/or particulate clogging the filter 20 can be relocated. For example, the rapid air flow change can create a shockwave-like effect that can cause the filter 20 to at least partially change geometries (e.g., deform). Because of the filter 20 changing geometries, at least a portion of the debris received by the filter 20 during operation of the vacuum system 10 can be loosened and move from portions of the filter 20 substantially adjacent to filter aperture 26, as reflected by the arrows adjacent to the filter 20 in FIG. 4.

As result of the debris dislodging from the shockwave-like effect of the change in air flow direction, the vacuum system 10 can become at least partially unclogged, which can result in improvements in operational efficiency. As shown in FIG. 6, results of experiments conducted on both conventional vacuum systems and vacuum systems 10 comprising the valve assembly 22 show that the movement of the dampers 38, 40 and the support member 36 can impact filter 20 efficiency over time. The following discussion of experimental results is included to provide those of ordinary skill in the art with a complete disclosure and description of particular manners in which some embodiments of the present invention can be practiced and evaluated, and are not intended to limit the scope of the invention.

In the experiment detailed in FIG. 6, vacuum systems including permanent filters 20 (e.g., cloth-based filters) and filter bags 20 (e.g., pulp-based filters) were compared with and without the valve assembly 22 configuration detailed above. Additionally, a vacuum system comprising a conventional cyclonic configuration was also evaluated. In the experiments, the vacuum systems were activated to constantly remove debris and/or particulates for multiple hours so that each hour of constant use was generally equivalent to two months of use in a conventional structure, however, the experimental model does not necessarily correlate to every conventional structure (e.g., a very dirty structure). After each hour (corresponding to two months of use in a conventional structure), the support member 36 and dampers 38, 40 were briefly moved from the first position 46 to the second position 50 in the conditions comprising the valve assembly 22 as described above. Those conditions that did not comprise the moveable support member 36 and dampers 38, 40 were allowed to normally operate throughout the duration of the experiments.

Vacuum systems 10 comprising the valve assembly 22 (i.e., the moveable support member 36 and dampers 38, 40) demonstrated improved operational efficiency relative to conventional vacuum systems. As shown in FIG. 6, in all conditions, after the equivalent of two months use, the efficiency of the vacuum systems began to decrease. However, movement of the support member 36 and dampers 38, 40 in some of the systems led to improved efficiency. For example, in systems comprising a permanent filter 20, briefly moving the support member 36 from the first position 46 to the second position 50, at two-month intervals, enabled those systems 10 to continue to operate at approximately 93% efficiency (as measured in cubic feet per minute of air moved relative to an unused vacuum system 10) for the equivalent of at least ten months. The efficiency of the same permanent filter 20 vacuum system 10 functioning without the valve assembly 22 drops to 30% after the equivalent of two-months use and continues to drop until it reaches an efficiency level near zero at around the equivalent of ten-months use.

Similarly, in systems comprising a bag filter 20, briefly moving the support member 36 from the first position 46 to the second position 50, at two-month intervals, enabled those systems 10 to continue to operate at approximately 85% efficiency for the equivalent of at least ten months. Also similarly, the efficiency of the same bag filter 20 vacuum system 10 functioning without the valve assembly 22 drops to about 45% during the equivalent of ten-months use. Accordingly, movement of the support member 36 and dampers 38, 40 from the first position 46 to the second position 50 can improve operational efficiency during the life of vacuum systems 10 when the movement is activated on a regular basis (e.g., about every two months).

In some embodiments, the valve assembly 22 can be configured and arranged to reduce the risk of and/or prevent damage to the motor 18 due to blockage of some portions of the vacuum system 10. In some embodiments, the dampers 38, 40 can comprise different sizes. For example, as shown in FIGS. 3-5, the second damper 40 can comprise a smaller size (e.g., a smaller area, perimeter, circumference, etc.) relative to the first damper 38. When the system 10 is active, the motor 18 can generate a vacuum within the manifold 24 (e.g., the motor aperture 28) and, under some blockage conditions, the filter aperture 26 can be substantially or completely blocked leading to the generation of a significant vacuum between the dampers 38, 40. In some embodiments, the exposure of the differently-sized dampers 38, 40 to the vacuum created as a result of the blockage can create unequal pressure forces on the differently-sized dampers 38, 40. As a result of the unequal pressure forces, the support member 36 can move (e.g., linearly move) because the pressure forces generated by the vacuum can be of sufficient magnitude to overcome the biasing force exerted by the biasing member 44. For example, the support member 36 and dampers 38, 40 can begin to move toward the second position 50, although these elements need not actually reach the second position 50. As a result of the dampers 38, 40 moving, the first damper 38 can move away from the first seating region 42a to fluidly connect the secondary intake aperture 58 and the motor aperture 28 to enable air or other fluids to enter the motor 18, which can aid in cooling the motor 18 and preventing damage and/or reducing the risk of damage to the motor 18. Accordingly, some embodiments of the invention can provide for a mechanism to self-clean portions of the vacuum system 10 (i.e., the filter 20) and a mechanism to prevent and/or reduce the risk of damage to the motor 18 by functioning as a relief valve because of the differently-sized dampers 38, 40.

In some embodiments, the vacuum system 10 can comprise other configurations that can enable the self-cleaning mode of operation. As shown in FIG. 7, in some embodiments, the vacuum system 10 can comprise an electromagnetic actuation device 62 coupled to the filter 20 (e.g., coupled to a center of the filter 20) or disposed substantially adjacent to the filter 20. In some embodiments the electromagnetic actuation device 62 can comprise a magnet 62a and a non-moving coil 62b disposed around an outer perimeter of the magnet 62a. The magnet 62a can be coupled to the filter 20, as shown in FIG. 7. In some embodiments, the coil 62b can be energized and de-energized in a pre-determined sequence so that the magnet 62a moves the filter 20 to dislodge at least a portion of the debris and/or particulate caught within the filter 20, which can lead to improved system efficiency.

In some embodiments, the vacuum system 10 can comprise a mechanical actuation device 64, as shown in FIG. 8. The filter 20 can be coupled to a movement source (e.g., an apparatus and/or device configured and arranged to rotate, oscillate, or otherwise move) (not shown), which can cause the filter 20 to move, leading to dislodging of at least a portion of the debris and/or particulate clogging the filter 20. For example, the filter 20 can be coupled to a first end of an actuation member 64a and a movement member 64b (e.g., a cam) can be coupled to a second end of the action member 64a. The movement member 64b can be coupled to a device that is configured and arranged to transmit motive energy, such as motor (not shown). As a result, the motor can move the movement member 64b, moving the actuation member 64a, which can lead to movement of the filter 20. The movement can dislodge at least a portion of the debris and/or particulate clogging the filter 20. In some embodiments, the mechanical actuation device 64 can comprise other structures, such as a solenoid assembly and/or a motor and eccentric weight apparatus coupled to the actuation member 64a to produce movement of the filter 20 and dislodging of materials clogging the filter 20.

In some embodiments, the vacuum system 10 can comprise a non-motorized mechanical actuation configuration, as shown in FIG. 9. In some embodiments, the filter 20 can comprise one or more flexible members (not shown). For example, the filter 20 can comprise a structure configured and arranged to change geometries when air or other fluids pass through the filter 20. As shown in FIG. 9, the filter 20 can comprise a spring-like infrastructure that can move in a first direction when air passes from the inlet 14 and once the airflow is reduced or eliminated, the spring-like infrastructure can cause the filter 20 to change shapes (e.g., rapidly change shapes), which, as previously mentioned, can lead to dislodging of at least a portion of the debris. As a result, the vacuum system 10 can continue to operate without significant clogging of the filter 20.

In some embodiments, other self-cleaning configurations can be used in lieu of or together with some of the previously mentioned embodiments. For example, mechanical rubbing or other form of contact can be applied to the filter 20 to dislodge at least a portion of the debris potentially clogging the filter 20. In some embodiments, the vacuum system 10 can include an integrated filter 20 and filter brushing system (not shown) that can be activated at predetermined time intervals to contact the filter 20 and move against a surface of the filter 20 to at least partially unclog the filter 20. In some embodiments, in lieu of being activated at predetermined time intervals, the filter brushing system 10 can be activated on an as-needed basis (e.g., when there is a reduction in filter 20 efficiency).

In some embodiments, the vacuum system 10 can comprise other configurations that can lead to relatively enhanced filter 20 efficiency over some or all of the lifespan of the system 10. For example, as shown in FIG. 10, the filter 20 can comprise an alternative configuration that can enable the filter 20 to operate at a relatively desirous efficiency. As shown in FIG. 10, the filter 20 can be configured and arranged to move. For example, the vacuum system 10 can comprise a plurality of support members 66 configured and arranged to move portions of the filter 20. A first support member 66a can comprise at least a portion of unused or partially unused filter 20 (e.g., substantially unclogged filter 20). In some embodiments, the used or partially unused filter 20 can be wound around the first support member 66a or can be otherwise coupled to and/or supported by the support member 66a. In some embodiments, a second and a third support member 66b, 66c, can be disposed substantially adjacent to the first support member 66a and substantially parallel to each other, although the second and third support members 66b, 66c need not be parallel to each other. In some embodiments, the system 10 can comprise a fourth support member 66d comprising at least a portion of used and/or partially clogged filter 20, as shown in FIG. 10.

In some embodiments, during, before, and/or after operation of the vacuum system 10 relatively unused and/or unclogged filter 20 can be moved from the first support member 66a and can be supported by the second and third support members 66b, 66c. As a result of being disposed substantially between the second and third support members 66b, 66c, the filter 20 can be disposed along the flow path of air or other fluids entering the housing 12 via the inlet 14. The debris within the air can be removed by the segment of the filter 20 disposed between the second and third support members 66b, 66c and can pass through the outlet 16. In some embodiments, the filter 20 can then be moved to a position more adjacent to the fourth support member 66d so that a relatively unused and/or unclogged portion of the filter 20 can be used to ensure a sufficient amount of airflow efficiency. In other embodiments, the vacuum system 10 can comprise any number of support members 66 to enable sufficient operations.

It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims.

Claims

1. A vacuum system comprising:

a housing;

at least one filter being disposed within the housing; and

a valve assembly being at least partially disposed within the housing and being in fluid communication with the at least one filter, the valve assembly further comprising a manifold, a support member coupled to a plurality of dampers, the plurality of dampers including a first damper and a second damper, wherein the first damper and the second damper comprise unequal sizes, and the support member and the plurality of dampers being configured and arranged to move between a first position and a second position.

2. The vacuum system of claim 1 and further comprising a motor coupled to the valve assembly.

3. The vacuum system of claim 1, wherein the at least one filter comprises at least one of a permanent filter and a bag filter.

4. The vacuum system of claim 1 and further comprising a movement device coupled to a portion of the valve assembly.

5. The vacuum system of claim 1, wherein the valve assembly comprises one or more biasing members.

6. The vacuum system of claim 1, wherein the manifold comprises one or more apertures.

7. The vacuum system of claim 1, wherein the manifold comprises one or more seating regions, wherein at least some of the seating regions are configured and arranged to engage at least one of the plurality of dampers.

8. The vacuum system of claim 7, wherein the manifold comprises a first seating region and a second seating region configured and arranged so that when the support member and the plurality of dampers are in the first position, the first damper is substantially adjacent to the first seating region and the second damper is substantially adjacent to the second seating region.

9. The vacuum system of claim 8, wherein the manifold comprises a third seating region and a fourth seating region configured and arranged so that when the support member and the plurality of dampers are in the second position, the second damper is substantially adjacent to the fourth seating region.

10. A vacuum system comprising:

a housing including a motor enclosure and a filter enclosure;

a filter being at least partially disposed in the filter enclosure;

a manifold at least partially disposed in the motor enclosure, the manifold including a support member coupled to a first damper and a second damper, wherein the first damper and the second damper are configured and arranged to function as a relief valve for a motor; and

a movement device coupled to at least a portion of the manifold, and wherein the movement device is configured and arranged to at least move the support member and the first and the second dampers from a first position to a second position.

11. The vacuum system of claim 10, wherein the first damper comprises a greater size than the second damper.

12. The vacuum system of claim 10, wherein the movement device comprises a damper motor.

13. The vacuum system of claim 10, wherein the filter comprises at least one of a permanent filter and a bag filter.

14. The vacuum system of claim 10, wherein the manifold comprises a plurality of apertures, and wherein the plurality of apertures includes at least one exhaust aperture and at least one motor aperture.

15. The vacuum system of claim 14, wherein the motor is coupled to the manifold substantially adjacent to the motor aperture.

16. The vacuum system of claim 14, wherein the housing comprises at least one inlet and at least one outlet, and wherein the at least one exhaust aperture is in fluid communication with the at least one outlet.

17. The vacuum system of claim 10 and further comprising at least one biasing member at least partially positioned within the manifold.

18. The vacuum system of claim 10, wherein the manifold comprises a plurality of seating regions that are configured and arranged to engage at least one of the first damper and the second damper.

19. A method for assembling vacuum system, the method comprising:

positioning a filter at least partially within a housing;

disposing a valve assembly at least partially within the housing so that the valve assembly is in fluid communication with the filter, the valve assembly including a manifold comprising a support member coupled to a first damper and a second damper, and wherein the first damper and the second damper comprise different sizes; and

coupling a movement device to the valve assembly, wherein the movement device is configured and arranged to at least move the support member and the first and the second dampers from a first position to a second position.

20. The method of claim 19, and further comprising positioning a biasing member at least partially within the manifold.