WASHING MACHINE FILTRATION

Provided are methods, apparatuses and washing machines that involve the filtration of microparticulate from liquid effluent of laundry apparatuses and systems. For example, steps involved in the inventive method may include: collecting the liquid effluent from the output of the outer tub of the washing machine; establishing a continuous high-pressure state to at least a portion of collected liquid effluent by a pumping device, based at least in part on a signal; and directing a threshold amount of high-pressure liquid effluent by a pumping device through a microparticulate filtration system, wherein the threshold amount is based at least in part on a first aspect of the pumping device and/or a microparticulate filtration system.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Ser. No. 63/113,902, entitled “Microplastic Hydrocyclone Washing Machine Filtration,” filed Nov. 15, 2020, by inventor Steve R. Antell, to U.S. Provisional Patent Application Ser. No. 63/205,641, entitled “Microplastics Hydrocyclone Washing Machine Filtration,” filed Jan. 29, 2021, by inventor Steve R. Antell, to U.S. Provisional Patent Application Ser. 63/205,642, entitled “Microplastics Washing Machine Filtration,” filed Feb. 9, 2021, by inventor Steve Ross Antell, to U.S. Provisional Patent Application Ser. 63/215,107, entitled “Microplastic Filtration washing Machine,” filed Jun. 25, 2021, by inventor Steve R. Antell, and to U.S. Provisional Patent Application Ser. No. 63/231,246, entitled “Microfiber Removal Washing Machine,” filed Aug. 10, 2021, by inventor Steve Ross Antell, the disclosures of which are each, separately and in combination, incorporated by reference in their entireties.

BACKGROUND Field of the Invention

The invention generally relates to filtration of washing machine effluent. In particular, the invention relates to methods and systems for filtering microparticulates, e.g., microplastics, from liquid effluent of a washing machine.

Background Art

In modern days, laundry is typically done through the use of automatic washing machines. In millions of homes in the United State alone, water and laundry detergent are combined in automatic washing machines to clean clothing. Mechanically, laundry machines can be top loading or front location.

There are numerous components to washing machines. For example, washing machines typically include an inner drum and an outer tub. In addition, some washing machines include drums, gear boxes, motors, solenoid valves, plumbing such as dedicated water hookups for cold and optionally hot water supplies, pumps, etc.

Laundry effluent contains many types of particles, including microplastics: micron size, plastic non-biodegradable fibers and fragments, separated from laundered synthetic textiles during the washing machines' wash, rinse and spin cycles. Laundry effluent also contains a great number of similar, small sized inorganic particles (e.g., “dirt”) than microplastics, along with cotton fibers, spores and other organic matter. Methods are not presently available to separate these microfibers from small non-plastic particles effectively and efficiently. In medium to large-sized loads, containing many types and ages of synthetic garments with different fiber lengths and weaving, it has been repeatedly found that 75 to 80% of all microplastics are smaller than 200 microns. Filtration removal methods of microplastics from washing machine liquid effluent is challenging for the following reasons:

Flow rates through porous membrane filters are affected by pore size and water pressure. Small membrane pores increase water resistance which decreases flow rates whenever water is forced through them.

Filtering out small microplastic particles, especially smaller than 200 microns, requires utilizing filter membranes with pores 200 microns or smaller. These small pore sizes require utilizing significantly higher water pressure, in order to push water through them, than what is available from washing machine's water pumps: approximately 3.2 psi continuous pump effluent pressure, when initially removing, through pumping, an outer drum's effluent, in the beginning period of the second half of every wash and rinse cycle.

Regardless of motor size and impeller design housing, washing machine's centrifugal pumps produce extreme low, intermittent pump pressure when their impellers are periodically not in contact with liquid effluent that have to pump. This situation always occurs within the second half of every washer's wash and rinse cycle when an incremental increasing centrifugal inner drum spinning extracts liquid effluent from wet garments, while continuous pumping removes this effluent from the outer tub: approximately 4 to 10 minutes, during which the washer's centrifugal pump pressure consistently remains at 0.2 to 0.8 psi.

Additionally, washing machine effluent discharge contains many 200 micron and smaller-sized dirt and non-plastic organic particles. These particles rapidly fill and clog filtering membrane pores requiring additional pump pressure to push water through them, and reduces their efficacy over time.

High efficiency (HE) washing machines temporarily stop operating whenever their discharge wastewater outlet becomes severely restricted or blocked. I have repeatedly experienced these occurrences when trying to filter laundry effluent wastewater through small pore size filtration membranes, especially at 200 microns or less in size.

Older model washing machines, having direct drive water pumps, experience a significant greater incidence of premature motor, transmission and belt failure when trying to filter out laundry effluent wastewater with them using inline, small pore size filtration membranes, especially at 200 microns or less in size.

In any case, waste discharge from washing machines can be viewed as environmental pollutants. This phenomenon is discussed, e.g., in Napper et al. (2020), “The efficiency of devices intended to release microfibres during clothes washing,” Science of the Total Environment, Journal Homepage. See www.elsevier.com/locate/scitotenv. In addition, Galvao et al., (2020) “Microplastics in wastewater: microfiber emissions from common household laundry,” Environmental Science and Pollution Research, 27: 2643-43 (see http://doi.org/10.1007/s11356-020-0876506) also treats microfiber emission as waste. Seventy years of discharging microplastics, from laundered synthetic garments, into sewers has distributed 14 million metric tons of microplastics into the world's oceans and inland water ways; evaporation, wind current and rain have recently transported microplastics to every place on the planet (Synthetic microfiber emmisions to land rival those to waterbodies and are growing see https://journals://plos.org/plosone/article?id=10.1371/journal.pone.0237839). Because 840 million existing washing machines are used all around the world twenty-four hours a day, seven days a week, and 65 million new washers are manufactured every year, there is a worldwide need to deal with microplastic effluent from automatic washing machines.

Thus, there exist personal and industrial opportunities to address perceived problems and other issues with waste discharge from washing machines.

SUMMARY OF THE INVENTION

In a first embodiment, a method is provided for filtering microparticulates such as microplastics from liquid effluent of a washing machine that may have an outer tub and an inner drum. The method comprises: collecting the liquid effluent from the outer tub so as to accumulate a threshold amount of collected liquid effluent; and directing the threshold amount of collected liquid effluent through a microparticulate filtration system and optional hydrocyclone sand filter, wherein the threshold amount of the liquid effluent is based at least in part on a first aspect of the microparticulate filtration system.

This embodiment comprises raising pressure and flow rate of the collected liquid effluent to a specific pressure and flow rate value by a pumping device, before directing the collected liquid effluent through the microparticulate filtration system. Periodically, the filtration device may be emptied in a manner to allow accumulated microplastics and the like to be removed from the discharge waste streams of washing machines, so that such waste do not end up in rivers and seas.

In another embodiment, an improved washing machine is provided. The washing machine may include an apparatus for filtering microparticulate from liquid effluent of a washing machine having an outer tub, a means for delaying at least a measured portion of the liquid effluent in an accumulation device from leaving the washing machine during a particular wash cycle, a collector for collecting the liquid effluent from the accumulation device so as to accumulate a threshold amount of collected liquid effluent.

The measured portion of liquid effluent is greater than approximately 250 cubic centimeters. The Measured portion of liquid effluent may be less than approximately 2 liters.

There may be a director for directing the threshold amount of collected liquid effluent through a microparticulate filter, wherein the threshold amount of the liquid effluent is based at least in part on a first aspect of the microparticulate filter. The first aspect of the microparticulate filter may be whether the microfilter need replacing. Another aspect of the microparticulate filter may involve refurbishing, cleaning, refreshing, or replacing the microfilter so that the washing machine performance is optimized. Thus, for example, the washing machine may use hydrocyclone technology in combination with any of the inventive embodiments.

Other variations include incorporating either of the earlier two listed embodiments within an external filter device that is connected to a washing machine's effluent discharge port by a hose. The external filter device receives and collects at least a measured portion of a washer's outer tub's liquid effluent, utilizes a pumping device, based on a signal, to create and direct high pressure liquid effluent through a microparticulate filtration system. The external filtering device, thereby filters microplastics from the liquid effluent of the washing machine.

BRIEF DESCRIPTION OF THE DRAWINGS

In general, the drawings depict aspects and various embodiments of the invention but may not do so to scale. Certain features of the drawings may be exaggerated for clarity of presentation rather than to serve as a precise physical schematic of how the invention works.

FIG. 1 is a cut-away side view diagram of the present invention of a top and front loading, high efficiency CPU controlled washing machines having a diaphragm pump that removes plastic microparticulates from the washing machines' waste effluent water discharge.

FIG. 2 lists component parts of FIG. 1.

FIG. 3 is a cut-away side view diagram of the present invention of a top and front loading, high efficiency CPU controlled washing machines having a centrifugal or diaphragm pump that removes microplastics from the washing machine' waste effluent water discharge.

FIG. 4 lists component parts of FIG. 3.

FIG. 5 is an electrical circuit diagram for controlling pump and filtration operations of FIG. 3.

FIG. 6 lists component parts of FIG. 5.

FIG. 7 is a diagram of the present invention having an external filtration device, with a diaphragm pump connected by hose, that removes microplastics from a washing machine's waste effluent water discharge.

FIG. 8 lists component parts of FIG. 7.

FIG. 9 is a diagram of the present invention having an external filtration device, with a centrifugal or diaphragm pump connected by hose, that removes microplastics from a washing machine's waste effluent water discharge.

FIG. 10 is an electrical circuit diagram for controlling pump operations of FIG. 9.

FIG. 11 lists component parts of FIG. 9.

FIG. 12 lists component parts of FIG. 10.

FIG. 13 is a diagram of the present invention removing microplastics from a laundromat or large volume laundry facility, manufacturing plant, and water treatment facility.

FIG. 14 lists component parts of FIG. 13.

FIG. 15 is a diagram of the present invention removing microplastics from a laundromat or large volume laundry facility, manufacturing plant, water treatment facility, and different parts of aquatic, terrestrial and atmospheric systems contaminated with microplastics.

FIG. 16 lists component parts of FIG. 15.

FIG. 17 is a diagram of the present invention utilizing multiple sets of hydrocyclone sand filters, filtration systems and diaphragm pumps removing: microplastics from a laundromat or large volume laundry facility, manufacturing plant, water treatment facility, and different parts of aquatic, terrestrial and atmospheric systems contaminated with microplastics.

FIG. 18 lists component parts of FIG. 17.

 DETAILED DESCRIPTION OF THE INVENTION

Before describing the present invention in detail, it is to be understood that the invention is not limited to specific washing machine types, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

In addition, as used in this specification and the appended claims, the singular article forms “a,” “an,” and “the” include both singular and plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a particle” includes a plurality of particles as well as a single particle, reference to a “microfiber” includes a single microfiber as well as a combination of microfibers, and the like.

Furthermore, terminology indicative or suggestive of a particular spatial relationship between elements of the invention is to be construed in a relative sense rather an absolute sense unless the context of usage clearly dictates to the contrary

In this specification and in the claims that follow, reference will be made to a number of terms that shall be defined to have the following meanings, unless the context in which they are employed clearly indicates otherwise:

The terms “actuate” and “actuator” are used in their ordinary sense and refers to actions that cause a device or the like to operate.

The term “effluent” is used herein in its ordinary sense and refers to liquid waste or sewage may be ultimately discharged into a river or the sea.

The term “high-Pressure” as in “high pressure state” refers a condition of water (or a gas) that is measurable at an above average pressure. Additional information about pressures associated with the invention are discussed below for washing machines.

The terms “hydrocyclone” and “hydrocylonic” generally mean technology that may be used to classify, separate or sort particles in a liquid suspension, aqueous or nonaqueous, based on the ratio of their centripetal force to fluid resistance. As discussed further below, this ratio is high for dense (where separation by density is required) and coarse (where separation by size is required) particles, and low for light and fine particles.

The terms “measure” and “measured” are used herein in their ordinary sense and refers to the act of ascertaining the size, amount, or degree of (something) by using an instrument or device marked in standard units or by comparing it with an object of known size.

The prefix “micro” as in a “microparticulate” is used herein in its ordinary sense meaning extremely small. Typically, the term is to be interpreted in metric measurements rather than nonmetric measurements. Thus, when microparticulates take the form of grains of sand, they may have a critical diameter of no greater than about 500 to about 1000 micrometers. Similarly, when microparticulates take the form of microfibers, the microfibers may have a minimum critical dimension of no more than about 1 to 20 micrometers or so. Further similarly, “microplastics” means to extremely small form of plastics.

The terms “optional” and “optionally” are used in their ordinary sense and when used to modify a referent item or referent step, the referent item or step may or may not be present.

The term “sensor” is used herein in its ordinary sense and refers a device which detects or measures a physical property and records, indicates, or otherwise responds to it.

The term “washing machine” is used in its ordinary sense and refers to an appliance for home or commercial use to wash laundry. The term is mostly applied to machines that use water as opposed to dry cleaning (which uses alternative cleaning fluids and is performed by specialist businesses) or ultrasonic cleaners. The operator of the washing machine adds laundry detergent, which is sold in liquid or powder form, to the wash water. Washing machines may include a washer unit and an optional dryer unit in which the washer and dryer units are integrated.

Inventive Overview

Thus, the invention relates to filtration of microparticles, microfibers, microplastics and the like with respect to laundering machines like washing machines and dryers. As to the state of the art, the invention may involve using existing washing machine technology, building new washing machine systems, and/or retrofitting old washing machines, so that in some instances, aftermarket items may be used.

The invention may involve a process that selectively may separate out dirt and other non-plastic organic particles, removes and captures microplastics in washing machine effluent discharge. This invention relates to filters designed to capture microplastics from washing machines when laundering synthetic garments.

Microplastics are tiny, non-biodegradable plastic fragments that separate from synthetic textiles such as garments and blankets laundered in washing machines. Laundry effluent wastewater contains these plastic particles that are then discharged into sewer drains. There are approximately 840 million washing machines in use worldwide today, producing and discarding microplastic into the environment. Within only 70 years, 14 million metric tons of these microfibers have accumulated, dispersed throughout Earth's ecosystems, and become a vast environmental pollution disaster, second only to global warming.

The claimed invention is the most effective, service free and inexpensive filtration device to remove microfibers and/or microplastics from washing machine effluent discharge. It removes 95% of all microplastics from washing machine effluent discharges. In addition, it has extended filtration service life, up to 2½ to 3½ months between changes. Furthermore, it represents the least expensive, most effective washer microplastic filtration device to own and operate for it incorporates utilizing existing pumps and filter parts. The invention also involves minimal retooling costs for washer manufacturers. Finally, the invention is compatible to retrofit all existing manufactured washers and able to be up-scaled to work in commercial laundering facilities.

Microfibers, Microplastics, and Other Microparticles

To provide some context associated with the invention, it is important to describe the scope of microparticles and microplastics associated with the invention. Micron sized pieces of material and other attached particles separate from fabrics as they get washed. Synthetic garments are primarily composed of polyester, acrylic, nylon and polypropylene fabric. When laundered, these fabrics shed synthetic particles into the waste water. The inventor has sampled these particles and found they have an approximate size frequency distribution pattern averaging:

>200 microns 20-25% <200 microns & >100 microns 30-35% <100 microns & >60 microns 30-35%  <60 microns 2-5% Inorganic material like silt, sand average <40 microns. Plant parts including spores, spun cotton fibers average >70 microns

Porous Membrane Filters

The invention may use dense, porous membrane filters. Such filters allow the separation of particles from a fluid moving through a filter; particles are separated based on pore size. Water fluid movement through a membrane filter is principally regulated by initial water pressure and pore size (pore's edges also contribute a tiny amount to water friction).

Particles caught in a pore membrane filter increasing restrict both the number of pores available for water to flow through, (reducing flow rate) and the future number of similar size particles that can be caught (filtered) from the fluid;

Higher water pressure enables water to flow through a higher density matrix of smaller-sized pore membranes, allowing the filtration of a greater number of similar-size smaller particles;

Lower water pressure limits water's ability to pass through smaller-sized pore membranes, limiting filtering removal to larger-size particles utilizing lesser dense membranes.

To make an effective washing machine microparticulate filtration device that removes 95% synthetics particulates and has a long-lasting filter life, one must utilize high density, small pore membrane filtration and significantly increase washer effluent discharge pressure to the filter.

All washing machines are capable of pumping their waste effluent water to their exit hose port and into an adjoining wall sewer standpipe connection. However, washers are not designed, configured or built to produce anything but low effluent discharge pump pressure which frequently is close to 0 psi during extended periods of centrifugal spinning. Existing aftermarket inline microparticulate filter devices, including a OEM washer with a built in microparticulate filter only work by compromising their ability to remove synthetic particulates (e.g., smaller than 200 microns) and/or possess limited filter particulate holding capacity. This is because electronically controlled, high efficiency washers experience significant sudsing problems (suds cannot fully be removed from washer in a designated rinse cycle period and/or create overly extended cycle length times) when their effluent discharge slows down because an inline or OEM filter, having a high density matrix filter and/or with filter pores less than 200 microns in size, is attached in line with the drain hose. Such sudsing or overly extended cycle times produce a CPU error code within the electronically controlled, high efficiency washers, causing the washer to stop operating until the effluent discharge blockage is removed.

Water Pumps

Water pumps are also used with the invention. For example, centrifugal pumps may be used. As a matter of physics, a centrifugal pump's motor kinetic energy transfers to liquid by a spinning impeller; the presence/absence of fluid affects energy transfer for the generated pressure rise (head) is proportional to the density of fluid discharged. The rate of effluent discharge from the outer tub of a washing machine during its spin cycle is exceedingly small, frequently non-existent, resulting in minimal pump pressure availability during washer spin draining. All efficient washers (manufactured beginning about 2000) use centrifugal pumps to remove their discharge effluent.

Diaphragm pumps move fluids by trapping a fixed volume (usually in a cavity), and then forcing that trapped fluid into a discharge pipe; pump pressure (head) remains constant regardless of fluid intake availability. Unlike centrifugal water pumps, diaphragm water pumps can be run dry, do not get hot or require pump priming, produce both positive and negative pump pressures. Diaphragm water pumps are also able to significantly increase their pressure output upon demand while maintaining a near similar flow rate; this is useful for sedimentary filter's experience significant increases in their differential pressures as their filter pores collect increasing numbers of particulates.

Washing Machine/Method/System Embodiments

There are two main types of washing machines, top load and front load washers. Both types clean clothes by agitating them with water in a porous drum; the drum is surrounded by a tub that retains the water. In each cycle, clean water is added to the drum in a series of events. Both types utilize cycles during clothes washing. In each cycle, clean water is added to the drum in a series of events, agitation occurs, there is a short interval of continuous pumping out of the dirty water which clothes are immersed, followed by a longer interval of intermittent pumping out the remaining water, centrifugally removed from the clothes themselves.

Top load and front load washers' cycles though operate in different ways. The following details relate to the exemplary operation of a top load high efficiency washer, HE:

(a) Uses 1-2 cycles per wash: cycle is composed of wash agitation, rinse agitation and fast spinning. Cycle is controlled by computer and sensors;

(b) Up to 85% of all water used in a cycle is delivered to the wash tub in the first minutes (5 to 7 gallons); wash agitation begins (when there is no initial soaking period); water gets drained upon completion;

(c) Additional water (up to 15% of total), is then added during the rinse agitation; water gets drained upon completion;

(d) A short continuous spinning cycle then commences where all remaining water is removed;

(e) Short period of initial wash & rinse effluent discharge is about 3.2 psi; centrifugal spinning discharge pressure is about 0.2-0.8 psi.

(f) Top load washers use more water and electricity than front load washers; shorter amount of time wash than front load. Most all of the world's operating washers (840 million) are top load washers; HE top load washers were introduced around 2000.

Front load high efficiency (HE) washing machines were introduced to the market around 2000. The following sets for the operation parameters associated with front load high efficiency washers are as follows:

(i) They usually have 2-3 cycles per wash: each cycle is composed of wash agitation, rinse agitation and fast spinning action. Cycles are controlled by computer and sensors; longer wash times than top loaders, washes clothes better.

(ii) 65% of all water used in a cycle is delivered to the wash tub in the first few minutes (4 to 5 gallons); agitation (forms of a slower spinning) begins; takes approximate ½ of complete cycle time before ending, then quickly drains.

(iii) Wash agitation (up to 35% of water) takes most of remainder approximate ½ of cycle time; adding water, wash agitation and drain occur intermittently with one another.

(iv) A continuous spinning then commences where all remaining water is removed.

(v) Short period of initial wash & rinse discharge is about 3.2 psi; centrifugal spinning discharge pressure is about 0.2-0.8 psi

The following table sets forth examples of washing machines types and their associated cycle activities.

TABLE CYCLE ACTIVITY TOP LOAD FRONT LOAD Number of cycles Usually 2 Usually 2-3 11 to 18 minutes/cycle 10 to 24 min/cycle Adding water 100% of all water delivered Multiple intermittent times Up to 2 minutes 30 seconds to 2 minutes Agitation Intermittently, multiple Intermittently, multiple directions and speeds directions/speeds 9 to 20 minutes 15 seconds to 5 minutes 1st water discharge 1 continuous time 1 continuous time 3.2 psi, 1 gal/6.5 sec 3.2 psi, 1 gal/6.5 sec 6.8 psi, 1 gal/5 sec (Up to Up to 4.5 gallons 24 gallons for older machies. Remaining water discharge 1 continuous time Multiple intermittent times Up 0.3-3 psi, 1 gal/3 minutes to 0.2-0.8 psi, 1 gal/5-9 min. Up to 2.5 gallons Up to 2 gallons

Thus, the invention may take the form of a method for filtering microplastics from liquid effluent of a washing machine having an outer tub. The method involves: collecting the liquid effluent from the output of the outer tub of the washing machine; establishing a continuous high-pressure state to at least a portion of collected liquid effluent by a pumping device, based at least in part on a signal; and directing a threshold amount of high-pressure liquid effluent by a pumping device through a microparticulate filtration system, wherein the threshold amount is based at least in part on a first aspect of the pumping device and/or a microparticulate filtration system, thereby filtering microplastics from the liquid effluent of the washing machine.

The continuous high-pressure state may be at least about 4.0 psi and/or no greater than about 40 psi. The washing machine may comprise the pumping device or may be separate from the pumping device. A continuous high-pressure state of a washer's liquid effluent discharge may be created utilizing a diaphragm water pump, or a water pump receiving collected and delayed effluent from an accumulator device. Such pumps may be actuated according to timed or other types of signals, e.g., by a sensor device.

The collected liquid effluent is measured or detected by a sensor device. Microplastics from collected liquid effluent may be separated and removed by the microparticulate filtration system. Flow of the collected liquid effluent may be regulated by a management system.

The invention may involve a method that comprises using a management system that directs collected liquid effluent from an accumulation device, raising the collected liquid effluent to a continuous high-pressure state, and directing the continuous high-pressure pressure state liquid effluent, based at least on a signal, through the microparticulate filtration system. In some instances, the collected liquid state fluid has a specific pressure or flow rate value is determination based at least in part on a second aspect of the pumping device that is optionally of a pumping system and/or the microparticulate filtration system. A sensor, an accumulator device, a pumping device, a microparticulate filtration system and a management system may reside with the washing machine or may reside at least partially outside the washing machine. The accumulation device may an accumulator tank or the outer tub.

The method may involve storing at least a measured portion of the liquid effluent, while delaying the liquid effluent from leaving an accumulation device. The collected liquid effluent may be collected by-way-of a hose or other hollow transport device. In any case, microplastics within the washing machine's liquid effluent discharge may be collected and removed from the liquid effluent by a filtration system, without fear of overheating a pump.

Typically, the measured portion of liquid effluent is greater than approximately 400 cubic centimeters. In some cases, the measured portion of liquid effluent is less than approximately 2 liters. The accumulation device is an accumulator tank or the washer's outer tub.

In another embodiment, an apparatus is provided for filtering microplastics from liquid effluent of a washing machine having an outer tub. The apparatus comprises: a collector for collecting the liquid effluent from output of the washing machine's outer tub; a device that establishes a continuous high-pressure state to at least a delayed portion of collected liquid effluent by a pumping device, based at least in part on a signal; and a director that directs a threshold amount of high-pressure liquid effluent by a pumping device through a microparticulate filtration system, wherein the threshold amount is based at least in part on a first aspect of the pumping device and/or microparticulate filtration system.

Also included may be a sensor device that measures presence, pressure or rate of flow based in at least in part on a quantity of the liquid effluent. The sensor device may measure presence, pressure or rate of flow based on an aspect of the pumping device and/or filtration system. Additionally, or in the alternative, the sensor device may measure an aspect of the threshold amount of liquid effluent within the accumulation device.

In some embodiments of the invention, the apparatus includes an interstitial space located between an inner drum's bottom of the washing machine and an outer tub's bottom of the washing machine that is utilized for sensor detection placement to measure presence, pressure, or rate of flow in at least in part on a quantity of the liquid effluent. For example, a management device, e.g., that forms a part of a management system may detect presence, pressure or rate of flow based on an aspect of the pumping device and/or filtration system. Liquid effluent may be released from an accumulation device to a pumping device.

When a filtration device is provided, a pump may send liquid effluent to the filtration system. In such a case, the filtration system filters out microplastics from liquid effluent of a washing machine. Thus, the management system may regulate liquid effluent of the sensor, an optional accumulator device, pumping device and filtration system.

In some instances, the filtration system is a single filter housing and a single replicable filter cartridge, or a plurality of similar or different filter housings and replaceable filter cartridges, including, but not limited to a hydrocyclone sand filter. In any case, the accumulation device may utilize a single orifice, functioning as both an inflow and outflow port.

In certain embodiments, the filtration system has a constrictive effect capable of removing microplastics to 5 microns in size, utilizing high density, small pore membranes having great particulate holding capacity that maximize extended user filter life before needing to be replaced. Additionally, or in the alternative, a separate device may be provided independent of a washing machine, compromising a sensor device, an optional accumulation device, pumping device, filtration system and management system, that removes the microplastics from a washing machine's liquid effluent discharge. Thus, liquid effluent discharge may be received from a washing machine, by-way-of an intake hose or other hollow transport device affixed to the washing machine's liquid effluent output discharge port or outer tub, and from an output hose or other hollow transport device transferring microplastic effluent water to a collection area or sewer connection port.

Further, within a washing machine, a sensor, accumulator tank, pump, filtration system and management system may remove microplastics from liquid effluent coming from the outer tub. Similarly, within a washing machine, a diaphragm pump, pumping liquid effluent out of the washer, may be controlled directly or indirectly from the washing machine's electric control system. In a highly specific embodiment, the invention provides an accumulation tank, hydrocyclone sand filter or hydrocyclone, filtration system and pumping device, that are employed to remove microplastics from a large volume laundry facility, effluent of a manufacturing or water treatment facility, and aquatic, terrestrial or atmospheric systems contaminated with microplastics.

In a further embodiment, the invention provided one or more washing machines, each having an outer tub. At least one washing machine comprises: a means for collecting liquid effluent as output from an outer tub of the washing machine, a means for establishing a continuous high-pressure state to at least a portion of collected liquid effluent by a pumping device, based at least in part on a signal, and a means for directing a threshold amount of high pressure liquid effluent by a pumping device through a microparticulate filtration system, wherein the threshold amount is based at least in part on a first aspect of the pumping device and/or microparticulate filtration system.

In some cases, a means is provided for raising pressure to a specific pressure value after a means is invoked for directing at least a stored portion of the liquid effluent by a pumping device through the microparticulate filtration system. A means may also be provided to remove microplastics from effluent water of the washing machine, before transferring microplastic-free effluent water to a collection area or sewer connection site. Liquid effluent may be stored by an accumulation means. Flow may be delayed by one or more delay means. Hydrocyclone technology may be used.

As shown in the drawings, the invention may also take the form of a method, process and/or system. Such systems are discussed with a number of flow diagrams, schematics and diagrams associated with the drawings.

Referring now to the invention in greater detail, FIG. 1 (and FIG. 2) shows two washing machines, i.e., a top load high efficiency washing machine 10 is shown side by side with a front load washing machine 10A. The washing machines 10, 10A are arranged as an apparatus that allows the invention to be carried out. The inner drum 120 of the washing machine drum is a container, perforated by holes, receiving clothes which spins and/or agitates the clothes around a central axis of a surrounding outer tub. The washing machine intermittently adds water to the inner drum during wash and rinse cycles whereby such water drains through the inner drum's holes and is retained in an outer tub. Water is also expelled through the inner drum's holes by centrifugal spinning wet clothes during the draining cycle periods. As the surrounding outer tub's water level raises above the inner drum's bottom, the inner drum's water level rises and becomes equal to that of the surrounding outer tub.

Interstitial space 130 is provided between washing machine's inner drum 120 and outer tub 140. The outer tub 140 is shown as a container encapsulating the drum 120 that receives clean water during the beginning of wash and rinse cycles; the outer tub receives this water as it passes through the perforated inner drum's sides. The outer tub's water level rises or falls relative to the amount of water either added to the inner drum, or removed from the outer tub through the outer tub's bottom drain outlet. The volume of water retained in the outer tub during each cycle period of washing, rinsing, or soaking may be approximately 16-28 liters for front loaders and 16-32 liters for top loaders. The volume of interstitial space between the tub's bottom and the drum's bottom may be approximately 0.5 to 2 liters.

Outer tub's drain outlet 150 is located where a washing machine's liquid effluent empties and leaves the outer tub 140 at a recessed floor area. A hose 160 or other hollow transport like tube or pipe, made out of plastic, metal or other suitable materials may be used to transport liquid effluent from to a prefilter 170. The prefilter 170 may be made of plastic or other appropriate material, e.g., having an internal filter to collect large particles greater than approximately 3 mm. In some instances, a filter may be used that is user accessible by a screwed-on access lid or similar port type, enabling facile cleaning and/or removal of captured large particles.

Also shown is a hose 180 that allows for transferring waste effluent water to a filtration system 190. The filtration system may comprise a housing and a cartridge, receiving up-stream, continuous negative high-pressure diaphragm pumping. Parts of the sediment filter housing of the filtration system 190 are traditionally designed and commercially available, having a screw top lid to access filter cartridge. A filter cartridge housing can have, and not be limited to, input and exit port shut off valves, pressure relief valves, access ports, gauges, sensors, or monitor(s) displaying differential pressures. Filter cartridge housing can be a single cartridge housing or a plurality of filter cartridge housings. Parts of the sediment filter are traditionally designed and commercially available, that can have, and not be limited to, filter designs consisting of a pleated membrane composed of dense, small micron size pores. Such filter captures microplastics and non-plastic particles while allowing waste effluent water to pass thru it. Filter cartridge can be a single cartridge or a plurality of filter cartridges that are replaceable. Alternatively, there also can be a filter design of less dense, small micron pore membrane(s) and/or hydrocyclone sand filter associated with or inside the filtration system.

Also as shown, a hose 200 connects the filtration system to a diaphragm pump 210. Similarly, a hose 220 connect the diaphragm pump to a sewer discharge port 230.

The diaphragm pump establishes both continuous downstream, negative liquid effluent high-pressure state, and a continuous up-stream, positive liquid effluent high-pressure state. Alternatively, a diaphragm pump can be positioned downstream of a filtration system, to produce continuous positive liquid effluent high-pressure state through the filtration system for filtering microplastics. The diaphragm pump receives its electrical power from the washer throughout the tub's draining cycle periods. The diaphragm pump can operate continuously during these cycle periods, removing both the initial wash and rinse water and all subsequent water generated from drum centrifugal spinning wet clothes. The diaphragm pump stops pumping when the draining period of each wash and rinse cycle is completed.

A variant of the setup shown in FIG. 1 is presented in FIGS. 3 and 4. However there are a number of differences in the placement of items of the setups depicted in FIGS. 1 and 3.

In some situations, the present invention utilizes directing threshold amounts of constantly collected washer's outer tub liquid effluent through a centrifugal pump's impeller or diaphragm pump to establish a continuous liquid effluent high-pressure state.

As shown in FIG. 5, the invention may involve use of electrical setups through electrical power input 520. In the diagram referred to in FIGS. 5 and 6, water sensors are positioned to a washing machine's outer tub interstitial space, controlling a relay which receives continuous electrical power throughout the tub's drain cycle periods. Sensor 1, referred to with reference number 522, normally open, is positioned near the outer tub's bottom and closes when clean wash or rinse water enters the outer tub. Sensor 2, also referred with reference number 524, is normally open and positioned under the inner drum's bottom, such that when the outer tub's water level continues to rise, a measured volume of water is obtained, closing sensor 524. When the washer's outer tub draining cycle part begins, sensors 522 and 524 are closed, triggering a relay 530 (normally open) to close. This relay 530 starts the centrifugal or diaphragm pump 532 (normally off). This results in the outer tub rapidly emptying, opening sensor 524, of all of its standing liquid effluent as a continuous flow to the pump's impeller or diaphragm pump. When the outer tub is empty of liquid effluent, sensor 522 opens, which triggers relay 530 to open and stop the centrifugal or diaphragm pump 532.

As the cycle continues, the inner drum begins to spin, forcing wet clothes' water out through its porous walls and into the outer tub. This liquid effluent slowly accumulates at the outer tub's interstitial bottom, closing sensor 522, and to gradually reach the level of sensor 524, closing it; this activates the centrifugal or diaphragm pump, emptying the outer tub of its present accumulated liquid effluent. The repeated filling and emptying the outer tub of accumulated liquid effluent continues. This method stores at least a measured portion of the liquid effluent, while delaying it from leaving an accumulation device. At the completion of all wash and rinse cycles, two paired timing relays 528 briefly activate the pump 532, emptying any remaining liquid effluent that might be retained in the washer's outer tub.

As shown in FIG. 7 and referred to in FIG. 8, another variant of the invention utilizes an external filtration device, comprised of a pre-filter, optional hydrocyclone sand filter, filtration system and diaphragm pump, connected by a hose to a washer's external discharge port. All reference numbers of this variant lead with a “7.” For example, the filtration device 724 receives all of a washing machine's intermittent low-pressure liquid effluent discharge through its optional hydrocyclone sand filter (not shown but may be formed as a part of items, e.g., 724, 730), and a filtration system, by an up-stream diaphragm pump that establishes a continuous negative liquid effluent water high-pressure state. The optional hydrocyclone sand filter and a filtration system, removes non-plastic micro particulates and microplastics; the microplastic free liquid effluent then is disposed into a sewer discharge port. The diaphragm pump can also be positioned downstream of an optional hydrocyclone sand filter and a filtration system, to produce continuous positive liquid effluent high-pressure state, filtering non-plastic micro particulates and microplastics. An electrical senor positioned adjacent the hose detects the presence/absence of transferred liquid effluent, relaying its signals to an electrical relay, controlling when pumping occurs.

An additional embodiment of the invention the invention is depicted in FIG. 9 and referred to in FIG. 11 utilizes an external filtration device comprised of check valves, accumulation tank/overflow port/mixing box, pre-filter, centrifugal or diaphragm pump, optional hydrocyclone sand filter or hydrocyclone, and a filtration system, connected by a hose to a washer's discharge port.

As shown in FIGS. 9 and 10 and referred to in FIG. 12, the accumulation tank receives all of a washer's intermittent low-pressure liquid effluent discharge; the tank's two electrical sensors and relay then create threshold amounts of liquid effluent that is sent through a centrifugal pump's impeller or diaphragm pump. This method stores at least a measured portion of the liquid effluent, while delaying it from leaving an accumulation device. The centrifugal or diaphragm pumping produces a continuous positive high-pressure liquid effluent state, transporting the effluent through a filtration system, where microplastics are removed, before being disposed of into a sewer discharge port.

Another embodiment of the present invention includes removing microplastic from effluent of a laundromat or large volume laundry facility, manufacturing or water treatment facility, and aquatic, terrestrial and atmospheric systems contaminated with microplastics from washing machines. A continuous high-pressure liquid effluent state is created through a differential pump, sending effluent through a microparticulate filtration system. See FIGS. 13 through 16. An additional embodiment of the present invention utilizes multiple sets of hydrocyclone sand filters, filtration systems, and diaphragm pumps removing: microplastic from effluent of a laundromat or large volume laundry facility, manufacturing or water treatment facility, and aquatic, terrestrial and atmospheric systems contaminated with microplastics from washing machines (FIGS. 17 and 18).

Hydrocyclone Versions of the Invention

As alluded to above, a cyclone is a separator separating phases of materials mainly on basis of differences in gravity. In some situations, a hydrocyclone sand filter collects high density particles. A hydrocyclone may collect high density particle without the sand filter attachment, by streaming underflow effluent through a narrower apex discharge hole. Typically, but not necessarily, the invention involves wet hydrocyclonic technology in which solids are separated from liquid water. In some exceptional situation, cyclonic separation may be used to separate solids from gasses.

Thus, the following parameters are relevant to cyclonic action for washing machines: the specific weight/density difference between microfiber and water; the shape of the solids involved, the centripetal forces involved, etc. Other parameters relevant to cyclonic action for washing machines and laundry may be discovered upon routine experimentation in view of the present specification.

Accordingly, the invention is associated with numerous environmental implications, and variations of the present invention will be apparent to those of ordinary skill in the art in view of the disclosure contained herein. For example, the invention may be constructed to contain or exclude specific features according to the intended use of the invention. For example, different types of pumps, e.g., centrifugal, electromechanical and/or diaphragm pumps, or even different configurations and type of filters within a microparticulate filtration system, may be used in conjunction with the invention, depending on the other limitations of the invention's intended use.

In addition, the invention provides a number of novel and nonobvious aspect to known washing machine technologies. For example, with the use of the present invention, the lifespan of washing machines may be extended. In addition, the invention may be used to improve the lifespan and environmental performance of combination washer and dryer units, which may include a single unit casing and a single rotating drum.

The invention stands out because it removes microplastic particles from washing machine effluent discharge by utilizing new techniques that include:

Establishing a continuous high-pressure state to at least a portion of collected liquid effluent by a pumping device;

Directing a threshold amount of high-pressure liquid effluent by a pumping device through a microparticulate filtration system;

Utilizing a diaphragm water pump to create a high-pressure liquid effluent state;

Delaying and storing at least a measured portion of liquid effluent to enable a centrifugal water pump to create a high-pressure liquid effluent state;

Transforming variable volumes, flow rates, and pressures of effluent discharges into consistent volumes, flow rates and pressures throughout the working cycle;

Utilizing high density, small pore filtration membranes, smaller than 200 microns, to remove microplastics from washing machine effluent discharge;

Creating a series of processes to utilize a hydrocyclone to separate plastic from nonplastic particles in washing machines; and

Filtering and removing microplastic particles down to 5 microns in sizes both: within a washing machine; with an attached external filtration device connected to a washer with at least a hose or other hollow transport device; within an external filtering device, connected to a single or collection of washing machines, water treatment facilities, and aquatic, terrestrial and atmospheric systems contaminated with microplastics from washing machines.

The processes of separating microplastics from non-plastic particles also can be applied to many other applications, including but not limited to removing microplastics from industrial waste, soils/sands in terrestrial habitats, both fresh and sea water in aquatic habitats, rainwater from the atmosphere, and tissue fluids from organisms; and

The external microplastic hydrocyclone washing machine filtration device operates independently, controlling all of its functions, and is not affected by the variability exhibited of a washing machine's effluent's pressure and flow rates, water volume, timing, number, or wash and rinse sequence order; it is connected to a washing machine only with an effluent transfer hose.

It is to be understood that, while the invention has been described in conjunction with the preferred specific embodiments thereof, the foregoing description merely illustrates and does not limit the scope of the invention. Numerous alternatives and equivalents exist which do not depart from the invention set forth above. For example, any particular embodiment of the invention, e.g., those depicted in any drawing herein, may be modified to include or exclude features of other embodiments. Other aspects, advantages, and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains.

Claims

1. A method for filtering microplastics from liquid effluent of a washing machine having an outer tub, the method compromising:

collecting the liquid effluent from the output of the outer tub of the washing machine;
establishing a high-pressure state to at least a portion of collected liquid effluent by a pumping device, based at least in part on a pressure signal; and
directing an amount of high-pressure liquid effluent by a pumping device that includes at least one or two pumps having a centrifugal, electromechanical, and/or diaphragm construction through a microparticulate filtration system that is effective for filtration of microplastics, wherein the amount is based at least in part on a first aspect of the pumping device and/or a microparticulate filtration system the first aspect selected from pressure and/or flow rate of the device or system, thereby filtering microplastics from the liquid effluent of the washing machine.

2. The method of claim 1, wherein the continuous high-pressure state is at least about 3.2 psi.

3. The method of claim 1, wherein the continuous high-pressure state is no greater than about 40 psi.

4. The method of claim 1, wherein the washing machine comprises the pumping device.

5. The method of claim 1, wherein the pumping device is separate from the washing machine.

6. The method of claim 1, wherein the collected liquid effluent is measured or detected by a sensor device in terms of volume of the liquid effluent.

7. The method of claim 1, wherein the collected effluent is collected and is delayed in an accumulator device.

8. The method of claim 1, wherein a high-pressure state of liquid effluent is created by at least one pumping device having a centrifugal, electromechanical, or diaphragm construction.

9. The method of claim 1, wherein microplastics from collected liquid effluent are separated and removed by the microparticulate filtration system.

10. The method of claim 1, wherein flow of the collected liquid effluent is regulated by a management system.

11. The method of claim 1, comprising using a management system that directs collected liquid effluent from an accumulation device, raising the collected liquid effluent to a continuous high-pressure state, and directing the high-pressure pressure state liquid effluent through the microparticulate filtration system.

12. The method of claim 11, the collected liquid state fluid has a specific pressure or flow rate value is determined based at least in part on a second aspect of the pumping device that is different from the first aspect, optionally of a pumping system and/or the microparticulate filtration system.

13. The method of claim 11, wherein a sensor, the accumulator device, the pumping device, the microparticulate filtration system and the management system reside with the washing machine.

14. The method of claim 11, wherein a sensor, the accumulator device which is optional, the pumping device, the microparticulate filtration system or the management system reside at least partially outside the washing machine.

15. The method of claim 1, wherein an accumulation device is provided that includes an accumulator tank or the outer tub.

16. The method of claim 1, wherein the method involves storing at least a measured portion of the liquid effluent, while delaying the liquid effluent from leaving an accumulation device.

17. The method of claim 1, wherein the collected liquid effluent is collected by-way-of a hose or other hollow transport device.

18. The method of claim 1, wherein microplastics within the washing machine's liquid effluent discharge are collected and removed from the liquid effluent by a filtration system.

19. (canceled)

20. An apparatus for filtering microplastics from liquid effluent of a washing machine having an outer tub, the apparatus comprising:

a collector for collecting the liquid effluent from output of the washing machine's outer tub;
a device that establishes a high-pressure state to at least a portion of collected liquid effluent by at least one or two pumping devices, the pumping devices having a centrifugal, electromechanical, or diaphragm construction, based at least in part on a signal; and
a director that directs a amount of high-pressure liquid effluent by the pumping device or devices through a microparticulate filtration system that is effective for filtration of microplastics, wherein the amount is based at least in part on a first aspect of the pumping device or devices and/or microparticulate filtration system, the first aspect selected from pressure and/or flow rate of the device, devices or system.

21. The apparatus of claim 20, wherein the measured portion of liquid effluent is greater than approximately 250 cubic centimeters.

22. The apparatus of claim 20, wherein the measured portion of liquid effluent is less than approximately 2 liters.

23. The apparatus of claim 20, wherein the accumulation device is an accumulator tank or the outer tub.

24. The apparatus of claim 20, further comprising a sensor device that measures presence, pressure or rate of flow based in at least in part on a quantity of the liquid effluent.

25. The apparatus of claim 20, wherein a sensor device measures presence, pressure or rate of flow based on an aspect of the pumping device and/or filtration system.

26. The apparatus of claim 20, wherein a sensor device measures an aspect of the threshold amount of liquid effluent within the accumulation device.

27. The apparatus of claim 20, wherein the apparatus includes an interstitial space located between an inner drum's bottom of the washing machine and an outer tub's bottom of the washing machine that is utilized for sensor detection placement to measure presence, pressure, or rate of flow in at least in part on a quantity of the liquid effluent.

28. The apparatus of claim 20, wherein a management device detects presence, pressure or rate of flow based on an aspect of the pumping device and/or filtration system.

29. The apparatus of claim 20, wherein liquid effluent is released from an accumulation device to a pumping device.

30. A washing machine having an outer tub, the washing machine comprising: a means for collecting liquid effluent as output from an outer tub of the washing machine, a means for establishing a high-pressure state to at least a portion of collected liquid effluent by a pumping device or devices, the pumping device or devices having a centrifugal, electromechanical, or diaphragm construction, based at least in part on a signal, and a means for directing a amount of high-pressure liquid effluent by pumping device or devices through a microparticulate filtration system that is effective for filtration of microplastics, wherein the amount is based at least in part on a first aspect of the pumping device and/or microparticulate filtration system, the first aspect selected from pressure and/or flow rate of the device, devices or system.

31. The washing machine of claim 30, further comprising a means for raising pressure to a specific pressure value before invoking a means for directing, sometimes, at least a stored portion of the liquid effluent by a pumping device through the microparticulate filtration system.

32. The washing machine of claim 31, further comprising a means to remove microplastics from effluent water of the washing machine, before transferring microplastic-free effluent water to a collection area or sewer connection site.

Patent History
Publication number: 20220154385
Type: Application
Filed: Nov 10, 2021
Publication Date: May 19, 2022
Inventor: Steve Ross Antell (LaGrande, OR)
Application Number: 17/523,830
Classifications
International Classification: D06F 39/08 (20060101); D06F 39/10 (20060101); D06F 58/50 (20060101);