Patent Application
20120260418
1. Field of the Invention
The present invention relates in general to the field of lavatory systems. More particularly, the present invention relates to a lavatory system containing a combination wash basin with faucet, soap dispensing system, and bidirectional hand dryer which are triggered by sensors. Preferably, the system also has a number of unique use, overflow prevention, and cleaning features.
2. Discussion of the Related Art
As is known to those skilled in the art, lavatories in public places such as schools, libraries, airports, train and bus terminals, and shopping centers can be very busy at times. Further, depending on the volume of use and staffing, they can be messy, germ-filled environments that may be difficult for staff to adequately keep clean and safe. Thus, a previously recognized problem has been that often paper toweling runs out and waste baskets overflow. Further, the toweling and disposal thereof is costly. Moreover, hand-washing and drying stations, countertops, and floors in such public buildings easily become wet and dirty and are rarely configured for efficient use, cleaning, and maintenance.
While electronic hand dryers have been around for decades, this previously recognized solution also has the disadvantage of relatively high cost. Further, because of how such dryers are manufactured and sold, they are normally stand-alone units that are mounted some distance from the wash station. This forces users to wash, then drip water across the floor and dry their hands in another area of the room. The water on the floor may pool creating an unsafe, slippery, and germ-filled area. Further, as building construction and maintenance costs have risen and staffing is reduced, a preferred solution will be seen by the purchaser as being cost effective. A solution is cost effective when it is seen by the purchaser as compelling when compared with other potential systems that the purchaser could obtain with limited resources.
In light of the above, it is desirable to have a lavatory system that is efficiently configured to use, maintain, and clean and that helps provide a more safe environment for lavatory users.
By way of summary, the present invention is directed to a lavatory system. In one embodiment, the lavatory system includes a wash basin having a faucet operably connected to the wash basin and a soap dispensing system having a spout operably connected to the wash basin. A hand drying system is in fluid communication with the wash basin. The hand drying system includes a hand-receiving cavity, a top portion with an air outlet, and a bottom portion with an air outlet. The hand drying system also includes a motor in fluid communication with the air outlets for blowing air through the outlets. Multiple proximity sensors are operably connected to the motor and turn the motor on and off when triggered by an object. The lavatory system preferably also includes a mechanism to prevent water from entering the air outlets and the motor. For example, in one embodiment, small frustoconical protrusions preferably extend from the bottom portion air outlets to prevent water from entering into the air outlets and the motor.
The lavatory system also preferably includes a countertop integral with the wash basin. A frame under the countertop generally supports the countertop, wash basin with drainpipe, and motor. The frame includes a first generally triangular bracket mounted to a lavatory wall and a second generally triangular bracket mounted to a lavatory wall. A cover and end caps fit under the wash basin and countertop and mask the frame, motor, and drainpipe. A primary air inlet is in fluid communication with the motor and includes a small gap between the cover and/or at least one end cap and a lavatory wall to further attenuate the sound and minimize foreign object pick-up. An overflow prevention mechanism may include a lip integral with the wash basin that is located on a left side front edge of the wash basin and is lower than the bottom portion air outlets.
In use, at least one hand of a user is inserted into the hand drying system cavity at nearly an oblique angle, e.g., from about 5 to 50 degrees, from the horizontal. Four sensors located in and around the cavity are continuously queried by a microcontroller to detect the presence of such an object, e.g., the hand, in the cavity. The sensors are controlled by the microcontroller which is located on a sensor control board. A second microcontroller is located on a motor control board. This microcontroller operates the motor so that when the object is detected, the motor ejects air from the air outlets at preferably about 2.2 to 2.9 pounds per square inch (PSI) at the user's hand. Both microcontrollers control a preferable pre-programmed activation delay of approximately 400-800 milliseconds (ms) to delay, e.g., the starting of the motor.
The lavatory system has a service mode wherein one sensor is triggered to allow the hand-receiving cavity to be temporarily disabled. For example, if the right-most sensor consistently detects an object, the hand dryer is disabled for about 30 to 60 seconds to facilitate cleaning of the hand cavity.
The motor is surrounded by a motor housing that has an upper or outer casement, an intake cover and a rubber motor mounting isolation ring and housing gasket operably connected to the motor. The microcontroller preferably operates the motor to push air out a first and second outlet port each connecting to a hose. A preferably high efficiency particulate air (HEPA) media filter is contained in the housing to prevent debris from entering the motor and provide filtered air to the user. Sound-reducing techniques are also preferably employed in the motor housing. For example, foam insulation is provided to isolate and deaden the sound of the motor. A filter cover covers the filter and is configured to shift the direction of the air stream entering the motor housing. The filter cover also contains acoustical foam to reduce the operating volume of the motor and fan. As an added safety feature, the motor's air outlet ports are preferably covered by grates to prevent an object from being inserted into the ports.
The top portion air outlet and bottom portion air outlet are respectively fluidly connected to a first plenum and a second plenum that respectively connect via the hoses to the first outlet port and second outlet port in the motor housing. Each plenum is formed from two pieces of injection-molded plastic. In one embodiment, the central axes of the holes in the first or upper plenum are configured to emit air at an angle about 1 degree from vertical so as to aim the air toward the back side of the cavity. The central axes of the holes in the second or lower plenum are offset at an angle to emit air at about 37 degrees from horizontal and aim the air toward the back of the cavity. The plenums' two injection-molded pieces are preferably bonded and screwed together and a center post screw may be provided, as needed, to minimize the deflection of the plenums when pressurized.
Another embodiment of the lavatory system includes a wash basin, a faucet protruding from the wash basin, a soap dispensing spout protruding from the wash basin, and a hand dryer integral with the wash basin having a cavity, a top portion with air holes, and a bottom portion with air holes. Sensors along with lights, e.g., light-emitting diodes (LEDs), are operably connected to the hand dryer to continuously illuminate the hand dryer cavity at a low intensity level when a sensor does not detect the presence of an object and at a high intensity level when sensors detect that an object has entered into the dryer cavity. The LEDs may also serve to instruct a user to follow a certain path when using the system.
In one embodiment, a motor housing having a motor and an outer casement is operably connected to the hand dryer. Within the casement, a fan and an integral control are operably connected to the motor. A motor housing cap is operably connected to the casement and has perforations for air intake which are positioned to help reduce the sound volume of the motor and fan. A rubber motor mounting isolation ring and housing gasket operably connect to the motor. An outlet for connecting to a hose contains an integral grate to prevent a user from touching any of the motor's electrical or rotating parts. A filter is provided to prevent debris from entering the motor and foam is used to isolate the sound of the motor. A filter or intake cover covers the filter. The motor housing has an aluminum cover plate to provide a shield for electrical components, a heat sink, a structural mount for cable interfaces, and a common grounding point.
The system preferably has an overflow mechanism for preventing the motor and bottom portion air holes of the hand dryer from being filled with water. The mechanism may include an overflow lip integral with the wash basin and lower than the bottom portion air holes, and/or frustoconical protruding nozzles connected to the air holes. Other overflow mechanisms can include a standard overflow in either the wash basin or cavity or an overflow/drain located near the lower nozzle portion or plenum.
In another embodiment, a hand dryer is operably connected with a wash basin having a faucet and soap dispenser. The hand dryer has a top wall, bottom wall, back wall, and single side wall that create a hand cavity with a front and single side opening to allow a hand to enter only at an oblique angle. A plurality of nozzles is provided along the top wall and bottom wall for ejecting air at the hand. A motor having a first output and second output is in fluid communication with the top and bottom wall nozzles. The motor has a motor control circuit board. A motor housing surrounds the motor and includes an air intake manifold or cap and further contains an air filter. A primary air inlet is in fluid communication with the motor and includes a small gap between a trap cover and a wall to minimize ingestion of foreign materials into the motor and improve acoustical sound attenuation.
Ultraviolet (UV) lighting or some other sterilization technique may be provided to further disinfect hands and the hand cavity. Certain dryer components, including the nozzles, may have an antimicrobial additive that is added during the manufacture of the plastic part or sprayed on later.
Preferably, a single drain is contained in the wash basin and outside of the hand cavity. The drain is in fluid communication with the hand cavity and preferably eliminates the need for another device to catch water from the dryer and that must eventually be emptied.
The wash basin, bottom wall, a back wall, and single side wall are formed from a solid polymeric or a polymeric and stone material and the top wall is formed, in part, by a top plenum portion that is relatively horizontal and further serves as a shelf.
The nozzles are configured to eject air at speeds of approximately 340-360 miles per hour (MPH) at approximately 2.2-2.9 PSI. Preferably, the air creates high speed cylindrical upper and lower columns of air that collide to cause an s-shaped air flow pattern. The s-shaped air pattern directs water blown off of a user's hand to the bottom wall and back wall and helps minimize splashing of water back onto the user. The high speed cylindrical air columns and air flow pattern further minimize the net force exerted by the air on a users' hands and arms so as not to push the user's hands or arms into the top or bottom walls/surfaces of the hand dryer cavity.
A second row of holes, a slot, or a port may be provided to present a lower velocity air stream and further minimize splashing of water onto a user.
A sensor circuit board preferably controls a single bank of the sensors. The sensors are proximity sensors that measure distance by triangulation. If one of the sensors is activated by an object in the hand cavity, the microcontroller on the sensor board rechecks the activated sensor multiple times to validate that an object is actually present in the hand cavity and to minimize false activations by the hand dryer.
A programmable unit is also preferably present on the sensor board and includes a time delay in communication with an on/off switch for the motor. The delay mechanism allows the user to enter the user's hands fully into the hand cavity prior to the motor achieving full speed.
The microcontroller present on the sensor circuit board also controls LEDs. Some of the LEDs preferably continuously illuminate the hand cavity. However, when the sensors detect a user's hand in the cavity, LED illumination of the cavity increases.
In yet another embodiment, the lavatory system includes a bidirectional hand dryer having a top side, bottom side, back side, right side, and upper and lower nozzles respectively connected to upper and lower plenums. At least two flexible air delivery hoses connect to the plenums. A motor housing is provided including a motor, ports connected to the hoses, and a motor control.
A hand-receiving cavity between the top, back, right, and bottom sides receives at least one hand of a user. Upper and lower nozzle tips connect to the nozzles and emit high speed colliding columns of air to shear water off of the user's hand. The columns of air are spaced and calibrated in such a way as to reduce forces on the user's hand that would otherwise move the hand toward the upper or lower plenums or the sides and surfaces thereof.
The upper to lower nozzle tip spacing is about 3.5 inches with a hand cavity width of about 10 inches to provide the user with optimal comfort when using. The tips are pointed protrusions and help pull static air into the air columns. The pointed shape also prevents water from entering the nozzles.
In one embodiment, multiple distance sensors are present about the cavity and utilize triangulation or some other process to detect an object one sensor at a time and from left to right in the sensor's field of view. The sensors are positioned so that they are slightly recessed and aimed vertically into the hand cavity. The sensor board is preferably programmed so that all sensors are checked at about 130 ms intervals, and, when a sensor flags a detection, it is then rechecked 15 times over about a 15 ms period to ensure it was not a false trigger.
The lavatory system preferably also includes a touchless cleaning mode feature wherein if one sensor is the only sensor activated within the last two seconds, and if activated continuously for about three seconds, the dryer will enter the mode to allow cleaning of the dryer for about 30-60 seconds without dryer activation and then return to normal operation. Lights are provided in the system that flash twice when entering a cleaning mode and three times when approaching a time near the end of a cleaning cycle which is approximately 5 seconds before the end of an about 30-60 second cleaning cycle.
These and other aspects and objects of the present invention will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
A clear conception of the advantages and features constituting the present invention and of the construction and operation of typical mechanisms provided with the present invention, will become more readily apparent by referring to the exemplary, and therefore non-limiting, embodiments illustrated in the drawings accompanying and forming a part of this specification, wherein like reference numerals designate the same elements in the several views, and in which:
In describing the preferred embodiment of the invention that is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the words “connected”, “attached”, or terms similar thereto are often used. They are not limited to direct connection but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art.
The present invention and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments described in detail in the following description.
Now turning generally to
A soap dispensing system 26 is near the faucet 24 and in the wash basin 20. The soap dispenser 26 includes a spout 28 and a soap dispensing sensor (located behind sensor window 29) to detect an object, such as a user's hand 166 (See, e.g.,
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Bottom nozzles 160b are provided, again, preferably by molding into the lower plenum 144. Lower nozzles 160b, like the upper nozzles 160a, preferably have protruding frustoconical nozzle tips 162b each of which has a nozzle hole 164b therethrough. The shape of the nozzle tips 162b on the lower plenum 144 further acts as a flood prevention mechanism 40 to protect the motor 74.
The hand dryer blower motor 74 and motor housing 70 are best shown in
A filter or intake cover 96 may also be provided in the housing 70 to contain or to hold the filter 84 in place. To further attenuate sound generated by the fan motor 74, insulation or acoustical foam 97 is placed on the inside of the intake cover 96. The cover 96 is preferably further configured to redirect the intake air 90 degrees from the axial center of the fan 76 and motor 74. This design promotes reflection of acoustical waves off of the noise reducing acoustical foam 97. A wire 87 is provided to keep the filter cover 96 in place.
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The frame 120 and drain pipe 127 are preferably covered by a lavatory system cover 130 (best seen in
In a preferred embodiment, upper and lower nozzle tips 162a, 162b connected to the nozzles 162a, 162b emit high speed colliding columns of air to shear water off the user's hand. The tips, holes, and resulting air columns are spaced and calibrated in such a way as to reduce forces on the user's hand which would otherwise move the hand toward the upper or lower plenums or the side surfaces. As mentioned, one way of accomplishing this spacing and calibration is to have the axis of the air flow from upper plenum 142 nozzle holes 164a angled about 1 degree from vertical and aimed toward the cavity back wall 60 (
In one embodiment, the nozzles 160a, 160b preferably have tips 162a, 162b that are pointed protrusions that help pull static air into the air columns. These rows of nozzles are preferably mounted on two, approximately ten (10) inch, rectangular blocks or blades that fit, respectively, into the top and bottom air outlets 54, 56. The blades are preferably integral with the upper and lower plenums 142, 144. There are approximately 20 nozzles with tips formed or molded into each blade. These tips are approximately 0.050-0.060 inches long and have a diameter at the base of approximately 0.160-0.220 inches. The holes therein are preferably about 0.101 inches in diameter. From the center of one nozzle hole to the center of the next nozzle hole, it is preferably about 0.50 inches. As mentioned, the tips 162a, 162b preferably have a generally frustoconical shape to help prevent water from entering the nozzles 160a, 160b and also have about a 6 degree taper. In one preferred embodiment, the tips have a smooth, slightly rounded side wall to prevent catching of clothing or jewelry. When the dryer 50 is in use, the user's hands are preferably about 0.75 inches away from the nozzle tips.
As discussed, in one embodiment the nozzles and holes on the top blade and the nozzles and holes on the bottom blade are at different angles from the horizontal plane and vertically aligned with one another so that the collision of the upper and lower streams of air provide a unique air flow pattern. This configuration helps to generate an s-shaped airflow pattern. However, in another alternative embodiment, the holes and nozzles are lined up directly across the cavity from each other.
In one embodiment, the bidirectional or dual-sided dryer uses 1600 watts (or 13.7 amps) and will dry hands in about 15 seconds at 80 decibels (dB) with 70 cubic feet per minute (CFM). In this embodiment, the dryer runs off a 120V outlet and requires a dedicated 20 ampere (amp) circuit. Ground fault interruption (GFI) circuit protection is preferred.
Referring now primarily to
In one preferred embodiment, the LEDs 108a-m are operably connected to the hand dryer 50. For example, LEDs 108a-d continuously illuminate the hand-receiving cavity 52 at a low intensity level when a sensor does not detect the presence of an object, i.e., the cavity is not in use or in “stand-by”. However, when a sensor detects that an object has entered into the hand-receiving cavity 52, and during dryer 50 activation, preferably the LEDs 108e-h and 108i-l also illuminate cavity and thus increase the overall intensity level of light in the cavity. In another embodiment, LEDs 108a—do not begin to illuminate the cavity until the soap is dispensed or the water begins to flow in the basin.
In a preferred embodiment, when a staff member wishes to clean and service the lavatory system 10 the staff member may engage a service mode. Here the LEDs 108a-d and 108e-h continuously illuminate the hand-receiving cavity 52. Activation of hand dryer 50 is also suppressed by communication between microcontroller 78 and microcontroller 99. In one embodiment, service mode activation is accomplished by triggering a sensor, e.g., the right-most sensor 103d in the upper portion of the hand-receiving cavity 52, for an extended time period. Thus, if this one sensor consistently detects an object in the hand-receiving cavity 52, the hand dryer 50 is disabled for about 30 to 60 seconds and some of the LEDs, e.g., LEDs 108e-h, may be illuminated at a high-intensity level. This allows the hand-receiving cavity 52 to be temporarily cleaned without further engaging the hand dryer 50.
The LEDs, e.g., 108i-l, may flash in certain ways when the service mode has been started and/or is about to end. For example in one embodiment, prior to the service mode, one row of 4 white LEDs provides lower level illumination of the hand dryer cavity. However, if the rightmost sensor is triggered within the last 2 seconds and if a hand is placed over the rightmost sensor for the period of 3 seconds, a row of 4 amber LEDs will rapidly flash twice to designate that the unit is entering the service mode. At the same time, a second row of 4 white LED's will turn on to increase the illumination of the hand cavity for approximately 30 seconds to assist in cleaning. After approximately 25 seconds from when the service mode was started, the row of 4 amber LEDs will flash three times to indicate that the service mode cycle is nearing completion. At the end of the service mode cycle (5 seconds after the 4 amber LEDs flash three times or about 30 seconds in total service cycle length), the second row of white LEDs will turn off and the hand dryer cavity will remain lit at the lower level of illumination by the first row of 4 LEDs.
In one embodiment, the service mode includes a microcontroller with a programmed touchless cleaning mode feature wherein if one sensor is the only sensor activated within the last two seconds and if activated continuously for about three seconds, the hand dryer 50 will enter the mode to allow cleaning of the hand dryer 50. This mode lasts for about 30 seconds without activation of the dryer and then the microcontroller will return the system to normal operation. The microcontroller will flash the LED lights twice when entering the cleaning mode and three times when approaching a time near the end of a cleaning cycle which is approximately 25 seconds into an about 30 second cleaning cycle. If the cleaning mode is longer in another embodiment, the lights will flash 3 times 5 seconds before the end of the cleaning cycle.
The sensor detection modules 105a and 105b utilize an internal triangulation algorithm to sense IR light, 106a and 106b respectively, when an object is in the sensor's field of view. When a user's hand 166 enters the hand-receiving cavity 52, the sensor detection modules 105a and 105b output an electrical signal (e.g. a 5 volt signal). This signal is used by the microcontroller 78 to determine whether to activate the hand dryer (50) and LED lights 108e-l (see
A programmable unit may be present on the sensor control board 100 and/or motor control board 98 and preferably includes a time-delay mechanism, for example, in communication with an on/off switch for the motor 74. In this embodiment, when one of the sensors 103a-d is activated by an object in the hand-receiving cavity 52, the microcontroller 78 rechecks the activated sensor multiple times to validate that an object is in the hand-receiving cavity 52. Then the delay mechanism allows users to enter their hands 166 fully into the hand-receiving cavity 52 prior to the hand dryer motor 74 achieving full speed. This minimizes the potential of any splashing of water back on the user as a result of the fully active hand dryer imposing a shearing action on water present on the user's hands. There may be additional sensors (not shown) that may inhibit the dispensing of water or soap or activation of the dryer when a critical water level is reached in the wash basin and thus prevent overflow, flooding, and/or motor damage.
In one embodiment, multiple distance sensors 103a-d utilize triangulation one at a time and from left to right in their field of view to detect an object. These sensors are preferably positioned so they are recessed in the upper portion 53 and aimed vertically into the hand-receiving cavity 52. Recessing is minimal, however, to avoid adversely impacting sensor operation. In one embodiment, the sensor board 100 is programmed to check all sensors at about 130 milliseconds (ms) intervals. When a sensor flags a detection, it is then rechecked 15 times over about a 15 ms period to ensure the detection was not a false trigger.
The temperature rise of the air during a drying cycle is dependent upon how long the user keeps the hand dryer 50 activated. Since the system 10 does not use an auxiliary air heater, the air temperature rise is a result of the heat generated by the inefficiency of the motor 74. The other factor dictating the motor temperature rise is how frequently the motor 74 is activated. In a high usage environment (airport, sports arena, etc.), the motor 74 will not typically cool down very much between cycles and the air temperature rise experienced by the user will be significantly higher than that of a hand dryer which operates infrequently. The following chart shows some typically temperatures.
30 seconds
In one embodiment, additional safety and cleaning features may be present. For example, UV lighting or some other sterilization technique to disinfect the hand-receiving cavity 52 may be provided. Further, only one drain may be provided between the wash basin 20 and outside of hand-receiving cavity 52 to eliminate the need for another device to catch water from the dryer 50 that must be emptied and can collect harmful molds or germs. Certain dryer components, like the nozzles 160a, 160b, may have an antimicrobial additive molded into the plastic. Further, the entire wash basin 20 and hand-receiving cavity 52 may be constructed, in part, of an antimicrobial material or may be coated with such a material during manufacture.
In one embodiment, a second row of holes, a slot, and a port are present to provide a lower velocity air stream to further minimize water splashing onto a user.
In the embodiment shown in
A bottom portion 255 includes a lower air outlet 256. The bottom portion 255 is formed, in part, by a bottom wall or side 259. The bottom portion 255 of the hand-receiving cavity 252 also includes a back wall or side 260, front wall or side 261, and side wall 262. A front ledge 263 is integral with the front wall 261. The hand-receiving cavity 252, therefore, is preferably configured to have a front opening 264 and a side opening 265 (shown on the left side). In this embodiment, the dryer's configuration and placement preferably allows the user to easily transition the hands from the wash basin to the dryer without dripping water onto the floor.
In one preferred embodiment, a mechanism 240 for preventing flooding and damage to the hand dryer motor is provided as well as to prevent water blown from a users' hands from falling to the floor and creating a slip hazard or unsanitary conditions. The mechanism 240 may include a flood relief rim 244 located on, for example, the left side of the hand-receiving cavity 252 at the opening 265. The flood relief rim 244 is provided below the lower portion's air outlet 256 and the nozzle tips 262b as shown. Thus, water flows over the flood relief rim 244 and not down the nozzle holes 264b and into the motor (not shown). In addition, another motor protection mechanism 240 may be the frustoconical lower nozzle tips 262b which resist the entry of water.
Other preferred embodiments of the hand dryer 250 may include a side wall 262 on the left side and an opening 265 on the right side. In yet another preferred embodiment, the hand dryer 250 may include both a left side side wall and a right side side wall.
The primary components of the inventive lavatory system including the dryer bottom wall, a back wall, and single side wall are preferably formed from a plastic and/or resin material. In one embodiment, the system components may be formed from a solid polymeric and/or a polymeric and stone material. In another embodiment, the system components may be manufactured from Terreon® or TerreonRE® which are low emitting, e.g., Greenguard™ materials and available from the Bradley Corporation of Wisconsin.
In another embodiment, as best shown in
Thus, it is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but includes modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.
