Patent Application
20060150360
The present invention relates to vacuum systems and, more particularly, to a central vacuum system for an inhabitable structure.
Central vacuum systems are often mounted in inhabitable structures, such as, for example, homes, commercial buildings, and the like. In many cases, central vacuum systems include a system of ducts, which extend throughout the structure into various rooms of the structure. Vacuum hoses or nozzles can be connected to the ducts to collect debris. Central vacuum systems generally include a housing supporting a vacuum motor which draws debris through the hoses and the ducts and into a collection chamber.
Some embodiments of the present invention provide a central vacuum system connectable to an interior portion of an inhabitable structure. In some embodiments, the central vacuum system includes a housing having an upper end, a lower end, and a side wall defining a collection chamber, the side wall defining an opening communicating between atmosphere and the collection chamber, and a vacuum motor supported in the housing and being operable to move debris from the interior portion into the collection chamber.
In addition, some embodiments of the invention provide a vacuum bag assembly for a central vacuum system, the central vacuum system including a housing defining a collection chamber and having a bag mounting assembly extending into the collection chamber. In some embodiments, the vacuum bag assembly can include a flange connectable with the bag mounting assembly to secure the bag in the collection chamber, the flange defining an inlet and supporting a cover, the cover being moveable relative to the flange between a closed position, in which the cover substantially covers the inlet, and an opened position, in which at least a portion of the cover is moved away from the inlet. The cover can be connectable to the bag mounting assembly so that, when the flange is disconnected from the bag mounting assembly, the cover is moved between the opened position and the closed position.
Some embodiments of the invention provide a central vacuum system including a housing having a wall defining a collection chamber, a bag mounting assembly extending into the collection chamber, a bag having a flange connectable with the bag mounting assembly to secure the bag in the collection chamber, the flange defining an inlet and supporting a cover, the cover being moveable relative to the flange between a closed position, in which the cover substantially covers the inlet, and an opened position, in which at least a portion of the cover is moved away from the inlet, and a vacuum motor supported in the housing and being operable to move debris from the interior portion into the bag. The cover can be connectable to the bag mounting assembly so that when the flange is removed from the bag mounting assembly, the cover is moved between the opened position and the closed position.
In addition, some embodiments of the invention provide a method of operating a central vacuum system connectable to an interior portion of an inhabitable structure, the central vacuum system including a housing having an upper end, a lower end, and a side wall defining a collection chamber, the side wall defining an opening communicating between atmosphere and the collection chamber. Some embodiments include the acts of providing a vacuum motor supported in the housing, inserting a bag into the collection chamber through the opening in the side wall, and directing debris from the interior portion into the bag with the vacuum motor.
Some embodiments of the invention provide a method of operating a central vacuum system connectable to an interior portion of an inhabitable structure, the central vacuum system including a housing having a wall defining a collection chamber, a vacuum motor supported in the housing, and a bag mounting assembly extending into the collection chamber. In some embodiments, the method can include the acts of inserting a bag into the collection chamber, the bag having a flange defining an inlet and supporting a cover, connecting the flange to the bag mounting assembly, moving the cover relative to the flange toward an opened position, in which the cover is moved away from the inlet, connecting the cover to the bag mounting assembly, moving debris from the interior portion into the bag with the vacuum motor, disconnecting the flange from the bag mounting assembly, and removing the bag from the collection chamber. When the flange is disconnected from the bag mounting assembly, the cover can be moved relative to the flange between the opened position and a closed position, in which the cover substantially covers the inlet.
Some embodiments of the invention provide a central vacuum system including a housing having a wall defining a collection chamber, a vacuum motor supported in the housing and being operable to move debris from the interior portion into the collection chamber, a sensor positioned in the collection chamber and being operable to record pressure data in the collection chamber, and a controller supported in the housing and being in communication with the sensor to receive the pressure data from the sensor, the controller being operable to calculate a quantity of debris in the collection chamber using the pressure data.
Some embodiments of the invention provide a method of operating a central vacuum system connectable to an interior portion of an inhabitable structure, the central vacuum including a housing having a wall defining a collection chamber, a sensor positioned in the collection chamber, and a controller supported in the housing. In these embodiments, the method includes the acts of moving debris from the interior portion into the collection chamber, recording pressure data in the collection chamber with the sensor, transmitting the pressure data from the sensor to the controller, and estimating a quantity of debris in the collection chamber using the pressure data from the sensor.
Some embodiments of the invention further provide a central vacuum system connectable to an interior portion of an inhabitable structure, including a housing having a wall defining a collection chamber and a motor housing, the motor housing having an elliptical cross section, and a vacuum motor supported in the motor housing and being operable to move debris from the interior portion into the collection chamber.
Further aspects of the present invention, together with the organization and operation thereof, will become apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the drawings.
Before the various embodiments of the present 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 arrangements of components set forth in the following description or illustrated in the 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 phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like “front”, “rear”, “up”, “down”, “top”, “bottom”, and the like) are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation. The vacuum system and elements of the vacuum system referred to in the present invention can be installed and operated in any orientation desired. Similarly, the vacuum bag and elements of the vacuum bag referred to in the present invention can be installed and operated in any orientation desired. In addition, terms such as “first”, “second”, and “third” are used herein and in the appended claims for purposes of description and are not intended to indicate or imply relative importance or significance.
As partially shown in
The vacuum system 10 can have a housing 18 having any shape desired, such as a round shape, a rectangular, triangular, or other polygonal shape, an irregular shape, and the like. By way of example only, the housing 18 of the illustrated embodiment has a generally elongated configuration and has an elliptical cross sectional shape. In addition, in some embodiments, such as the illustrated embodiment of
As shown in
The housing 18 of the central vacuum system 10 can be installed in a number of locations throughout the structure, such as, for example, in the garage, basement, or utility room of a home or a business, or alternatively, the housing 18 can be installed in a closet. To simplify installation and to provide a maximum number of possible installation options, the illustrated embodiment includes a number of inlet openings 32, each of which can be connected to the duct system 14 to fluidly connect the housing 18 (and the vacuum motor 48, which is described in greater detail below) to the duct system 14. In the illustrated embodiment of FIGS. 2, 4-8, 11-14, 17, and 19A, inlets 32 are located on the left and right sides of the housing 18. In other embodiments, inlets 32 can extend through other portions of the housing 18 and can have other orientations to provide further installation options.
During installation, the housing 18 is secured to the structure and the housing 18 is oriented so that one of the inlets 32 can be connected to the duct system 14. A connector 34 is then inserted into the inlet 32 to fluidly connect the housing 18 to the duct system 14 (and the vacuum motor 48, which is described in greater detail below). In some embodiments, such as the illustrated embodiment of
An elastomeric material can also or alternately be positioned between the connector 34 and a portion of the duct system 14 to sealingly connect the connector 34 and the duct system 14. Covers 35 are then placed over the other inlets 32 to seal these inlets 32.
As shown in
In the embodiment of
In still other embodiments, such as the illustrated embodiment of
In some embodiments, elements of the vacuum system 12, such as, for example, the cap 36, the motor cage 38, the baffle 40, and/or the second module 22, can be constructed so that common elements can be used in constructions of the vacuum system 12 having one or more vacuum motors 48 located in any number of locations in the drive space 26. In these embodiments, no or relatively minor modifications are made to assemble various vacuum systems 12 having a number of different configurations.
In some embodiments, such as the illustrated embodiment of
With reference to
In some embodiments, acoustic dampening material (e.g., elastomeric materials, such as, for example, polyester, polyurethane, melamine, and the like) 64 can be positioned in the drive space 26 to absorb noise generated by air flowing through the drive space 26. In the illustrated embodiment of
The vacuum system 10 can also include an exhaust system 66, which provides an exit for air exhausted from the vacuum motor 48. As shown in
In the illustrated embodiment of
The exhaust system 66 and the acoustic dampening system 68 of the illustrated embodiment also include an elbow 71 connected to a downstream end of the muffler 69 and a dampening chamber 72 defined between a first dampening wall 73 and a second dampening wall 74. As shown in
As mentioned above, portions of the second and third modules 22, 24 substantially enclose the collection chamber 28. The second module 22 defines an upper portion of the collection chamber 28 and includes an upper wall 54 and a side wall 80 having a downwardly extending ridge 82. An opening 84 extends through the side wall 80 and provides access to the collection chamber 28 and, in embodiments having vacuum bags 12, provides access to vacuum bags 12 located in the collection chamber 28. In some embodiments, the opening 84 also provides access to other elements and systems of the vacuum system 10, such as, for example, the vacuum motor 48 and the controller 160 (described below) so that operators can perform maintenance operations.
In some embodiments, such as the illustrated embodiment of
As shown in
The third module 24 defines the lower portion of the collection chamber 28 and includes a bottom wall 96 and a side wall 98. Together, the bottom and side walls 96, 98 can define a pail 100, which is operable to collect and contain debris and/or support a vacuum bag 12. In some embodiments, the third module 24 can also support one or more replacement bags 12. In other embodiments, replacement bags 12 can be housed in other locations throughout the housing 18.
In some embodiments, the vacuum system 10 can include a locking assembly 104 for securing the third module 24 to the second module 22. In the illustrated embodiment of
The locking assembly 104 of the illustrated embodiment of
With reference to the illustrated embodiment of
In some embodiments, such as the illustrated embodiment of
As shown in
The vacuum system 12 can also include an adapter 116, which extends into the collection chamber 28 and is engageable with a vacuum bag 12 to fluidly connect the vacuum motor 48 and the duct system 14 to the vacuum bag 12. As shown in
The vacuum system 10 can also include a bag mounting assembly 118, which extends into the upper portion of the collection chamber 28 and is operable to support a vacuum bag 12 in the housing 18. In some embodiments, such as the illustrated embodiment of
In the illustrated embodiment of
In the illustrated embodiment of
In embodiments, such as the illustrated embodiment of
In some embodiments, such as the illustrated embodiment of
As shown in
In some embodiments, such as the illustrated embodiment of
To facilitate filter replacement, the filter 154 can include a tab 156, which extends downward into the collection chamber 28. In these embodiments, the tab 156 is oriented to be accessible through the opening 84.
In some embodiments, an operator can clean the filter 154 by inserting a hand into the collection chamber 28 through the door 88 and tapping or shaking the filter 154. Debris trapped in the filter 154 will then fall to the bottom of the collection chamber 26.
The vacuum system 10 can also include a controller 160 operable to control and monitor operation of the vacuum system 10 and a display panel 162 for displaying system data relating to the operation of the vacuum system 10. In the illustrated embodiment of
The vacuum system 10 can also include a number of sensors 164 distributed throughout the housing 18 for monitoring and controlling operation of the vacuum system 10. In the illustrated embodiment of
In these embodiments, a base pressure value corresponding to an empty collection chamber 28 or empty bag 12 is stored in the controller memory unit. As the collection chamber 28 or a bag 12 supported in the collection chamber 28 is filled, the air pressure in the collection chamber 28 increases. The pressure sensor 164 records these increases and transmits the pressure data to the controller 160. The controller 160 continuously compares the pressure data from the sensor 164 to the base pressure value to calculate the volume of debris in the collection chamber 28 or in a bag 12 supported in the collection chamber 28. Alternatively or in addition, the controller 160 continuously compares the pressure data from the sensor 164 to the base pressure value to calculate the volume of empty space or capacity remaining in the collection chamber 28 or in a bag 12 supported in the collection chamber 28 as debris is collected.
In other embodiments, a maximum pressure value corresponding to a full collection chamber 28 or a full bag 12 is stored in the controller memory unit. In operation, the pressure sensor 164 records the increases in pressure as debris is collected in the collection chamber 28, or alternatively, in a bag 12 supported in the collection chamber 28. The pressure sensor 164 transmits the pressure data to the controller 160 and the controller 160 continuously compares the pressure data from the sensor 164 to the maximum pressure value to calculate the volume of debris in the collection chamber 28 or in a bag 12 supported in the collection chamber 28. Alternatively or in addition, the controller 160 continuously compares the pressure data from the sensor 164 to the maximum pressure value to calculate the volume of empty space or capacity remaining in the collection chamber 28 or in a bag 12 supported in the collection chamber 28 as debris is collected.
In some embodiments, the display panel 162 displays the remaining capacity in the collection chamber 28 or in the bag 12 supported in the collection chamber 28, or alternatively, displays the volume of debris in the collection chamber 28 or in the bag 12 supported in the collection chamber 28. In the illustrated embodiment of
It has been found that, in some embodiments, the vacuum motor 48 can become overheated and/or damaged when the vacuum system 10 is operated after the collection chamber 28 or a bag 12 supported in the collection chamber 28 is filled to a maximum allowable capacity.
In some embodiments, the controller 160 is operable to shutdown the vacuum motor 48 when the collection chamber 28 or a bag 12 supported in the collection chamber 28 is fill to prevent damage to the vacuum motor 48. In these embodiments, a maximum allowable pressure value corresponding to a maximum allowable capacity of debris is stored in the controller memory unit. When the pressure sensor 164 records a pressure value in the collection chamber 28 which is greater than or equal to the maximum allowable pressure value, the controller 160 shuts down the vacuum motor 48. Alternatively or in addition, the controller 160 can be programmed to display a warning message or to activate a warning light when the pressure sensor 164 records a pressure value in the collection chamber 28 which is greater than or equal to the maximum allowable pressure value.
In some embodiments, the vacuum system 10 includes temperature sensors 168, which are positioned in the drive space 26 and are operable to record the temperature of the vacuum motor 48. In these embodiments, a maximum temperature value corresponding to a maximum allowable motor temperature is stored in the controller memory unit. When the temperature sensor 168 records a temperature value in the drive space 26 which is greater than or equal to the maximum allowable temperature, the controller 160 shuts down the vacuum motor 48 to prevent or reduce damage to the vacuum motor 48. Alternatively or in addition, the controller 160 can be programmed to display a warning message or to activate a warning light when the temperature sensor 168 records a temperature value in the collection chamber 28 which is greater than or equal to the maximum allowable temperature value.
In other embodiments, other sensors can be positioned in the collection chamber 28 to record data corresponding to the capacity of the collection chamber 28 or a bag 12 supported in the collection chamber 28 to monitor operation of the vacuum system 10. For example, the vacuum system 12 can include microphones positioned in the collection chamber 28. In these embodiments, sound data is transmitted from the microphones to the controller 160 and the controller 160 calculates the capacity of the collection chamber 28 or a bag 12 supported in the collection chamber 28.
The controller 160 can also include a timer. In these embodiments, a maximum motor operation time is stored in the controller memory unit and the controller 160 is programmed to alert the operator or shut down the vacuum motor 48 when the vacuum motor 48 is operated longer than the maximum motor operation time. For example, the controller 160 can be programmed to shut down the vacuum motor 48 if the vacuum motor 48 is continually operated for 3 hours. Alternatively or in addition, the controller 160 can be programmed to shut down the vacuum motor 48 when the vacuum motor 48 is operated for more than 3 hours during a 4 hour period.
In embodiments having a timer, the controller 160 can be programmed to estimate the length of time the vacuum motor 48 is operated between bag replacements or occasions in which the collection chamber 28 is emptied. In these embodiments, the controller 160 can be programmed to progressively illuminate lights on the control panel 162 corresponding to the length of time the vacuum motor 48 has been operated between bag replacements or occasions in which the collection chamber 28 is emptied. For example, in some embodiments, the controller 160 is programmed to illuminate a first green light after one hour of vacuum motor operation, a second green light after a second hour of vacuum motor operation, an amber light after a third hour of vacuum motor operation, and a red light after a fourth hour of vacuum motor operation.
In embodiments having a controller 160, the vacuum system 10 can also include a reset button 170. In the illustrated embodiment of
In embodiments having a reset button 170, an operator can press the reset button 170 to restart the vacuum motor 48 after replacing the full vacuum bag 12 with a new bag 12 or after the operator empties the collection chamber 28. In embodiments having a pressure sensor 164, the controller 160 can be programmed to record a new pressure value in the collection chamber 28 after the reset button 170 has been pressed. If after being shut down, the pressure sensor 146 again records a pressure value greater than the maximum allowable pressure value, the controller 160 can be programmed to shut down the vacuum motor 48 or to alert the operator. In other embodiments having other sensors, such as, for example, temperature sensors or microphones, the controller 160 can be programmed to record new values after the reset button 170 is pressed and to compare these new values to predetermined maximum values. If the new values remain greater than the predetermined allowable values, the controller 160 can be programmed to shut down the vacuum motor 48 a second time, or alternatively, to alert the operator (e.g., by illuminating a warning light on the display panel 162.
In embodiments having a bag mounting assembly 118 for supporting a vacuum bag 12, an operator opens the door 88 to insert a new bag 12 into the collection chamber 28. The operator then pivots the bag plate 122 downwardly from the locking position toward the unlocking position. Next, the operator inserts a vacuum bag 12 into the collection chamber 28 so that the body 132 extends downwardly into the third module 24 and aligns the flange 134 of the vacuum bag 12 with the rails 130 of the bag plate 122. The operator then moves the flange 134 into engagement with the bag plate 122. As the flange 134 is engaged with the bag plate 122, the cover 138 is moved forwardly with respect to the flange 134 to align the opening 140 in the cover 138 with the inlet 136 in the flange 134 and to engage the protrusion 146 of the bag mounting assembly 118 in the recess 148 in the cover 138.
The operator next pivots the bag plate 122 upwardly toward the locking position, moving the flange 134 into engagement with the adapter 116 so that at least a portion of the adapter 116 extends through the inlet 136 in the flange 134 and through the opening 140 in the cover 138. The operator then secures the bag plate 122 in the locking position with the latch 144 and closes the door 88, sealing the bag 12 in the collection chamber 28.
The operator can then operate the vacuum system 10 in a conventional manner to draw debris into a hose, nozzle, or other port and through the duct system 14 toward the adapter 116, which directs the debris into the vacuum bag 12.
Over time, the vacuum system 10 fills the bag 12 with debris. In embodiments of the vacuum system 10 having a controller 160 and a display panel 162, the controller can be operable to alert the operator when the bag 12 is filled and when bag replacement is necessary, as mentioned above. Alternatively or in addition, the operator can open the door 88 to determine when bag replacement is necessary or the operator can look through the viewing window 92 in the door 88 to determine when bag replacement is required.
When bag replacement is required, the operator shuts down the vacuum motor 48 and opens the door 88. The operator then grasps the latch 144 to unlock the bag assembly 118 and pivots the bag plate 122 and the bag flange 134 downwardly toward the unlocking position. The operator then slides the bag flange 134 forwardly along the rails 130 and away from the bag mounting assembly 118.
As the bag flange 134 is moved away from the bag mounting assembly 118, the protrusion 146 on the bag mounting assembly 118 remains engaged in the recess 148 in the cover 138, causing the cover 138 to move relative to the flange 134 from the opened position toward the closed position so that the cover 138 extends across and substantially covers the inlet 136 in the flange 134. The operator then removes the bag flange 134 from the bag mounting assembly 118 and lets the bag 12 fall to the bottom of the collection chamber 28 (i.e., the bottom of the third module 24).
Next, the operator moves the locking assemblies 104 from the locking positions toward the unlocking positions and removes the third module 24 (and consequently the bag 12 supported in the third module 24) from the second module 22. The operator can then remove the bag 12 from the third module 24 and dispose of the bag 12 in a conventional manner.
Once the bag 12 has been removed, the operator reconnects the third module 24 to the second module 22 and moves the locking assemblies 104 toward the locking positions to secure the third module 24 to the second module 22. The operator can then insert a new bag 12 into the collection chamber 28, as explained above.
In embodiments not having a bag mounting assembly 118 for supporting a vacuum bag 12, the operator operates the vacuum system 10 in a conventional manner to draw debris into a hose or nozzle and through the duct system 14 toward the adapter 116, which directs the debris into the collection chamber 28.
Over time, the vacuum system 10 fills the collection chamber 28 with debris. In embodiments of the vacuum system 10 having a controller 160 and a display panel 162, the controller can be operable to alert the operator when the collection chamber 28 is filled and when it is necessary to empty the collection chamber 28, as mentioned above. Alternatively or in addition, the operator can open the door 88 to determine when it is necessary to empty the collection chamber 28, or alternatively, the operator can look through the viewing window 92 in the door 88 to determine when it is necessary to empty the collection chamber 28.
When it is necessary to empty the collection chamber 28, the operator shuts down the vacuum motor 48. The operator then moves the locking assemblies 104 from the locking positions toward the unlocking positions and removes the third module 24 (and the debris contained in the third module 24) from the second module 22. The operator can then empty the third module 24 and dispose of the debris in a conventional manner.
Once the debris has been removed from the third module 24, the operator reconnects the third module 24 to the second module 22 and moves the locking assembly 104 toward the locking position to secure the third module 24 to the second module 22. The operator can then resume operation of the vacuum system 10.
In some embodiments, such as the illustrated embodiment of
As shown in
The third module 24A defines the lower portion of the collection chamber 28A and includes a bottom wall 96A and a side wall 98A. Together, the bottom and the side walls 96A, 98A can define a pail 100A, which is operable to collect and contain debris. As shown in the illustrated embodiment of
The vacuum system 10A can also include a filter mounting assembly 118A for supporting a filter 12A in the collection space 28A. In the illustrated embodiment of
As shown in
As shown in
In some embodiments, the side wall 80A of the second module 22A defines an inlet 228 communicating between atmosphere and the collection chamber 28A. In embodiments of the vacuum system 10A having a mounting plate 120A, such as the illustrated embodiment of
During operation, an operator connects a hose or nozzle to the duct system 14 and activates the vacuum motor 48A, which operates to draw debris and air through the duct system 14 and into the collection chamber 28A through the conduit 234. In embodiments of the vacuum system 10A having a filter mounting assembly 118A and a filter 12A supported in the collection chamber 28A, air and debris entering the collection chamber 28A move the filter 12A relative to the mounting plate 120A from the deflated orientation toward the inflated orientation. The filter 12A can then operate as a filter, allowing air to move upwardly through the collection chamber 28A and outwardly toward the exhaust system 66A while preventing debris from exiting the collection chamber 28A. In addition, the filter 12A can prevent or reduce movement of debris from the collection chamber 28A into the drive space 26A.
In embodiments, such as the illustrated embodiment of
To remove debris from the collection chamber 28A, the operator shuts down the vacuum motor 48A and removes the third module 24A from the second module 22A. The operator can then empty the third module 24A and dispose of the debris in a conventional manner.
In embodiments, such as the illustrated embodiment of
Various alternatives and embodiments are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention.
