Fluid Decontamination Assembly

I hereby claim the benefit under 35 U.S.C. Section 119(e) of U.S. Provisional application Ser. No. 63/636,911, filed on Apr. 22, 2024.

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The disclosure relates to fluid separation device and more particularly pertains to a new fluid separation device for efficiently separating a contaminant from a fluid.

The prior art relates to fluid separation devices, and in particular to fluid skimmers. Fluid skimmers are often used in industrial fluid operations, where a waste fluid, such as oil, contaminates a non-waste fluid, such as a coolant. For example, many industrial machines utilize coolant fluids to facilitate machining and metal cutting operations. Coolants lower the temperature of these machines. In a more specific illustration, coolants may reduce the temperature of a blade or other tool at the point where it is cutting another object. The coolant may also be used to wet the surfaces of the blade and the object being cut, reducing wear on the blade, after which the coolant is drained into a sump.

Moving parts of these machining tools also commonly need to be lubricated with an oil, again reducing wear from friction as these moving parts interact with each other. Oils are also often used to prevent rust from forming on metal stock materials as those stock materials wait to be machined. During the machining process, these lubricating and rust preventative oils mix with the coolant, and the entire mixture is collected in the sump.

The lubricating and rust preventative oils, which collectively are sometimes referred to as “tramp oils,” carry bacteria, yeast, fungus, and mold. Those contaminants reduce the lifetime of the coolant. They can also create smoke and cause other air quality issues during the machining process. Solid debris, such as metal chips and fines from the stock material being processed, can further contaminate the coolant when it is drained into the sump.

Because coolants tend to have relatively high values compared to oils and other waste fluids, it is often desirable to recapture the coolant and separate the coolant from the tramp oils so that the coolant can be recirculated. Recirculating the coolant reduces operating costs, creating a strong financial incentive for manufacturers to decontaminate the coolant rather than simply disposing it.

Various remediation processes are employed to separate the coolant, and other non-waste fluids, from the tramp oils, and other waste. Skimming is a preferred remediation processes when the non-waste fluid has a higher density than the waste fluid, such that gravity helps to separate the non-waste fluid from the waste fluid. If the fluids are left standing in a container for a sufficient amount of time, the waste fluid will form a stratified layer on top of the non-waste fluid. The skimmer drives a belt with an affinity to collect tramp oil through the sump. The belt carries these contaminants out of the sump to a scraper that removes the tramp oil from the belt for collection in a separate container.

The present inventor disclosed some improvements over standard skimmers in U.S. Pat. Nos. 9,248,388, 9,849,410, and 10,543,438, all of which are incorporated by reference, in their entireties, into this disclosure. The present disclosure provides further improvements. Through extensive field and laboratory research, the present inventor discovered that the location at which the belt enters and exits the sump can significantly increase the amount of oil which the belt can remove. Because the oil tends to have a lower density than the coolant, the closer the entry and exit points of the belt can be to the upper surface of the fluids within the sump, the more efficiently the belt can separate the fluids. However, as the fluids are deposited into and removed from the sump, the upper surface of the fluids continuously changes position, rising as more coolant is dumped into the sump and falling as the oil is removed. Existing skimming systems are unable to automatically control the position of the entry and exit points of the belt relative to the surface of the fluids.

For example, the belts of previous skimming machines often extend far below the upper surface of the coolant before the belt pulls the oils out of the sump for collection in the separate container. Because such a significant portion of the belt is submerged in coolant, the coolant rinses the oil off of the belt such that the oil is re-mixed with the coolant inside the sump. One existing solution is to use a fixed adjustment for the length of an arm that positions the belt within the sump, allowing a user to periodically reposition the belt relative to the upper surface of the coolant. However, such solutions fail to address the constantly rising and falling levels of the fluids within the sump during the machining process. Thus, there is a need for a skimmer device that automatically adjusts the position of the belt within the sump as the levels of the fluids change.

An embodiment of the disclosure meets the needs presented above by generally comprising a receiving vessel and a motor that has a housing and a drive shaft. A drive wheel is coupled to the drive shaft. Rotation of the drive shaft rotates the drive wheel. A follower wheel is aligned with the drive wheel along a longitudinal axis. A belt couples the drive wheel to the follower wheel wherein the belt forms a loop extending between the drive wheel and the follower wheel. The belt, which is formed of an elastomeric material, rotates in the loop while the drive wheel is rotated. An arm extends between the drive wheel and the follower wheel wherein opposing ends of the arm define the longitudinal axis.

A pivot assembly pivotably couples the arm to the housing of the motor. The arm is pivotable upwardly and downwardly relative to the receiving vessel. Specifically, a pivot bearing bracket is coupled to the arm. The pivot bearing bracket extends upwardly relative to the arm wherein the pivot bearing bracket is positioned adjacent to the housing of the motor. A fixing bracket is fixedly coupled to the pivot bearing bracket and pivotably coupled to the housing of the motor wherein the arm is pivotable upwardly and downwardly relative the receiving vessel while the arm remains fixedly positioned relative to the drive wheel.

A contaminated fluid vessel is positioned proximate to the receiving vessel. The arm extends from the housing of the motor into the contaminated fluid vessel. The contaminated fluid vessel holds a mixture of a first fluid and a second fluid. The follower wheel is positionable within the contaminated fluid vessel to position the belt in contact with the mixture of the first fluid and the second fluid. The elastomeric material of the belt removably adheres to the first fluid as the loop travels upwardly from the contaminated fluid vessel toward the receiving vessel whereby the belt facilitates removal of the first fluid from the contaminated fluid vessel for deposit of the first fluid in the receiving vessel.

There has thus been outlined, rather broadly, the more important features of the disclosure in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the disclosure that will be described hereinafter and which will form the subject matter of the claims appended hereto.

The objects of the disclosure, along with the various features of novelty which characterize the disclosure, are pointed out with particularity in the claims annexed to and forming a part of this disclosure.

With reference now to the drawings, and in particular tothereof, a new fluid separation device embodying the principles and concepts of an embodiment of the disclosure and generally designated by the reference numeralwill be described.

As best illustrated in, the fluid decontamination assemblygenerally comprises a receiving vesselwhich as an interior space. The receiving vesselgenerally includes a base walland a peripheral wallthat is coupled to and extends upwardly from the base wallto define the interior space. The peripheral wallmay have an upper edgedefining an opening into the interior space.

A motoris coupled to the receiving vessel. The motormay be positioned proximate to the upper edgeof the peripheral wall. The motorgenerally includes a housingand a drive shaftthat is rotatably coupled to the housing. The drive shaftextends outwardly from the housingover the receiving vessel. Typically, the motoris a rotational motor. In preferred embodiments, the motoris a gearmotor with an integrated gear reduction system which may be referred to as a “gearbox”. The gearbox is positioned within the housingand may thus be referred to as an “internal component” of the motor. The gearmotor is preferred because a speed of the gearmotor (measured in revolutions per minute, or “RPM”) and a torque (or “load”) of the motorcan be changed. Speed and torque are inversely proportional. As the speed at which the drive shaftis rotated increases, less torque forces are exerted on the gearbox and other internal components of the motorto reduce wear and tear on the internal components.

A drive wheelis coupled to the drive shaftof the motor. Rotation of the drive shaftrotates the drive wheelin the same direction in which the drive shaftis rotated. For example, the drive shaftmay be rotated clockwise, thus rotating the drive wheelclockwise. As shown most clearly in, the drive wheelgenerally includes a pair of opposing rimsand a neckthat extends between the pair of opposing rims. The neckmay be concavely arcuate between the pair of opposing rims, such that the neckresembles a groove extending between the pair of opposing rims.

An exposed surfaceof the drive wheelmay have a raised texture. In certain embodiments, the raised texture may be positioned on each opposing rim of the pair of opposing rimsand on the neck. However, embodiments wherein the raised texture is positioned only on the neckare also contemplated. The raised texture may have various shapes and patterns, including, but not limited to, a threaded texture, a plurality of straight lines, a plurality of dots arranged in adjacent lines, a plurality of curled lines, and other patterns. The raised texture is more generally configured to improve the ability of the drive wheel to grip an object that is being rotated by the drive wheel and thus typically extends between the pair of opposing rimsas shown in. For example, the raised texture may be perpendicular to the pair of opposing rims.

A follower wheelis coupled to the drive wheel. The follower wheelis aligned with the drive wheelalong a longitudinal axis. As shown in, the follower wheelgenerally has a structure which is similar to, or the same as, the structure of the drive wheeldescribed above.

A beltcouples the drive wheelto the follower wheel. More specifically, the beltforms a loop extending between the drive wheeland the follower wheel. The beltrotates in the loop while the drive wheelis rotated. The loop has a top sectionmoving from the follower wheelto the drive wheel. A bottom sectionof the loop moves from the drive wheelto the follower wheel.

The beltmay be formed of an elastomeric material, which is preferably oleophilic. Oleophilic materials have an affinity to oils and to non-polar substances. Thus, oleophilic materials readily absorb and adhere to oils and non-polar substances. Sometimes, oleophilic materials are referred to as hydrophobic because oleophilic materials have an aversion to water. The beltis therefore more prone to pick up and removably adhere to oils than to water. Examples of elastomeric materials which are oleophilic include, but are not limited to, synthetic materials such as polyethylene terephthalate (PET), polyurethane, and certain carbon-based materials.

The beltmay be positioned to extend between the pair of opposing rimsof the drive wheelwherein the pair of opposing rimsand the exposed surfaceof the drive wheelis contact with the beltto facilitate rotation of the beltwhen the drive wheelis rotated. For example, the beltmay have a width exceeding a width of the neckof the drive wheelwherein the pair of opposing rimsinhibit lateral movement of the belton the neckof the drive wheel. In other words, the neckof the drive wheelmay have a width that is less than a width of the belt, which is particularly preferred when the belthas a rounded cross-section as indicated in.

When the width of the neckis less than the width of the belt, the beltmay be positioned on each opposing rim of the pair of opposing rims. In essence, the drive wheelis undersized in comparison to the beltin these embodiments. The pair of opposing rimssqueeze the beltto pull the beltfrom the follower wheelto the drive wheel. Tension on the belt, caused by a distance between the drive wheeland the follower wheel, pulls the beltbetween the pair of opposing rims and into the concavely arcuate surface of the neck, inhibiting lateral movement of the beltto keep the beltfrom slipping off of the drive wheel. Because the beltis positioned on the pair of opposing rims, the pair of opposing rimsalso pull the beltto rotate the loop. Such embodiments therefore preferably have the raised texture on the pair of opposing rims.

Alternative embodiments of the belt, for example with a flat cross-section, are also contemplated. A flat cross-section may increase a surface area of the belt. In such embodiments, the beltgenerally has a width that is less than a distance between the pair of opposing rimssuch that the beltsits on, and is pulled by, the neckof the drive wheeland not the pair of opposing rims. In other words, the drive wheelmay be oversized in comparison to the belt, particularly when the belthas the flat cross-section. The raised texture on the exposed surfaceof the drive wheelis preferably positioned on the neckin these embodiments. The raised texture facilitates the neckof the drive wheelin pulling the beltfrom the follower wheeltoward the drive wheel. Tension on the beltalso facilitates smooth rotation of the beltand inhibits slippage of the beltwhen the belthas the flat cross-section.

An armis coupled to the housingof the motor. The follower wheelis generally coupled to the armwherein opposing ends of the armdefine the longitudinal axis. The armtypically includes a tubewith a top endand a bottom end. The top endis positioned proximate to the upper edgeof the peripheral wallof the receiving vessel.

A rodis nested within the tube. The rodis extendable and retractable relative to the tubeto retain a constant tension on the beltbetween the drive wheeland the follower wheel. For example, the rodmay have an upper endthat is positioned within the tube. A lower endis distally positioned relative to the tube. Thus, the lower endof the rodand the top endof the tubedefine the opposing ends of the arm. The follower wheelis coupled to the lower endof the rodwherein the follower wheelis distally positioned on the longitudinal axis relative to the drive wheel.

A springis also positioned within the tube, between the upper endof the rodto the top endof the tube. Opposing ends of the springmay be coupled to the upper endof the rodand the top endof the tube, such that the spring couples the upper endof the rodto the top endof the tube. The springis expandable and compressible to retain the constant tension on the beltbetween the drive wheeland the follower wheel. The constant tension is important to inhibit the beltfrom slipping off of the drive wheeland the follower wheelwhile the beltis rotated in the loop.

The constant tension on the beltalso facilitates rotation of the follower wheelas the beltis rotated. Rotation of the follower wheelminimizes resistance applied to the drive wheeland the motor, which in turn inhibits wear and tear to those components. The constant tension on the beltresults in constant tension exerted by the drive wheelon the drive shaftof the motor, which allows the motorto rotate the drive shaftat an increased rate, or RPM, while also minimizing torque forces is applied to the drive shaftand the internal components within the housingof the motor. The constant tension is achieved because the springcan adjust a position of the top endof the tuberelative to the lower endof the rodin real time.

A pivot assemblypivotably couples the armto the housingof the motor. The armis pivotable upwardly and downwardly relative to the upper edgeof the peripheral wallof the receiving vessel. The drive shaftof the motordefines a pivot point about which the armmay be pivoted upwardly and downwardly relative to a transverse planeextending through the drive shaft. The transverse planeis parallel to the upper edgeof the peripheral wallof the receiving vessel. In other words, the armcan glide upwardly and downwardly relative to a centerline of the drive shaft.

The pivot assemblymay include a pivot bearing bracketthat is coupled to the top endof the tubeof the arm. The pivot bearing bracketextends upwardly relative to the tubewherein the pivot bearing bracketis positionable adjacent to the housingof the motor.provide an exemplary depiction of the positioning of the pivot bearing bracketrelative to the tube. The armis fixedly coupled to the pivot bearing bracket.

A pivot bearingcouples the pivot bearing bracketto the drive shaftof the motor. The drive wheelis rotatably coupled to the drive shaftadjacent to the pivot bearingsuch that the drive wheelis rotatable about the pivot bearingwhen the drive shaftis rotated. The pivot bearingsupports a combined weight of the drive wheel, the follower wheel, the belt, and the armon the drive shaft. By supporting the combined weight of these elements, the pivot bearinginhibits damage to the motorwhile the beltis rotated and while the armis pivoted.

The pivot bearingeffectively redistributes the combined weight of the drive wheel, the follower wheel, the belt, and the armon the drive shaftwhile the armis pivoted and the drive wheelis rotated. Redistributing the combined weight prolongs a lifetime of the gearbox, internal bushings and other internal components of the motorwhich are coupled to the drive shaftwithin the housing. An overhung load on the internal components of the motoris thus limited to the combined weight of the drive wheel, the follower wheel, the belt, and the arm, which is preferably between 1.5 pounds and 2.5 pounds. Moreover, the follower wheelis only coupled to the drive wheelvia the belt, such that the weight of the follower wheeldoes not pull, or put tension on, the drive shaft.

The pivot bearingis rotatably coupled to the pivot bearing bracketvia a pressed fittingwherein the pivot bearingis rotated when the drive shaftis rotated. Because the pivot bearingis rotated, the pivot bearing bracketis inhibited from being rotated when the drive shaftis rotated. In this sense, the pivot bearingmay be thought of as freewheeling within the pivot bearing bracket, allowing the pivot bearing bracketto remain statically positioned relative to the drive shaft. The pivot bearing bracketalso pulls the drive wheelflush against the pivot bearing bracket, allowing the drive wheelto remain in a fixed lateral position relative to the drive shaft. Because the position of the drive wheelrelative to the drive shaftis fixed, the drive shaftcan be rotated at increased speeds, or RPMs, which reduces the torque forces applied to the motor.

A fixing bracketmay be coupled to and extend from the pivot bearing bracket. The fixing bracketis coupled to the housingof the motor. More specifically, the fixing bracketis fixedly coupled to the pivot bearing bracketand pivotably coupled to the housingof the motor. This configuration allows the armto pivot upwardly and downwardly relative to the upper edgeof the peripheral wallof the receiving vesselwhile the armremains fixedly positioned relative to the drive wheel.

The fixing bracketmay include a bodyextending upwardly and outwardly relative to the receiving vesselwherein the bodyis angled to extend upwardly and outwardly relative to the arm. The bodyhas a first endand a second end. The pivot bearing bracketis fixedly coupled to the first end. The second endis distally positioned on the bodyrelative to the first end. A channelmay extend through the bodybetween the first endand the second end.

A knobmay couple the bodyto the housingof the motor. The knobis rotatably coupled to the housing. Specifically. the knobis rotatable in a first direction to tighten the fixing bracketagainst the housing. While the knobis tightened, the armis inhibited from pivoting upwardly and downwardly relative to the upper edgeof the peripheral wallof the receiving vessel. The knobis rotatable in a second direction to loosen the fixing bracketfrom the housing. While the knobis loosened, the armis able to pivot upwardly and downwardly relative to the upper edgeof the peripheral wallof the receiving vessel.

The knobis positioned to extend through the channel. The first endof the bodymoves toward the knobwhen the armis pivoted upwardly relative to the upper edgeof the peripheral wallof the receiving vessel. The first endof the bodymoves away from the knobwhen the armis pivoted downwardly relative to the upper edgeof the peripheral wall.provides an exemplary depiction of the movement of the bodyrelative to the knobas the armpivots upwardly and downwardly.

A contaminated fluid vesselis positioned proximate to the receiving vessel. The armextends from the housingof the motorabove the receiving vesselinto the contaminated fluid vessel. The contaminated fluid vesselholds a mixtureof a first fluidand a second fluid.

The follower wheelof the armis positionable within the contaminated fluid vesselto position the beltin contact with the mixtureof the first fluidand the second fluid. The elastomeric material of the beltabsorbs, the first fluid. In other words, the first fluidremovably adheres to the beltas the top sectionof the loop travels upwardly from the contaminated fluid vesseltoward the receiving vessel. The elastomeric material of the beltrepels second fluidwherein the second fluidis inhibited from adhering to the beltas the top sectionof the loop travels upwardly from the contaminated fluid vesseltoward the receiving vessel. Accordingly, the beltfacilitates removal of the first fluidfrom the second fluid. The first fluidmay be a trampoil and the second fluidmay be a coolant.

The first fluidgenerally has a density that is less than a density of the second fluid. The density of the second fluidis configured to facilitate gravity in inducing separation of the first fluidfrom the second fluidthereby resulting in a stratified arrangement of the first fluidand the second fluid. The stratified arrangement may be positioned within each of the receiving vesseland the contaminated fluid vessel, depending on how long the first fluidand the second fluidare left standing in the receiving vesseland the contaminated fluid vessel. However, turbulence within the contaminated fluid vesselmay mix the first fluidwith the second fluid, limiting the ability of gravity to create the stratified arrangement. The receiving vesselmay have a height exceeding a height of the contaminated fluid vessel. The height of the receiving vesselis configured to facilitate gravity in inducing separation of the first fluidfrom the second fluidwithin the receiving vessel. The receiving vesselmay also have a volume exceeding a volume of the contaminated fluid vesselto inhibit the receiving vesselfrom overflowing as the first fluidis collected in the receiving vessel.

A floatmay be slidably coupled to the rodof the arm. For example, a buoythat is coupled to the rodof the armwherein the buoyis positionable within the contaminated fluid vessel. The buoygenerally floats on, or near, an upper surface of the mixture. For example, the buoymay have a density that is less than a density of the mixtureof the first fluidand the second fluid. Floatation of the buoyinhibits the follower wheelfrom being fully submerged in the mixtureof the first fluidand the second fluid. Thus, the buoyinhibits the bottom sectionof the loop from being fully submerged in the second fluid, which helps to retain the first fluidon the beltas the beltis rotated from the drive wheelto the follower wheeland back toward the drive wheel.

For example, without the buoy, the follower wheelmay sink between 10.0inches and 14.0 inches beneath the upper surface of the mixture. With the buoycoupled to the arm, the follower wheelmay only sink between 1.0 inches and 2.5 inches into the mixturewithin the contaminated fluid vessel. Thus, the buoykeeps the beltcloser to the upper surface of the mixturewhere the first fluidis more prevalent because of the density differential between the first fluidand the second fluiddescribed above. The second fluidis also inhibited from rinsing the first fluidoff of the beltas the beltreturns from the drive wheelto the follower wheeland is rotated back toward the drive wheel.

The buoymay also urge the armto pivot downwardly within the contaminated fluid vesselas a volume of the mixtureof the first fluidand the second fluiddecreases within the contaminated fluid vessel. In other words, as the upper surface of the mixturemoves downwardly, the buoyalso moves downwardly to urge the armdownwardly. This coordinated movement maintains contact between an outer periphery of the loop and the first fluid. The outer periphery of the loop is positioned around the follower wheelwherein the outer periphery of the loop defines a junction between the top sectionand the bottom sectionof the loop.

Conversely, the buoymay urge the armto pivot upwardly within the contaminated fluid vesselas the volume of the mixtureof the first fluidincreases within the contaminated fluid vessel. By urging the armupwardly as the volume of the mixtureincreases, the buoyand the arminhibit the beltfrom being fully submerged within the second fluid.

The buoymay be referred to as “ocean floats” which generally submerge further into water than they submerge into oils. For example, the buoymay only submerge between approximately 10.0% and 20.0% of its mass into water (an example of the second fluid). Comparatively, the buoymay submerge between approximately 15.0% and 25.0% of its mass into oil (an example of the first fluid). Such relative buoyance helps keep the buoyclose to the upper surface of the mixtureof the first fluidand the second fluid, which helps keep the outer periphery of the beltin more contact with the first fluidthan the second fluid. The size of the buoycan vary, for example to optimize performance based on factors including, but not limited to, the size of the contaminated fluid vesseland the characteristics of the first fluidand the second fluid. The size of the buoymay also be determined based on the desired depth at which the buoywill submerge, or sink, into the mixture.