Dust Collector Bag and Filter

This application claims the benefit of U.S. provisional patent applications 63/633,841 filed Apr. 14, 2024 and 63/691,274 filed Sep. 5, 2024.

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The present invention relates to dust collector bags with filters for floor sanders, canister-type shop vacuums, backpack-type shop vacuums and other types of vacuums.

In an embodiment of the invention, a dust collection bag and filter is used in floor finishing. In the installation of, or renovation of, hardwood flooring, the surface of hardwood floors must be sanded. Sanding is usually carried out with a drum sander. This piece of equipment comprises a cylindrical drum, around which a strip of abrasive material is secured. A motor rotates the drum. The drum is moved around the hardwood floor surface and sands it smooth. The dust created by sanding is collected in the dust collector bag. The effectiveness of the bag is limited by the air flow from the blower, the permeability of the bag, and other dust collector bag characteristics. U.S. Pat. No. 8,721,402 discloses a dust collector bag.

In another embodiment of the invention, the dust collection bag and filter is used with shop vacuums. This invention is directed to heavy-duty vacuum cleaners of the type used in woodshops, machine shops, or for industrial applications, and commonly referred to as shop vacuums or shop vacuum cleaners. The shop vacuum can be a canister-type, a backpack-type, or other design. The invention is more particularly concerned with a shop vacuum in which the large majority of the dust being deposited into a canister-type drum or barrel, and the remaining dust that is carried in the vacuum machine air stream is filtered out in a final cartridge filter, so that the vacuum cleaner machine exhausts clean, filtered air into the ambient.

Shop vacuum cleaners are often employed for picking up dust that has accumulated on the shop floor and on surfaces of equipment, or may also be connected to a dust outlet of a dust-producing tool, i.e., wood working machines, such as sanders, joiners, and the like, or machines that process metals, plastics, or other composites such as concrete or stone. The most challenging dust to vacuum is dry wall dust. In these shop vacuum devices, a vacuum head, which sits on top of a drum or barrel, has a blower that is powered by an electric motor induces a suction to draw a stream of air into the machine. The airstream is then directed into the barrel, where dust collects. The air stream then passes through a cartridge filter, and is exhausted to the ambient air.

In most cases, the shop vacuum filter does not filter out fine dust, and there is always at least some of the dust that passes out and back into the ambient air. This airborne fine dust can present a health hazard, and in a woodshop environment is a serious quality issue as the airborne dust can contaminate varnish or other wood finish. Additionally, the dust that is collected can quickly clog and blind the cartridge filter, which limits air flow and diminishes the efficiency of the shop vacuum. Moreover, filling of the filter material requires that the vacuuming operation be interrupted frequently for cleaning and/or replacing of the filter, which can be costly.

A shop-type vacuum cleaner with a cartridge type final filter to capture fine dust particles has been proposed previously, and an example of such a shop vacuum is described in U.S. Pat. No. 5,069,696. In that case, an externally-mounted filter is located in the exhaust air stream in a housing that is disposed outside the vacuum machine drum or canister. This arrangement exhausts significantly cleaner air back into the ambient, but because the air passes directly from the main collection drum out to the filter housing, the filter accumulates dust quickly and requires frequent cleaning for effective operation.

It has been proposed previously to employ a cyclonic separator in line in a vacuum hose in advance of a shop vacuum cleaner for pre-separating particulate matter, and then connecting the outlet pipe of the cyclonic separator to the inlet of the vacuum cleaner. This arrangement is described, for example, in U.S. Pat. No. 7,282,074 and U.S. Pat. No. 8,161,597. This system can result in removal of about ninety percent, or more, of the dust from the air stream ahead of the vacuum cleaner, so that the vacuum cleaner operates longer and more efficiently in most applications. However, this arrangement requires attaching the cyclone as a separate element in between the shop vacuum cleaner and the dust producing tool or dust pick-up tool.

The dust collector bag of the present invention does not use a cyclone to remove dust.

In a first embodiment, the present invention relates to floor sanders. A typical floor sander is a floor sander comprising a drive motor, a horizontal rotating drum, a sander housing, a drum blower impeller, a vented impeller housing, and a fluid channel. The horizontal rotating drum is driven by the drive motor and has a top and a bottom. The sander housing covers the top of the rotating drum and has an inside proximate the rotating drum and an outside. The rotating drum supports and drives a sandpaper, and the bottom of the rotating drum is exposed for the sandpaper to sand a floor. The sander housing outlet directs air containing sawdust and other dust to the dust collector bag. The dust collector bag of the present invention has an internal sleeve and a divider which provides improved dust collection and performance.

In a second embodiment, the present invention relates to shop vacuum cleaners. For canister-type shop vacuums, the shop vacuum cleaner has a vacuum head, which sits on top of a drum, and has a blower that is powered by an electric motor to induce a suction to draw a stream of air. The airstream is then directed into the barrel through a vacuum port, where dust collects. The air stream then passes through a cartridge filter, and is exhausted to the ambient air. For a backpack-type vacuum, the vacuum head sits on top of a backpack. The air stream is directed into the backpack to collect dust and filter the exhaust air.

In the present invention, the dust collector bag is fluidly connected to the vacuum port and is located inside the barrel or the backpack. The dust collector bag of the present invention has an internal sleeve and a divider which provides improved dust collection and performance. The dust collector bag is made of a gas-permeable fabric that catches the dust, but allows the air to pass through.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

In a first embodiment,show examples of a prior art floor sanderhaving a drive motor, a horizontal rotating drumhaving a topand a bottomdriven by the drive motor and a sander housingcovering the top of the rotating drum, wherein the rotating drum supports and drives sandpaper, and the bottomof the rotating drum is exposed to sand a floor. The preferred mechanism for driving the rotating drum with the drive motor is a beltand pulleys.

The prior art floor sander has a motor blower impellerdriven by the drive motor to create an air flow directed across the drive motor for cooling. The impelleris attached directly to the motor's rotating shaft. The impeller is covered with a vented drive motor coverto allow air intake to blow across the motor to cool it. Optionally, the floor sander has a sander outlet impellerdriven by the drive motor, which creates a suction air flow from the sander housing air inletto the sander housing outletwhich removes dust from the work environment and directs it to a collector bag. The sander outlet impelleris attached to the drive motor by means well known in the art such as belts and pulleys or gear mechanisms. The sander housing covers the moving parts and also directs the air flow up and out to the outlet.

As the rotating drummoves the sandpaperacross the floor to sand it, saw dust and other dust is created. The dust is carried by air up the sander housing inlet and is moved by air blown by motor blower impellerand the outlet impellerthrough the sander housing outletto the dust collector bag.

The effectiveness of the dust collector bagto collect and hold dust is critical. The present invention provides an improved dust collector bag, as shown in, has a top, a bottom, a side oneand a side two. Fluidly attached to top is dust and air inlet.

In a preferred embodiment, the length L of the dust collector bag is from about 25 to 30 inches. The width W of the dust collector bag is from about 15 to 20 inches. The height H of the air inletis from about 5 to 8 inches. The air inletis positioned approximately in the middle of the width of the dust collector bag. However, the air inlet can be positioned proximate either side one or side two.

As is shown in, the inflated dust collector bag has a sleevefluidly connected from the air inletthrough a divider. Preferably, the sleeve is from about 4 to 8 inches in diameter. The divideris approximately round and flat, and is approximately the same diameter as the inflated interior of the dust collector bag. Both the sleeve and the divider are air permeable, but of a tight enough weave to catch most of the dust. The divider is attached to the interior sides of the dust collector bag around the entire interior perimeter.

The divider is located approximately half way along the length L of the dust collector bag. In a preferred embodiment, the divider is not horizontal, but angled inside the dust bag. In a more preferred embodiment, the divider is attached at side oneapproximately halfway down the length L. On the opposite side at side two, the divider is attached about ¼ of the way down the length L. This creates a tilted divider. Along side two, the angle x is an acute angle. Preferably, the angle is from about 20 to 60 degrees. In a preferred embodiment, the sleeve is attached to the divider next to wall at side one. This is the lower side for attachment and creates the openingat the lower side of the divider.

Any suitable means of attaching the divider to the interior sides can be used, including stitching, gluing and releaseably attaching using Velcro or zippers. Where the sleeve is attached to the divider, an openingis created, and air and dust from the air inletpass through the opening.

The divider creates two chambers in the dust collector bag, the top chamberand the bottom chamber. The inside walls of the dust collector bag are covered with an inner layer. The inner layeris covered by the outer layer. The inner layer and the outer layer are essentially continuous in creating the dust collector bag. Both layers are air permeable, but are a tight enough weave to catch most of the dust that enters the bag.

In a preferred embodiment, the sleeve, the divider and the inner layer are made of TenCate Polyfelt® TS geotextiles which are mechanically bonded continuous-filament nonwovens manufactured from UV-stabilized polypropylene. More preferably, the Polyfelt used is PE-11-070, which is 2 mm thick, and 11 oz. per square yard. In a preferred embodiment, the outer layeris a Raschel warp knitted fabric.

As shown in, the cross section from, when the dust collector bag is inflated and in use, the dividerseparates the top chamberfrom the bottom chamber. The dust-containing air travels down the sleeve, through the divider at opening. The air flows into the bottom chamber and deposits the dustat the bottom of the dust collector bag. The air escapes through the sides one and two, the divider to the top and out of the bag.

As shown in, the bag, when attached to the sander, hangs down. The top of the bag is attached to the sander housing outlet. The positioning of the bottom chamber allows the heavier dust particles to be directed to the bottom of the dust collector bag when in use. This uses gravity to the advantage of dust removal. Additional dust removal occurs in the top chamber, but typically, it is the finer dust particles.

In a preferred embodiment, the bottom of the dust collector bag has a resealable bottom opening. Preferably, the opening is the entire width W of the bottom of the bag. The opening is sealed using a releaseable sealing device, such as a zipper or Velcro. In another preferred embodiment, the side of the dust collector bag has a side resealable opening, which can be sealed using a zipper or Velcro. The side opening is to empty the top chamber. The bottom opening is to empty bottom chamber.

The dust collection bag of the present invention is not limited to rotary floor sanders, but can be used with other sanding devices, or other dust-collection devices.

In a second embodiment, shown in, dust bag and filter of the present invention are used with shop vacuums.show examples of a prior art shop vacuum cleaner.

The prior art shop vacuum cleanerhas a vacuum head, which sits on top of a drum, and has a blower (not shown) that is powered by an electric motor to induce a suction to draw a stream of air. The airstream is then directed into the barrel through a vacuum port, where dust collects. The air stream then passes through a cartridge filter, and is exhausted to the ambient air.

The present invention provides an improved dust collector bag, as shown in, has a top, a bottom, a side oneand a side two. Fluidly attached to top is dust and air inlet.

In a preferred embodiment, the dust collector bag is designed to nest inside the bottom of the drum, positioned below the cartridge filter. In a preferred embodiment, the height H of the dust collector bag is from about 5 to 10 inches. The width W of the dust collector bag is from about 15 to 20 inches. The length L of the air inletis from about 10 to 20 inches. In a preferred embodiment, the proximate end of the air inletis stiffened so that when vacuum is applied, the inlet does not collapse. In a more preferred embodiment, the stiffening is applied to the sleeveas well. The stiffening is cylindrical, approximately the same diameter as the air inlet, and is provided by cardboard, plastic, or other suitable material. At the distal end of the air inlet, stiffening is not applied to facilitate attaching the dust collector bag to the vacuum port, by means such as a drawstring, Velcro or other appropriate means of fastening. The air inletis positioned to the side of the dust collector bag, about 1 to 2 inches from the sideor. However, the air inlet can be positioned proximate either side, or in the middle.

As is shown in, the inflated dust collector bag has a sleevefluidly connected from the air inletthrough a divider. Preferably, the sleeve terminates at the divider, creating an opening. Preferably, the sleeve is from about 4 to 8 inches in diameter. The divideris approximately round and flat, and is approximately the same diameter as the inflated interior of the dust collector bag. Both the sleeve and the divider are made of air permeable fabric, but of a tight enough weave to catch most of the dust. The divider is attached to the interior sides of the dust collector bag around the entire interior perimeter.

The divider is located approximately half way along the height H of the dust collector bag. In a preferred embodiment, the divider is horizontal. In a more preferred embodiment, the divider is attached at sides oneandapproximately halfway down the height H. In a preferred embodiment, the sleeve is attached to the divider proximate a wall on side one.

Any suitable means of attaching the divider to the interior sides can be used, including stitching, gluing and releaseably attaching using Velcro or zippers. Where the sleeve is attached to the divider, an openingis created, and air and dust from the air inletpass through the opening.

The divider creates two chambers in the dust collector bag, the top chamberand the bottom chamber. All of the surfaces of the dust collector bag are air permeable, but are a tight enough weave to catch most of the dust that enters the bag.

In a preferred embodiment, the sleeve, the dust collector bag is made of TenCate Polyfelt® TS geotextiles which are mechanically bonded continuous-filament nonwovens manufactured from UV-stabilized polypropylene. More preferably, the Polyfelt used is PE-11-070, which is 2 mm thick, and 11 oz. per square yard.

As shown in, the cross section from, when the dust collector bag is inflated and in use, the dividerseparates the top chamberfrom the bottom chamber. The dust-containing air travels down the sleeve, through the divider at opening. The air flows into the bottom chamber and deposits the dustat the bottom of the dust collector bag. The air escapes through the sides one and two, and the divider to the top and out of the bag.

As shown in, the bottomof the dust bagrests on the bottom of the shop vacuum cleaner drum. The top of the bag, the sleeveis attached to the vacuum port. The positioning of the bottom chamberallows the heavier dust particles to be directed to the bottom of the dust collector bag when in use. This uses gravity to the advantage of dust removal. Additional dust removal occurs in the top chamber, but typically, it is the finer dust particles.

In a preferred embodiment, the bottom of the dust collector bag has a resealable bottom opening. Preferably, the opening is the entire width W of the bottom of the bag. The opening is sealed using a releaseable sealing device, such as a zipper or Velcro. In another preferred embodiment, the side of the dust collector bag has a side resealable opening, which can be sealed using a zipper or Velcro. The side opening is to empty the top chamber. The bottom opening is to empty bottom chamber.

The dust collection bag of the present invention is not limited to shop vacuum cleaners, but can be used with other dust-collection devices.

The embodiments were chosen and described to best explain the principles of the invention and its practical application to persons who are skilled in the art. As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the invention, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.