Systems and methods related to filter sound dampening

Abstract

Systems and methods according to the present invention relate to a sound dampening system comprising separable pieces, the system configured to be placed in an airflow of a blower, vacuum or other device using an air filter. One or more types of foam pieces provide sound dampening within the air filter. A first type of foam piece is shaped as a cylinder extending along a cylinder height between a first end and a second end. A second type of foam piece is a hollow cylinder extending from a first open end to a second open end. The second type of foam piece may be formed as a rectangular piece of foam with ends folded towards each other or as an extruded cylinder.

Description

[0001]

[0002] Systems and Methods Related to Filter Sound Dampening

[0003] Related Applications

[0004] This application claims the benefit of United States Provisional Patent Application Serial No. 63 / 665,801, filed 28 June 2024, and entitled “Systems and Methods Related to Filter Sound Dampening,” which is incorporated herein by reference in its entirety.

[0005] Background of the Invention

[0006] This invention relates generally to noise dampening technology and specifically to sound dampening within machinery, and even more specifically to sound reduction in air filter structures. Excessive noise caused by machinery can be both distracting and potentially harmful to human health. Working in excessively noisy environments, especially long-term, is unpleasant and has a substantial chance of negatively affecting worker hearing. Thus, taking steps to decrease unwanted sound exposure is good for both safety and productivity.

[0007] Past methods of dampening sound include various forms of noise reducers used in direct connection to the machine and / or ear plugs / muffs worn by each individual person in the machine’s vicinity. In some cases, it is more efficient for the sound dampener to be located within the machine than attached or near the outside. For instance, in machines that work in narrow spaces, large sound dampeners, such as mufflers, can be impractical. Similarly, it may be more advantageous for sound dampeners to be made of materials other than metal. Softer materials may be just as efficient as a metal sound dampener, while also having the added benefit of being moldable to a given space, such as inside a machine. Optimal efficiency is difficult to achieve, thus improved sound dampeners for machines are continuously desired.

[0008] Summary of the Invention

[0009] Embodiments of apparatus and methods according to the present invention relate generally to systems and methods for sound dampening in machines. Specifically, the present invention relates to the combined use of foam pieces in specific formations to achieve sound dampening within a machine filter, namely an air filter.

[0010] According to an aspect of an embodiment of a system according to the present invention, a noise dampener abuts a blower, the noise dampener comprising a substantially tubular air filter disposed between a vent and a cover. The air filter includes an open center and a filter radius, wherein a first foam member (preferably open-cell foam) is disposed within the filter open center, the first foam member comprising a length, a width, a first side, and a second side, the second side comprising a plurality of parallel formations (e.g., triangular prisms, pyramidal formations or wavy protrusions) formed integrally with the first foam member. The first foam member may be formed into a coil, having a coil radius that is smaller than the filter radius and a central open space, and being disposed with the first side facing away from the central open space and the second side facing toward the center open space. Where the second side formations are triangular prisms, each prism comprises two walls meeting at a peak along a peak length, the peak length being substantially equal to the first foam member width.

[0011] According to another aspect of an embodiment of a system according to the present invention, a bolt is affixed to the vent and extends through the central open space of the first foam member coil, the open center of the air filter, and the cover, where it is selectively removably secured by a fastener. The vent may be a grate having a plurality of openings, the grate being a circular shape, having a vent radius larger than the filter open center. The cover may be substantially solid except for a hole through which the bolt extends, the cover having a cover radius larger than the filter open center.

[0012] According to still another aspect of an embodiment of a system according to the present invention, a noise dampener abuts a blower, the noise dampener comprising a substantially tubular air filter disposed between a vent and a cover. The air filter includes an open center and filter radius. A first foam member is disposed within the filter open center, the first foam member comprising a length, a width, a first side, and a second side, the second side comprising a plurality of parallel protrusions formed integrally with the first foam member. A second foam member abuts the first foam member, the second foam member comprising a third side and a fourth side, the third side comprising a plurality of projections formed integrally with the second foam member. The first and second foam members may be formed from open-cell foam.

[0013] According to yet another aspect of an embodiment of a system according to the present invention, the first foam member is formed into a coil, having a coil radius that is smaller than the filter open center and a central open space, and being disposed with the first side facing away from the center open space and the second side facing toward the center open space. The second foam member may have a substantially cylindrical shape, with a radius substantially equal to the coil radius of the first foam member. The second foam member projections preferably abut the first foam member and the cover abuts the fourth side of the second foam member. The second foam member includes a central screw hole or slot, and a bolt is affixed to the vent and extends through the central open space of the first foam member coil, the screw hole of the second foam member, the open center of the air filter, and the cover, where it is selectively removably secured by a fastener. The vent may be a grate having a plurality of openings, the grate being a circular shape, having a vent radius larger than the filter open center. The cover may be substantially solid except for a hole through which the bolt extends, the cover having a cover radius larger than the filter open center.

[0014] Brief Description of the Drawings

[0015] Figure la is a perspective view of a sound dampening system according to the present invention.

[0016] Figure lb is a perspective view of the system of Figure la, prior to insertion of dampening members.

[0017] Figure 2 is a perspective view of the sound dampening system of Figure 1 secured to a blower.

[0018] Figure 3 is an exploded view of the sound dampening system of Figure 1.

[0019] Figure 4 is a perspective view of a first foam member according to the present invention.

[0020] Figure 5 is a left side elevation view of the first foam member of Figure 4.

[0021] Figure 6 is a top plan view of the first foam member of Figure 4.

[0022] Figure 7 is a bottom plan view of the first foam member of Figure 4.

[0023] Figure 8 is a perspective view of a first foam member coil according to the present invention.

[0024] Figure 9 is a top plan view of the first foam member coil of Figure 8.

[0025] Figure 10 is a perspective view of a second foam member according to the present invention.

[0026] Figure 11 is a left side elevation view of the second foam member of Figure 10.

[0027] Figure 12 is atop plan view of the second foam member of Figure 10.

[0028] Figure 13 is a bottom plan view of the second foam member of Figure 10.

[0029] Figure 14 is atop plan view ofthe first foam member coil inserted into a filter according to the present invention.

[0030] Figure 15 is a perspective view of a second foam member being installed onto the sound dampening system according to the present invention.

[0031] Figure 16 is a perspective view of a cover and fastener being installed onto the sound dampening system according to the present invention.

[0032] Description of the Preferred Embodiment

[0033] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention.

[0034] Turning now to Figures 1-16, systems and methods related to sound dampening in machines or filters may be seen. Many machines, particularly vacuums and / or blowers, include an air filtration system that works in conjunction with a motor (blower) to move air through the machine. For instance, a blower may generally include an air filter disposed in an air channel (e.g., abutting a motor and / or fan housing), the filter acting to remove particulates from the air as the motor and fan work to move air through the system. A blower can be seen in Figure 2. An embodiment of a sound dampening system according to the present invention, generally seen in Figures 1 and 2, comprises a sound dampening system 100 abutting or near a blower 10 that preferably contains a motor and fan (not shown) that draws air through the system 100 and forces it out of a hose 12. The blower 10 may be a conventional mechanism as known in the art. When the blower 10 is powered on, an electric motor (and fan) produces noise. The noise dampening system 100 absorbs some of the noise, reducing noise decibels considerably.

[0035] As seen more particularly in Figures la-b and 3, the sound dampening system 100 generally includes an air filter 110 disposed between a vent 120 and cover 130. The filter 110 may be a conventional air filter known in the art, such as paper, foam, or cotton filter, that comprises a substantially tubular shape having an open center 112 and a filter radius 1 lOr. In assembly of the system 100, a bolt 140 is preferably removably or permanently affixed to the vent 120, preferably extends through the open center 112 and the cover 130, and is preferably selectively removably secured by a fastener 142. This arrangement keeps the system 100 held together while in use.

[0036] The vent 120 is preferably metal, such as stamped steel or aluminum, and comprises a grate having small openings which allow air to pass through relatively uninhibited. The openings can be of any shape or size, but are preferably small enough to prevent debris larger than air particulates from entering the system 100. The vent 120 is also preferably circular (or other shape to mate a mounting location on the blower 10) and has a radius larger than the open center 112 (but it may be smaller than the filter radius 1 lOr), which keeps the vent 120 from falling into the filter open center 112.

[0037] On the opposite end of the filter 110, the cover 130 is preferably substantially solid, except for a possible hole for the fastener 142, to prevent air from entering the system 100 without going through the filter 110. The cover 130 may be made from almost any solid material, but is most preferably molded plastic to be cost efficient and easily manufacturable. Similar to the vent 120, the cover 130 preferably comprises a radius larger than the open center 112 (but it may be smaller than the filter radius 1 lOr), which keeps the vent 120 from falling into the filter open center 112.

[0038] To provide improved sound dampening, preferably located within the open center 112 of the filter 110 is at least a first foam member 150 and / or preferably a second foam member 160. The members 150,160 are preferably comprised of foam, such as polyurethane or extruded melamine foam, cut and / or otherwise formed as described below. Most preferably the foam members 150,160 are comprised of open-cell foam, which allows air to flow through it while also absorbing sound waves. The result is that the performance of the air filter 110 is relatively unaffected (less than a 5% reduction in airflow through the filter 110, and preferably about a 2% reduction in airflow), while the noise transmission is massively reduced. For example, some measurements have shown a noise reduction of approximately 72-78 decibels when the system 100 is employed versus when no noise reduction system is used.

[0039] The first foam member 150 is preferably a substantially rectangular strip of foam of a length 150a and width 150b, further comprising a filter side 151a opposing a prism side 151b. The filter side 151a is preferably substantially flat, while the prism side 151b preferably comprises a series of parallel extrusions formed integrally from the prism side 151b of the first foam member 150. Though both sides 151 a,b could be substantially flat, having either side with variable dimensions (prismatic, triangular, sinusoidal) has been found to prove beneficial. In the embodiment shown in the figures, the extrusions take the form of triangular prisms 152. However, other shaped extrusions are also contemplated, such as blocks, semicircles, or bumps. Each triangular prism 152 preferably comprises two walls 154 meeting at a peak 156 along a length 152a that is most preferably substantially equal to the width 150b of the first foam member 150.

[0040] In use, the first foam member 150 may be rolled or formed into a coil 158 (or the member 150 could be extruded integrally in this shape and cut to width 150b), preferably of a radius 158r slightly less than the radius of the opening 112, with the filter side 151a facing out and the prism side 151b facing in. The first foam member length 150a then becomes the circumference of the coil 158. Most preferably, the first foam member 150 is coiled such that the ends (at either end of the length 150a) of the first foam member 150 meet or at least be in close proximity, causing the walls 154 of adjacent prisms 152 to at least partially abut. The resulting coil 158 of the first foam member 150 most preferably leaves an open space 159 in the middle, where air may enter uninhibited and where the bolt 140 sticks through.

[0041] The second foam member 160 preferably comprises a cylindrical shape, having a first substantially flat surface 160a opposing a second surface 160b. Preferably the second surface 160b includes a series of projections 162. Preferably the projections 162 are formed integrally with the second foam member 160. While it is contemplated that the projections may take any shape, in the preferred embodiment the projections have a generally quadri-pyramidal formation. Though both sides 160a,b could be substantially flat, having either side with variable dimensions (prismatic, triangular, sinusoidal) has been found to prove beneficial. The second foam member 160 preferably has a radius 160c substantially equal to the first foam member coil radius 158r and slightly less than the radius of the opening 112. Further, the second foam member 160 preferably has a screw hole 164 extending therethrough along the axis of the cylinder (or substantially near the axis) such that a bolt 140 may be placed therethrough. It is contemplated that the screw hole 164 will also extend through any projection 162 that is located at the point the screw hole 164 extends through the second surface 160b.

[0042] When the system 100 is assembled, the filter 110 is abutted against the vent 120, with the bolt 140 extending through the filter open center 112. Next, the first foam member 150 is coiled as described above and inserted into the filter open center 112, again with the bolt 140 extending through the first foam member open space 159. This step is seen in Figure 14, where the first foam member coil 158 is seen within the open center 112 of the filter 110. Next, the second foam member 160 is placed by inserting the bolt 140 through the screw hole 164, as seen in Figure 15. The second foam member second surface 160b is preferably facing into the filter 110, such that the projections 162 abut the first foam member coil 158. The second foam member 160 may be slightly pressed into the first foam member 150 to ensure a snug fit.

[0043] Finally, the cover 130 is placed over the second foam member flat surface 160a, abutting the filter 110, and the bolt 140 is removably secured to the cover 130 using the fastener 142. In preferable formations, the fastener 142 may be tightened to ensure the system 100 does not fall apart in manufacturing or use.

[0044] The unit 100 is then placed proximate (and preferably secured) to a blower 10 (or vacuum), externally or internally, which can then be operated as normal.

[0045] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, because numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention.

Claims

What is claimed is:

1. A sy stem compri si ng : a noise dampener abutting a blower, the noise dampener comprising a substantially tubular air filter disposed between a vent and a cover, wherein the air filter comprises an open center and filter radius, and wherein a first foam member is disposed within the filter open center, the first foam member comprising a length, a width, a first side, and a second side, the second side comprising a plurality of parallel extrusions formed integrally with the first foam member.

2. The system of claim 1, wherein the first foam member is formed into a coil, having a coil radius that is smaller than the filter radius and a central open space, and being disposed with the first side facing away from the central open space and the second side facing toward the center open space.

3. The system of claim 2, wherein the extrusions comprise triangular prisms.

4. The system of claim 3, wherein each prism comprises two walls meeting at a peak along a peak length, the peak length being substantially equal to the first foam member width.

5. The system of claim 4, wherein the first foam member comprises open-cell foam.

6. The system of claim 5, wherein a bolt is affixed to the vent and extends through the central open space of the first foam member coil, the open center of the air filter, and the cover, where it is selectively removably secured by a fastener.

7. The system of claim 6, wherein the vent comprises a grate having a plurality of openings.

8. The system of claim 7, wherein the vent further comprises a circular shape, having a vent radius larger than the filter open center.

9. The system of claim 8, wherein the cover is substantially solid except for a hole through which the bolt extends.

10. The system of claim 10, wherein the cover further comprises a circular shape, having a cover radius larger than the filter open center.

11. A system comprising: a noise dampener abutting a blower, the noise dampener comprising a substantially tubular air filter disposed between a vent and a cover, wherein the air filter comprises an open center and filter radius, wherein a first foam member is disposed within the filter open center, the first foam member comprising a length, a width, a first side, and a second side, the second side comprising a plurality of parallel extrusions formed integrally with the first foam member, and wherein a second foam member abuts the first foam member, the second foam member comprising a third side and a fourth side, the third side comprising a plurality of projections formed integrally with the second foam member.

12. The system of claim 11, wherein the first and second foam members comprise open-cell foam.

13. The system of claim 12, wherein the first foam member is formed into a coil, having a coil radius that is smaller than the filter open center and a central open space, and being disposed with the first side facing away from the center open space and the second side facing toward the center open space.

14. The system of claim 13, wherein the second foam member comprises a substantially cylindrical shape, having a radius substantially equal to the coil radius of the first foam member.

15. The system of claim 14, wherein the second foam member projections abut the first foam member and the cover abuts the fourth side of the second foam member.

16. The system of claim 15, wherein the second foam membercomprises a central screw hole.

17. The system of claim 16, wherein a bolt is affixed to the vent and extends through the central open space of the first foam member coil, the screw hole of the second foam member, the open center of the air filter, and the cover, where it is selectively removably secured by a fastener.

18. The system of claim 17, wherein the vent comprises a grate having a plurality of openings.

19. The system of claim 18, wherein the cover is substantially solid except for a hole through which the bolt extends.

20. The system of claim 19, wherein the vent and cover each comprise a circular shape, having radii that are larger than the filter open center.

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