Ambient Air Dryer with Improvements in Performance, Safety, Ease of Use and Cost of Manufacture

Abstract

The already energy saving ambient air dryer is improved in methods of manufacture, performance, increased safety devices, and storage options which include in part: construction in pieces of different manufacture for assembly to lower cost, added inhibitors to extend life and durability, extrusions on the drum functioning as scoops to cause additional ambient air to be passed through the clothes, light and reflector system so moving drum may be visible at night or in partial light, non-defeating GFCI system, specific designed energy efficient motor, programmed functions such as stopping the drum in “access” or “park” position and sounding alarm for pre-determined operational issues, remote control as well as control box on dryer frame, a system for capturing lint and particulates, motion/heat detectors which eliminate need for safety guard surrounding moving drum, sound emitters to keep animals away, security codes for operation, and collapsible drum and frame for compact storage.

1 . An improved apparatus for drying clothes in open, ambient air which includes the following:
 a drum using a combination of components for ease and savings in manufacture, construction and shipping costs such as:   a blow molded drum frame;   appropriately designed, framed or unframed molded plastic, metal mesh or other appropriate perforated material attached to drum frame;   drum formed in any rotatable configuration such as circular or octagon and driven by belt or rollers; and   drum constructed in pieces for assembly.   
     
     
         2 . Said drum of  claim 1 , wherein extrusions are attached or formed within the construction of the drum members;
 said extrusions functioning as scoops to cause an additional amount of ambient air to be passed through the clothes with corresponding moisture laden air expelled through the openings of the drum.   
     
     
         3 . Said drum of  claim 2 , whereby re-cycled resins may be used in part or used completely for manufacture to reduce the cost of making the drum or parts of the drum and dramatically reducing the energy required for the manufacture of the resin used. 
     
     
         4 . Said drum of  claim 3 , whereby a UV inhibitor is used in manufacture, such as carbon black (the most efficient UV inhibitor in addition to being the most cost effective) to extend the life and durability of the resin when apparatus is used outdoors in the sunlight. 
     
     
         5 . Said drum of  claim 4 , further comprising a cover on bearing mount with lights such as LED lights so moving dryer drum can be seen at night or in partial light;
 said drum including reflectors situated along outside edge of dryer;   lights on bearing mount of said drum positioned to shine toward reflectors to further illuminate moving dryer in the dark or in partial light; and   said reflectors situated to reflect the light produced by lights on the dryer frame as well as light from other sources.   
     
     
         6 . Said drum of  claim 5  mounted on an appropriate frame with a suitably mounted purpose-designed motor to rotate said drum; said motor with following features:
 slow start up speed increasing to operational speed over a sufficient period of time to prevent loss of traction due to the possible high moment of inertia at start up; 
 high energy efficiency; 
 over-heating shut down designed to stop if over-loaded; 
 equipped with a demand sensor which utilizes less energy as the clothes become lighter weight as they dry; 
 designed to slow speed of revolution before stopping at pre-programmed point of rotation for access position for easy access for loading and unloading; 
 designed to slow speed of revolution before stopping at an additional pre-programmed point of rotation for park position to position door by frame members of the dryer so door cannot be opened; and 
 equipped with a variable speed making it possible to control the point at which the clothes free fall within the dryer. 
 
     
     
         7 . Said apparatus of  claim 6 , whereby is used an electronically programmed sequence which cycles the motor on and off to pre-dry hard to dry fabrics to provide greater efficiency. 
     
     
         8 . Said apparatus of  claim 7 , further including devices, many commonly available but used in a new application, to enhance safety and ease of use which include:
 motion and/or heat sensors which will immediately stop dryer if anyone approaches operating dryer at a preset unsafe distance from any direction;   a sound emitter at frequencies not detectable to human ears to repel small animals and birds from immediate area of the dryer;   a system for turning on the dryer which requires a code to start;   a requirement for the operator to move back to a pre-determined safe distance as detected by motion/heat sensors after turning on the dryer before dryer actually begins to operate;   an upset switch which will immediately stop the dryer in case it is tipped over;   a “park position” which stops the dryer drum in such a position that the door of the dryer drum cannot be opened when dryer is not in use;   a double insulated electrical design where no parts subject to electrical current are accessible;   electrical grounding provided through all parts to the wheels; and a   Ground Fault Circuit Interrupter to halt power supply to the unit if proper ground is lost.   
     
     
         9 . Said apparatus of  claim 8  further comprising a system for capturing lint which includes:
 a lint screen type filter located under the drum at the point where lint and particles from drying clothes exit the drum; 
 a soft brush attached to the filter housing touching the dryer drum along perimeter of the drum at point where lint and particles from drying clothes exits the drum to further sweep lint into the filter; 
 a small fan under lint filter drawing air through the filter; and 
 a sensor attached to filter which indicates by sound and/or message on messaging screen on the control or remote control when the filter is plugged. 
 
     
     
         10 . Said apparatus of  claim 9  further comprising a control panel including a GFCI (ground fault circuit interrupter) with an on/off switch, typical wireless key pad, messaging display screen, menu button, sound emitter button, alarm light, and speaker for audio messaging and alarms positioned on frame of dryer specifically programmed with the following functions:
 keypad for entering start-up code and moving through and responding to menu options; 
 “on” function requiring code to start and operator to move away to pre-determined safe distance before initiating rotating drum operation; 
 “off” function which ceases power to dryer; 
 menu with messaging on display screen for functions available on dryer which include: 
 instructions for general use (ie. “on”, “off”, entering secure start up code, manually setting sound emitter to continue to function when dryer is off, setting delayed start, setting on/off rotation of drum for pre-drying hard to dry items); information (humidity at dryer location, elapsed time since load put into dryer, estimated dry time, time and date); error messages (plugged filter, overloaded, heavy point weight, water on dryer, fire, dryer moved or tipped); 
 speaker which sounds an alarm for pre-determined critical error messages (water on dryer, fire, dryer tipped over); 
 said speaker which sounds a repeating lesser sound for pre-determined error messages (plugged filter, overloaded, heavy point weight); 
 said speaker for audio messaging for all functions on the menu; and 
 Ground Fault Circuit Interrupter which halts power supply to the unit if proper ground is lost. 
 
     
     
         11 . Said apparatus of  claim 10  including a typical wireless remote control with an on/off switch, key pad, messaging display screen, menu button, alarm light, and speaker for audio messaging and alarms specifically programmed with the following functions:
 keypad for entering start-up code and moving through and responding to menu options; 
 “on” function requiring code to start and operator to move away to pre-determined safe distance before initiating rotating drum operation; 
 “off” function which slows, then stops dryer drum at “access” or “park” position; 
 said “off” function which can halt the power supply to the unit; 
 menu with messaging on display screen for functions available on dryer which include: instructions for general use (ie. “on”, “off”, entering secure start up code, manually setting sound emitter to continue to function when dryer is off, setting delayed start, setting on/off rotation of drum for pre-drying hard to dry items); information (humidity at dryer location, elapsed time since load put into dryer, estimated dry time, time and date); error messages (plugged filter, overloaded, heavy point weight, water on dryer, fire, dryer moved or tipped); 
 speaker which sounds an alarm for pre-determined critical error messages (water on dryer, fire, dryer tipped over); 
 said speaker which sounds a repeating lesser sound for pre-determined error messages (plugged filter, overloaded, heavy point weight); and 
 said speaker which gives verbal messages for all functions on the menu. 
 
     
     
         12 . Said drum of the apparatus of  claim 11  wherein is added a non static electricity additive to resin to help prevent any sparking from dried items in dryer. 
     
     
         13 . Said frame of apparatus of  claim 12  whereby extensions on the frame are able to lift the apparatus for ease in use. 
     
     
         14 . The apparatus for drying clothes, further comprising optional drum and framework designs to increase portability and storage options such as:
 the bracket holding the dryer drum designed to be disengaged so the drum may be lifted or rolled out of the frame;   support members of frame specifically designed to facilitate rolling disengaged drum out of frame;   drum of apparatus made in two halves designed to be disassembled to fit one inside the other for storage;   a foldable frame to allow frame to be folded flat for storage when drum removed;   silicon inserts or other appropriate flexible perforated material attached to a framework making it possible to flatten the drum for storage; and   framework for attached flexible inserts comprised of gradated sized shapes making it possible for each shape to fit within the next larger shape when the drum is flattened.