HUMIDIFIER

Abstract

A humidifier has a base and a housing. The housing has a steam exhaust vent and a vaporizer. The vaporizer includes a heating element surrounded by a removable porous sleeve that protrudes downwardly into water within a reservoir of the base. The sleeve wicks the water including its minerals and impurities into contact with the heating element wherein energization of the heating element causes the wicked water to convert to steam that rises through the exhaust vent and from the housing during a humidification mode.

Claims

1. A humidifier comprising: a housing having; a top side with a steam exhaust vent and a fill opening there-through, a tank adapted to receive water through the fill opening, and a one-way fill valve to allow the water downwardly through the fill opening but otherwise close the fill opening; and a vaporizer comprising a heating element surrounded by a removable porous sleeve, the sleeve protruding downwardly from the housing and in fluid communication with the steam exhaust vent; a base adapted to removably receive the housing there-atop, and including a reservoir for receiving water from the tank and the porous sleeve; whereby, the porous sleeve wicks water from the reservoir including minerals and impurities therein into contact with the heating element, wherein energization of the heating element causes the wicked water to convert to steam which rises through the steam exhaust vent and from the housing during a humidification mode, and wherein the minerals and impurities remain within the porous sleeve.

2. The humidifier of claim 1 wherein the steam exhaust vent further comprises a normally open exhaust valve which is closed during a sterilization mode to prevent the steam from rising through the steam exhaust vent, whereby the steam circulates within the humidifier to sterilize surfaces and components therein.

3. The humidifier of claim 2 further comprising a water level sensor in electrical communication with the heating element and the exhaust valve and adapted to sense a water level within the reservoir to enable energization/de-energization of the heating element and opening/closing of the exhaust valve according thereto.

4. The humidifier of claim 3 wherein the tank comprises a normally closed water-release valve that prevents the outflow of water from the tank when the tank is not properly received by the base, and the base comprises a valve actuator adapted to open the water release valve and allow water from the tank into the reservoir there-through until a water level in the reservoir rises to a first water level.

5. The humidifier of claim 4 wherein the water level sensor enables energization of the heating element when the water level in the reservoir rises to the first water level to thereby enable the humidification mode.

6. The humidifier of claim 5 wherein the water level sensor is adapted to sense when the water level in the reservoir falls to a second water level lower than the first water level and to then close the exhaust valve to thereby enable the sterilization mode.

7. The humidifier of claim 6 wherein the water level in the reservoir falls to the second water level when the tank has become empty of water.

8. The humidifier of claim 7 wherein the water level sensor is adapted to sense when the water level in the reservoir falls to a third water level lower than the second water level and to then de-energize the heating element.

9. The humidifier of claim 8 wherein the water level sensor is adapted to enable re-opening of the exhaust valve when the water level in the reservoir falls to the third water level.

10. The humidifier of claim 9 wherein the valve actuator is a float that rises and falls with the water level in the reservoir.

11. The humidifier of claim 10 wherein the housing comprises the water level sensor.

12. The humidifier of claim 11 wherein the top side is a cover removable from the housing and comprising the steam exhaust vent, the fill opening, the exhaust valve, and the one-way fill valve.

13. The humidifier of claim 12 wherein the housing further comprises a cover lock adapted to secure the cover to the housing and prevent its removal during the sterilization mode.

14. The humidifier of claim 7 wherein the reservoir is at or near devoid of water at the third water level.

15. The humidifier of claim 7 further comprising a timer adapted to de-energize the heating element when a predetermined sterilization period has passed.

16. The humidifier of claim 15 wherein the timer is adapted to enable re-opening of the exhaust valve when the predetermined sterilization period has passed.

17. The humidifier of claim 16 wherein the porous sleeve is comprised of a heat-tolerant material and the predetermined sterilization period is long enough to ensure that the porous material has wicked all water from the reservoir during the sterilization period.

18. The humidifier of claim 17 wherein the valve actuator is a float that rises and falls with the water level in the reservoir.

19. The humidifier of claim 18 wherein the housing comprises the water level sensor.

20. The humidifier of claim 19 wherein the top side is a cover removable from the housing and comprising the steam exhaust vent, the fill opening, the exhaust valve, and the one-way fill valve.

21. The humidifier of claim 20 wherein the housing further comprises a cover lock adapted to secure the cover to the housing and prevent its removal during the sterilization mode.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] FIG. 1 is a perspective view of an exemplary humidifier according to or useful in practicing the invention;

[0032] FIG. 2 is an exploded view of the major components of the humidifier of FIG. 1;

[0033] FIG. 3 is a front view of the humidifier of FIG. 1;

[0034] FIG. 4 is a top view of the humidifier of FIG. 1;

[0035] FIG. 5 is a side view of the humidifier of FIG;

[0036] FIG. 6 is a rear view of the humidifier of FIG. 1;

[0037] FIG. 7A is a cross-sectional view of the humidifier of FIG. 1 during filling, taken at line 7-7 of FIG. 4;

[0038] FIG. 7B is a cross-sectional view of the humidifier of FIG. 1 during humidifying, taken at line 7-7 of FIG. 4;

[0039] FIG. 7C is a cross-sectional view of the humidifier of FIG. 1 during sterilizing, taken at line 7-7 of FIG. 4;

[0040] FIG. 8A is a cross-sectional perspective view of the humidifier of FIG. 1, taken at line 8-8 of FIG. 4;

[0041] FIG. 8B is a cross-sectional view of the humidifier of FIG. 1, taken at line 8-8 of FIG. 4;

[0042] FIG. 9A is a break-away view of the humidifier of FIG. 1 during the humidification mode;

[0043] FIG. 9B is a break-away view of the humidifier of FIG. 1 during the sterilization mode;

[0044] FIG. 10 is a partial cross-sectional view of the cover of the humidifier of FIG. 1 during non-filling and during use;

[0045] FIG. 11 is an exploded view of the cover assembly of the humidifier of FIG. 1;

[0046] FIG. 12A is a close-up view of the fill valve of the humidifier of FIG. 1 in its unlocked state;

[0047] FIG. 12B is a close-up view of the fill valve of the humidifier of FIG. 1 in its locked state;

[0048] FIG. 13 is an exploded view of the humidifier of FIG. 1;

[0049] FIG. 14A is a partial cross-sectional view of an alternate water-release valve and valve actuator pair in its closed state; and

[0050] FIG. 14B is a partial cross-sectional view of the alternate water-release valve and valve actuator pair of FIG. 14A in its opened state.

DETAILED DESCRIPTION OF THE INVENTION

[0051] Referring to FIGS. 1 through 13, there is shown an exemplary tabletop humidifier 100 which includes a hollow housing 102, a base 104, a cover 106, and a porous absorption sleeve 108, all seen best in FIG. 2

[0052] Referring to FIGS. 2, 4, and 7A through 8B, the cover forms a top side of the housing when mounted thereon and is removable therefrom for accessing the inside components thereof. The housing has a steam exhaust vent 112 avoided by the cover and the cover a fill opening 114 there-through. Grill 115 overlays the exhaust vent and prevents objects for falling therethrough while allowing ventilation.

[0053] The housing contains a water tank 116 which communicates with and is adapted to receive water through the fill opening as in FIG. 7A. The fill opening includes a normally closed one-way fill valve 118 which allows water downwardly through the fill opening but otherwise closes the fill opening. The fill valve hingedly affixed to and removable with the cover and is a torsion spring-biased and counterbalanced flapper valve seen best in FIGS. 7A, 7B, and 11 through 12B.

[0054] The housing includes a controller 122. Vaporizer 124 includes a PTC heating element 126 electrically controlled by the controller and depending downwardly from the housing and surrounded by the removable porous absorption sleeve. The sleeve is made of a heat-resistant non-flammable wicking material, preferably polyester felt because it has good wicking qualities, is tolerant or the high temperatures needed for steam generation, is germ-resistant, is dishwasher-safe, and is acid resistant. The sleeve may be a cylindrical tube or sock that slides up and tightly around the heating element of may be a sheet which wraps tightly around the heating element and is secured by such means as hook-loop fastening. The sleeve is thereby easily removable from the heating element for changing and cleaning, and hangs from the housing below the heating element. The sleeve and heating element are below and in fluid communication with the steam exhaust vent though vertical chimney 127.

[0055] The base is adapted to removably receive the housing there-atop and includes a reservoir 128 for receiving water from the water tank and for receiving the lower end 132 of the porous sleeve, whereby when water is within the reservoir and submerges at least a portion of the lower end, the porous sleeve wicks the water up, around, and in contact with the heating element, including minerals and impurities that may reside within that water. Energization of the heating element then causes the wicked water to convert to clean pure steam 134 which rises through the steam exhaust vent and from the housing during a humidification mode, and the minerals and impurities remain within the porous sleeve. This is depicted in FIG. 7B.

[0056] The steam exhaust vent includes a normally open exhaust valve 136 including and controlled by a stepping motor 138. The exhaust valve is an unbiased butterfly valve having only two functional positions as controlled by the stepping motor; the open position of FIG. 7B and the closed position of FIG. 7C. It is open during the humidification mode as seen best in FIG. 7B to allow rising humidity to pass thereby, and it is closed during a sterilization mode to prevent the steam from rising through the steam exhaust vent and cause it to circulate within the humidifier to sterilize the surfaces and components therein, as seen best in FIG. 7C.

[0057] The housing includes a water level sensor 142 in electrical communication with the heating element and the exhaust valve's stepping motor. The sensor is adapted to sense the water level within the reservoir to enable energization/de-energization of the heating element and opening/closing of the exhaust valve according thereto.

[0058] The tank has a normally closed water-release valve 144 that prevents the outflow of water from the tank when the tank is not properly received by the base. The water-release valve is a compression spring-biased stem valve. The base includes a valve actuator 146 adapted to open the water release valve and allow water from the tank into the reservoir there-through until the water level in the reservoir rises to a first water level 148, being the normal operating level during the humidification mode. The valve actuator includes a float 152 that is hingedly connected to the base so that it is free to rise and fall with the water level in the reservoir.

[0059] The water level sensor then enables energization of the heating element when the water level in the reservoir rises to the first water level to thereby enable the humidification mode.

[0060] The water level sensor is disposed and adapted to sense when the water level in the reservoir falls to a second water level 154 lower than the first water level and to then close the exhaust valve to thereby enable the sterilization mode. The water level in the reservoir falls to the second water level only after the tank has become empty of water.

[0061] The water level sensor is also disposed and adapted to sense when the water level in the reservoir falls to a third water level 156 lower than the second water level, where the reservoir is at or near to completely empty, and to then de-energize the heating element and terminate the sterilization mode. The water level sensor enables re-opening of the exhaust valve when the water level in the reservoir falls to the third water level.

[0062] The controller includes circuitry connected to a user interface control panel 158 and circuitry with switches, indicators, a power controller, a timer 162, and a humidity sensor to enable control of various operations, such as ambient humidity level and rate of humidity output. The indicators may include a display to indicate settings and ambient room temperature sensed by the humidity sensor. The controller is adapted to vary the heater wattage according to operational requirements or user selection. The timer allows the user to select a time period for humidification in the event that less than a full tank of humidity is needed or desired, such as when the humidifier is used in a small room or only needed until the user has fallen asleep.

[0063] Rather than rely on the water level sensor sensing the third water level to terminate the sterilization mode, the timer may alternatively disable the heater to terminate the sterilization mode after a predetermined period of time, a sterilization period, at the end of which the reservoir is expected to be at or near completely empty. The timer would then also be adapted to enable re-opening of the exhaust valve when the predetermined sterilization period has passed.

[0064] As an added safety feature, an electrical cover lock 164 within the housing and circuitry secures the cover to the housing to ensure that the cover cannot be removed during the sterilization mode. The lock is unlocked once the sterilization mode is terminated.

[0065] The sanitizing mode may also be initiated manually by the user at any time by activating a switch on the control panel. The controller may require that the water level sensor confirms that the water level is below the first water level before enabling such activation.

[0066] As a safety feature, the fill valve is adapted to lock in its closed position during the sterilization mode to avoid the burning of a hand or such by reaching inside the humidifier. This is accomplished by a heat-activated locking hinge 166 best seen in FIGS. 10 through 12B. While the valve is normally in its closed position as in FIGS. 10A and 12A, it is free to swing downwardly open about pin 168 against the bias of spring 172 by the weight and force of incoming water from above as shown in FIG. 10B. The spring then biases the valve back upward to the closed state of FIGS. 10A and 12A to prevent airborne germs and dust from falling into the water tank. During sterilization mode, bimetal stopper 174 expands by exposure to the high temperature of the sterilizing steam and interferes with the hinge components as shown in FIG. 12B to prevent opening of the cap.

[0067] FIGS. 14A and 14B depict an alternate humidifier embodiment 200 which is identical to the humidifier 100 except that rather than use a float as the valve actuator, a valve-actuating post 252 engages alternative water-release valve 244 when tank 216 is properly positioned on the base 204. The valve is surrounded by a cylindrical wall 245 that hangs into the base reservoir 228 and includes water level-establishing slots 247 adapted to prevent the water level in the reservoir from rising above the first water level 248 and to maintain that water level throughout the humidification mode.

[0068] Various aspects of the humidifier are worthy of special mention and repeat; [0069] Minerals and impurities are retained within the removable/replaceable wicking sleeve, which can be placed in a dishwasher, soaked in vinegar, otherwise cleaned, or simply replaced. [0070] While the pure output of a vaporizer or properly-maintained warm mist humidifier is achieved, there is no boiling and no heater submerged in the water where it would otherwise be plated by the water's minerals. [0071] The heating element does not need to be heated to a temperature high enough to cause boiling during humidification as in warm mist humidifiers and vaporizers . . . it needs only to get hot enough to cause evaporation of the moisture within the sleeve. This provides not only a safety and energy benefit, but also enables the humidity output rate to be varied simply by varying the heater wattage. [0072] The heater is operated at full wattage during the sterilization mode to ensure that the steam produced is hot enough to sterilize. [0073] The base reservoir is emptied with every cycle to prevent the growth of germs in the water and the odors related thereto. [0074] The sleeve is dried out with every cycle to prevent the growth of mold and the subsequent emission of mold spore. [0075] The user never needs to sterilize the humidifier and its components by hand or bay some arbitrary schedule . . . each operation cycle includes a sterilization routine that is adequate for proper and safe operation. [0076] There is absolutely no noise during operation . . . no fan noise, no impeller noise, no boiling noise. [0077] Neither the top cover nor the water tank needs to be removed for filling. The entire humidifier remains stationary in its desired location. [0078] Because the water tank is opened-topped within the housing, it is treated by the steam as well during the sterilization mode. [0079] For additional cleaning, if desired, the base, housing, and cover are easily separated to access internal surfaces