DUAL STAGE CYCLONE SEPARATOR AND VACUUM SYSTEMS

Inventor: Eric Frederick Wood FIELD

The present invention is related generally to the field of particle separation. More particularly, the present invention relates to dual stage cyclone particle separators. BACKGROUND

The ideal vacuum cleaner is one that efficiently draws in particulates, separates the particulates from the airstream so as to deposit the particulates into an appropriate receptacle and exhausts particulate-free air. Various apparatus for separating the particulates from the airstream have been tried in the past with varying degrees of effectiveness. Some of these apparatus include various incarnations of a filter screen, vacuum bag, and cyclone separator, and combinations of these.

Vacuum cleaners that pass the airstream through a filter screen or vacuum bag, or both, are problematic. A large amount of very fine dust produced by, for example, typical wood-working tools, can quickly clog a filter screen or fill a vacuum bag. Furthermore, as the filter screen or vacuum bag clog and fill, the vacuum decreases over time as the airstream encounters more resistance as it passes through the clogged filter screen or vacuum hag. This lowered vacuum reduces the efficiency with which the particulates are collected. In addition, when cutting and machining materials commonly used in woodwork produce particulates so fine that they will pass through both a vacuum bag and filter screen and exit through the exhaust to the ambient air.

A cyclone separator is a device for removing particulates from the airstream through vortex separation. Rotational effects and gravity act on the particulates in an airstream in an attempt to have the particulates fall out of the airstream. Particulates above a certain mass have too much inertia to follow the tight curve of the airstream produced by the cyclone separator and thus settle out of the airstream and fall into a receptacle under the effects of gravity . Particulates below a certain mass remain entrained within the airstream and exit the cyclone separator via the separator outlet. In some apparatus, a filter screen or vacuum bag is used in an attempt to capture those remaining particulates exiting the separator outlet,

A vacuum system that includes a cyclone separator and does not have a filter screen or vacuum bag does not have the disadvantage of a decreasing vacuum over time due to the clogging _, of a filter screen or vacuum bag, Various designs of. cyclone separators have been tried in the past to reduce the amount of particulates exiting the separator outlet, Particulate removal is dependent in part on the size of the cyclone separator, and thus there are design challenges for smaller vacuum systems used in residential and small industrial applications. Examples of smaller vacuum systems include, portable upright and canister vacuum, cleaners and non-portable central vacuum cleaners used in home and shop environments.

There exists a need in the art for cyclone separators and vacuum systems incorporating cyclone separators that are more efficient in removing particulates from the airstream.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings, in which like references may indicate similar elements throughout the various figures unless otherwise specified.

FIG. 1 is a perspective, partial cut-away view of a dual. stage cyclone separator assembly, in accordance with an embodiment;

FIG, 2 is a perspective, partial cut-away view of a dual stage cyclone separator in accordance with an embodiment;

FIG. 3 is a top view of the embodiment of FIG. 1 ;

FIG. 4 is. a perspective exploded view of the embodiment of FIG. 1 ,

FIG. 5 is a detail cross-sectional view showing how the angled lid flange fits onto a receptacle in accordance with an embodiment;

FIG. 6 is a detail view showing a slot in the outer edge of the lid to aid in removal of lid for emptylng the receptacle, in accordance with an embodiment;

FIG- 7 shows the airstream cyclonic flow pattern inside the first cyclonic housing, in accordance with the embodiment of FIG. 1 ;

FIG. 8 is a perspective exploded view of the adaptor flange operable to couple the lid to a larger auxiliary receptacle, in accordance with an embodiment; and FIG _. 9 is an embodiment of an inlet opening, in accordance with an embodiment.

DETAILED DESCRIPTION

in the following description, embodiments of apparatus and methods will be disclosed. For purposes of explanation, specific numbers, materials, and/or configurations are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to those skilled in the art that the embodiments may be practiced without one or more of the specific details, or with other approaches, materials, components, etc. In other instances, well-known structures, materials, and/or operations are not shown and/or described in detail to avoid obscuring the embodiments. Accordingly, in some instances, features are omitted and/or simplified in order to not obscure the disclosed embodiments.

Furthermore, it is understood that the embodiments shown in the figures are illustrative representations and are not necessarily drawn to scale.

Reference throughout this specification to 'One embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of claimed subject matter. Thus, the appearances of the phrase "in one embodiment" or "an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in one or more embodiments.

Reference will now be made to embodiments illustrated in the drawings and specific language which will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended.

Alterations and further modifications of the illustrated embodiments and further applications of the principles of the invention, as would normally occur to one skilled in the art to which the invention relates, are also within the scope of the invention.

Embodiments presented herein provide dual stage cyclone separators that may be stand-alone systems operable to be coupled to a vacuum source or integrated into a vacuum system, such as, but not limited to, an upright or canister vacuum cleaner. For purposes of describing the embodiments, reference will be made to vacuum systems suitable for wood shop operations. It-will nevertheless be understood that no limitation of the scope of the invention is thereby intended. FIG. 1 is a perspective, partial cut-away view of a dual stage cyclone separator assembly 100 in accordance with an embodiment. FIG. 2 is a perspective, partial cut-away view of a dual stage cyclone separator 1 in accordance with an embodiment; FIG. 3 is a top view of the embodiment of FIG. 1. FIG. 4 is a perspective exploded view of the embodiment of FIG. 1. The dual stage cyclone separator assembly 100 comprises a dual stage cyclone separator 1 coupled to a first receptacle 7. The dual stage cyclone separator 1 comprises a first cyclone separator vessel 120 and a second cyclone separator vessel 140.

The first cyclone separator vessel 120 comprises an outer cylindrical tube 16, an outer truncated cone 19, and a plate 13. The outer cylindrical tube 16 includes an outer cylindrical tube first end 122 and an outer cylindrical tube second end 124. The outer truncated cone 19 includes an outer truncated cone first end 192 and an outer truncated cone second end 194. The outer truncated cone first end 192 has a larger diameter than the outer truncated cone second end 194. The outer truncated cone first end 192 has the same diameter as the outer cylindrical tube second end 124 and is coupled thereto. The outer cylindrical tube 16 and the outer truncated cone 19 define an outer cone assembly 150. The outer cone assembly 150 defines an outer cone assembly inner surface 152 and an outer cone assembly outer surface 154.

The plate 13 defines a circular plate having a diameter at least as large as the diameter of the outer cylindrical tube first end 122 and is coupled thereto. The plate 13 defines an outlet aperture 132 and an outlet tube 3 coupled about the outlet aperture 132 providing fluid communication from one side of the plate 13 to the other side of the plate 13. The outlet tube 3 may be operable for coupling to an outlet hose 2, as shown in FIG. 1.

The first cyclone separator vessel 120 defines an axis of symmetry X that extends through the outlet tube 3, the outer cylindrical tube 16, and the outer truncated cone 19.

The first cyclone separator vessel 120 further comprises an inner cylindrical tube TO and an inner truncated cone 14, both of which are smaller than the outer cylindrical tube 16 and the outer truncated cone 19. The inner cylindrical tube 10 includes an inner cylindrcal tube first end 112 and an inner cylindrical tube second end 114. The inner truncated cone 14 includes an inner truncated cone first end 142 and an inner truncated cone second end 144. The inner truncated cone first end 142 has a larger diameter than the inner truncated cone second end 144. The inner truncated cone first end 142 has the same diameter as the inner ^" cylindrical tube second end 114 and is coupled thereto. The inner cylindrical tube 10 and the inner truncated cone 14 define an inner cone assembly 16Q. The inner cone assembly 160 defines an inner cone assembly outer surface 162 and an inner cone assembly inner surface 164,

The inner cylindrical tube first end 112 is coupled to the plate 13 and is coaxial with the axis of symmetry X.

The first cyclone separator vessel 120 further comprises a second receptacle: 32 coupled to the inner truncated cone second end 144. The second receptacle 32 is operable to prevent fluid communication between the first cyclone separator vessel 120 and a second cyclone separator vessel 140 via the inner truncated cone second end 144. As will be described below, the second receptacle 32 is operable, to retain, any particulates that drop out of the airstream while the airstream traverses the inner cyclone chamber 180 within the second cyclone separator vessel 140. The second receptacle 32 is removably coupled to the inner truncated cone second end 144 such that the second receptacle 32 may be removed from the inner truncated cone second end 144 for emptying of particulates therefrom..

The outer cylindrical tube 16 defines an inlet aperture 17 and an inlet tube 4 coupled about the inlet aperture 17 providing fluid communication from outer cone assembly outer surface 154 and the outer cone assembly inner surface 152. The in!et tube 4 is operable for coupling to an inlet hose 5, as shown in FIG. 1 by way of example. The inlet tube 4 is operable to direct the airstream substantially tangential to the outer cone assembly inner surface 152 so as to direct the airstream in a cyclonic manner about the axis X.

The inner cone assembly 160 is nested within and co-axial with the. outer cone assembly 150 defining an outer cyclone chamber 121 therebetween. The outer cyclone chamber 121 comprises an outer cyclone chamber first end 123 adjacent the outer truncated cone first end 192 and an outer cyclone chamber second end 125 adjacent the outer truncated cone second end 194.

The second cyclone separator vessel 140 comprises the inner cone assembly

160 and a cylindrical vortex finder 9, The cylindrical vortex finder 9 is a cylindrical tube and includes a cylindrical vortex finder first end 196 and a cylindrical vortex finder second end 197. The cylindrical vortex finder 9 has a smaller diameter than the inner cylindrical tube 10 and is operable to extend co-axially within the inner cylindrical tube 10 defining an inner cyclone chamber 180 therebetween. The cylindrical vortex finder first end 196 is coupled to the plate 13 and is coaxial with the axis of symmetry X.

The second cyclone separator vessel 140 defines an axis of symmetry X that extends through the outlet tube 3, the inner cylindrical tube 10, and the inner truncated cone 14.

The inner cyclone chamber 180 comprises an inner cyclone chamber first end 182 adjacent the inner cylindrical tube 10 and an inner cyclone chamber second end 184 adjacent the inner truncated cone second end 144.

The inner cylindrical tube 10 defines a vortex aperture 109 and a first vortex finder 11 coupled about the vortex aperture 109 and extends from the inner cone assembly outer surface 152. The first vortex finder 11 defines a vortex finder opening 119 that is substantially perpendicular to the inner cone assembly outer surface 162 providing fluid communication from the outer cyclone chamber 121 to the inner cyclone chamber 180 adjacent the inner cyclone chamber first end 182. The first vortex finder 11 is operable to accept the airstream that is directed substantially tangential to the inner cone assembly outer surface 162.

The dual stage cyclone separator assembly 100 comprises a dual stage cyclone separator 1 coupled to a first receptacle 7. The first receptacle 7 is operable to couple with the cuter truncated cone second end 194. The first receptacle 7 is operable to retain any particulates that drop out of the airstream while the airstream traverses the outer cyclone chamber 121.

As shown in FIGs. 1 2, 4, and 7, the second cyclone separator vessel 140 is coaxial with and nested within the first cyclone separator vessel 120.

As shown in FIG 7, the dual cyclone assembly 110 is operable such that the airstream enters the inlet tube 4 into the outer cyclone chamber first end 123 directed in a cyclonic motion adjacent the outer cone assembly inner surface 152. The airstream descends toward the outer cyclone chamber second end 125 and ascends to the outer cyclone chamber first end 123 in a cyclonic motion adjacent the inner cone assembly outer surface 162. Tie airstream is directed by cyclonic motion into the vortex finder opening 111 substantially tangential to the inner cone assembly inner surface 164 so as to direct the airstream in a cyclonic manner about the axis X within the inner cyclone chamber 180. The airstream descends in cyclonic motion toward the inner cyclone chamber second end 184 and ascends to the inner cyclone chamber first end 182 in a cyclonic motion within a core of a cyclone formed within the inner cyclone chamber 180 and into the cylindrical vortex finder second end 197, and exhausting through the cylindrical vortex finder 9 to the outlet tube 3.

In accordance with embodiments, the dual stage cyclone separator 1 may be provided to the consumer without a first receptacle 7 such that a suitable receptacle of the consumer's choice may be used. Such suitable receptacles include, but are not limited to, a bucKet, trash can, 55-galion drum, and purposely-build containers suitable for the particular purpose.

In accordance with other embodiments, the dual stage cyclone separator 1 may be provided to the consumer with a first receptacle 7. The consumer may couple the outlet hose 2 to a suitable vacuum source. Such suitable vacuum sources include, but are not limited to, a portable shop vacuum, canister vacuum, and central vacuum.

In accordance with other embodiments, the dual cyclone assembly 1 10 may be provided as a part of larger vacuum systems, such as, but not limited to, residential and commercial upright and canister vacuum cleaners.

Referring to FIG. 4, in accordance with an embodiment, the outer truncated cone second end 194 is coupled to an annular ring 18 defining a circular opening 12. Coupled to an outer edge of an underside of the annular ring 18 is a short cylinder which creates a lip 6 and flange 20 with a slight inward angle that cooperates with a taper on a five gallon pail, as shown in FIG. 5. The annular ring 18 and lip 6 are sized so that the dual stage cyclone separator 1 snugly fits a five gallon pail as the first receptacle 7. At.five equally spaced intervals around the circumference of the lip 6 are small slots 24 into which a screwdriver may be inserted so as to pry off the dual stage cyclone separator 1 in the event it is stuck, as shown in FIG. 6. Also equally spaced around the outer truncated cone second end 194 are five triangular supporting members 8 such that the bottom of the triangular supporting members 8 is joined to the annular ring 18 and one adjacent side of the triangular supporting members 8 is joined to the outer truncated cone second end 194.

In accordance with an embodiment, the second receptacle 32 comprises a flat circular bottom plate 29 onto which is joined a cylinder 23 onto which is joined a conical top 22 defining an opening 2i operable to couple with the inner truncated, cone second end 144. The conical top 22 is operable to redirect the descending airstream toward the outer cyclone chamber first end 123. The conical top 22 of the second receptacle 32 acts as a vortex stabilizer for the tail end of the vortex, preventing the vortex from drifting off center and scavenging particulate that is drifting down the outer cone assembly inner surface 152.

In accordance with and embodiment as shown in FIG. 1 , the inner truncated cone second end 144 extends beyond the outer truncated cone second end 194 and into the first receptacle 7. This extension of the inner truncated cone second end 144, and thus the second receptacle 32, from the outer truncated cone, second end 194 further enhances the removal of particulate from the airstream.

FIG. 8 is an embodiment of an adaptor ring 127 comprising a tapered cylinder 25 joined to an annulus 26 such that the taper matches a taper of the flange 20, as shown in FIG. 4. A suitable number of equally spaced holes 30 allow the adaptor ring 127 to be bolted through an air tight gasket 27 to the lid 28 of the first receptacle 7.

Embodiments provided herein provide a means of ensuring that there is no loss of vacuum with continued use, thus providing for an efficient method of particulate capture using a typical shop vacuum.

Embodiments of the dual stage cyclone separator, when inserted between the airstream from the tool and the shop vacuum, traps particulates in the airstream and deposits them in an auxiliary container. The cleaned air exiting the cyclone separator then flows into the shop vacuum, resulting in minimal dust entering a vacuum bag and filter attached thereto, resulting in a constant and high level of suction to provide efficient dust collection. Even under heavy use conditions, the rate of vacuum bag and filter use will be only a tiny fraction of what it would be otherwise, resulting in a lower operating cost for the shop vacuum.

Embodiments of the dual stage cyclone separator traps dust and debris generated by typical home power tools before it reaches the shop vacuum;

eliminates or dramatically reduces the need for vacuum bags in a shop vacuum; eliminates or dramatically reduces the need for filter cleaning and replacement in a shop vacuum; ensures a constant high level of vacuum regardless of the amount of dust collected by the shop vacuum; provides an almost dust free air stream to return to the ambient air; provides a simple and convenient method for ensuring an air tight vacuum system: provides a simple and convenient method for emptylng the auxiliary dust receptacle on which the dual stage cyclone separator is placed; provides a simple and convenient method for adapting the dual stage cyclone separator for mounting on a variety of different styles of auxiliary dust receptacle, for example, five gallon pails, fiber drums, plastic and metal drums and so on; and, provides a simple and convenient method for ensuring that in the event ^' of a stoppage in the dust stream, the shop vacuum will not produce a strong enough level of suction to cause the auxiliary dust receptacle to buckle or break.

By way of example, utility vacuums, often referred to as shop vacuums, are commonly used for dust control in small home workshops; and, many modern tools, such as, but not limited to, routers, band saws, and miter saws, have dust ports that allow an inlet hose from the shop vacuum to be attached directly to the power tool.

Even a small shop vacuum has sufficient air flow and velocity to do a good job of capturing dust when it is operating at full vacuum.

The nesting relationship of the first cyclone separator vessel 120 and a second cyclone separator vessel 140 provides a much smaller dual stage cyclone assembly as would otherwise be if they were not nested.

The cylindrical portion of the second cyclone separator vessel 140 creates a channel which constrains the airstream entering the inlet tube 4 to flow in the space between the inner cylindrical tube 10 and the outer cylindrical tube 16. This acts as a flow stabilizer and tends to minimize turbulence in the original airstream. The cylindrical vortex finder 9 does the same for the airstream entering the inner cyclone chamber 180 through the first vortex finder 11. lt also prevents particulates being sucked into the outiet tube 3 before it is spun against the sides of the inner truncated cone 14, a concern where the distance between the cylindrical vortex finder second end 197 and outlet tube 3 is as small as it is in the inner cyclone chamber 180.

The cylindrical vortex finder 9 acts as a vortex finder for the upwardly spiraling air.

The second receptacle 32 collects the residual dust left after the first cleaning and so it can be relatively small and this means that it does not affect the airflow for the primary vortex.

Taken together these features significantly improve the ability of a mini cyclone system to remove dust and particulate matter from _. a . dust stream, even very fine dust

One alternative embodiment would use the adapter ring, as shown in FIG. 8, to attach it to any larger dust receptacle that has an airtight sealing mechanism, for example, either fiber or plastic drums with snap ring closures. Another alternative- embodiment would add a vacuum relief valve to ensure that if used with a very powerful shop vacuum a blocked input hose would not result in the crushing of the dust receptacle or the cyclone body itself. One such embodiment might be a simple sprung flap (with appropriate seal) mounted on the underside of the annular ring 18 which closes over a hole in said annulus. Under typical operating conditions the flap is held in place over the hole by the spring and the unit operates normally. If the inlet tube is blocked, the shop vacuum produces a higher than norma! vacuum inside the separator body and ambient air pressure pushes the flap open thereby allowing air to enter and prevent damage to the parts of the apparatus.

Another alternative embodiment would make the secondary cyclone removable so that in the event a large volume of coarse material, say chips from a planer, needed to be trapped, there would be no danger of the secondary cyclone (which is designed for extra fine dust anyway) becoming blocked.

Another alternative embodiment would alter the structure of the inlet tube to provide a different means of drawing the airstream into the first cyclone separator vessel 120. as shown in FIG. 9. The outer cylindrical tube 16 defines an inlet aperture 117 and an inlet channel 115 coupled about the inlet aperture 117 providing fluid communication from outer cone assembly outer surface 154 and the outer cone assembly inner surface 152, The inlet channel 115 defines an inlet aperture 1 13 that is operable for coupling to an inlet hose 5, such as shown in FIG. 1 by way of example. The inlet channel 1 15 is operable to direct the airstream substantially tangential to the outer cone assembly inner surface 152 so as to direct the airstream in a cyclonic manner about the axis X.

While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modification and this application is intended to cover any variations, uses, or adaptations of the invention following, in genera), the principles of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as fall within the scope of the invention and the limits of the appended claims.