(12) United States Patent
`Masters
`
`IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
`US006485536B1
`(10) Patent No. :
`US 6, 485, 536 E1
`(45) Date of Patent:
`Nov. 26, 2002
`
`1/1992
`6/1992
`8/1992
`7/1993
`10/1993
`12/1993
`11/1995
`11/1995
`10/1999
`10/1999
`2/2000
`6/2000
`7/2000
`8/2002
`
`Finke
`Gorlich et al. . . .
`Carter, Jr.
`Duczmal et al. .
`Finke
`Soler et al.
`Bachand et al.
`Moorehead et al
`Parmentier et al.
`. . . . . . . . . .
`Kammel
`Wright et al. . . . .
`Bair et al.
`Fumagalli
`Bair et al.
`
`. . . . . . . .
`
`. . . . . 55/97
`. . . 55/457
`55/399
`. . . 209/12
`55/337
`15/327. 5
`. . . 451/75
`. 210/205
`92/28
`. . 210/243
`. . . 15/347
`. . . 15/347
`55/345
`. . . 55/318
`
`(54) VORTEX PARTICLE SEPARATOR
`
`(75)
`
`Inventor:
`
`Steven E. Masters, Boise, ID (US)
`
`(73) Assignee: Proteam, Inc. , Boise, ID (US)
`( * ) Notice:
`
`the term of this
`Subject to any disclaimer,
`is extended or adjusted under 35
`patent
`U. S. C. 154(b) by 0 days.
`
`(21) Appl. No. : 09/710, 247
`Nov. S, 2000
`(22) Filed:
`(51) Int. Cl. . . . . . . . . . . . . . . . . . . . . . . . . . . B01D 50/00; B01D 45/12
`(52) U. S. Cl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/337; 55/426; 55/429;
`55/452; 55/457; 55/467; 55/DIG. 3
`(58) Field of Search
`. . . . . . . . . . . . . . . . . . . . . . . . . . 55/337, 426, 429,
`55/452, 456, 457, 467, DIG. 3; 15/353
`
`(56)
`
`References Cited
`U. S. PATENT DOCUMENTS
`
`3, 693, 791
`3, 875, 061
`4, 008, 059
`4, 043, 513
`4, 162, 906
`4, 581, 050
`5, 028, 318
`
`9/1972 Beck . . . . . . . . . . . . . .
`A
`A
`4/1975 Pal ma
`2/1977 Monson et al. .
`A
`A
`8/1977 Hoberg et al.
`A * 7/1979 Sullivan et al. .
`A
`4/1986 Krantz
`A
`7/1991 Aslin
`
`. . . . . 209/144
`. . . . . 210/223
`. . . . . . . 55/396
`. . . . . . . 241/24
`210/512. 1
`55/269
`210/85
`
`5, 080, 697 A
`5, 120, 335 A
`5, 137, 554 A
`5, 224, 604 A
`5, 254, 147 A
`5, 267, 371 A
`5, 468, 174 A
`5, 470, 465 A
`5, 968, 231 A
`5, 972, 215 A
`6, 026, 540 A
`6, 070, 291 A
`6, 083, 292 A
`6, 428, 589 B1
`* cited by examiner
`Primary Examiner~obert A. Hopkins
`(74) Attorney, Agent, or Firm~obert L. Shaver; Frank J.
`Dykas; Stephen M. Nipper
`ABSTRACT
`
`(57)
`
`is a particle
`separates
`separator which
`The
`invention
`from a fluid. The particle separator
`entrained particulates
`an auger enclosed within
`utilizes
`to form a
`a cylinder
`is propelled. The
`cyclonic chamber,
`through which air
`centrifugal motion of particles within
`the air causes
`the
`particles to exit the cyclonic chamber
`through ducts, and the
`in collection chambers.
`particles are separated
`
`47 Claims, 12 Drawing Sheets
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`56
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`40
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`16
`38
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`44
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`50
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`48
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`26
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`42
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`52
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`z4 s'
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`20
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`i8
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`28
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`4
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`FIG. 2
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`US 6, 485, 536 E1
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`Nov. 26, 2002
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`18
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`f2
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`9
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`FIG. 5B
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`FIG 5A
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`Nov. 26, 2002
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`Sheet 9 of 12
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`66 ~i
`10~
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`L
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`34 32
`p4
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`I
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`l
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`22
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`Nov. 26, 2002
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`Sheet 12 of 12
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`

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`US 6, 485, 536 B1
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`1
`VORTEX PARTICLE SEPARATOR
`
`BACKGROUND OF THE INVENTION
`1. Field of the Invention
`relates to devices which
`The present
`invention generally
`from flowing fluids, and more specifi-
`separate particulates
`force for
`cally to vacuum cleaners which use centrifugal
`such as cyclonic or vortex vacuum
`particle
`separation,
`cleaners.
`2. Background
`Information
`There are a large number of designs of vacuum cleaners,
`but two basic styles are prominent. One of these styles is a
`vacuum which utilizes a bag to collect filtered dirt. The bag
`serves as the filter and accumulates dust until full, at which
`time it is emptied. A stream of air is drawn
`into the bag, and
`pores in the bag wall stop particles which are in the air, but
`allow air to exit the bag. A problem with vacuums which
`utilize bags, is that the bag must be somewhat porous
`in
`order to allow the passage of a large flow of air. Bags which
`the passage of a large
`are fairly porous can also allow
`volume of particulates. As much as 40% of the dust can pass
`through such a bag and reenter
`the house, suspended
`in air
`currents, until it settles out.
`As soon as the vacuum cleaner begins to accumulate dust,
`the pores of the bag begin to be blocked, and the air flow
`decreases. As the air flow decreases,
`the vacuum cleaner
`floor tool can pass over particles, and the air flow may not
`to lift them olf the surface and into the vacuum
`be enough
`cleaner. As the bag fills with particles, the volume of air flow
`filtration power of the
`becomes
`less and
`less, and
`the
`vacuum bag becomes more and more, until
`the filtration
`el5ciency
`that not even air can exit the bag.
`is so high
`Another disadvantage of bag systems
`is the expense and
`messiness of a bag. When a bag is full of dirt, the vacuum
`cleaner must be opened and the bag removed and replaced
`with a new one. If large numbers of bags are used,
`the
`expense of new bags is undesirable.
`Still another problem with vacuums which use a bag is
`that users will try to continue using
`the vacuum as long as
`there is space in the bag to hold more dirt. However, a bag
`may be totally used up by filtering a small amount fine dust
`particles. These fine powders can completely block every
`pore in the filter bag, and reduce
`the air flow through
`the
`filter bag to zero. Auser may be dissatisfied with the vacuum
`when he opens the filter and finds that it is not full of dirt,
`but merely has a small amount of dirt on the inside of the
`bag. Some users may continue
`to use a vacuum
`in
`trying
`that the usefulness of
`such a state, either not understanding
`the bag has ended, or trying
`to conserve money by getting
`the most life out of every bag.
`A second type of vacuum cleaner uses cyclonic separation
`of particulates
`from the air. The typical cyclonic vacuum
`cleaner is configured so that a stream of air enters a vacuum
`to the cylindrical wall of the vacuum
`chamber at a tangent
`the wall of the container,
`chamber. The air circulates around
`to the wall or
`the heavier particles moving adjacent
`with
`bouncing against the wall, and the swirling air in the center
`of the chamber being more free of particulate matter. An air
`located at the
`tube to the motor and fan is typically
`intake
`bottom of the canister and runs vertically
`the center
`through
`of the canister, so that the cleaner central air is drawn
`into
`the top of
`the central intake tube, and is drawn back towards
`the container, where it may exit the vacuum cleaner. In many
`cyclonic designs, a supplemental
`filter is also placed so that
`filter before exiting
`air is filtered
`through a particulate
`the
`vacuum cleaner.
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`that
`
`Examples of cyclonic vacuum
`cleaners
`include
`in U. S. Pat. No. 5, 080, 697, to Fink.
`described
`Another type of cyclonic vacuum cleaner is shown in U. S.
`Pat. No. 6, 026, 540 to Wright et al. In Wright, as shown
`in
`the vacuum chamber at I and circulates
`FIG. 4, air enters
`the dirt cup 52. Dirt accumulates
`in the
`around
`spirally
`bottom of the dirt cup as the heavier particulates
`fall out of
`the air stream. A main filter element K is situated
`in the
`center of the cyclonic air flow chamber 54, and the cleaner
`air from the center of the spiraling air stream enters the main
`filter element K, and is drawn by a vacuum motor into an
`exhaust channel 60. As can be seen,
`the cyclonic elfect
`serves to keep heavier particles out of the filter element K.
`it is the fine particles which will occlude the filter
`However,
`and stop air flow, and the filter can be clogged and inelfec-
`tive long before the dust cup 52 is full.
`type of cyclonic vacuum cleaner
`is that sold by
`One
`Hoover as the Vortex model. In the Hoover vacuum cleaner,
`air enters a cyclonic chamber
`and spins around
`tangentially,
`the side of the cylindrical chamber. Heavier particles fall to
`the bottom of this chamber and out of the main air flow. Air
`from the center of this cylindrical chamber and
`is drawn
`to a second stage centrifugal
`chamber
`passes
`separating
`is stacked on top of the first stage. Particles which
`which
`the outside circumference of the second cylin-
`travel around
`drical chamber are again separated from the main air stream,
`the center of the chamber goes into a third
`and air from
`centrifugal or cyclonic separation chamber. This chamber is
`also stacked on top of the previous chamber, and further
`separates particles from air in the center of the chamber.
`example of prior art cyclonic vacuums
`is a
`Another
`vacuum made by Eureka, and sold as the True HEPA Model.
`This vacuum cleaner is an upright, with a clear chamber
`in
`the center of the upright portion of the vacuum. Visible
`to be a funnel on
`the clear chamber
`is what appears
`inside
`the right, and a collection chamber
`in the left side. The
`funnel is actually a cyclonic chamber,
`in which air enters at
`the funnel, finally exiting at the
`a tangent and spins around
`bottom of the funnel. As the air enters
`it is
`the funnel,
`spinning, and large particles that are suspended
`in the air are
`expelled from the air stream before they enter the funnel.
`The large particles enter a chamber olf to one side of the
`funnel which collects these
`large particles. The particles
`in this initial separation chamber
`which are not separated
`continue on through
`the funnel, and eventually encounter a
`filter which filters particulates before the air stream enters
`is typical of a large number of
`the fan. The Eureka vacuum
`in which a centrifugal or cyclonic cham-
`cyclonic vacuums,
`ber is used as a prefilter,
`to separate larger particles from the
`air stream, and a pleated paper or fibrous filter is utilized
`to
`filter the fine particles out of the air stream. The Phantom
`is
`another example of this type of filtration.
`It is an object of the invention
`to provide a bagless particle
`separator based on cyclonic separation of particles. It is a
`further object to provide a high el5ciency separation device
`which separates particles from moving
`fluid, and sorts the
`particles according to size. It is a further object to provide a
`vacuum cleaner which operates without bags, and which
`el5ciently separates particles from air.
`
`SUMMARY OF THE INVENTION
`
`These and other objects are achieved by a vortex particle
`is a highly elfective
`separator. The vortex particle separator
`for use in a vacuum cleaner. It is also
`particle separator
`in which particles need to be removed
`useful in any situation
`from a fluid flow. This can include use as a room air purifier,
`
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`US 6, 485, 536 B1
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`to remove smoke particles, pollen and dust from the room
`air. It is also elfective at separating particles
`from air in
`such as in a smoke stack, either as a
`situations,
`industrial
`prefilter for a bag house, or as a replacement
`for bag filters.
`This vortex separator can also be used to sort materials by
`size.
`The vortex particle separator utilizes a cyclonic chamber
`is an auger or spiral ramp, confined within a cylin-
`which
`drical tube. Air is drawn
`this cyclonic chamber, and
`through
`the periphery of the cyclonic
`particles which move
`to
`chamber exit the cyclonic chamber by centrifugal force, and
`in a collection chamber.
`are captured
`In its simplest format, the vortex particle separator utilizes
`a single stage for separation of particles. In this version of
`the vortex particle separator, a housing encloses the cyclonic
`chamber. The housing has an intake port and an exhaust port,
`and the housing may be closed at top and bottom, forming
`an enclosed chamber. The housing can be a rigid chamber,
`such as a plastic or metal chamber, and it can also be made
`of a flexible material, such as paper, fabric or plastic. The
`housing of the vortex particle separator can be porous or
`non-porous. If porous it would typically be a paper, fabric,
`and or a fabric bag. The housing may include a mechanism
`top and bottom end of the
`for opening
`and closing
`the
`housing.
`is located an auger or spiral ramp. The
`Within the housing
`spiral ramp is enclosed by a cylindrical
`tube, called the core
`the cylindrical core
`shroud. The spiral ramp enclosed within
`shroud forms the cyclonic chamber. The spiral ramp has an
`the outside edge
`inside edge and an outside edge, with
`inside edge cylindrical core shroud,
`to the
`adjacent
`and
`the core shroud. The cylindrical core shroud
`sealed against
`has an interior surface and an exterior surface, and encloses
`the spiral ramp or auger. The core shroud and the spiral ramp
`for air through
`form a pathway
`the housing, and confine the
`air to the spiral pathway of the cyclonic chamber.
`a means of excluding
`The cyclonic chamber
`includes
`from the cyclonic chamber. This can include a
`particulates
`means of keeping particulates
`the cyclonic
`from entering
`chamber, or a means of expelling
`the particulates after they
`the cyclonic chamber, or both. The cyclonic
`have entered
`chamber can terminate before it connects to the intake port
`of the housing, so that there is space between
`the beginning
`of the cyclonic chamber and the inlet of the housing. This
`space forms a gap or debris opening and allows the passage
`of large particulates out of the air flow and into the housing.
`to an air outlet of the
`The cyclonic chamber
`attaches
`through which air exits the cyclonic chamber and
`housing,
`the housing. A suction creating means
`is included, and is
`typically a motor with a fan. The fan propels air through
`the
`the housing. A means of
`cyclonic chamber
`and
`through
`connecting
`the fan and motor to the housing is also included,
`to the motor shaft, or by belt,
`such as by direct attachment
`chain, or gear connection.
`If the cyclonic chamber
`is spaced apart from the air inlet
`of the housing,
`is mounted
`the air propulsion means
`then
`to the air outlet of the housing. When
`adjacent
`the air
`propulsion means, typically a fan and motor, is activated, a
`stream of air races through
`the cyclonic chamber, and forms
`a vortex of air beyond the inlet to the cyclonic chamber and
`the air inlet of the housing. As air and
`extending
`into
`this vortex,
`particulates
`enter
`the air assumes a spiraling
`the air inlet. Since there is a gap
`pathway as it passes through
`the air inlet and the inlet to the cyclonic chamber,
`between
`the cyclonic cham-
`the heavier particles are thrown outside
`ber and
`the air which enters
`into
`the housing,
`the
`and
`is free of these particulates.
`cyclonic chamber
`
`5
`
`10
`
`15
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`20
`
`25
`
`30
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`35
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`40
`
`45
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`50
`
`55
`
`60
`
`65
`
`A particulate
`filter may optionally be mounted between
`the air outlet of the housing and the fan.
`A means
`in the vortex particle separator
`is provided
`to
`debris
`remove
`from
`particulate
`the accumulated
`the air
`the housing and the core shroud.
`chamber formed between
`The means of removing
`the particulates can be by removing
`top of the
`the bottom of the housing, by removing
`the
`the housing split open in a clam shell
`housing, by having
`fashion, or any other means which
`is typically used in the
`If the housing
`it can be
`is a flexible material,
`industry.
`disposed of with the dirt enclosed. The top of the housing
`typically be an attached plate which includes
`would
`the air
`inlet for the housing. A vacuum hose would
`typically be
`attached to the air inlet, and would extend to a floor tool or
`other intake or cleaning tool. The bottom of the housing may
`be removable, and may serve as a means of debris removal.
`In some configurations of the vortex particle separator,
`the
`outside of the
`air propulsion means could be mounted
`at the air inlet, and would push air through
`the
`housing
`cyclonic chamber.
`is mounted
`In another version,
`the air propulsion means
`the housing and adjacent to the air outlet, and pulls
`outside
`the cyclonic chamber. The vortex particle sepa-
`air through
`rator can be configured
`to include a particulate
`filter in the
`air stream which exits the cyclonic chamber. The vortex
`particle separator can also be configured so that air speed is
`increased in the cyclonic chamber due to the spiral ramp and
`in radius. This would cause
`the cyclonic chamber decreasing
`air to move faster around
`the smaller radius, which would
`smaller particulates. The air speed can
`aid in separating
`the cyclonic chamber by a change in pitch
`increase through
`of the spiral ramp also. The vortex particle separator can also
`increases
`be configured
`so
`that air speed
`the
`through
`cyclonic chamber by the inner core of the cyclonic chamber
`in diameter, so that there is less volume for air in
`increasing
`the spiral ramp of the cyclonic chamber.
`Another embodiment of the vortex particle separator can
`be constructed with all of the variations
`listed for the first
`and which also includes a second stage for
`embodiment,
`separation of particles separate
`the first stage. The
`from
`second stage could be divided from the first stage either by
`a partition which separates
`the two stages vertically
`from
`each other, or by a partition which separates
`the two stages
`from each other. Particle separation
`is more
`horizontally
`elficient when larger particles are removed first, and smaller
`later. This is because the bouncing of
`particles are removed
`the larger particles
`introduces
`into the airflow,
`turbulence
`the path of the smaller particles. The
`and may disturb
`multiple stages can also be used to sort particles by size in
`some applications.
`A third embodiment of the vortex particle separator
`is a
`unit with three stages. This embodiment can have all of the
`variations noted for the previous
`two embodiments,
`and
`for collection of
`three separate chambers
`includes
`further
`particles of dilferent
`sizes. These
`three chambers can be
`from each other or horizontally.
`divided vertically
`Still other objects and advantages of the present invention
`will become readily apparent
`to those skilled in this art from
`the following detailed description wherein I have shown and
`described only the preferred embodiment of the invention,
`simply by way of illustration of the best mode contemplated
`invention. As will be realized,
`by carrying out my
`the
`is capable of modification
`in various obvious
`invention
`invention.
`respects
`from
`all without
`the
`departing
`the drawings and description of the preferred
`Accordingly,
`are to be regarded as illustrative
`embodiments
`in nature, and
`not as restrictive.
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`US 6, 485, 536 B1
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`separator
`
`the core
`
`5
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a cross sectional view of a three stage vortex
`particle separator.
`FIG. 2 is a cross sectional view of a single stage particle
`separator which utilizes a gap between the cyclonic chamber
`and the air inlet.
`FIG. 3 is a cross sectional view of a single stage unit,
`to remove particulates.
`which utilizes debris openings
`FIG. 4 is a cross sectional view of a
`two stage
`the two stages are separated verti-
`embodiment,
`in which
`cally.
`FIG. 5a is an exploded view of a vortex particle separator
`removed.
`with the housing
`FIG. 5b is a top view of a vortex particle separator.
`FIG. 6 is a perspective view of the compartment divider
`and debris deflector cap of a vortex particle separator.
`FIG. 7 is a perspective view of the housing of a vortex
`particle separator.
`FIG. II is a side cut-away view of a vortex particle
`separator configured as a canister vacuum.
`FIG. 9 is a front view of a vortex particle
`configured as a backpack vacuum.
`FIG. 10 is a side cut away view of a vortex particle
`separator configured as an upright vacuum.
`FIG. 11 is a side view of a spiral ramp with
`to increase air speed.
`increasing
`in diameter
`FIG. 12 is a side view of a spiral ramp with the spiral ramp
`to increase air speed.
`decreasing
`in diameter
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`is susceptible of various modifica-
`While
`the invention
`constructions,
`certain
`tions and alternative
`illustrated
`thereof have been shown in the drawings and
`embodiments
`will be described below in detail. It should be understood,
`that there is no intention
`to
`however,
`to limit the invention
`the specific forms termed "preferred", but, on the contrary,
`is to cover all modifications,
`invention
`alternative
`the
`constructions,
`and equivalents
`falling within
`the spirit and
`scope of the invention as defined
`in the claims.
`FIGS. 1 — 12 shows some of the preferred embodiments of
`the invention.
`One preferred embodiment of the particle separator of the
`in FIG. 2. This is a single stage particle
`is shown
`invention
`It includes a housing 12, in which
`is centrally
`separator.
`located a spiral ramp 14, which
`is surrounded
`by a core
`the two form a cyclonic chamber 20.
`shroud 1II, in which
`The housing 12 has an inlet 22 and an outlet 24. In this
`a fan (not shown) driven by a motor (not
`embodiment,
`shown) is mounted adjacent the air outlet 24. The fan pulls
`the cyclonic chamber and through
`the air inlet.
`air through
`The air inlet is attached
`to an air source (not shown), which
`can be an air hose, ducting, or simply a connection
`to a dust
`such as in a room or in an industrial stack.
`filled environment
`When the fan is activated, air is pulled
`the cyclonic
`through
`the spiral ramp. A
`chamber and in a spiral pathway
`through
`vortex 26 of air forms in the cyclonic chamber, and extends
`into the air inlet. As air enters
`beyond the cyclonic chamber
`the spiral shape of the vortex, and
`the air inlet, it assumes
`enters the housing 12 in this spiral pathway. Particles which
`the periphery of the
`than air are forced towards
`are heavier
`vortex, and when the air enters the housing 12, particles 2II
`are thrown out of vortex through
`the air gap 36 and into the
`housing 12. The elficiency of this single stage cyclonic filter
`depends on the speed of rotation of the vortex.
`
`Another single stage version of the particle separator 10
`in FIG. 3. In this version, a vortex 26 is formed in
`is shown
`into the air inlet 22. However,
`the same way, and extends
`there is no air gap 36, as there was in FIG. 2. FIG. 3, the
`means of removing particles from the air stream is by way
`of a number of debris openings 16. As in the device shown
`in FIG. 2, centrifugal
`force forces the particles 2II to the
`periphery of the vortex 26, where
`they exit the cyclonic
`the debris opening 16. The features of
`chamber 20 through
`the single stage separator of FIG. 2 can be combined with
`those of FIG. 3 to produce a device which includes an air gap
`36 as well as one or more debris openings 16.
`FIG. 4 shows a two stage particle separator 10. This
`particle separator 10 includes a housing 12, a spiral ramp 14,
`the spiral ramp 14
`a core shroud 1II, which
`together with
`forms the cyclonic chamber 20. Debris openings 16 are also
`included. The device has an air inlet 22 and air outlet 24, and
`is attached to a motor (not shown) and a fan (not shown). An
`air gap 36 is present between
`the spiral ramp 14 and the air
`inlet 22. The device
`divider 3II,
`includes a compartment
`in shape, and is
`which in this case is generally frustoconical
`attached at one end to the core shroud, and at the other end
`to the interior housing wall. The compartment
`divider 3II
`into a first chamber 42 and a second
`divides
`the housing
`chamber 44. In this version, a deflector plate 30 is mounted
`the cyclonic chamber 20.
`in the second chamber 44 around
`This deflector plate 30 serves to keep particles 2II in the
`lower part of the second chamber 44, and helps prevent them
`the debris openings 16. In
`from being drawn back into
`this version of the particle separator 10 operates
`operation,
`by forming a vortex in the cyclonic chamber, which extends
`into the air inlet. As air enters the housing,
`larger particles
`the air gap 36 into the
`of debris 2II are thrown out through
`first chamber 42. Particles which continue on with the vortex
`into the cyclonic chamber have another chance to exit the
`vortex through debris opening 16. Since there is less inter-
`in the vortex
`action between particles, and
`the air speed
`increases as it approaches
`the air outlet, more particles, and
`smaller particles are separated
`the debris openings
`through
`16 in the cyclonic chamber 20. Having more
`than one
`chamber allows for more elficient separation of particles,
`and also allows for sorting of material.
`in FIGS. 1, 5a,
`is shown
`Another preferred embodiment
`5b, and 6. This is a particular configuration of three stage
`in FIG. 1, this version of the
`particle separator. As shown
`particle separator 10 includes a housing 12, a spiral ramp 14,
`a core shroud 1II, to form a cyclonic
`enclosed within
`chamber 20. Over the top of the cyclonic chamber is located
`a debris deflector or cyclonic chamber cap 40. The housing
`12 has an air inlet 22 and an air outlet 24. This version of the
`device preferably uses a fan and a motor for propelling air,
`and the fan and motor may be mounted either adjacent to the
`air inlet or adjacent to the air outlet. A particulate
`filter (not
`down-
`typically be mounted operationally
`shown) would
`stream from the air outlet 24 of the housing 12. This would
`the purpose of removing
`the very smallest particles
`serve
`which were not removed by the cyclonic chamber. The
`is to have the
`for this embodiment
`preferable configuration
`motor and fan mounted adjacent to the air outlet 24 of the
`housing 12, and
`to have a particulate
`filter (not shown)
`the air outlet 24. In
`from
`downstream
`this
`mounted
`air would be pulled
`the cyclonic
`configuration,
`through
`chamber 20 and would
`form a vortex
`the cyclonic
`in
`chamber. The flow of air would pull air in passages under the
`cyclonic chamber cap 40, and into the housing 12 through
`the air inlet 22. Larger particles 2II would
`fall into a first
`chamber 42. A second chamber 44 would be formed by a
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`Dyson Ex1022
`Page 16
`
`

`

`US 6, 485, 536 B1
`
`is attached
`the core
`divider 3II which
`from
`compartment
`shroud 1II to the housing floor 4II. Debris opening 16 would
`allow passage of particles 2II into the second chamber 44. A
`divider 50 extends
`the core
`second compartment
`from
`shroud 1II to the housing floor 4II, and forms a third chamber
`52. Abase 54 surrounds
`the air inlet 24, and abuts the core
`shroud 1II of the cyclonic chamber 20. The raised base 54
`forms one wall of the third chamber 52, and at least one
`debris opening 16 provides communication
`between
`the
`cyclonic chamber and the third chamber 52.
`this version of the device would deposit the
`In operation,
`size
`larger particles
`in the first chamber 42, intermediate
`in the second chamber 44, and the finest particles
`particles
`in the third chamber 52. The particles 2II could be removed
`from this device by removal of the housing floor 4II. It may
`also be desirable
`to provide particle removal by opening
`the
`in a clam shell fashion, or by removing
`the housing
`housing
`top 56. Once
`top 56 is removed,
`the entire
`the housing
`inside can be removed from the housing floor 4II,
`structure
`for disposal of particles 2II.
`FIG. 5A shows and exploded view of the
`three stage
`version of the particle separator 10. Shown in FIG. 5A is the
`raised base 54, the housing
`floor 4II, the second compart-
`ment divider 50, the cyclonic chamber 20 with
`the core
`shroud 1II and debris opening 16 visible, and a spiral ramp
`14.
`FIG. 5B is a top view of this device with housing
`the cyclonic chamber 20, the spiral ramp
`removed, showing
`14, debris opening 16, and the housing
`floor 4II.
`FIG. 6 shows a view of the cyclonic chamber cap 40 in
`and a top view, and the structure of the com-
`perspective
`partment divider 3II.
`FIG. 7 shows the housing 12 which would fit on the three
`stage device of FIG. 1 The preferred embodiment of this
`is a rigid plastic
`device
`but other preferred
`structure,
`rigid structures of metal and paper,
`embodiments
`include
`and flexible and/or porous structures of fabric, paper, or
`plastic.
`FIG. II shows the cyclonic separator of FIG. 1 mounted
`in
`a canister vacuum 5II, and show the motor 34, a fan 32, and
`a particulate or HEPA filter 46. Also shown
`is the housing
`12, the first chamber 42, the compartment divider 3II, and the
`cyclonic chamber cap 40. An air inlet 22 is shown attached
`to a vacuum hose 60 with an attached floor tool 62.
`FIG. 9 shows the embodiment of the three stage particle
`in a backpack vacuum version. This
`separator mounted
`straps 64 by a user 66. It
`is worn with shoulder
`version
`includes all of the features
`thus described, such as housing
`12, the first chamber 42 being visible in this view, as well as
`the compartment divider 3II. Shown is the preferred cyclonic
`chamber cap 40. A motor 34 and a fan 32 are shown, as well
`filter or HEPA filter 46.
`as a particulate
`FIG. 10 shows the three stage cyclonic separator of FIG.
`1, mounted
`in an upright vacuum cleaner which utilizes all
`of the previously mentioned components.
`FIG. 11 shows a one preferred version of the spiral ramp
`14 which
`includes a ramp core 6II. In this version of the
`spiral ramp, the ramp core increases in diameter from a first
`end 70 to a second end 72 of the spiral ramp 14. The first end
`70 of the spiral ramp is mounted
`towards
`the air inlet, and
`the second end 72 of the spiral ramp is preferably mounted
`the air outlet. As air flows through
`towards
`this spiral ramp
`enclosed in the core shroud 1II, the cross sectional diameter
`of the air path decreases, which causes an increase
`in air
`speed. This air of increased speed passes by debris opening
`16, and increasingly smaller particles of air can be separated
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`said
`
`for separating
`
`entrained
`
`because of the increased air speed. This version of a spiral
`ramp can be used in all of the embodiments of the vacuum
`cleaner.
`FIG. 12 shows another design of the spiral ramp which
`the cross sectional diameter
`increases air flow by decreasing
`of the cyclonic chamber.
`the first end of the
`In this unit,
`than the second end of
`spiral ramp 70 is wider in diameter
`ramp 72. Air enters at the first end 70, and
`the spiral
`towards the second end 72, increasing
`in speed as
`progresses
`the diameter of the cyclonic chamber decreases.
`While there is shown and described
`the present preferred
`embodiment of the invention,
`it is to be distinctly understood
`is not limited thereto but may be variously
`that this invention
`the scope of the following
`to practice within
`embodied
`claims. From the foregoing description,
`it will be apparent
`that various changes may be made without departing
`from
`the spirit and scope of the
`as defined by the
`invention
`following claims.
`I claim:
`1. A vortex particle separator,
`particulates
`from air, comprising:
`a vacuum housing, with at least one sidewall, a top end
`and a bottom end;
`at least one air inlet in said housing, for entry of air into
`said housing;
`at least one spiral ramp enclosed by a generally cylindri-
`cal core shroud,
`in which said spiral ramp comprises a
`top end, and bottom end, and an inside edge and a