Centrifugal dirt separation configurations for household-type and shop-type vacuum cleaners

Abstract

A cyclonic separation device in accordance with an embodiment of the present application preferably includes a first cyclone chamber having a cylindrical shape with a predetermined diameter, the first cyclone chamber including, a tangential inlet positioned on a first longitudinal end of the first cyclone chamber, a baffle plate positioned in the first cyclone chamber a predetermined distance from the tangential inlet, a tangential dirt outlet positioned on a second end of the cyclone chamber, opposite the inlet and on an opposite side of the baffle plate from the tangential inlet and a center exit duct mounted in the center of the cyclone chamber having an inlet opening positioned upstream from the baffle plate such the centrifuged fluid without particles flows into the center exit duct and out of the cyclone chamber.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a The arrows A included in FIGS. FIGS. 4, 8a, 9 and 15 illustrate the flow of air though the vacuum cleaner 1.
where “F” represent the centrifugal force, “w” represents the weight flow, g is a gravitational constant, “v” is the velocity of the air and “r” is the inside radius of the chamber 10. The dirt particles move down the chamber 10 and pass the baffle plate 12 to be discharged from the chamber 10 at high velocity out of tangential outlet 23. The outlet 23 is preferably connected to the collection chamber 14, or to a bag to collect the dirt. The lighter air that accompanies the dirt into the chamber 14 is recirculated back as is illustrated by the line 23c of FIG. 12 and into the chamber, or swirl area 27 downstream of the baffle 12 and recirculated in this area. The air flow exits the cyclone separator chamber through the holes 25 in the duct 16. This exit air is very clean due to the high centrifugal force in the chamber 10, which separates particles form the airflow. Only the clean air near the center of the chamber 10 is allowed to exit.

FIG. 13 shows a side view of the primary cyclone separator chamber 10 with an additional perforated liner duct, or insert, 17 inserted into the duct 16 to provide sound (noise) dampening. The duct 17 is designed to provide a Helmholtz resonator effect due to its hole sizes and cavity spacing behind the liner walls to reduce the noise emitted from the cleaner 1, for example.

FIG. 10a shows a conceptual perspective view of a canister type or shop vacuum cleaner 100 in accordance with another embodiment of the present application. The cleaner 100 preferably includes a top cover and frame 102 on which the basic vacuum cleaner elements may be mounted, including, suction fan motor and fan assembly 120, centrifugal separator 122, and final filter 108. A vacuum hose (not shown) may be attached to the suction fan inlet 110. Further, there is preferably a carrying handle 125 provided along with a lower dirt collecting housing 114.

FIG. 11a illustrates cleaner 100 of FIG. 10a without the dirt collecting housing 114 such that the mounting of the basic components 120, 122, 118/108 can be seen as well as the tangential inlet 111 to the centrifugal separator 122 and the suction fan tangential discharge port 116 as well as the tangential dirt discharge port 23 of the centrifugal separator 122.

In FIG. 10b, the suction fan inlet 110 is shown connected to the inside top area of 120 of the primary dirt collection chamber 114a where the inlet 110b to the vacuum cleaner 100b is moved to enter the primary dirt collection chamber 114a. This positioning allows nails or other large items of debris commonly cleaned using a shop vacuum to be collected before the air passes through the fan. In addition, if the vacuum 100b is used to pick up water, for example, the majority of the water will be trapped in the main container 114a before complete separation is achieved by the primary cyclone separation chamber. Thus, the collector chamber preferably includes low pressure side 114a and a fan discharge pressure side 114b that collects dirt or water separated from the suction air and discharged from the separator 122 out tangential discharge outlet 123 into the chamber 114b.

The design of FIG. 10b represents a much improved shop vacuum (or wet pick-up shop vacuum) which typically only clean air with a washable sponge or cloth filter such that the discharged air is often very dusty. Similarly, when liquid is picked up, the discharge air tends to be very wet since the filter is saturated by water still in the air that is passing through the discharge opening.

FIG. 11b shows the under side of the vacuum top assembly of FIG. 10b with the container 114 removes. The motor and suction fan inlet 110 is now relocated inside the vacuum cover 120 to provide suction by inlet 110 directly into the container portion 114a.

FIG. 14a illustrates an alternate configuration of the vacuum cleaner 100 of FIG. 10a with a non-porous plastic or paper bag 86 attached to the cyclone chamber's tangential discharge 123. The throw away bag 86 is preferably held in place with a roll spring 85 which can be rolled over the bag opening to clamp it to the tangential dirt discharge duct. FIG. 14b shows the vacuum cleaner 100 with the dirt bag 86 removed and the retention spring 85 rolled back to expose slot 87 which is preferably formed on the outlet 123 to accommodate the spring 85 to keep the bag 86 in place. The shop vacuum cleaner of FIGS. 10b and 11b may also utilize a bag as well to collect discharge dirt, if desired. The bag may be positioned in, or in place of the chamber 114b, if desired

FIG. 15 is a partial sectional view of the HEPA type very small particle filter 18 that is shown on the upright floor sweeper vacuum cleaner 1 of FIG. 1, or on the alternative embodiment of FIG. 22, discussed below. The filter 18 preferably receives air discharged from the secondary cyclone separator 65 in FIG. 1, or to the air discharge duct of the primary or secondary separator sections of the embodiment of FIG. 22. The filter 18 provides for final air filtration if desired. The filter 18 preferably includes a housing 84 and an inlet 82 into which the cleaner air from the primary and secondary cyclone separation sections 22, 65 pass for final filtering.

FIG. 16 illustrates a compact, light weight cyclone (centrifugal) dirt separator, bagless re-circulated air and sound suppressed vacuum cleaner 200 in accordance with an embodiment of the present application. The vacuum cleaner 200 preferably includes a suction fan drive motor 220, fan 206, a large dirt centrifugal separator section 222 connected to the suction fan inlet 217 and a large collection chamber 214, where all of these components are mounted in the floor housing 201. See also FIG. 17

A handle 205 is preferably pivotally attached to the housing 201. A secondary cyclone separator section 260 is preferably mounted on the handle 205, which is at least partially hollow to allow air to flow from housing 201 to the separator 264. A second removable dirt collector 265 is provided with the secondary separator 264 which is for very fine dirt and need only be cleaned periodically. In addition, a HEPA filter 284 may also be provide to provide additional final filtering, if desired, as shown in FIG. 22.

FIG. 17 shows an internal perspective view of the housing 201 with a bottom cover removed such that the major components are visible. As illustrated, the primary cyclone separator section 222 is mounted adjacent to the suction fan motor and housing 220. The fan 206 rotates to create suction and pull dirt and air from the pick up head area 209 through the tangential inlet 211 and into the cyclone chamber 219 of the separator 222. The dirt rotates in the chamber 210 at high velocity and moves to the inner surface of the outer walls of the chamber and past the baffle 212 into the discharge area 227 from which it is discharged through tangential outlet 223 into the removable large dirt collector or bag 214 shown in FIG. 16. A belt 218 is preferably connected to a shaft of the motor or fan and is used to rotate brush 215 in the pick up head area 209 to help lift dirt off the floor. An exit duct 216 is positioned in the chamber 219 to allow the cleaned air to exit the chamber through the holes 225 formed in a wall therein. The duct 216 is connected to the fan inlet at 217. Element 227 refers to the dirt swirl section, or collection section, of the chamber 219 which is downstream of the baffle 212 and includes the tangential dirt discharge outlet 223 for the dirt to be blown into the removable large dirt container 214. Another advantage of discharging the dirt from the cyclone chamber is that the large dirt collection chamber or bag can take any desired shape to maximize dirt volume storage efficiency.

The suction fan 206 air is discharged into the hollow handle mounting 204 with some or most of it being provided to the collection duct 270 for connection to a jet assist slot 271 (See FIG. 18) in the bottom cover 205. Jet assisted suction is discussed above with reference to the vacuum cleaner 1 of FIGS. 1-9, for example. Generally, the high velocity air produces a low-pressure area just above the carpet or floor due to the Bernoulli effect.

FIG. 18 shows a bottom view of the vacuum cleaner 200 of FIG. 17 with the bottom cover replaced. In addition, a recirculation air jet assist slot 271 around the suction pick-up opening 209 is shown with the rotating floor brush 215.

FIG. 19 illustrates a cross sectional view of the housing 201 illustrating how a portion of the cleaned air from the chamber 10 can be redirected to the jet assist slot 271 of the head area 209 while other air is directed up the hollow handle portion 204 to the secondary separator 265.

FIG. 20 is a schematic view of the centrifugal dirt separator section 222 and suction fan 206. As illustrated, the exit air duct 216 of the chamber 210 is connected to the inlet of the fan 206. FIG. 20 also illustrates the relationship of the tangential inlet 211 of the chamber 210 and the tangential dirt outlet 223 as well as the openings 225 that are preferably formed to provide an inlet for the exit duct 216 to allow the cleaned air to escape chamber 222. The suction fan 206 is shown attached to the centrifugal separator exit duct 216 so as to provide noise isolation from the intake of the vacuum cleaner 200 near the suction head area 209

FIG. 21 is an improvement on the features illustrated in FIG. 20. In this embodiment, a second insert 280 provided in the air exit duct 216 to provide Helmholtz dampening of sound. This absorbs the high velocity fan blade and high velocity air noise from coming back out the inlet 211.

FIG. 22 illustrates the secondary cyclone separator 260 mounted on the handle 205 of the cleaner 200. The separator 264 is optimized for separating very small particles from the cleaned air provided from the primary separator 222. The separator chamber 264 thus includes a plurality of small diameter chambers 290 similar to the chambers 60 described above with reference to FIGS. 8a and 8b. The chambers include small tangential inlets and tapered walls but are arrange around the handle 204. Slots are provided in the handle 205 to correspond to these inlet slots. The cup 265 is provided for dirt collection and is preferably removable. In one embodiment a disposable bag may be placed into the cup 265 to collect dirt.

FIG. 23 illustrates an alternative embodiment of a vacuum cleaner 300 where the primary cyclone separator 322 is mounted on hollow handle 308 and the larger dirt and much of the very small dirt is deposited into a non-porous bag or container 314. The container 314 may be made larger in this embodiment since it is not part of the floor assembly. Secondary cyclone separation is provided in the separator 360, which may also include a HEPA filter, if desired. The first and second separators 322, 360 however are similar to those described above with reference to vacuum 200.

FIG. 24 shows the application of the disclosed cyclone separator illustrated in FIGS. 6 and 12, for example, in place of the cleanable filter 403 commonly used in central vacuum systems. Generally, in conventional systems such as system 400 dirt is sucked into a removable container 414 as shown in FIG. 24, so it can be discarded. However, the air is typically filtered by a cloth bag or other cleanable filter (see element 403, for example) which is dusty to clean and reduces performance of the system as it gets clogged with dirt and dust.

In accordance with the present application, the central vacuum 410 has element 401 which represents a suction fan drive motor, and element 402 representing the suction fan while the cyclone separator is identified as element 413 which can be used to replace the filter 403 in the housing of a central vacuum cleaner 400. The inlet port 406 from the central home vacuum is connected to the house vacuum piping which is connected to the tangential inlet of the separator 413. A center air discharge duct similar to duct 16 of FIG. 6 is preferably connected to the suction fan inlet 402 to allow the suction fan to draw air at high velocity through the tangential inlet of the cyclone centrifugal separator 413. The separated dirt is discharged out tangential discharge 416 and drops into the container 414.

Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.

Claims

1. A vacuum cleaner, comprising:

a handle; and

a floor housing to which the handle is pivotally connected, wherein

the floor housing further comprises:

a suction fan motor;

a suction fan driven by the suction fan motor and including a plurality of fan blades driven at a high velocity by the suction fan motor to suck a fluid from a first side of the fan to a second side of the fan;

a pick up head positioned adjacent to a floor and in fluid communication with the suction fan; and

a cyclonic separator device comprising:

a cyclone chamber having a cylindrical shape with a predetermined diameter, the cyclone chamber further comprising:

a tangential inlet duct positioned on a first longitudinal end of the cyclone chamber;

an opening formed in an outer wall of the cyclone chamber at a second end of the cyclone chamber, opposite the inlet through which particles exit the cyclone chamber; and

a center exit duct mounted substantially in the center of the cyclone chamber having an inlet opening positioned such the centrifuged fluid without particles flows into the center exit duct and out of the cyclone chamber, wherein

the pick up head and suction fan are connected in fluid communication with the cyclone chamber such that fluid flows from the pick up head through the tangential inlet into the cyclone chamber and rotates therein at high velocity such that particles in the fluid are forced out to the inner surface of the outer wall of the cyclone chamber and are discharged through the opening.

2. The vacuum cleaner of claim 1, wherein the inlet of the center exit duct includes a sleeve including a plurality of perforations formed therein, such that the perforations prevent particles from entering the inlet.

3. The vacuum cleaner of claim 1, further comprising a jet assist duct connected between the center exit duct and the pick up head and a jet assist nozzle positioned on the pick up head and connected to the jet assist duct to provide a stream of high velocity air in a direction parallel to the floor to be cleaned to aid in sucking particles off the floor and into the pick up head.

4. The vacuum cleaner of claim 3 further comprising a collection chamber in fluid communication with the opening and structured to store separated particles from the fluid.

5. A canister-type vacuum comprising:

a top cover; and

a bottom particle container portion;

the bottom particle container portion including;

a suction fan motor;

a suction fan driven by the motor and including a plurality of fan blades driven at a high velocity to suck fluid from a first side thereof to a second side thereof;

a cyclonic separation device comprising:

a cyclone chamber substantially cylindrical in shape and having a predetermined diameter; the cyclone chamber further comprising:

a tangential inlet formed on a first longitudinal end thereof and in fluid communication with the second side of the suction fan;

a particle opening formed on a second longitudinal end thereof, opposite the first longitudinal end, and configure for particles to pass out of the cyclone chamber;

a particle container aligned with the particle opening to store particles; and

an exit opening formed in a top of the cyclone chamber, between the first and second longitudinal ends and configured for fluid to leave the cyclone chamber.

6. A canister-type vacuum comprising:

a top cover; and

a bottom particle container portion;

the bottom particle container portion including:

a suction fan motor;

a suction fan driven by the motor and including a plurality of fan blades driven at a high velocity to suck fluid from a first side thereof to a second side thereof;

a cyclonic separation device comprising:

a cyclone chamber substantially cylindrical in shape and having a predetermined diameter; the cyclonic chamber further comprising:

a tangential inlet formed on a first longitudinal end thereof;

a particle opening formed on a second longitudinal end thereof, opposite the first longitudinal end and configured for particles to pass out of the cyclone chamber; and

an exit opening formed in a top of the cyclone chamber, between the first and second longitudinal ends and configured for fluid to leave the cyclone chamber, wherein the suction fan is positioned downstream of the exit opening.

7. A vacuum system comprising:

a housing;

a hose connected to the housing; and

a pick up head connected to the hose;

the housing further comprising;

a suction fan motor;

a suction fan driven by the motor and including a plurality of fan blades driven at a high velocity to suck fluid from a first side thereof to a second side thereof;

a cyclonic separation device comprising:

a cyclone chamber substantially cylindrical in shape and having a predetermined diameter; the cyclonic chamber further comprising:

a tangential inlet formed on a first longitudinal end thereof and in fluid communication with the hose;

a particle opening formed on a second longitudinal end thereof, opposite the first longitudinal end and configured for particles to pass out of the cyclone chamber; and

an exit opening formed in a top of the cyclone chamber, between the first and second longitudinal ends and configured for fluid to leave the cyclone chamber, wherein the suction fan is positioned downstream of the exit opening.

8. The vacuum system of claim 7, wherein the hose is made of a flexible material.

9. The vacuum system of claim 7, wherein the hose is a pipe.