U.S. patent application number 10/436988 was filed with the patent office on 2003-10-30 for method and apparatus of particle transfer in multi-stage particle separators.
Invention is credited to Conrad, Wayne Ernest.
Application Number | 20030200734 10/436988 |
Document ID | / |
Family ID | 24382067 |
Filed Date | 2003-10-30 |
United States Patent
Application |
20030200734 |
Kind Code |
A1 |
Conrad, Wayne Ernest |
October 30, 2003 |
Method and apparatus of particle transfer in multi-stage particle
separators
Abstract
An improved two-stage separator uses reusable containers for
collecting particles separated by each separation stage. The
reusable containers are constructed such that a user empties both
reusable containers by the actions required to empty just one of
the reusable containers.
Inventors: |
Conrad, Wayne Ernest;
(Hampton, CA) |
Correspondence
Address: |
BERESKIN AND PARR
SCOTIA PLAZA
40 KING STREET WEST-SUITE 4000 BOX 401
TORONTO
ON
M5H 3Y2
CA
|
Family ID: |
24382067 |
Appl. No.: |
10/436988 |
Filed: |
May 14, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10436988 |
May 14, 2003 |
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10022534 |
Dec 20, 2001 |
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6582489 |
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10022534 |
Dec 20, 2001 |
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09595175 |
Jun 16, 2000 |
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6344064 |
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09595175 |
Jun 16, 2000 |
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09239860 |
Jan 29, 1999 |
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6334234 |
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Current U.S.
Class: |
55/337 |
Current CPC
Class: |
A47L 9/1683 20130101;
A47L 9/0009 20130101; A47L 9/009 20130101; B01D 50/20 20220101;
A47L 9/1641 20130101; A47L 5/28 20130101; B01D 45/12 20130101; B01D
50/002 20130101; B01D 45/16 20130101; Y10S 55/03 20130101; A47L
9/1625 20130101 |
Class at
Publication: |
55/337 |
International
Class: |
B01D 050/00 |
Claims
1. A vacuum cleaner comprising: (a) a cleaner head having a dirty
air inlet; and, (b) a casing having a filtration member, the
filtration member having an inlet in fluid flow communication with
the dirty air inlet and an outlet in fluid flow communication with
a source of suction, the filtration member comprising at least one
upstream particle separator having an associated upstream particle
collector and at least one downstream particle separator having an
associated downstream particle collector disposed adjacent the
upstream particle separation member, the particle collectors are
configured such that the downstream particle collector is emptied
by transferring its contents into the upstream particle
collector.
2. The vacuum cleaner of claim 1 wherein at least a portion of the
upstream particle separator is removable from the casing.
3. The vacuum cleaner of claim 1 further comprising a particle
transfer member positioned between one of the particle separation
members and its associated particle collector whereby particles
separated by the said particle separation member are conveyed to
said particle collector.
4. The vacuum cleaner of claim 3 wherein at least a portion of the
particle transfer member is angled downwardly whereby particles
travel to said particle collector at least partially under the
influence of gravity.
5. The vacuum cleaner of claim 2 wherein the downstream particle
collector has side walls and a bottom that is mounted for movement
between a closed position and an open position and the bottom moves
to the open position as the upstream particle collector is prepared
for emptying.
6. The vacuum cleaner of claim 5 wherein the bottom is maintained
in the closed position by interaction between the bottom and a
member positioned on a portion of the vacuum cleaner that is not
removed with the upstream particle collector.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 10/022,534 which is a continuation of U.S.
patent application Ser. No. 09/595,175, now U.S. Pat. No.
6,344,064, which is a continuation-in-part application of U.S.
patent application Ser. No. 09/239,860, now U.S. Pat. No.
6,334,234.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the transfer and
removal of particles separated in multi-stage separators such as
may be used by vacuum cleaners. In one particular application, the
invention relates to the multi-stage separation having upstream and
downstream separation stages wherein the position at which the
separated particles exit from the downstream separation stage is
positioned above the position at which the separated particles exit
the upstream separation stage.
BACKGROUND OF THE INVENTION
[0003] The use of multiple cyclones connected in parallel or series
has long been known to be advantageous in the separation of
particulate matter from a fluid stream. Typically, a relatively
high speed fluid stream is introduced tangentially to a generally
cylindrical or frusto-conical first stage cyclone separator,
wherein the dirty air stream is accelerated around the inner
periphery of the first stage cyclone separator. Fluid exiting the
first stage cyclone separator is fed to the inlet of a second stage
cyclone separator wherein the described separation process is
repeated. Typically, successive separators are configured to remove
ever-smaller particles from the fluid stream, until a desired
cleaning efficiency is achieved. Particulate matter disentrained
from the fluid flow is typically collected at the bottom of each
stage.
[0004] The advantages of multi-stage cyclonic separation are
disclosed in U.S. Pat. No. 3,425,192 to Davis. As shown in FIG. 1,
multistage separator 10 essentially comprises a large, lower first
stage cyclone separator 12 connected in series with a plurality of
smaller, parallel second stage cyclone separators 14 disposed over
cyclone separator 12. A motor (not shown) draws air through a
cleaning head and into a dirty air inlet 16 of the first stage
cyclone separator 12. From first stage cyclone separator 12, the
air flows into second stage cyclone separators 14 and, from there,
continues on through the vacuum motor to a clean air exhaust port
(not shown). Particles separated from the fluid flow are deposited
by first stage cyclone separator 12 into a primary collector 20,
while particles separated from the fluid flow by second stage
cyclone separators 14 are deposited into a secondary collector 22,
vertically disposed over primary collector 20. When primary and/or
secondary collectors 20 and 22 become laden with deposited
particles, and must therefore be emptied, two distinct emptying
steps are required to clear the collectors of their contents.
SUMMARY OF THE INVENTION
[0005] In accordance with the instant invention, there is provided
a vacuum cleaner comprising a cleaner head having a dirty air
inlet; and, a casing having a filtration member, the filtration
member having an inlet in fluid flow communication with the dirty
air inlet and an outlet in fluid flow communication with a source
of suction, the filtration member comprising at least one upstream
particle separator having an associated upstream particle collector
and at least one downstream particle separator having an associated
downstream particle collector, the particle collectors are
configured such that the downstream particle collector is emptied
by transferring its contents into the upstream particle
collector.
[0006] In one embodiment, at least a portion of the upstream
particle separator is removable from the casing and the downstream
particle collector is emptied into the upstream particle collector
when the when the portion of the upstream particle collector is
removed from the casing.
[0007] In another embodiment, the vacuum cleaner further comprises
a particle transfer member positioned between one of the particle
separation members and its associated particle collector whereby
particles separated by the said particle separation member are
conveyed to said particle collector.
[0008] In another embodiment, at least a portion of the particle
transfer member is angled downwardly whereby particles travel to
said particle collector at least partially under the influence of
gravity.
[0009] In another embodiment, the downstream particle separation
member is chosen from the group of a cyclone, a Prandtl layer
turbine and an electrostatic filter.
[0010] In another embodiment, the downstream particle collector is
positioned in the upstream particle separation member.
[0011] In another embodiment, the downstream particle collector is
pivotally mounted above the upstream particle collector.
[0012] In another embodiment, the downstream particle collector has
side walls and a bottom that is mounted for movement between a
closed position and an open position and the bottom moves to the
open position as the upstream particle collector is prepared for
emptying.
[0013] In another embodiment, the bottom is maintained in the
closed position by interaction between the bottom and a member
positioned on a portion of the vacuum cleaner that is not removed
with the upstream particle collector.
[0014] In another embodiment, the downstream particle collector is
disposed adjacent the upstream particle separation member.
[0015] In accordance with another aspect of the instant invention,
there is provided a separator for separating entrained particles
from a fluid flow, the separator comprising a first particle
separation member; a reusable particle collector disposed beneath
the particle separation member, the particle collector having a
moveable member movably mounted between a closed position and an
open position; and, a particle receiving chamber disposed beneath
the particle collector, wherein when the moveable member moves from
its closed position to its open position, particles collected in
the particle collector are substantially transferred to the
particle receiving chamber.
[0016] In accordance with another aspect of the instant invention,
there is provided a separator comprising an inlet in fluid flow
communication with a source of fluid having particles therein; a
particle separation member; a first particle collector disposed
below the particle separation member; and, a particle transfer
member positioned between the particle separation member and the
particle collector whereby particles separated by the particle
separation member are conveyed to the particle collector.
[0017] In accordance with another aspect of the instant, invention,
there is provided a separator for separating entrained particles
from a fluid flow, the separator comprising first separating means
for separating particles from the fluid flow; second separating
means for separating particles from the fluid flow; first particle
collecting means for collecting particles separated from the fluid
flow by the first separating means; second particle collecting
means for collecting particles separated from the fluid flow by the
second separating means; and, directing means for directing
particles from the first particle separating means to the first
particle collecting means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For a better understanding of the present invention, and to
show more clearly how it may be carried into effect, reference will
now be made by way of example to the accompanying drawings.
[0019] The drawings show a preferred embodiment of the present
invention, in which:
[0020] FIG. 1 is a vertical cross section through a multi-stage
cyclonic separator according to the prior art;
[0021] FIG. 2 is a perspective view of a multi-stage separator
according to the present invention;
[0022] FIG. 3a is an exploded perspective view of the multistage
separator of FIG. 2;
[0023] FIG. 3b is an exploded perspective view of an alternate
embodiment of the multi-stage separator of FIG. 2;
[0024] FIG. 4 is a perspective view of the multi-stage separator of
FIG. 2, with the second stage collector shown in a partially open
position;
[0025] FIG. 5 is a perspective view of a household vacuum cleaner
according to the present invention;
[0026] FIG. 6 is a perspective view of an alternate embodiment of a
multi-stage separator having a particle transfer member according
to the present invention;
[0027] FIG. 7 is a perspective view of a further alternate
embodiment of a multi-stage separator having a particle transfer
member according to the present invention;
[0028] FIG. 8 is a perspective view of a further alternate
embodiment of a household vacuum cleaner having a particle transfer
member according to the present invention;
[0029] FIG. 9 is a perspective view of a further alternate
embodiment of the second stage particle collector according to the
present invention; and,
[0030] FIG. 10 is an enlarged side view of the second stage
particle collector of FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention relates to multi-stage particle
separation systems wherein the particles separated in a second (or
downstream) separation stage are transported to a position wherein
they may be removed from the multi-stage particle separation
systems together with the particles separated in a first (or
upstream) separation stage. The improvements may be used in any
multi-stage separation system wherein material separated by a
second stage separation process is to be stored in a storage
container which is to be periodically emptied. The downstream
separation stage may use any separation technique, e.g. a cyclone
separator, a Prandtl layer turbine, an electrostatic precipitator
or the like, which produces separated particles that must be
handled in such a way that they will not be re-entrained in fluid
flowing through the downstream separation stage (e.g., stored in a
reusable container). Preferably, the downstream and the upstream
separation stages use such separation techniques.
[0032] The preferred embodiment of the present invention is
described in its use with a vacuum cleaner and in particular an
upright vacuum cleaner. It will be appreciated that the
improvements in multi-stage separation described herein may be used
with canister vacuum cleaners, back pack vacuum cleaners, central
vacuum cleaner systems as well as single and multi-stage separators
of any sort, including industrial dust or particle collection
systems wherein particles are to be removed from a fluid (i.e. a
liquid and/or a gas).
[0033] An improved multi-stage separator according to the present
invention is shown generally in the Figures at 30. Referring to
FIG. 2, separator 30 comprises a first stage cyclone 32 and a
plurality of second stage cyclones 34. First stage cyclone 32 has a
first stage collector 36 and second stage cyclones 34 have a second
stage collector 38. First stage cyclone 32 and second stage
cyclones 34 are housed within a housing 40 having a top 41, a lower
portion comprising container 66 and an upper portion comprising
second stage assembly 51. As shown in FIG. 2, top 41 comprises a
mesh screen that is positioned upstream of a motor driven fan.
However, it will be appreciated that second stage assembly 51 may
be open or it may be closed if it is provided with a fluid outlet.
First stage cyclone 32 has an fluid inlet 42, fed by a fluid feed
conduit 45, and a fluid outlet 46. Fluid outlet 46 feeds a transfer
conduit 44 which is in fluid communication with a plurality of
second stage cyclones 34 via a plurality of inlets 47. Second stage
cyclones 34 each have a fluid outlet 49 positioned beneath mesh
screen 41.
[0034] As shown in FIG. 2, transfer conduit 44 extends above mesh
screen 41 to engage a support member (not shown) to fix second
stage cyclones 34 in position. The interior of conduit 44 is sealed
to cause the air to enter second stage cyclones 43. Alternately,
transfer conduit 44 may terminate at inlets 47 and alternate
support means may be provided to position second stage cyclones 34
in second stage assembly 51 (eg. by means of support members
attached to the inner wall of second stage assembly 51).
[0035] While the first and second stages are connected in series,
it will be appreciated that the improvements disclosed herein may
be used in a system wherein the first and second stages are
connected in parallel. It will also be appreciated that additional
separation stages may be positioned upstream, downstream or both
upstream and downstream from the first and second separation
stages. It will further be appreciated that first stage cyclone 32
may comprise a plurality of cyclones and/or that the second stage
may comprise only one second stage cyclone 34 (see for example FIG.
7). The fluid may be propelled through separator 30 by any means
known in the art. For example, a pump may be positioned upstream of
separator 30 or, in the case of a vacuum cleaner, a source of
suction (eg. a motor driven fan) may be positioned downstream from
separator 30.
[0036] Beneath second stage cyclones 34 is a particle transfer
member 48 which slopes downwardly to second stage collector 38.
Second stage collector 38 has side walls 50 and a bottom 52.
Referring to FIG. 3a, bottom 52-is separable from side walls
50.
[0037] In the embodiment wherein separator 30 is used in a vacuum
cleaner (see, for example, FIG. 5), a motor-driven fan draws
particle-laden fluid via a feed conduit into first stage inlet 42
via fluid feed conduit 45. The fluid flows cyclonically within a
first stage cyclone 32 depositing particles in first stage
collector 36 (which may be the bottom surface of container 66). The
fluid exits first stage cyclone 32 via outlet 46 and is delivered
by conduit 44 to the inlets 47 of second stage cyclones 34.
Cyclonic flow in second stage cyclones 34 further separates
particles from the fluid flow, which particles fall on to particle
transfer member 48 for transfer to second stage collector 38. The
fluid flow then exits second stage cyclones 34 via outlets 49, and
is expelled from separator 30. The separated particles travel under
the influence of gravity along particle transfer member 48 to
second stage collector 38.
[0038] Preferably, as shown in FIG. 2, transfer member 48 comprises
a helical ramp which slopes downwardly, around centre conduit 44,
to second stage collector 38. Transfer member 48 is preferably
angled sufficiently to cause the particles to slide easily down
transfer member 48 to second stage collector 38 under the influence
of gravity without substantially collecting on the surface of
transfer member 48. Preferably, the motor-driven fan is mounted as
part of the casing in which separator 30 is mounted. Accordingly,
vibration from the operation of the motor-driven fan may assist the
particles to travel along particle transfer member 48 under the
influence of gravity (in which case particle transfer member may be
at a lesser incline).
[0039] Deposited particles accumulate in second stage collector 38
and, eventually, second stage collector 38 must be emptied. In
accordance with one aspect of the instant invention, second stage
collector is configured so that it is emptied when first stage
collector 36 is emptied. For example, as shown in FIGS. 3a, 4, 9
and 10 second stage collector may be constructed so that the
contents of second stage collector 38 are emptied into first stage
collector when container 66 is removed from second stage assembly
51. Alternately, as shown in FIGS. 3b, 6 and 7, second stage
collector 38 is constructed so that it is emptied when first stage
collector 36 is emptied (eg. by inverting container 66). Container
66 may completely contain first stage cyclone 32, or may comprise
only a portion thereof. It will be understood that container 66
need only comprise first stage collector 36 and such additional
portion as necessary to permit collectors 36 and 38 to be emptied
and removed as described herein.
[0040] As illustrated in FIG. 3a, second stage collector 38 is
separable into two components, namely side walls 50 and bottom 52.
Bottom 52 is affixed to the interior of container 66 while side
walls 50 are affixed to second stage assembly 51, such as to first
stage outlet 46 or the lower surface of particle transfer member
48. Referring to FIG. 4, to empty the contents of second stage
collector 38 into first stage collector 36, container 66 is rotated
in the direction of arrow A so that bottom 52 moves relative to
side walls 50 thereby causing the contents of second stage
collector 38 to fall into first stage collector 36 which acts as a
particle receiving chamber. Container 66 may then emptied by
inverting container 66 over a garbage container. Thus, only a
single emptying step is required to empty separator 30.
[0041] Referring again to FIG. 4, side wall 50 preferably has a
lower edge 54 which moves over the surface of bottom 52, as bottom
52 moves away from side walls 50, to sweep the surface of bottom 52
to assist in removing particles therefrom. Bottom 52 may optionally
also be canted relative to the horizontal (not shown) to encourage
particles thereon to slide off into first stage collector 36 when
bottom 52 is moved away from side walls 50.
[0042] In the embodiment of FIGS. 9 and 10, bottom 52 is hingedly
connected to side walls 50 by a hinge 56, rather than completely
separable therefrom. A cam 58 positioned on the inner surface of
container 66 is moveable (when container 66 is rotated relative to
assembly 51) between a closed position in which it is positioned
beneath bottom 52 (FIG. 9) and an open position in which it has
been moved away from bottom 52 (solid lines in FIG. 10). When
container 66 is rotated in the direction of Arrow B in FIG. 10, cam
58 is moved to a position beneath side walls 50 and bottom 52
follows cam 58 into a position beneath side walls 50 (as
illustrated in dotted outline in FIG. 10), thereby closing second
stage collector 38. When cam 58 is moved away from side walls 50,
by the rotation of container 66, bottom 52 is permitted to swing
freely to its open position due to gravity thereby dumping the
contents of second stage collector 38 into first stage collector
36.
[0043] In the embodiment of FIG. 3b, second stage collector 38 is
affixed to the inner surface of container 66. In this embodiment,
when assembly 51 is removed from container 66, second stage
collector 38 is positioned inside container 66. Thus when first
stage collector 36 is emptied, e.g. by inverting container 66,
second stage collector 38 is also emptied.
[0044] Referring to FIG. 5, upright vacuum cleaner 200 has a
cleaner head 202 with rear wheels 204 and front wheels (not shown)
for moving cleaner head 202 over a floor, a casing 206 which is
pivotally mounted to cleaner head 202 and a handle 208 for moving
of vacuum cleaner 200 over the floor. Casing 206 houses separator
30 according to the present invention. Vacuum cleaner 200 may be of
any construction provided that container 66 is removable from
vacuum cleaner 200 for emptying. Air inlet 42 of separator 30
communicates with a dirty air inlet (not shown) adjacent the floor
in the lower surface of cleaner head 202. Container 66 is removable
from main casing 206, via a handle 212, for the periodic emptying
of the particles therein. It will be understood by one skilled in
the art that only the lower portion of first stage cyclone 32 (i.e.
the portion with collector 36) may be removable from housing 40
provided that the contents of second stage collector 38 are emptied
into first stage collector 36 prior to the removal of first stage
collector 36 from vacuum cleaner 200. Accordingly, neither second
stage collector 38, second stage cyclones 34 nor the entirety of
first stage cyclone 32 need be disposed interior of the portion of
container 66 which is removable from housing 40, but rather may be
fixedly located in main casing 206 above the portion of container
66 which is removable from housing 40. In this embodiment, first
stage collector 36 comprises a chamber positioned below first stage
cyclone 32 and separated therefrom by a plate 68 having a plurality
of openings 69 therein.
[0045] In the embodiment of FIG. 6, second stage collector 38
comprises a side container 70 having an inlet at an upper portion
thereof and a bottom 72 positioned at a location beneath the inlet.
As shown in FIG. 6, bottom 72 is substantially planar with the
bottom of first stage collector 36. Side collector is preferably a
one piece assembly with container 66 so that container 66 and side
container 70 are removed as a one piece assembly from casing 206.
Thus container 70 may be have a lower portion 71 that is integrally
formed with container 66. Alternately, the may be individually
moulded and then assembled together to form a one piece unit. In
either case, when first stage collector 36 is removed from casing
206 for emptying, e.g. by inverting container 66, lower portion 71
of container 70 is also removed from casing 206 and emptied.
[0046] Particle transfer member 48 is configured to convey
particles separated by the second stage to second stage collector
38. It will be apparent to one skilled in the art that the
configuration of transfer member 48 will vary depending upon the
position of second stage collector 38. For example, referring to
FIG. 6, transfer member 48 comprises a disc canted to direct
deposited particles laterally to side container 70. In this
embodiment, guide or spout 74 is optionally provided to direct
particles from transfer member 48 to side container 70. It will
also be apparent that collector 38 is disposed below particle
transfer member 48 so that particles may travel across transfer
member 48 and be deposited into collector 38.
[0047] Referring to FIG. 7, transfer member 48 is shown used with
advantage in a multi-stage separator 300 having its filtration
stages arranged in a side-by-side configuration. Here, separator
300 comprises a first stage cyclone 32 and a second stage cyclone
34, the first stage and second stage being connected in series.
First stage cyclone 32 has an fluid inlet 42 and a fluid outlet 46
which is in fluid flow communication with conduit 44 which is in
fluid communication with second stage cyclone 34 via inlet 47.
Second stage cyclone 34 has a fluid outlet 49 in communication with
a conduit leading to a driving member (e.g. a motor-driven fan
which is not shown). Particle transfer member 48 is positioned at
the bottom of first stage cyclone 32 and comprises a sloped member
canted to direct deposited particles substantially laterally from
first stage separator 32 to second stage collector 38 (which is
also positioned at the bottom of second stage separator 34) via
opening 78 in assembly 51. Thus, in essence, in this embodiment
first stage collector 36 and second stage collector 38 are one and
the same. A spout member 74 is optionally provided to assist in
transferring particles from transfer member 48 to collector 36/38
and, thus, it is only necessary to remove collected particles from
the one collector 36/38. It will be apparent that collector 36/38
is disposed below particle transfer member 48 so that particles may
travel across transfer member 48 and be deposited onto collector
36/38.
[0048] The present invention can also be used advantageously with a
single stage filtration means wherein it is desirable to transfer
the contents of the single stage collector to a more accessible
position prior to emptying. For example, referring to FIG. 8,
vacuum cleaner 220 has a single stage of cyclonic cleaning, namely
a cyclone 32 having an adjacent external container 70. Struts 222
extend between the upper and lower portions of casing 206. Transfer
member 48 transfers particles deposited by the cyclone to side
container 70. Side collector 70 is separable from container 66 and
casing 206, thereby permitting the user to empty particles
collected by cleaner 220 simply by detaching external container 70
from the container 66 and appropriately emptying its contents.
[0049] Therefore, the transport member according to the present
invention advantageously provides convenience in transporting
collected particles to a collector for more convenient emptying
thereof. The convenience added by the present invention permits a
wider configuration of multi-stage separation devices to be used
conveniently in domestic and household applications.
[0050] The collector according the present invention also
advantageously increases the flexibility of various multi-stage
separation mechanisms for facilitating ease-of-use and convenient
operation of household vacuum cleaners. As stated above, the
upstream and downstream separation stages may use any separation
technique which produces separated particles that must be handled
in such a way that they will not be re-entrained in fluid flowing
out of the separation stage (i.e. the stage is capable of
depositing and storing separated particles in a reusable container)
such as, for example, a cyclone separator, a Prandtl layer turbine,
an electrostatic filter, a fibre filter or the like.
[0051] While the above description constitutes the preferred
embodiments, it will be appreciated that the present invention is
susceptible to modifications and change without departing from the
fair meaning of the proper scope of the accompanying claims.
* * * * *