U.S. patent application number 11/114237 was filed with the patent office on 2005-12-01 for air flow passage for a vacuum cleaner.
This patent application is currently assigned to GBD Corporation. Invention is credited to Conrad, Helmut Gerhard, Conrad, Wayne Ernest, Szylowiec, Ted.
Application Number | 20050262658 11/114237 |
Document ID | / |
Family ID | 22853479 |
Filed Date | 2005-12-01 |
United States Patent
Application |
20050262658 |
Kind Code |
A1 |
Conrad, Wayne Ernest ; et
al. |
December 1, 2005 |
Air flow passage for a vacuum cleaner
Abstract
A vacuum cleaner is provided having improved pressure loss
characteristics. A fluid supply conduit in flow communication with
an inlet to a cyclone is integrally formed as part of a cyclone
bin. The present invention may be adapted for use with cyclonic
separation devices of all types, including single- and multi-stage
cyclonic separators.
Inventors: |
Conrad, Wayne Ernest;
(Hampton, CA) ; Conrad, Helmut Gerhard; (Hampton,
CA) ; Szylowiec, Ted; (Hampton, CA) |
Correspondence
Address: |
BERESKIN AND PARR
40 KING STREET WEST
BOX 401
TORONTO
ON
M5H 3Y2
CA
|
Assignee: |
GBD Corporation
Hampton
CA
|
Family ID: |
22853479 |
Appl. No.: |
11/114237 |
Filed: |
April 26, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11114237 |
Apr 26, 2005 |
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10816840 |
Apr 5, 2004 |
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6902596 |
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10816840 |
Apr 5, 2004 |
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10322451 |
Dec 19, 2002 |
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6736873 |
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10322451 |
Dec 19, 2002 |
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10188412 |
Jul 8, 2002 |
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6599340 |
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10188412 |
Jul 8, 2002 |
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09227534 |
Jan 8, 1999 |
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6141826 |
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10188412 |
Jul 8, 2002 |
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09480168 |
Jan 10, 2000 |
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6391095 |
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Current U.S.
Class: |
15/353 |
Current CPC
Class: |
A47L 9/1641 20130101;
A47L 9/0009 20130101; Y10S 55/03 20130101; B04C 5/02 20130101; A47L
9/1666 20130101; A47L 5/30 20130101; A47L 9/1691 20130101; B04C
5/103 20130101; A47L 9/165 20130101; B01D 45/16 20130101; A47L
9/1625 20130101 |
Class at
Publication: |
015/353 |
International
Class: |
A47L 009/16 |
Claims
1. A vacuum cleaner comprising: (a) a cleaning head for cleaning a
surface; (b) a cyclone container having a wall having an inner
surface and a longitudinally extending axis; (c) a fluid inlet to
the at least one cyclone container; and, (d) a fluid conduit
integrally formed as part of the cyclone container.
2. The vacuum cleaner as claimed in claim 1 wherein the fluid
conduit extends through a central portion of the cyclone
container.
3. The vacuum cleaner as claimed in claim 1 wherein the fluid
conduit includes an exit portion which extends within the cyclone
container from the central portion outwardly to the fluid
inlet.
4. The vacuum cleaner as claimed in claim 1 wherein the fluid inlet
is positioned adjacent the inner wall of the cyclone container.
5. The vacuum cleaner as claimed in claim 1 wherein the fluid
conduit has an outlet portion, and the outlet portion and the fluid
inlet are configured to redirect air traveling there through in a
first direction towards the wall and in a second direction to
introduce the fluid tangentially to the cyclone container.
6. The vacuum cleaner as claimed in claim 1 wherein the fluid
conduit is positioned exterior to the cyclone container.
7. The vacuum cleaner as claimed in claim 1 wherein in the fluid
conduit extends linearly.
8. The vacuum cleaner as claimed in claim 1 wherein the fluid
conduit is positioned exterior to the cyclone container and the
fluid conduit extends linearly.
9. The vacuum cleaner as claimed in claim 1 wherein the fluid
conduit extends through the cyclone container to an opening in the
bottom of the cyclone container and comprises an air exit for the
cyclone container.
10. The vacuum cleaner as claimed in claim 9 wherein the fluid
conduit extends linearly.
11. A vacuum cleaner comprising: (a) a cleaning head for cleaning a
surface; (b) a cyclone container having a wall having an inner
surface and a longitudinally extending axis; (c) a fluid inlet to
the at least one cyclone container; and, (d) a fluid conduit
extending through the cyclone container to an opening in the bottom
of the cyclone container and comprises an air exit for the cyclone
container.
12. The vacuum cleaner as claimed in claim 11 wherein the fluid
conduit extends through a central portion of the cyclone
container.
13. The vacuum cleaner as claimed in claim 11 wherein the fluid
inlet is positioned adjacent the inner wall of the cyclone
container.
14. The vacuum cleaner as claimed in claim 11 wherein in the fluid
conduit extends linearly.
15. The vacuum cleaner as claimed in claim 12 wherein in the fluid
conduit extends linearly.
Description
[0001] The application is a continuation of application Ser. No.
10/816,840, filed on Apr. 5, 2004 which is a continuation of
application Ser. No. 10/322,541, filed on Dec. 19, 2002 (which is
still pending) which is a continuation of application Ser. No.
10/188,412, filed on Jan. 7, 2000 now U.S. Pat. No. 6,599,340 which
is a continuation-in-part of application Ser. No. 09/227,534, filed
Jan. 8, 1999 and which has issued as U.S. Pat. No. 6,141,826, and
is a divisional of application Ser. No. 09/480,168, filed on Jan.
10, 2000 and which has issued as U.S. Pat. No. 6,391,095.
FIELD OF THE INVENTION
[0002] The present invention relates generally to cyclonic
separators. In one particular application, the invention relates to
a vacuum cleaner which uses the cyclonic separation of dirt from an
air flow as the primary dirt separation mechanism.
BACKGROUND OF THE INVENTION
[0003] The use of a cyclone, or 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 container, wherein the
dirty air stream is accelerated around the inner periphery of the
container. The centrifugal acceleration caused by the travel of the
fluid in a cyclonic stream through the cyclone causes the
particulate matter to be disentrained from the fluid flow and, eg.,
to collect at the bottom of the container. A fluid outlet is
provided for the extraction of the fluid from the centre of the top
of the cyclone container, as is well known in the art.
[0004] A typical flow path in a cyclone separator is as follows.
Fluid to be treated is introduced tangentially at a fluid inlet
located at the upper end of the cyclone container (if the cyclone
container is vertically disposed). The fluid stream rotates around
the inner surface of the cyclone container, and spirals generally
downwardly around the inner surface. At the bottom end of the
cyclone container the fluid stream travels radially inwardly,
generally along the bottom of the container and then turns upwardly
and proceeds vertically up and out of the cyclone container. The
particulate matter separating action of the cyclonic flow occurs
substantially around the inner surface. Once the air moves inwardly
to the centre of the container, and upwardly there through, there
is little or no dirt separation achieved.
[0005] Various types of vacuum cleaners are traditionally produced.
These include built in vacuum cleaners, canister vacuum cleaners
and upright vacuum cleaners. Upright vacuum cleaners have a ground
engaging portion (a cleaning head) and an upwardly extending or
main body portion. The ground engaging portion typically has wheels
for movement of the cleaning head across a floor and a suction
inlet for the intake of dirty air into the vacuum cleaner. The
upwardly extending portion comprises the filter means for removing
dirt which is entrained in the air. The upwardly extending portion
generally has a handle for guiding the vacuum cleaner across the
floor.
[0006] Traditionally in upright vacuum cleaners, the motor to draw
the dirty air through the vacuum cleaner is positioned in the
ground engaging head and the upward extending portion is pivotally
mounted to the upper portion of the ground engaging member at a
position adjacent the motor.
[0007] The advantages of cyclonic separation have been combined
with an upright vacuum cleaner to provide a household cyclonic
vacuum cleaner, as shown in U.S. Pat. No. 4,593,429 to Dyson. As
shown in FIG. 1, this vacuum cleaner 10 essentially comprises a
large, outer cylindrical cyclone 12, with an inner cyclone 14
nested therein, which is mounted on a floor-cleaning head and
provided with a push handle for convenient movement of the unit. A
motor, located in the floor cleaning head, draws air through the
cleaning head and into an intake conduit 16, which delivers air to
the dirty air inlet 18 of the outer cyclone container 12. From the
outer cyclone the air flows into inner, nested dust separating
cyclone 14, and from there, continues on through the vacuum motor,
which is positioned in the ground engaging member, to a clean air
exhaust port.
[0008] The air intake conduit 16 connects the floor cleaning head
and the dirty air inlet in air flow communication. Air intake
conduit 16 extends upwardly along the outside of outer cyclone
container 12 generally parallel to the longitudinal axis of the
cyclones 12, 14. At a position adjacent air inlet 18 to outer
cyclone 12, air intake conduit 16 bends 90.degree. twice to travel
inwardly and to provide a tangential air flow to air inlet 18 of
outer cyclone container 12.
[0009] In use, air intake conduit 16 may become blocked. If the
blockage occurs at a midpoint of the conduit, it may be difficult
to clear the blockage. While a clean out port may be provided, the
port may not be located near where the blockage occurs. Further,
the addition of a port increases the cost and complexity of the
manufacture of the product.
[0010] A bend in a conduit for a fluid causes a turbulent pressure
loss in the conduit as the fluid travels through the bend in the
conduit and the greater the sharpness of the bend, the greater the
pressure loss. The pressure loss in the air flow decreases the
amount of suction which can be generated at the cleaning head of
the vacuum cleaner for any given motor in the vacuum cleaner and
therefore the efficiency of the vacuum cleaner.
SUMMARY OF THE INVENTION
[0011] In accordance with the instant invention, there is provided
a vacuum cleaner having a source of dirty air to be treated and a
housing, the vacuum cleaner comprising a cyclone bin removable from
the housing and having a bottom, a wall having an inner surface and
a cyclone axis; a fluid inlet to the cyclone bin; and, a fluid
supply conduit extending along the length of the cyclone bin from
the bottom to the fluid inlet and communicating with the source of
dirty air to be treated and with the fluid inlet, the fluid supply
conduit is removable with the cyclone bin from the housing.
[0012] In accordance with the instant invention, there is also
provided a vacuum cleaner comprising cleaning head means for
cleaning a surface; cyclone separation means having a cyclone axis
and a bin having a wall, the wall having an inner surface; fluid
inlet means for introducing fluid to the cyclone separation means;
and, fluid supply conduit means communicating with the cleaning
head means and with the fluid inlet means when the vacuum cleaner
is in use, the fluid supply conduit means extending through the
cyclone separation means, the fluid supply conduit is removable
with the cyclone separation means from the housing.
[0013] In accordance with the instant invention, there is also
provided a method comprising providing a fluid having a first
element and a second element; conveying the fluid in a conduit
longitudinally through a cyclone having a cyclone bin, a cyclone
axis and an inner longitudinally extending surface, the cyclone bin
removably mounted in a housing and the conduit removable with the
cyclone bin from the housing; and, passing the fluid through the
cyclone to remove at least a portion of the first element from the
fluid and obtaining at least one treated stream having a reduced
concentration of the first element.
[0014] In accordance with the instant invention, there is also
provided a vacuum cleaner having a source of dirty air to be
treated and a housing, the cyclonic separator comprising a cyclone
removably mounted in the housing and having a bottom, a fluid
inlet, a wall having an inner surface and a longitudinally
extending axis; and a fluid supply conduit extending along the
length of the cyclone from the bottom to the fluid inlet, the fluid
supply conduit conveying the dirty air substantially axially to the
fluid inlet, the fluid supply conduit communicating with the source
of dirty air when the cyclonic separator is in use, the fluid inlet
redirecting the dirty air from an axial flow to a tangential flow
and the fluid inlet is positioned within the cyclone.
[0015] The configuration of the air intake conduit according to the
present invention advantageously permits a substantial reduction in
the back pressure caused by the air flow conduit which conveys the
dirty air stream to the cyclone separation means. This reduction in
pressure loss in the intake conduit may be used to improve the
overall performance of the cyclone separation device. For example,
a deeper vacuum may be drawn at the air intake of the cleaning head
or other vacuuming device for a given vacuum motor size.
Conversely, using the air flow path of the instant invention, the
motor size may be reduced without a reduction in cleaning
efficiency, thereby permitting a comparable vacuum cleaner to be
provided at lesser cost.
[0016] In one embodiment, the fluid supply conduit extends through
a central portion of the cyclone. The fluid supply conduit
preferably extends coaxially with the axis of the cyclone and the
fluid inlet preferably extends outwardly to the inner surface.
[0017] In another embodiment, the fluid inlet includes a curved
portion without any 90.degree. elbows.
[0018] In another embodiment, the fluid inlet comprises at least a
portion that extends in a continuous curve.
[0019] In another embodiment, the fluid inlet is curved in a first
direction towards the inner surface of the wall and is curved in a
second direction to introduce the dirty air tangentially to the
cyclone. The fluid inlet may be curved so as to sequentially
redirect the air in the first direction and then the second
direction. Preferably, the fluid inlet is curved so as to
simultaneously redirect the air in the first direction and the
second direction.
[0020] In another embodiment, the fluid inlet has a curved portion
to impart a rate of change of direction in the fluid travelling
there through in two axis simultaneously.
[0021] In another embodiment, the fluid supply conduit extends
longitudinally through the cyclone and the cyclone is removably
mounted in the housing.
[0022] In another embodiment, the downstream end of the fluid inlet
extends substantially horizontally.
[0023] In another embodiment, the downstream end of the fluid inlet
extends towards the bottom of the cyclone.
[0024] In another embodiment, the downstream end of the fluid inlet
extends towards the bottom of the cyclone at an angle of up to
10.degree. from a plane perpendicular to the axis.
[0025] In another embodiment, the cyclone has an outlet having a
wall and a portion of the fluid inlet is nested within the outlet
and a portion of the fluid inlet is positioned exterior the
outlet.
[0026] In accordance with the instant invention, there is also
provided a cyclonic separator having a source of fluid to be
treated, the cyclonic separator comprising a cyclone having a
bottom, a fluid inlet, a wall having an inner surface and a
longitudinally extending axis, the fluid inlet having an upstream
end and a downstream end; and, a fluid supply conduit extending
substantially along the axis of the cyclone from the bottom to the
upstream end of the fluid inlet, the fluid supply conduit
communicating with the source of fluid when the cyclonic separator
is in use, the fluid inlet is curved in a first direction towards
the wall and is curved in a second direction to introduce the fluid
tangentially to the cyclone.
[0027] In one embodiment, the cyclone has an outlet having a wall
and at least a portion of the fluid inlet is nested within the
outlet and extends through the wall of the outlet.
[0028] In another embodiment, the inlet comprises a duct extending
from point S1 to point S2 and comprises a space curve around which
the conduit is formed wherein the gradient of the space curve has
at least two non-zero components which vary along the arc length of
the curve. Preferably, the space curve comprises a helical
segment.
[0029] Preferably, the helical segment is defined by
S(t)=(G)*(cos(t),sin(t),t).(x,y,z)
[0030] whereby
[0031] (a) the gradient of the space curve has at least two
non-zero components which vary along the arc length of the
curve
[0032] (b) t<t<t2
[0033] (c) S(t1) is equal to S1; and,
[0034] (d) S(t2) is equal to S2.
[0035] Preferably, the duct comprises an envelope formed by a
radius r out from the central space curve which is itself formed
about a construction cylinder having a radius R and an axis wherein
the conduit the duct has a radius r where r<R and the space
curve at S1 smoothly becomes a straight line coincident with the
axis of the construction cylinder.
[0036] Preferably, the space curve at S2 smoothly becomes a
straight line coincident with the derivative of S(t) at point S2
with respect to the parameter t.
[0037] In accordance with the instant invention, there is also
provided a cyclonic separator having a source of fluid to be
treated, the cyclonic separator comprising cyclone separation means
having a longitudinally extending axis and a length; fluid supply
conduit means extending substantially along the length of the
cyclone separation means, the fluid supply conduit means
communicating with the source of fluid when the cyclonic separator
is in use; and, fluid inlet means for redirecting the fluid from a
substantially axial flow for introduction tangentially to the
cyclone means without any 90.degree. elbows.
[0038] In another embodiment, the cyclonic separator further
comprises housing means for removably receiving the cyclonic
separation means wherein the cyclone separation means has outlet
means having a wall and a portion which is removable with the
cyclone separation means from the housing means and the fluid inlet
means passes through the wall of the outlet means.
[0039] In accordance with the instant invention, there is also
provided a method comprising providing a fluid having a first
element and a second element; conveying the fluid in a conduit
longitudinally through a cyclone having a longitudinal axis and a
longitudinally extending surface; conveying the fluid in a conduit
laterally to the longitudinally extending surface; and, introducing
the fluid into the cyclone and passing the fluid through the
cyclone to remove at least a portion of the first element from the
fluid and obtain at least one treated stream having a reduced
concentration of the first element.
[0040] In one embodiment, the method further comprises conveying
the fluid centrally through the cyclone.
[0041] In another embodiment, the method further comprises
conveying the fluid around at least a portion of the longitudinal
axis of the cyclone as the fluid passes outwardly from the central
portion.
[0042] In another embodiment, the method further comprises
providing centrifugal acceleration to the fluid as it passes
outwardly from the central portion.
[0043] In accordance with the instant invention, there is also
provided a fluid supply conduit comprising a curved portion to
impart a rate of change of direction in the fluid travelling there
through in two axis simultaneously.
[0044] In accordance with the instant invention, there is also
provided a method comprising providing a fluid having a first
element and a second element; conveying the fluid to a cyclone;
introducing the fluid through an inlet to the cyclone to impart a
rate of change of direction in the fluid travelling there through
in two axis simultaneously; and passing the fluid through the
cyclone to remove at least a portion of the first element from the
fluid and obtain at least one treated stream having a reduced
concentration of the first element.
[0045] In accordance with the instant invention, there is also
provided an upright vacuum cleaner comprising a cleaning head for
cleaning a surface; an upper body portion mounted on the cleaning
head, the upper portion having a longitudinally extending axis and
comprising at least one cyclone having an air entry port; and a
motor positioned above the at least one cyclone and in air flow
communication with the at least one cyclone.
[0046] In accordance with the instant invention, there is also
provided an upright vacuum cleaner comprising a cleaning head for
cleaning a surface having a forward portion and two spaced apart
rear portions extending rearwardly from the forward portion; an
upper body portion mounted on the cleaning head, the upper portion
having a longitudinally extending axis and at least one cyclone
having an air entry port, the upper body portion mounted on the
cleaning head at a position forward of the spaced apart rear
portions, the spaced apart rear portions defining on open space
there between sized for receiving the upper body portion there
between when the upper body portion is in the lowered storage
position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] 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 drawing which
show a preferred embodiment of the present invention, in which:
[0048] FIG. 1 is a cross-sectional side elevation of an upright
cyclonic vacuum cleaner with an air intake conduit according to the
prior art;
[0049] FIG. 2 is a cross-section along line 2-2 in FIG. 4 of an
upright cyclonic vacuum cleaner with an air intake conduit
according to the present invention;
[0050] FIG. 3 is a perspective view of an upright vacuum cleaner
according to the instant invention;
[0051] FIG. 3a is a cross-section along line 3-3 in FIG. 3 of an
alternate preferred embodiment of an upright cyclonic vacuum
cleaner with an air intake conduit according to the present
invention;
[0052] FIG. 4 is a cross-section along line 4-4 in FIG. 2;
[0053] FIG. 5 is a cross-section along line 4-4 in FIG. 2 of an
alternate preferred embodiment;
[0054] FIG. 6 is a cross-section along line 6-6 in FIG. 7 of a
further alternate preferred embodiment of the instant
invention;
[0055] FIG. 7 is a cross-section along the line 7-7 in FIG. 6;
[0056] FIG. 8 is a cross-section along line 8-8 in FIG. 9 of a
further alternate preferred embodiment of the instant
invention;
[0057] FIG. 9 is a cross-section along the line 9-9 in FIG. 8;
[0058] FIG. 10 is a cross-section along line 10-10 in FIG. 11 of a
further alternate preferred embodiment of the instant
invention;
[0059] FIG. 11 is a cross-section along the line 11-11 in FIG.
10;
[0060] FIG. 12 is a cross-section along line 12-12 in FIG. 13 of a
further alternate preferred embodiment of the instant
invention;
[0061] FIG. 13 is a cross-section along the line 13-13 in FIG.
12;
[0062] FIG. 14 is a cross-section along line 14-14 in FIG. 15 of a
further alternate preferred embodiment of the instant
invention;
[0063] FIG. 15 is a cross-section along the line 15-15 in FIG.
14;
[0064] FIG. 16 is a cross-section along line 16-16 in FIG. 17 of a
further alternate preferred embodiment of the instant
invention;
[0065] FIG. 17 is a cross-section along the line 17-17 in FIG.
16;
[0066] FIG. 18 is a cross-section along line 18-18 in FIG. 19 of a
further alternate preferred embodiment of the instant
invention;
[0067] FIG. 19 is a cross-section along the line 19-19 in FIG.
18;
[0068] FIG. 20 is a cross-section along line 20-20 in FIG. 21 of a
further alternate preferred embodiment of the instant
invention;
[0069] FIG. 21 is a cross-section along the line 21-21 in FIG.
20;
[0070] FIG. 22 is an enlargement of the upper portion of the
cyclone chamber when positioned in the housing of the vacuum
cleaner of FIG. 3;
[0071] FIG. 23 is an exploded view of the cyclone chamber and
housing of the vacuum cleaner of FIG. 3;
[0072] FIG. 24 is a perspective view of the cyclone chamber when
removed from the housing of the vacuum cleaner of FIG. 3;
[0073] FIG. 25 is an exploded view of the cyclone chamber of FIG.
24;
[0074] FIG. 26 is an enlargement of the upper portion of the
downstream portion of the air supply conduit of the vacuum cleaner
of FIG. 3;
[0075] FIG. 27 is a top plan view of the upper portion of the
downstream portion of the air supply conduit of FIG. 26.
[0076] FIG. 28 is an alternate embodiment of the upper portion of
the downstream portion of the air supply conduit of FIG. 26;
[0077] FIG. 29 is a further alternate embodiment of the upper
portion of the downstream portion of the air supply conduit FIG.
26; and,
[0078] FIGS. 30 and 30a are an embodiment demonstrating the
construction of a three dimensional curve according to another
aspect of the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
[0079] The following description of improvements in cyclone
separators is described in their use with a vacuum cleaner and in
particular an upright vacuum cleaner. It will be appreciated that
the improvements in cyclonic separators described herein may be
used with canister vacuum cleaners, central vacuum cleaners, back
pack vacuum cleaners as well as cyclonic separation devices of any
sort, including industrial dust collection systems and
liquid/liquid, liquid/gas and gas/gas separation systems. For
example, they may be used with single or multiple stage of
filtration assemblies, and may even be utilized where nested serial
cyclones are employed.
[0080] An upright cyclonic vacuum 20 according to the present
invention is shown in the FIGS. 2, 3 and 3a. In the embodiment of
FIG. 2, the motor is positioned in the cleaning head and the
cleaned air is conveyed to the motor for cooling the motor.
According to the embodiment of FIGS. 3 and 3a, the motor is
positioned in the upper body portion of the vacuum cleaner. If the
vacuum cleaner is a canister vacuum cleaner or a central vacuum
cleaner, then the cleaning head may be in air flow communication
with the cyclone chamber via a flexible hose.
[0081] Referring to the embodiment of FIG. 2, a floor cleaning head
22, which may be any known in the art, is provided at the lower end
of cleaner 20. Head 22 comprises a vacuum fan motor 24, a bottom 25
and a transversely extending, floor-contacting rotating brush
member 26 which is connected for rotation to a shaft (not shown)
within an opening 27 in bottom 35. Motor 24 provides motive force
to rotate brush 26 by means of, for example, a belt (not shown).
Mounted on the cleaning head is a housing having a cyclonic dust
separation unit, indicated generally at 28. Cyclonic unit 28 may
comprise any type of dirt separation cyclone known in the art, e.g.
cylindrical or frusto-conical, and may comprise a single stage
cyclone or multiple stage cyclone (either in series and/or in
parallel). Clean air outlet 40 is in air communication with motor
24 via air exit conduit 41. Upper end 34 of container 30 is sealed,
such as by an upper panel 35. A handle 42 and wheels 44 may be
provided on cleaner 20 to facilitate movement of the unit for
cleaning of a floor, and the like.
[0082] Referring to FIGS. 3, 3a, 10 and 11, in this embodiment
vacuum cleaner 20 has a floor cleaning head 22, means for moving
cleaning head 22 across a floor (e.g. wheels 44 which may comprise
rear wheels or front and rear wheels), a housing 60 rotatably
attached to cleaner head 22, and a handle 42 for moving cleaner 20
across the floor. In this embodiment, cleaning head 22 comprises a
forward portion 21 and two rear portions 23 extending rearwardly
from the forward portion 21. Rear portions 23 are spaced apart and
define a space 118 there between. A valve means 68 (eg. a rotatable
valve as is known in the art) is provided in cleaning head 22 so as
to connect downstream portion 50 of air conduit 46 in air flow
communication with upstream portion 48 of air conduit 46 when
housing 60 is rotated rearwardly in the direction of arrow B in
which position vacuum cleaner 20 is configured for use for cleaning
a floor. Housing 60 houses at least one cyclone separator. In this
embodiment, cyclonic separator unit 28 uses one cyclone separator,
namely container or cyclone bin 30. It will be appreciated that a
second stage filtration means, which may comprise a single stage
cyclone or multiple stage cyclone (either in series and/or in
parallel), may be positioned downstream from container 30 such as
in cavity 62. If the second stage filtration means comprises a
plurality of cyclones, then the second stage cyclones are
preferably in parallel. The treated air travels upwardly from clean
air outlet 40 to motor 24 either directly or through a secondary
filtration stage which may optionally be positioned in cavity 62.
The cleaned air may then exit housing 60 via outlet 116 or it may
first optionally pass through chamber 144, which may contain a
further filtration means (e.g. a HEPA.TM. filter).
[0083] Cyclonic unit 28 comprises at least a first cyclone
container or bin 30 having an air inlet 56, preferably at upper end
34 thereof, adapted for providing an air flow tangentially to an
inner dirt rotation surface 36 of container 30. Air inlet 56 may be
configured to provide an axial flow of air to container 30 and
opening 32 at the downstream end of air inlet 56 may have vanes to
impart cyclonic flow to the air stream. Preferably, inlet 56 is
configured to introduce the air tangentially to container 30.
Container 30 also has a dirt collection surface or bottom 38 and a
clean air outlet 40.
[0084] In the embodiment of FIG. 2, conduit 41 may be positioned
exterior to container 30. In a preferred embodiment, conduit 41 is
provided on outer surface 37 of container 30 as shown in FIGS. 4,
18 and 20. In such an embodiment, conduit 41 is preferably provided
as a one piece assembly with container 30 (e.g. it may be made
integrally therewith or it may be made separately and then mounted
to outer surface 37 such as by being welded thereto or by being
removably attached thereto by mechanical locking means provided on
outer surface 37) so that conduit 41 is removable from housing 60
automatically with container 30. Alternately, conduit 41 may be
positioned within container 30 (either centrally as shown in FIG.
6, or adjacent surface 36 as shown in FIGS. 8, 12, 14 and 16).
Further, the treated air may optionally exit the vacuum cleaner at
any desired location if it is not required to cool the motor.
[0085] The air flow path through cleaner 20 commences with an air
supply conduit 46 having an upstream portion 48 and a downstream
portion 50. Upstream portion 48 is provided in head 22 and has a
first end 52 positioned adjacent brush member 26 or the like for
receiving the dirt laden air and a distal second end 54. Downstream
portion 50 has a upstream end 64 which is positioned in air flow
communication with second end 54 and a downstream end 66.
Preferably ends 54 and 64 are substantially sealed together to
prevent air and dirt leaking there from.
[0086] In one embodiment, upstream and downstream portions 48, 50
may comprise a single member (whether integrally formed or
connected together to form a continuous flow path). In such a case,
a separated dirt collection means may be positioned below container
30 or portions 48, 50 may be flexible so as to allow cyclone
container 30 to be removed from housing 60 and emptied. In another
embodiment, upstream and downstream portions 48, 50 are separate
elements and downstream portion 50 is removable with container 30
from housing 60 such that portions 48, 50 are in air flow
communication when container 30 is mounted in housing 60 of vacuum
cleaner 20. Thus, if a blockage develops in conduit 46, by removing
container 30 from housing 60 as shown in FIG. 23, portions 48 and
50 may be individually accessed at ends 54 and 64 to clean out the
blockage.
[0087] As shown in FIGS. 2, 3, 6, 8, 10, 12, 14 and 16 downstream
portion 50 may extend upwardly through container 30. Alternately,
as shown in FIGS. 18 and 20, downstream portion 50 may extend
upwardly at a position adjacent outer surface 37 of container 30.
Whether downstream portion 50 is provided internally or externally
to container 30, by manufacturing the vacuum cleaner so that
downstream portion 50 is removable with container 30 from housing
60 (i.e. in a single operation), access is provided at ends 54 and
64 in case of a blockage. Accordingly, multiple access ports are
effectively provided as part of the construction of the vacuum
cleaner. It will be appreciated that downstream portion 50 may be
manufactured as part of container 30 (such as by moulding it
integrally therewith). Alternately, it may be separately
manufactured (such as by extrusion) and subsequently affixed to
container 30 by any means known in the art (e.g. by welding,
engagement of male and female engagement members of the like). In
either event, downstream portion 50 and container 30 are a one
piece assembly so that when container 30 is removed from housing
60, downstream portion 50 is automatically removed at the same
time.
[0088] Downstream portion 50 may enter container 30 at any point
(e.g. via a side wall) but preferably enters through bottom 38.
Further downstream portion 50 preferably extends generally upwardly
through the central portion of container 30 which comprises the
area occupied by the vertical return path of the fluid as it
travels from bottom 38 to outlet 40. As shown in FIGS. 2 and 3a,
downstream portion 50 preferably extends coaxially with the
longitudinal axis A of container 30, however, it may be positioned
off centre either internal of container 30 (see for example FIG.
12) or external of container 30 (see for example FIGS. 18 and 20).
Since downstream portion and container 30 define a complete
container for the separated dirt, an advantage of this invention is
that, when it is desired to empty container 30, a complete dirt
container is removed from the vacuum cleaner in a single step
operation.
[0089] Downstream portion 50 is preferably positioned at any
location within container 30 where it does not unduly interfere
with the cyclonic flow of air within container 30. For this reason,
if downstream portion 50 is positioned within container 30, it is
preferably centrally located in container 30. In particular, in a
cyclone, the air travels generally in an annular band adjacent
surface 36 of container 30. The air travels generally downwardly
until it reaches a position towards bottom 38 of container 30 at
which point the air travels upwardly through the central portion of
cyclone container 30. In a most preferred embodiment of this
invention, downstream portion 50 is positioned within this central
portion of container 30 through which this up flow of air
passes.
[0090] As shown in FIGS. 12, 14 and 16, downstream portion 50 may
be positioned adjacent sidewall 36. In such cases, downstream
portion 50 is preferably constructed so as to minimize its
interference with the flow of air around surface 36. For example,
downstream portion 50 may be constructed with rounded surfaces so
as to direct the flow of air around downstream portion 50. Further,
downstream portion 50 need not be circular in shape but may be
elliptical or of other constructions wherein it has a
circumferential width (i.e. around inner surface 36) which is
substantially greater than its radial width in a direction
transverse thereto (i.e. radially inwardly). Thus, downstream
portion 50 would extend only slightly into container 30 and would
not substantially interfere with the cyclonic flow of air in
container 30. If conduit 41 is positioned adjacent inner surface
36, it is also preferably so shaped. It will be appreciated than
downstream portion 50 and conduit 41 may be positioned on opposed
portions of inner surface 36 (see FIG. 12) or at any other
location, such as adjacent each other (see FIG. 14).
[0091] In another embodiment, downstream portion 50 and outlet 40
may be nested one within the other. For example, as shown in FIGS.
6 and 7, downstream portion 50 may be positioned within, and
preferably co-axially within, conduit 41. Alternately, conduit 41
may be positioned within, and preferably co-axially within,
downstream portion 50. As shown in FIG. 16, conduits 41 and 50 may
be provided in a nested relationship adjacent surface 36. It will
also be appreciated that conduits 41 and 50 may be positioned
adjacent each other, for example, adjacent inner surface 36 as
shown in FIG. 14, or within the central portion of container 30
(not shown). Further, they may be nested within each other or
positioned adjacent each other when located adjacent the exterior
of container 30 as shown in FIGS. 18 and 20.
[0092] Air inlet 56 is positioned at the upper end of downstream
portion 50. Opening 32 is positioned at the distal end of air inlet
56 from end 66 of downstream portion 50. Air inlet 56 defines the
exit portion of the air supply conduit extending longitudinally
with the cyclone and may extend along any desired path from
downstream portion 50 to opening 32. Preferably, air inlet 56 is
wholly positioned within container 30 (e.g. it does not exit or
enter the container 30 through upper end 34).
[0093] Air inlet 56 may extend at a right angle to downstream
portion 50 as shown in FIG. 2. Further, it may extend in a straight
line to opening 32 as shown in FIG. 4. It will be appreciated that
opening 32 may be any inlet known in the cyclonic art to introduce
air tangentially into a cyclone and it may be positioned at any
point along the longitudinal length of container 30 as is known in
the cyclonic art.
[0094] Typically vacuum cleaners utilize 900 elbows to redirect an
air flow from one plane to a plane at right angles thereto. In
particular, the air travels in a first direction when it enters an
elbow and then, when it encounters the wall of the elbow, it is
directed to travel in a second direction which is at 90.degree. to
its first line of travel. The axis of flow of the inlet and the
outlet from a 90.degree. elbow are at right angles and exist in a
single plane. In order to change the direction of travel of the air
into another direction, a second 90.degree. elbow is used. With a
cyclone inlet, in is generally necessary to redirect an air flow
through two planes (i.e. an axial flow to a lateral flow and the
lateral flow to a tangential flow). A first 90.degree. elbow is
used to redirect the air from an axial flow to a lateral flow into
a cyclone and a second 90.degree. elbow is used to redirect the
lateral flow into a tangential flow.
[0095] In one preferred embodiment, air inlet 56 is constructed so
as not to have any 90.degree. elbows. Instead, air inlet 56
includes curved portions for redirecting the air so as to impart
circular momentum to the dirty air as it travels there through (as
shown in FIG. 5) and/or, air inlet 56 includes a curved portion for
redirecting the air from an axial flow to flow outwardly to inlet
32 (as shown in FIG. 26). By constructing the supply conduit in
this manner, 90.degree. elbows are not required to redirect the
dirty air to flow outwardly or to redirect the dirty air to enter
container 30 tangentially. In a typical application, replacing a
90.degree. elbow with a gradual curved path to redirect the dirty
air results in a about a 5 to 10% reduction in the loss of suction
as the air travels through the vacuum cleaner. Thus, a smaller
motor may be incorporated into the vacuum cleaner to obtain the
same pressure at opening 32 or the suction at end 52 may be
increased if the same motor is used.
[0096] Referring to FIG. 3a, it will be appreciated that the dirty
air travelling in downstream portion 50 must travel outwardly to
inlet 56. In the preferred embodiment of FIG. 3a, air inlet 56
curves gently from downstream end 66 of downstream portion 50 so as
to travel outwardly and generally radially towards opening 32. More
preferably, the change in direction of the dirty air from generally
vertical to generally horizontal and from generally horizontal to
generally tangential occurs so as to reduce the pressure drop
during its travel from downstream portion 50 to container 30.
Accordingly, the curved portion of inlet 56 is curved to direct the
dirty air from travelling generally vertically to generally
tangentially. This may be achieved by gradually redirecting the air
from a generally vertical flow (assuming the axis A of the cyclone
is vertical) to a generally horizontal flow and then from the
generally horizontal flow to a generally tangential flow or
alternately by gradually redirecting the air from a generally
vertical flow (assuming the axis A of the cyclone is vertical) to a
generally tangential flow and then from the generally tangential
flow to a generally horizontal flow. These redirections may occur
sequentially (in either order) or, preferably, at least a portion
of these redirections occurs simultaneously to impart a rate of
change of direction in the fluid travelling there through in two
axis simultaneously. Further the curved portion of the inlet may be
a continuous curve so as to continually impart changes to the
direction of the dirty air travelling there through or it may have
a straight portion incorporated therein. Preferably, it defines a
continuously curved member.
[0097] In accordance with a preferred embodiment of this invention,
three dimensional inlet 56 can be considered as an envelope built
around a space time. Every point on the space curve is a centre of
the cross section of the envelope built around it. The curve can be
defined by S(x,y,z). The curve joins together two points in space
not by a straight line but by means of a curve or, preferably a
helical curve or other related curve wherein the gradient of the
space curve has at least two non-zero components which vary along
the arc length of the curve.
[0098] Referring to FIGS. 30 and 30a, inlet 56 is a duct or conduit
comprising an envelope formed by a radius r out from a central
space curve 120 having an upstream end 122 and a downstream end 124
and which is itself formed about an imaginary cylinder 126. This
cylinder is imaginary in the sense that it is used for the purpose
of mathematically constructing the conduit. The central space curve
120 begins and ends at the points S1 and S2. The imaginary
(construction) cylinder 126 has a radius R. Radii r and R may
themselves be varied as functions of (x,y,z) provided that the duct
has a radius r where r<R functions. The helical segment of the
space curve 120 around which the duct is formed can therefore be
defined by S(t)=(G)*(cos(t),sin(t),t).(x,y,z) such that the
gradient of the space curve 120 has at least two non-zero
components which vary along the arc length of the curve 120.
Furthermore, t1<t<t2 and S(t1) is equal to S1 and S(t2) is
equal to S2. The space curve at S1 smoothly becomes a straight line
coincident with the construction cylinder's axis C of the
construction cylinder. The space curve 120 at S2 smoothly becomes a
straight line coincident with the derivative of S(t) at point S2
with respect to the parameter t.
[0099] It will be appreciated that this duct may be used with any
fluid stream (liquid or gaseous) and need not be used in
association with a cyclone separator. In particular, the three
dimensional duct may be used whenever it is desired to alter the
direction of travel of a fluid through more than one plane. Thus,
the three dimensional duct may be used with a fluid stream that has
entrained particulate matter such as a dirty air flow stream to a
vacuum cleaner (cyclonic or otherwise) or with a fluid stream which
does not contain any material to be separated but is flowing
through a system.
[0100] Centrally located in upper end 34 of container 30 is a clean
air outlet 40 for permitting withdrawal of air from container 30,
as will be described below. From clean air outlet 40, the air flow
may proceed, if desired, to a second stage of filtration, such as a
second cyclone or other filtration means (not shown). Subsequently,
it may be in air flow communication with vacuum fan motor 24 via
air exit conduit 41. Head 22 has an exhaust port (not shown) for
expelling clean air to the environment.
[0101] In operation, the vacuum fan motor 24 is activated to induce
an air flow through cleaner 20. The air flow causes a partial
vacuum to form at end 52. Air, and entrained dirt, is drawn into
upstream portion 48, with the aid of brush member 26. The dirty air
flow moves vertically in downstream portion 50 to opening 32 in air
inlet 56 and is introduced tangentially to container 30. The
airflow is then accelerated around dirt rotation surface 36, and
proceeds generally downwardly along and around dirt rotation
surface 36 until it reaches a position towards bottom 38 of
container 30, at which point the air flow travels upwardly through
the central portion of cyclone container 30. Wall 58 may provide an
extension of outlet 40 in container 30. Wall 58 assists in
preventing the treated air travelling upwardly to outlet 40 from
mixing with the dirty air which is introduced into container 30 via
inlet 56.
[0102] As can be seen by a comparison of intake conduits 16 and 46,
of cleaner 10 and cleaner 20 respectively, the reduction of bends
in the air conduit of the present invention beneficially results in
a significant reduction in the turbulent pressure loss in the
intake conduit, thereby markedly improving the efficiency of the
cyclonic separation device as a whole.
[0103] The presence of downstream portion 50 extending through the
centre of container 30 interferes minimally with the cyclonic
action of the air flow within container 30. Thus the presence of
downstream portion 50 does not significantly effect the efficiency
of the cyclone.
[0104] The removability of container 30 from housing 60 of vacuum
cleaner 20 is more particularly shown by reference to FIGS. 3a, 22
and 23. Housing 60 comprises a base 72, an upper portion 76 and
struts 74 which extend between base 72 and upper portion of housing
76 so as to define a cavity within which container 30 is received.
It will be appreciated that housing 60 may be of any configuration
which provides an area in which bin 30 may be received. For
example, it will be appreciated that if vacuum cleaner 20 is a
canister vacuum cleaner, that container 30 may extend horizontally,
or at any inclined angle to the horizontal and housing 60 may be of
any shape within which container 30 may be received.
[0105] Container 30 may be lockingly received in housing 60 by any
means known in the art. In the preferred embodiment, container 30
is provided with a lid 70 which has a recess 80 provided in handle
78 thereof. Container 30 and lid 70 comprise a cyclone chamber
which is removable received in housing 60. Lower surface 102 of
upper portion 76 of housing 60 is provided with a protrusion 92
which is receivable in recess 80. By moving handle 78 downwardly to
the position shown in dotted outline in FIG. 22, protrusion 82 is
removed from recess 80 allowing bin 30 to be removed from base 72
as is shown in FIG. 23. Recess 80 and protrusion 82 are a male and
female detent means. It will be appreciated that other male and
female detent means or the like which are known in the art may be
utilized so that container 30 may be releasably lockingly received
in housing 60.
[0106] In the embodiment of FIG. 3a, the cleaned air travels
upwardly out above container 30. Accordingly, lid 78 is provided
with an upper surface 84. Cylindrical wall 58 extends downwardly
from upper surface 84. The intersection of upper surface 84 and
wall 58 describes opening 40 which is the clean air outlet.
[0107] As can be seen in FIG. 23, downstream portion 50 of air
supply conduit 46 is removed from housing 60 with container 30. In
this embodiment, downstream portion 50 comprises a centre feed
tube. Upstream end 64 is removable from downstream end 54. Sealing
means, such as O-ring 104 may be provided to join ends 54 and 64 in
air flow communication when bin 30 is replaced in housing 60 so as
to prevent any leak or any substantial leak where ends 54 and 64
meet.
[0108] Lid 70 may be releasably mounted to container 30 by any
means known in the art. Referring to FIG. 25, lower end 86 of lid
70 is provided with a recessed surface 90 having two protrusions 92
provided therein. Upper end 88 of container 30 is provided with
bayonet mounts 94 for receiving protrusions 92. Accordingly, once
container 30 is removed from housing 60, lid 70 is rotated slightly
counter clockwise so as to release the bayonet mount whereby lid 70
may then be lifted from container 30 thus allowing container 30 to
be emptied.
[0109] As further exemplified in FIG. 25, in the preferred
embodiment, air inlet 56 is removed with lid 70 from container 30.
The construction of air inlet 56 is more particularly shown in
FIGS. 26-29. Referring to the preferred embodiment of FIG. 26, it
can be seen that air inlet 56 comprises a three dimensionally
curved member which curves first upwardly and outwardly from centre
feed tube 50 through wall 58 into the interior of container 30
which functions as the cyclone chamber. Inlet 56 then continues to
curve outwardly and radially so as to provide a tangential air
inlet to container 30.
[0110] Downstream end 66 of centre feed tube 50 is in air flow
communication with end 106 of air inlet 56. End 106 is provided
with a means such as a collar 108 into which end 66 is received so
as to join inlet 56 in air flow communication with centre feed tube
50. It will be appreciated that any other means known in the art
may be used to join centre feed tube 50 in air flow communication
with air inlet 56.
[0111] Referring to FIGS. 26 and 27, it can be seen that air inlet
56 has a longitudinally extending portion 110 at the end of which
is the curved inlet portion which ends at opening 32. In this
embodiment, the curved inlet portion comprises a continuous three
dimensional curve from upper end 112 of longitudinally extending
portion 110 through to the distal end which contains opening
32.
[0112] In a further alternate embodiment, as shown in FIG. 29, the
distal end of inlet 56 may have an extension member 100 provided on
the upper portion thereof. It will be appreciated that extension
member 100 may be provided either in the embodiment of FIG. 26 or
in the embodiment of FIG. 28.
[0113] Opening 32 and/or extension 100 may extend horizontally
(i.e. in a plane transverse to the longitudinal axis A of container
30). In a preferred embodiment, opening 32 extends downwardly at an
angle of about 1 to about 10.degree., preferably from about 5 to
about 10.degree. from the horizontal. In particular, referring to
FIG. 28, reference numeral 96 refers to a plane which is at right
angles to longitudinal axis A of container 30. Reference numeral 98
defines the axis of opening 32 (i.e. the end portion of curved
inlet 56 which extends along axis 98).
[0114] The configuration of the air intake conduit according to the
present invention advantageously permits a substantial reduction in
the pressure loss experienced in the intake conduit without
interfering with the overall performance of the cyclone separation
device. Thus, the present invention permits a deeper vacuum to be
drawn at the intake end 52, for a given vacuum motor size.
Conversely, the motor size may be reduced in conjunction with the
present invention without losing vacuum power over devices having
air intake conduits according to the prior art, thereby permitting
a comparable vacuum cleaner to be provided at lesser cost.
[0115] In the embodiment of FIG. 3a, it will be appreciated that
from second end 54, the dirty air travels upwardly through the
filtration stages and exits the vacuum cleaner at the top. In
particular, the air travels upwardly to air inlet 56 to cyclonic
unit 28. The air then travels upwardly from air outlet 40 to the
motor and, if desired, further upwardly to a further filtration
stage (eg. a HEPA.TM. filter) which may be positioned in chamber
114 which is provided in housing 60 above motor 24. Regardless of
the sequence of the filtration stages, or their number, the air
preferably continues to travel generally upwardly from one stage to
the next without 900 elbows being required to direct the air
flow.
[0116] While the above description constitutes the preferred
embodiments, it will be appreciated that the present invention is
susceptible to modification and change without departing from the
fair meaning of the proper scope of the accompanying claims.
[0117] It will be appreciated that if conduit 41 extends to a
position adjacent motor 24, then it is preferably constructed from
two portions in a similar fashion to supply conduit 46 such that
the upstream portion of conduit 41 is removable with container 30
from the vacuum cleaner and is in air flow communication with the
downstream portion of conduit 41 (see for example FIG. 6) when
container 30 is reinserted into the vacuum cleaner such that the
upstream and downstream portions of conduit 41 provide air flow
communication for the clean air to travel past the motor to provide
cooling therefor.
[0118] It will be appreciated by those skilled in the art that
various additions and modifications may be made to the instant
invention and all of these are within scope of the following
claims. For example, the cyclone separator may have a hopper of the
like provided in one end thereof for channeling the separated
particulate matter to a collection chamber positioned external to
the cyclone separator or to for other purposes downstream from the
cyclone separator.
* * * * *