PARTICLE SEPARATOR

[0001] This invention relates to particle separators for use, for example, in a household vacuum cleaner of the so-called “bagless” type.

[0002] Bagless vacuum cleaners separate particulate matter from an air stream entraining such particles by subjecting the air stream to a vortex in a centrifugal separator either of the centrifugal or swirl tube type, dust and other dirt particles settling under gravity for collection and disposal as the air stream loses its velocity and is exhausted to atmosphere in a relatively clean state.

[0003] Known household vacuum cleaners of the type described, while avoiding the problems of filters and bags (which, in use, become clogged with particulate matter and thus rapidly impair the flow rate through the cleaner) nevertheless have attendant disadvantages in that they can generally only capture particles larger than 5 microns in diameter and that there tends to be an element of re-entrainment of some particulates in the exhaust airflow, thus again contributing to a loss of efficiency. In known apparatus, these problems are exacerbated by turbulence induced in the entraining air stream, especially by vanes or other deflectors which are used to create rotary motion in the particle-laden air stream. In an attempt to avoid such disadvantages, conventional apparatus often uses a tangential inlet tube with the object of increasing the rotational velocity of the incoming air stream, and hence the centrifugal force acting on the particles entrained therein, as the air stream is constrained in a pathway of decreasing diameter on making the transition from the inlet to the centrifugal separator. Nevertheless, known apparatus still suffers from disadvantages associated with failure to achieve a clean cut between de-entrained particles and exhaust air.

[0004] In one aspect, the present invention provides apparatus for separation of particles from a fluid stream entraining said particles, the apparatus comprising an inlet zone, a centrifugal separation zone, particles collection means and exhaust means, in which the inlet and separation zones are in communication via a transition zone for inducing vortical flow in the fluid stream, the transition zone having a diameter greater than the diameter of the inlet zone and comprising means defining an outlet port to the separation zone, an entry port being formed in the transition zone upstream of the baffle means, the entry and outlet ports being mutually arranged to minimise fluid perturbation in the fluid stream in use.

[0005] In this specification, a zone having a particular function is to be understood to be a part of the apparatus defined by a boundary wall and being constructed and arranged to perform that function.

[0006] Apparatus according to the invention may comprise coaxial inlet, transition and centrifugal separation zones, in which the inlet zone has a diameter less than the diameter of the transition zone, whereby particles-laden fluid entering the transition zone from the entry port is induced to follow a vortical pathway having a greater or more expansive diameter than that of the inlet zone before passing to the separation zone. However, the inlet zone (or a plurality of inlet zones) may be axially parallel with but offset from the transition and separation zones, but preferably disposed to be within the region defined by and extending in an upstream direction from the outer wall of the separation zone. In another arrangement, the inlet zone is tangential to the separation zone, the transition zone including a curved pathway of decreasing radius to increase the radial component of the velocity of the particles before entry thereof to the separation zone.

[0007] Preferably, the entry and outlet ports are of substantially the same cross-sectional area to minimise fluid perturbation in use. By “substantially the same cross-sectional area” is meant that the outlet port to the separation zone is either the same in area as the entry port to the transition zone or, if different therefrom, is preferably larger but by no more than 20%, preferably no more than 10%, larger than the area of the entry port.

[0008] Where the inlet, transition and centrifugal separation zones are coaxial or axially in parallel, the means defining the outlet port from the transition zone to the separation zone preferably comprises a baffle means disposed across the inlet zone and partially separating the transition and separation zones, thereby defining the outlet port to the separation zone, and the entry port comprises a cut-away side portion of the wall of the inlet zone giving access to the transition zone. Where the inlet zone is tangential to the separation zone, the means defining the outlet port may comprise a baffle means disposed partially to separate the transition and separation zones and the entry port is defined by the lumen of the wall of the inlet zone as it assumes a curved pathway to become the transition zone. However, in such an arrangement, a baffle means is not essential for the purpose of inducing vortical flow and the outlet port to the separation zone may comprise a notional port region between the transition and separation zones, such zones being in open communication.

[0009] It has surprisingly been found, according to the invention and despite the fact that the incoming fluid stream experiences a transition from an essentially linear to a vortical flow, that nevertheless there is less flow disruption, turbulence and reduction in separation efficiency than is experienced in known apparatus. Indeed, overall, apparatus according to the invention operates at high efficiency with a low pressure drop for particulates having a wide range of particle size and density.

[0010] The vortical motion-inducing transition zone may comprise, as between the inlet and centrifugal separation zones, a scroll entry port of a known configuration but, in effect, applied in inverse relationship from conventional apparatus. Conventional scroll configurations are applied to tangential outlets to centrifugal separation apparatus and include 90%, 180%, 270% and 360% scrolls and logarithmic spiral scrolls. In apparatus according to the present invention and especially where the inlet and separation zones are coaxial or axially in parallel, rotary motion is induced by the scroll entry port and in the transition zone but commences upstream of the transition zone, in the downstream end region of the inlet zone, thereby enabling particulate matter entrained by the fluid stream to be moved towards the bounding wall of the inlet zone as a pre-separation step before entering the transition zone through the scroll entry port.

[0011] Preferably, the centrifugal separation means are also coaxial at least with the exhaust means and preferably also with the collection means. The particles-laden fluid stream, once within the centrifugal separation means, describes a helical pathway to the far or distal end, in which the particles are moved under centrifugal force towards the peripheral regions of the separation means and passed therefrom to the collection means through port means communicating between the separation and collection means. The centrifugal separation means may be tapered to provide a frusto-conical chamber and to induce acceleration of the airstream, and thus more efficient separation of particulates, towards the distal end. The fluid then passes back down the centre of the separation means in a helical pathway and enters the finder of the exhaust means. In apparatus according to the invention, the particles are thus separated from the fluid in a region remote from the flow of fluid towards the exhaust means, thereby significantly reducing re-entrainment of particles.

[0012] Optionally, the exhaust means extends to the proximal end of the separation means and is in communication therewith through an array of slots or other apertures formed in the wall of the exhaust means. The slots or other apertures may be radially formed through the wall of the exhaust means but, preferably, are formed at an angle in the direction of fluid flow, in order to improve efficiency and reduce back pressure. The slots or other apertures can extend along the exhaust means from the upstream or proximal end of the separation means for up to approximately 90% of the distance to the downstream or distal end of the separation means. In other embodiments, the exhaust means comprises an open-ended tube which is spaced from the proximal end of the separation means. The exhaust means may extend from the remote end of the apparatus (with respect to the inlet means) but alternatively, especially where the inlet means are axially offset from the separation means, may extend from the same end as the inlet means.

[0013] The particle collection means, which preferably surrounds at least the centrifugal separation means, may be formed with a removable base for the purpose of disposal of collected particulates or, alternatively, with an access door with suitable seal. Alternatively, the collection means may be removable together with the inlet and separation means, collected particles being thereafter removable therefrom. The particle collection means is constituted by a separate chamber from the separation zone, whereby the amount of particles collected has little or no effect on the separation efficiency, since there is significantly less air movement in the collection chamber with corresponding less tendency for re-entrainment of separated material.

[0014] In a preferred arrangement and in order to prevent trapping of particulates in the zone between the inlet and centrifugal separation zone, the base of the transition zone may be formed as a helix to ensure that all particles remain entrained in the fluid stream without becoming trapped.

[0015] In apparatus according to the invention, the arrangement of the component parts may be such that the direction of fluid flow in the inlet zone, separation zone and exhaust means is in counter-current to the direction of settlement of particles in the collection means, which takes place under the influence of gravity as kinetic energy is lost in the separation zone or, alternatively, such that the directions of fluid flow and settlement of particles are the same.

[0016] In another aspect, the invention provides a method for separation of particles from a fluid stream entraining said particles, the method comprising passing said stream is essentially linear flow through apparatus comprising an inlet zone and a centrifugal separation zone, in which the stream passes through a transition zone between the inlet and separation zones to induce a vortical flow pathway in the separation zone with minimal fluid perturbation in passing through the transition zone.

[0030] Referring firstly to FIGS. 1 and 2, the apparatus consists essentially of an inlet tube 11, a frusto-conical separation chamber 12, a collection chamber 13 and an exhaust duct 14. The parts 11, 12, 13 and 14 are arranged concentrically. The upper end of the inlet tube 11 is formed with a closure or baffle plate 15 which constitutes the effective lower end or base of the separation chamber, although the lower end of the cylinder which forms the separation chamber extends downwardly below the plate 15 to a lower wall 16. The plate 15 closes the upper end of the tube 11 and extends partially over the annular space defined between the tube 11 and chamber 12, as shown in FIG. 2, to define an access or inlet port providing a pathway for fluid between the inlet tube and separation chamber. In the transition zone between the plate 15 and the lower wall 16, the tube 11 has an exit or outlet aperture 11A which, in combination with the plate 15, induces a vortical motion in fluid flowing up the tube 11 and into the chamber 12, the fluid flow being illustrated by the heavy solid line X. The cross-sectional area of the exit or outlet aperture is the same as that of the access port.

[0031] In use, particulate matter entrained in the fluid flow is urged towards the outer periphery of the chamber 12 and, at the upper end of chamber 12, the particulate matter is urged by centrifugal force into the annular space defined between the chamber 12 and the collection chamber 13, as indicated at Y. The fluid, then relatively free of particulate matter and having lost a component of its kinetic energy, returns down the chamber 12, adjacent the wall of the outlet tube 14, and enters therein for escape to atmosphere, as indicated by the light-solid line Z. The particulates fall under gravity to the bottom of chamber 13 for subsequent removal.

[0032] With reference to FIG. 3, an alternative embodiment is illustrated which operates on a similar principle to the apparatus as illustrated in FIG. 1 but with the incoming fluid particulates-laden stream entering from above through tube 21 and being induced to follow vortical motion in separation chamber 22, which in this embodiment is cylindrical. Separated particulates are collected in collection chamber 23, an annular flange 24 being preferably provided around exhaust chamber 25 to encourage the fluid stream, relatively free of particulates, to return upwards to enter the upper end of the exhaust tube, bearing in mind that the fluid stream is inhibited from doing so in any event since the collection chamber 23 represents a closed system. In order to facilitate separation and collection of lighter, typically fibrous, material which, otherwise, may be re-entrained and expelled to atmosphere with the exhaust air, a collar 26 may be attached to the flange 24 in a downwardly-depending fashion; such a collar has been found significantly to improve retention of especially lighter particulates without materially affecting the retention volume provided by the collection chamber, since some collected material is held within the inverted cup-shaped space created by the collar and flange. In addition, the presence of stationary material in this region has also been found to enhance the stabilisation and to reduce the motion of incoming particulate material, thus again contributing to improved retention efficiency.

[0033] In the embodiment as shown in FIG. 3, exhaust air, substantially free of particulates, passes downwardly through exhaust tube 25.

[0034] With reference now to FIG. 4, an embodiment similar to that described with reference to FIGS. 1 and 2 is illustrated and the same reference numerals are used to depict the same functional component parts. However, in the embodiment of FIG. 4, the base 16 of the separation chamber 12 is replaced with an annular helical track 17, to prevent particulates becoming trapped in the blind end represented by 18 in FIG. 2, and the exhaust tube 14 of FIG. 1 is, in FIG. 4, extended downwardly in contact with plate 15, an array of vertically-disposed vanes or louvres 19 defining between them gaps 20 for ingress of exhaust air. As shown in FIG. 5, the vanes are preferably provided with angled edges so that the resulting slots 20 enable access of exhaust air substantially without the creation of unwanted back pressure.

[0035] FIG. 6 illustrates an embodiment similar to that described with reference to FIG. 3, particularly adapted for use in a self-contained vacuum cleaner unit. The same reference numerals are used for FIG. 6 as are used in FIG. 3 for corresponding parts. As with FIG. 3, particulates-laden fluid X enters at the upper end of the apparatus through tube 21 and is induced to follow a vortical pathway in separation chamber 22. Collected particulates 27 accumulate in the collection chamber 23. Exhaust air is then passed through a filter 28 to remove residual particulate matter; the filter 28 may be a relatively low-efficiency filter or a high-efficiency HEPA filter, depending on the level of filtration efficiency required. A motor unit and fan 29 is disposed below the filter unit 28 and thus draws air through the entire apparatus, exhaust air passing out through suitably-configured orifices 30. A rechargeable battery unit 31, with appropriate charging electronics and connections, may be disposed below the orifices 30 or, alternatively, for a mains-powered apparatus, a mains operated motor and fan may be utilised. The apparatus may be suspended either from a carrying handle attached for example to a shoulder strap, thus making a stable and portable unit, or otherwise adapted for travel on the floor.

[0036] With reference to FIGS. 7 and 8, the apparatus includes two inlet tubes 32 disposed diametrically opposite each other and on either side of exhaust duct 33. The separation chamber 34 is frusto-conical and particulates pass through the lower open end thereof for collection. As with FIG. 1, the direction of incoming particulates-laden air through the transition zone is shown by X, separation of particulates by Y and exhaust air by Z.

[0037] Referring to FIGS. 9 and 10, the apparatus has a tangential inlet pipe 41 which enters a transition zone defining a circular pathway 42 of decreasing radius, whereby incoming air is constrained to move along the pathway to experience a continual and increasing radial acceleration over an increased path length, compared with previously described embodiments. The airstream then passes through an opening formed in baffle plate 43 to the separation chamber 44. Particles 45 are collected in an annular collection chamber and exhaust air leaves the apparatus through exhaust duct 46. In an alternative configuration, the apparatus may be adapted to reverse-flow operation by including exhaust duct 47 with removal of the central part of baffle plate 43, indicated “A” in FIG. 9 and blocking or removal of exhaust duct 46, whereby exhaust air passes through duct 47. In this arrangement and because the incoming airstream is induced to follow a vortical flow in pathway 42, the baffle plate 43 may be omitted, the air passing freely to the separation chamber 44 through an open circular or annular region, according to whether the apparatus includes duct 47.

[0038] Referring to FIGS. 11 and 12, a reverse-flow coaxial arrangement of inlet and outlet ducts is shown with the inlet tube 50 surrounding the outlet tube 51, the overall arrangement being similar to that described with reference to FIGS. 1 and 2 but showing a counter current configuration. However, compared with FIGS. 1 and 2, the central part of the baffle plate 15 is absent in the apparatus as illustrated in FIGS. 11 and 12, in which the use of a standard inverted cyclone arrangement is possible with both inlet and outlet conveniently disposed at the lower end next to each other. It is also possible to use a cylindrical separator section in place of the frusto-conical section shown, provided that the dimensions of the collection chamber 52 are selected accordingly.

[0039] Although the invention has been described with particular reference to vacuum cleaners, in which the fluid is air, the invention may also be applied to other applications such as spark arrestors in automotive exhausts, also where the fluid is gaseous, or where the fluid is water or other liquid.