MONOLITHIC DUST SEPARATOR

[0001] Embodiments of the invention generally relate to systems for separating dust from a vacuum airstream.

[0002] Separating dust particles from an airstream created by a vacuum source has the benefit of collecting the dust particles into a convenient location, i.e. a dust receptacle so that the process dust can be easily collected and used or otherwise disposed of without filling the receptacle of the vacuum source or fouling a filter associated with the vacuum source. Some centrifugal collectors use cyclonic action to separate dust particles from a gas stream. In a typical cyclone chamber, the dust gas stream enters at an angle and is spun rapidly. The centrifugal force created by the circular flow throws the dust particles toward the wall of the cyclone chamber. After striking the wall, these particles fall into the receptacle located underneath. Existing solutions are bulky or awkward to use due to being made up of multiple pieces.

[0003] Embodiments of the invention address both of these problems by providing an integral, monolithic dust separator. In particular, in a first embodiment, the invention includes A monolithic dust separator for separating and collecting, from a stream of gas, dust particles suspended in the stream of gas while the stream of gas is in motion towards a vacuum source, the dust separator comprising: a vacuum port adapted to be connected to the vacuum source, a cyclone chamber, a tube in communication with the vacuum port and an upper end of the cyclone chamber, an input port adapted to be connected to a dust source, wherein the input port is formed in an upper portion of the cyclone chamber, and a dust receptacle comprising: an upper portion of the dust receptacle, the upper portion including a top upper surface, a port cover adapted to seal a port formed in the upper surface, wherein the port is adapted to empty the receptacle of collected dust particles, and a lower portion of the dust receptacle, wherein a lower portion of the cyclone chamber is integrally formed into the upper surface of the dust receptacle, and wherein the top upper surface slants downward from the cyclone chamber to the port cover.

[0004] In a second embodiment, the invention includes A monolithic dust separator for separating and collecting, from a stream of gas, dust particles suspended in the stream of gas while the stream of gas is in motion towards a vacuum source, the dust separator comprising: a vacuum port adapted to be connected to the vacuum source, a cyclone chamber, a substantially rigid tube in communication with the vacuum port and an upper end of the cyclone chamber, an input port adapted to be connected to a flexible hose adapted to ingest the dust particles, wherein the input port is formed in an upper portion of the cyclone chamber, and a dust receptacle comprising: an upper portion of the dust receptacle, the upper portion including a top upper surface, a dump-port cover adapted to seal a dump port formed in the upper surface, wherein the dump port is adapted to empty the receptacle of collected dust particles; and a bottom portion of the dust receptacle, the bottom portion comprising a tube support adapted to prevent deflection of the substantially rigid tube, wherein a lower portion of the cyclone chamber is integrally formed into the upper surface of the dust receptacle, and wherein the top upper surface slants downward from the cyclone chamber to the port cover.

[0005] In a third embodiment, the invention includes A monolithic dust separator for separating and collecting, from a stream of air, dust particles suspended in the stream of air while the stream of air is in motion towards a shop vacuum, the dust separator comprising: a vacuum port adapted to be connected to the shop vacuum, a cyclone chamber, a substantially rigid tube bent in an inverted-jay shape and in communication with the vacuum port and an upper end of the cyclone chamber, an input port adapted to be connected to a flexible hose for vacuuming up the dust particles, wherein the input port is formed in an upper portion of the cyclone chamber, and a dust receptacle comprising: an upper portion of the dust receptacle, the upper portion including a top upper surface, a dump-port cover adapted to seal a dump port formed in the upper surface, wherein the dump port is adapted to empty the receptacle of collected dust particles, a bottom portion of the dust receptacle, the bottom portion comprising a tube support adapted to prevent deflection of the substantially rigid tube, and a plurality of casters connected to the bottom portion of the dust receptacle, wherein a lower portion of the cyclone chamber is integrally formed into the upper surface of the dust receptacle, and wherein the top upper surface slants downward from the cyclone chamber to the port cover.

[0006] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the current invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.

[0016] The drawing figures do not limit the invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.

[0017] The subject matter of the invention is described in detail below to meet statutory requirements; however, the description itself is not intended to limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Minor variations from the description below will be understood by one skilled in the art and are intended to be captured within the scope of the claimed invention. Terms should not be interpreted as implying any particular ordering of various steps described unless the order of individual steps is explicitly described.

[0018] The following detailed description of embodiments of the invention references the accompanying drawings that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of embodiments of the invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0019] In this description, references to “one embodiment,” “an embodiment,” or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate reference to “one embodiment” “an embodiment”, or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, or act described in one embodiment may also be included in other embodiments but is not necessarily included. Thus, the technology can include a variety of combinations and/or integrations of the embodiments described herein.

[0020] FIGS. 1 through 3 illustrate an embodiment of monolithic dust separator 10. FIG. 1 is a perspective front view of one embodiment of monolithic dust separator 10. In some embodiments, the monolithic dust separator is formed as a single piece from caster supports 18 all the way up to integral cyclone chamber 12. In some embodiments, cyclone chamber 12 is a parabolic cyclone. In various embodiments, cyclone chamber 12 is formed separately and adhered to upper surface 21 of dust receptacle 13, for example, by way of receiving flange 19. In some embodiments, such a single-piece monolith is manufactured by way of an additive manufacturing process. In alternative embodiments, the single piece is manufactured using rotational molding (rotomolding). Rotomolding is a process of heating powder polymers (such as polyethelyne or nylon) in a hollow, metal mold as the mold is rotated. As the powder is heated, it melts and forms to the metal mold as the metal mold is rotated and gravity causes the melting powder (or pellets) to be dispersed along interior surfaces of the metal mold, gradually forming an integral plastic part having the form of the metal mold.

[0021] In one embodiment, the monolithic dust separator 10 has tee-shaped vacuum port 23, which is formed so that it can be connected to a vacuum source, such as a shop vacuum. In this embodiment, the shop vacuum (not shown) is connected via a flexible hose at vacuum port 23. In an alternative embodiment, vacuum port 23 is positioned at a height so that vacuum port 23 mates up directly with the input suction port of the shop vacuum and an intermediate flexible hose is not required. In this embodiment, the shop vacuum has casters similar to casters 16 on the monolithic dust separator 10, and the shop vacuum and the monolithic dust separator 10 become an integrated two-part system that can be rolled around and used to vacuum dust and separate it into dust receptacle 13 of the monolithic dust separator 10 with only a small amount of the ingested dust passing on to the shop vacuum, thereby preventing the shop vacuum from filling up with dust and from fouling a dust filter associated with the vacuum source.

[0022] In some embodiments the substantially rigid, cylindrical tube 20 that connects vacuum port 23 to cyclone chamber 12 is made up of several segments. In this embodiment, the segments include bent segment 14 that completes a bent portion of an inverted-jay shape that forms a bend from vacuum port 23 to a top portion of cyclone chamber 12. In some embodiments, bent segment 14 is connected to tube 20 by way of union 17. In such an embodiment, lower tube 24 is connected to tee-connector 22 which is further connected to tube support 26. Tube support 26 provides support to the overall tube structure to prevent it from deflecting in use and to provide an overall rigid connection point for vacuum port 23 to be connected to a vacuum source, either directly or via a flexible hose.

[0023] In some embodiments, input port 15 is integrated into cyclone chamber 12 such that it is typically adapted to connect to a flexible vacuum hose. The flexible vacuum hose can then be connected to any kind of a dust source, such as a mill or a saw that would produce sawdust as part of cutting or otherwise processing wood. In other embodiments, the dust source may be associated with other types of industrial processes, building construction, or demolition.

[0024] Once sufficient process dust is accumulated in dust receptacle 13, the accumulated dust may be emptied from dust receptacle 13. In some embodiments, an operator of the monolithic dust separator 10 can ascertain the amount of accumulated dust by looking into dust receptacle 13 through the substantially transparent or clear dump port cover 11, which covers a dump port in dust receptacle 13. If the operator determines that the dust receptacle 13 is sufficiently full of dust, the operator can remove dump port cover 11 by unscrewing or unthreading it from the lip formed in upper surface 21 of dust receptacle 13. In one embodiment, dump port cover 11 has an arrow indicium 32 indicating whether it is in a locked position (as indicated by lock indicium 31) or otherwise in an open position as shown in FIG. 1, with the arrow indicium pointing to unlocked indicium 33. When dump port cover 11 is in an open position, it can be removed. Once dump port cover 11 has been removed, the accumulated dust contents of the dust separator can be dumped out of the dust separator into a suitable dust disposal location, such as a dumpster or incinerator or any other suitable dust disposal location.

[0025] FIG. 2 is a side view of one embodiment of a monolithic dust separator. This side view provides an unobstructed side view of tube 20, which connects vacuum port 23 to cyclone chamber 12. In some embodiments, tube 20 is made up of several segments. In these embodiments, the segments include bent segment 14 that completes a bent portion of an inverted-jay shape that forms a bend from vacuum port 23 to a top portion of cyclone chamber 12. In some embodiments, bent segment 14 is connected to tube 20 by way of union 17. In such embodiments, lower tube 24 is connected to tee-connector 22 which is further connected to tube support 26. Tube support 26 provides support to the overall tube structure to prevent it from deflecting in use and to provide an overall rigid connection point for vacuum port 23 to be connected to a vacuum source, either directly or via a flexible hose. In some embodiments, lower tube 24 is held in place within tube support 26 with fastener 27. In some embodiments, fastener 27 is made up of a bolt and a threaded cap or nut and washer.

[0026] FIG. 3 is a sectional side view of one embodiment of a monolithic dust separator. In this sectional view, it can be seen that this particular embodiment, tube 20 may be a single, integral piece that extends from union 17 down through tee 22 and into tube support 26. In this embodiment, lower tube 24 is integral with tube 20. It can also be seen that tube 20 has an opening near vacuum port 23 so that the vacuum suction causes airflow outward from cyclone chamber 12 and out through vacuum port 23. Sectional portion 29 of fastener 27 is shown as it fastens lower tube 24 (here an integral part of tube 20) with tube support 26. In some embodiments, tubes 20 and 24 are separate and distinct. In some embodiments, internal cap 37 is inserted into a top portion of tube 24, creating an airpath outward through vacuum port 23, and also preventing dust particles or other materials from falling into the cavity below internal cap 37. Tube 24 as inserted into the bottom portion of tee 22 and being supported by tube support 26 provides extra rigidity for vacuum port 23, so that it can be rigidly connected directly to a shop vacuum or to a flexible hose that is connected to a vacuum source.

[0027] FIGS. 4 through 7 illustrate a first alternative embodiment of a monolithic dust separator. FIG. 4 is a perspective side view of the first alternative embodiment of a monolithic dust separator 100. In some embodiments, the monolithic dust separator 100 has vacuum port 123, which is formed so that it can be connected to a vacuum source, such as a shop vacuum. In these embodiments, the shop vacuum (not shown) is connected via a flexible hose at vacuum port 123. Bent segment 140 is connected to an upper portion of cyclone chamber 120. In some embodiments, bent segment 140 connects to cyclone flange 142, which fits atop cyclone chamber 120 and is integral to overall monolithic dust collector body 102. In some embodiments, such an overall monolithic dust collector body is manufactured by way of rotomolding processes or by way of additive manufacturing techniques. In some embodiments, input port 150 is integrated into cyclone chamber 120 such that it is typically adapted to connect to a flexible vacuum hose. The flexible vacuum hose can then be connected to any kind of a dust source, such as a mill or a saw that would produce sawdust as part of cutting or otherwise processing wood. In other embodiments, the dust source may be associated with other types of industrial processes, building construction, or demolition.

[0028] Once sufficient process dust is accumulated in dust receptacle 130, the accumulated dust may be emptied from dust receptacle 130. In some embodiments, the process of removing the contents from dust receptacle 130 involves moving the entire monolithic dust separator 100 to a convenient location, i.e., to a table or workbench, positioning the monolithic dust separator 100 on its side and opening dust dump port cover 110 to dump out the contents of dust receptacle 130. In some embodiments, monolithic dust separator 100 can be lifted by way of handles 134 above a suitable dust disposal location at which time dust dump port cover 110 can be removed to empty the contents of dust receptacle 130 into the suitable dust disposal location. In alternative embodiments, the monolithic dust separator 100 is mounted above the floor, for example on a wall or shelf. In some such embodiments, mounting recess 132 is adapted to receive a portion of a mounting bracket (not shown) to help support the monolithic dust separator 100 when mounted on a wall, for example. In such embodiments, a dump port hose or other channel can be connected to the dump port so that dust continually empties into a suitable dust disposal location or hopper. In some embodiments, dust port cover is threaded onto a flange integral to dust receptacle 130 (flange 111 of FIG. 6).

[0029] In some embodiments, cyclone chamber 120 sits directly atop dust receptacle 130. In alternative embodiments as illustrated in FIG. 4, cyclone chamber 120 is connected to dust receptacle 130 by way of vortex chamber 122. In some embodiments, cyclone chamber 120, vortex chamber 122, and dust receptacle 130 are made up of a single monolithic piece. In alternative embodiments, cyclone chamber 120, vortex chamber 122, and dust receptacle 130 are separate components. In one embodiment, cyclone chamber 120 is received by and adhered into vortex chamber 122 which is further connected to dust receptacle 130 by way of receiving flange 119. These individual connections can be permanently connected by way of a press-fit or glued together with a suitable epoxy glue or other adhesive. In some embodiments, optional casters 160 are employed so that the monolithic dust separator 100 can be wheeled around.

[0030] FIG. 5 is a perspective bottom view of the first alternative embodiment of the monolithic dust separator 100. From this bottom view, access port cover 210 is visible. In some embodiments, an associated access port, which access port cover 210 seals may be used for manufacturing, assembly, or repair of the monolithic dust separator 100. In some embodiments, access port cover 210 is threaded into the body of dust receptacle 130. In these embodiments, when access port cover 210 is not present in the body of the monolithic dust separator 100, an assembly or repair technician can reach into the body of the dust receptacle 130 to, for example, attach a fastener to casters 160. In some embodiments, casters 160 are threaded into threaded holes in the body of dust receptacle 130. In alternative embodiments, threaded studs of casters 160 are received in unthreaded holes in the dust receptacle 130. In these embodiments, an optional washer is placed over the threaded stud and a nut is threaded onto the stud and tightened to attach casters 160 to the dust receptacle 130. In some embodiments, the access port is used to insert a cyclone tube into the cyclone chamber 120 as further described in connection with cross-sectional FIG. 7 below.

[0031] FIG. 6 is a perspective side view of the first alternative embodiment of a monolithic dust separator. In some embodiments, the process of removing the contents from dust receptacle 130 involves moving the entire monolithic dust separator 100 to a convenient location, i.e., to a table or workbench, positioning the monolithic dust separator 100 on its side and opening dust dump port cover 110 (as shown) to dump out the contents of dust receptacle 130. In some embodiments, monolithic dust separator 100 can be lifted by way of handles 134 above a suitable dust disposal location at which time dust dump port cover 110 can be removed to empty the contents of dust receptacle 130 into the suitable dust disposal location. In alternative embodiments, the monolithic dust separator 100 is mounted above the floor, for example on a wall or shelf. In some such embodiments, mounting recess 132 is adapted to receive a portion of a mounting bracket (not shown) to help support the monolithic dust separator 100 when mounted on a wall, for example. In such embodiments, a dump port hose or other channel can be connected to the dump port so that dust continually empties into a suitable dust disposal location or hopper. In some embodiments, dust dump port cover 110 may be threaded onto flange 111. Bent segment 140 is shown expanded from an upper portion of cyclone chamber 120. In some embodiments, bent segment 140 is adapted to connect with cyclone flange 142, which fits atop cyclone chamber 120 and is integral to an overall monolithic dust collector body.

[0032] FIG. 7 is a sectional side view of the first alternative embodiment of a monolithic dust separator 100. Bent segment 140 is shown expanded from an upper portion of cyclone chamber 120. In some embodiments, bent segment 140 is adapted to connect with cyclone flange 142, which fits atop cyclone chamber 120 and is integral to an overall monolithic dust collector body. In some embodiments, dust dump port cover 110 may be threaded onto flange 111 as shown. In some embodiments, cyclone tube 124 is inserted into an upper portion of cyclone chamber 120 as shown. In some embodiments, cyclone tube 124 is adhered into an interior portion of flange 142 with glue or other adhesive. In alternative embodiments cyclone tube 124 is installed tightly by being force-driven into a press-fit at flange 142. In yet alternative embodiments, alternatively or in addition to adhesive and/or press fit, set screws (not shown) are employed to secure cyclone tube 124 into a stable position within cyclone chamber 120. In some embodiments, cyclone tube 124 functions to further facilitate dust separation and to limit ingestion of suspended dust into the airstream flowing into the vacuum source through vacuum port 123.

[0033] FIGS. 8 and 9 are perspective side views of a second alternative embodiment of a monolithic dust separator 800. In some embodiments, the monolithic dust separator is formed as a single piece from caster supports 818 all the way up to integral cyclone chamber 822. In alternative embodiments, cyclone chamber 822 is formed separately and adhered to optional vortex chamber 824 which is optionally integrated into dust receptacle 830, for example, by way of receiving flange 819. In some embodiments, bent segment 140 connects to cyclone flange 828, which fits atop cyclone chamber 822 and is integral to an overall monolithic dust collector body. In some embodiments, such a single-piece monolith is manufactured by way of an additive manufacturing process. In alternative embodiments, the single piece is manufactured using rotomolding techniques as described in connection with FIG. 1.

[0034] In one embodiment, the monolithic dust separator 800 has tee-shaped vacuum port 823, which is formed so that it can be connected to a vacuum source, such as a shop vacuum. In this embodiment, the shop vacuum (not shown) is connected via a flexible hose at vacuum port 823. In an alternative embodiment, vacuum port 823 is positioned at a height so that vacuum port 823 mates up directly with the input suction port of the shop vacuum and an intermediate flexible hose is not required. In this embodiment, the shop vacuum has casters similar to casters 860 on the monolithic dust separator 800, and the shop vacuum and the monolithic dust separator 800 become an integrated two-part system that can be rolled around and used to vacuum dust and separate it into dust receptacle 830 of the monolithic dust separator 800 with only a small amount of the ingested dust passing on to the shop vacuum, thereby preventing the shop vacuum from filling up with dust and from fouling a dust filter associated with the vacuum source.

[0035] In some embodiments the substantially rigid, cylindrical tube 820 that connects vacuum port 823 to cyclone chamber 822 is made up of several segments. In this embodiment, the segments include bent segment 840 that completes a bent portion of an inverted-jay shape that forms a bend from vacuum port 823 to a top portion of cyclone chamber 822. In some embodiments, bent segment 840 is connected to tube 820 by way of union 870. In such an embodiment, lower tube 825 (of FIG. 9) is connected to tee-connector 834 which is further connected to tube support 837. Tube support 837 provides support to the overall tube structure to prevent it from deflecting in use and to provide an overall rigid connection point for vacuum port 823 to be connected to a vacuum source, either directly or via a flexible hose.

[0036] In some embodiments, input port 850 is integrated into cyclone chamber 822 such that it is typically adapted to connect to a flexible vacuum hose. The flexible vacuum hose can then be connected to any kind of a dust source, such as a mill or a saw that would produce sawdust as part of cutting or otherwise processing wood. In other embodiments, the dust source may be associated with other types of industrial processes, building construction, or demolition. cyclone chamber 822 is connected to dust receptacle 830 by way of vortex chamber 824. In some embodiments, cyclone chamber 822, vortex chamber 824, and dust receptacle 830 are made up of a single monolithic piece. In alternative embodiments, cyclone chamber 822, vortex chamber 824, and dust receptacle 830 are separate components. In one embodiment, cyclone chamber 822 is received by and adhered into vortex chamber 824 which is further connected to dust receptacle 830 by way of receiving flange 819. These individual connections can be permanently connected by way of a press-fit or glued together with a suitable epoxy glue or other adhesive.

[0037] In such embodiments, lower tube 825 is connected to tee-connector 834 which is further connected to tube support 837. Tube support 837 provides support to the overall tube structure to prevent it from deflecting in use and to provide an overall rigid connection point for vacuum port 823 to be connected to a vacuum source, either directly or via a flexible hose. In some embodiments, lower tube 825 is held in place within tube support 837 with fastener 838. In some embodiments, fastener 838 is made up of a bolt and a threaded cap or nut and washer. Alternatively, fastener 838 may be a screw or a set screw that is adapted to fixedly hold lower tube 825 in place.

[0038] Once sufficient process dust is accumulated in dust receptacle 830, the accumulated dust may be emptied from dust receptacle 830. In some embodiments, an operator of the monolithic dust separator 800 can ascertain the amount of accumulated dust by looking into dust receptacle 830 through the substantially transparent or clear port cover 810. If the operator determines that the dust receptacle 830 is sufficiently full of dust, the operator can remove port cover 810 by unscrewing or unthreading it from the lip formed in dust receptacle 830. When port cover 810 is unthreaded, it can be removed. Once port cover 810 has been removed, the accumulated dust contents of the dust separator can be dumped out of the dust separator into a suitable dust disposal location, such as a dumpster or incinerator or any other suitable dust disposal location. In some embodiments, monolithic dust separator 800 can be lifted by way of handles 836 above a suitable dust disposal location at which time dust port cover 810 can be removed to empty the contents of dust receptacle 830 into the suitable dust disposal location. In alternative embodiments, the monolithic dust separator 800 is mounted above the floor, for example on a wall or shelf. In such embodiments, a dump port hose or other channel can be connected to the dump port so that dust continually empties into a suitable dust disposal location or hopper.

[0039] Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the scope of the claims below. Embodiments of the invention have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to readers of this disclosure after and because of reading it. Alternative means of implementing the aforementioned can be completed without departing from the scope of the claims below. Certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Although the invention has been described with reference to the embodiments illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.

[0040] Having thus described various embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following: