DUAL-STAGE CYCLONIC AIR SEPARATOR

Abstract

A dual-stage cyclonic separator is provided for separating debris from air in a bagless surface cleaning apparatus, along with a bagless surface cleaning apparatus incorporating such a cyclonic separator. A debris collection device used with a bagless surface cleaning apparatus is also provided, along with a method of separating debris from air using a bagless surface cleaning apparatus.

Description

TECHNICAL FIELD

This invention relates to bagless vacuum cleaners and cyclonic air separators used therewith.

BACKGROUND

Numerous configurations for bagless cleaning devices have been developed that effectively separate debris from an airflow when such cleaning devices are used with respect to a cleaning surface or medium. Such devices include a variety of bagless vacuum cleaners that successfully ensure enhanced suction levels. Inherent in the obviation of bags is the difficulty in disposing collected particulates and debris. Such particulates and debris include, but are not limited to, dust, dirt, fibers, food particles, buttons, small lids and caps (such as bottle caps), fur, hair, epidermis particles and the like.

Certain cyclonic separator devices have been developed for such vacuum cleaners, as is known in the art. Such devices create centrifugal airflow so that inherent centrifugal forces separate debris within that airflow for eventual disposal from a debris collection device (including, but not limited to debris collection devices that incorporate dust-collecting chambers such as dirt cups.

Despite these known devices, a need persists to effectively separate both coarse debris and fine debris from dirty air prior to expelling separated air from a surface cleaning device. For example, many existing devices effect coarse debris accumulation while neglecting efficient fine debris accumulation, thereby resulting in vacuum devices that have poor functionality. At least these deficiencies are overcome, and additional attributes are imparted, by the devices presently disclosed herein.

SUMMARY

A dual-stage cyclonic separator is provided for separating debris from air in a bagless surface cleaning apparatus. The cyclonic separator includes a cyclonic frustum having a frustum wall with an outer frustum wall for directing a preliminary centrifugal airflow thereabout and an inner frustum wall for directing ultimate centrifugal airflow therein. The frustum wall tapers generally inwardly from a frustum extent disposed adjacent a frustum extent opening toward an opposed frustum extent disposed adjacent a frustum egress. The cyclonic frustum also includes a cylindrical wall depending upwardly from an interface with the frustum extent opening and terminating in a cylindrical ingress. An airflow turret is provided at the cylindrical ingress that facilitates transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow.

The airflow turret incorporates at least two similarly configured and evenly spaced sails that are circumferentially arranged relative to the cylindrical ingress. Each sail has a guide surface to guide incoming air from the preliminary centrifugal airflow toward the cylindrical ingress. In preferred embodiments, the airflow turret comprises five sails and the guide surface of each sail exhibits a generally radial profile. Such profile includes an impact surface of predetermined concavity against which the incoming air strikes, and a terminal restraining edge for piloting the incoming air toward the cylindrical ingress. The terminal restraining edge includes a lead surface that leads the incoming air toward the impact surface. The terminal restraining edge also includes a trail surface that pilots the incoming air toward the cylindrical ingress during the transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow.

The lead surface of the terminal restraining edge leads the incoming air that enters through an adjacent velocity slot provided between adjacent sails. The velocity slot includes an entry ramp of predetermined camber that is configured to deliver the preliminary centrifugal airflow from the coarse debris collection area toward the cylindrical ingress. In exemplary embodiments, each guide surface exhibits a radius of about 38°; each lead surface exhibits a radius of about 14°; each trail surface exhibits a radius of about 14°; each velocity slot exhibits a cross-sectional area in a range from about 120 mm² to about 130 mm²; and each entry ramp exhibits a grade of about 48°.

In addition, the cyclonic separator includes a debris collection cup having a cup wall with an outer cup wall that, together with a debris collection device and the outer frustum wall, provides a coarse debris collection area within which debris is deposited by the preliminary centrifugal airflow. An inner cup wall provides a fine debris collection area within which debris is deposited by the ultimate centrifugal airflow. At least a portion of the opposed frustum extent depends inwardly into the debris collection cup such that the ultimate centrifugal airflow deposits debris directly within the fine debris collection area.

The cyclonic separator further includes a cyclonic sieve having a sieve wall coextensive with a turret extent for placement adjacent the airflow turret and an opposed debris restriction extent. A debris restriction flange may be provided adjacent the debris restriction extent of the cyclonic sieve and configured to deflect debris in the preliminary centrifugal airflow into the course debris collection area.

The sieve wall has a continuous portion for directing the preliminary centrifugal airflow about the frustum wall wherein the sieve wall is positioned relative to the debris collection device such that dirty air that enters the debris collection device tangentially impinges the continuous portion of the sieve wall. The sieve wall also includes a louvered portion incorporating a plurality of apertures for delivering airflow to the airflow turret. At least some of the apertures have rounded upstream edges and rounded downstream edges past which the preliminary centrifugal airflow is delivered to the velocity slot. The sieve wall exhibits a generally frustoconical geometry, and in some embodiments, the apertures are provided in a predetermined pattern along the louvered portion of the sieve wall.

In some embodiments, the airflow turret includes a turret seating flange having an upper turret seat and a lower turret seat. The cyclonic sieve may incorporate a corresponding sieve seating flange having an upper sieve seat and a lower sieve seat. In such embodiments, the cyclonic sieve is positioned relative to the cyclonic frustum such that the upper sieve seat is disposed adjacent the lower turret seat.

The cyclonic separator also includes an airflow outlet configured to deliver air from the debris collection device after depositing debris in the fine debris collection area. The airflow outlet may be provided in a support member that is disposed adjacent the upper turret seat and configured to direct outgoing air from the cyclonic separator.

In operation of the presently disclosed cyclonic separator, debris that is not deposited in the coarse debris collection area by the preliminary centrifugation airflow is deposited by the ultimate centrifugal airflow into the fine debris collection area through the frustum egress. In some embodiments, an optional sifter is disposed near the frustum egress and configured to direct debris that is deposited from the frustum through the frustum egress into the fine debris collection area.

A bagless surface cleaning apparatus is also provided that includes a base suction unit, an apparatus handle and a main body provided intermediate the base suction unit and the apparatus handle and operably supporting a debris collection device thereby. The cleaning apparatus incorporates a cyclonic separation system as presently disclosed such that dirty air that enters the debris collection device tangentially impinges the continuous portion of the sieve wall.

A debris collection device is also provided that is used with a bagless surface cleaning apparatus to separate debris from air. The debris collection device includes a debris collection canister, a debris collection cover coupled with the debris collection canister and a centrifugal separation system as presently disclosed.

A method of separating debris from air is provided that uses a bagless surface cleaning apparatus. The method includes providing a cyclonic separator as presently disclosed in a debris collection device that is operably mounted in the cleaning apparatus. The cyclonic separator is positioned so that dirty air that enters the debris collection device tangentially impinges the continuous portion of the sieve wall. The cyclonic sieve of the cyclonic separator is positioned so that the preliminary centrifugal airflow traverses the louvered portion of the sieve wall toward the cylindrical ingress during the transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow. The airflow outlet is configured to direct separated air from the cyclonic separator.

Additional aspects of the presently disclosed methods, devices and systems will be made apparent from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The nature and various advantages of the present invention will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:

FIGS. 1 and 1A show respective front and rear perspective views of an exemplary embodiment of a bagless surface cleaning apparatus.

FIG. 2 shows a cross-section along a longitudinal extent of an exemplary debris collection device used with the bagless surface cleaning apparatus of FIGS. 1 and 1A and having an exemplary dual-stage cyclonic separator incorporated therewith.

FIG. 3 shows a perspective view of the dual-stage cyclonic separator of FIG. 2 apart from the debris collection device.

FIG. 3A shows an exploded view of the exemplary dual-stage cyclonic separator of FIGS. 2 and 3.

FIG. 3B a cross-section of the exemplary dual-stage cyclonic separator of FIG. 3 along line A-A.

FIG. 4 shows a top perspective view of an exemplary airflow turret incorporated with the dual-stage cyclonic separator of FIGS. 2 and 3.

FIG. 4A shows a perspective cross-section of the airflow turret of FIG. 4 taken along line B-B.

FIG. 5 shows an exemplary path for preliminary and ultimate centrifugal airflow realized by the dual-stage cyclonic separator of FIGS. 2 and 3 within a debris collection device.

FIG. 6 shows a side perspective view of the debris collection device of FIG. 2 in a state on as to at least partially release collected debris from a collective debris release outlet of the debris collection device.

FIG. 7 shows a side perspective view of the debris collection device of FIG. 6 in a state so as to release all or almost all collected debris from the collective debris release outlet.

DETAILED DESCRIPTION

Now referring to the figures, wherein like numbers represent like elements, FIGS. 1 and 1A show an exemplary bagless surface cleaning apparatus 10 having a main body 12, a base suction unit 14 for cleaning a surface or medium and an apparatus handle 16 provided on main body 12 for propelling and maneuvering main body 12 and base suction unit 14 thereby. While cleaning apparatus 10 is shown generally as an upright vacuum cleaner as depicted, it is contemplated that the presently disclosed invention is amenable for use with other vacuum cleaner types, including but not limited to other upright vacuum cleaner configurations, hand-held vacuums, central particulate cleaner systems, steam cleaners, wet and wet-dry vacuums, and equivalent and complementary devices.

Main body 12 includes apparatus handle 16 that facilitates grasping and maneuvering of cleaning apparatus 10 by a user. Handle 16 may include at least a power button 18 integral therewith and in operational communication with a power source that actuates a vacuum motor (not shown). Such a power source, for example, may be electricity provided through a power cord 19 (shown in partial view in FIGS. 1 and 1A) in electrical communication with cleaning apparatus 10. When a user depresses power button 18, cleaner apparatus 10 is correspondingly activated or deactivated (or alternatively subject to a change in cleaning function selection) during a cleaning operation. One or more other actuators may be incorporated with handle 16 to execute one or more additional functions, including but not limited to buttons, dials or touch displays for optional speed settings and cleaning surface settings (e.g., wood and laminate floor settings, low-, medium- and high-pile carpet settings, upholstery and drapery settings, etc.).

As used herein, “cleaning surface”, “surface” and “cleaning medium” are used interchangeably to include any area, region, substrate, surface and other medium that can be acted upon by cleaning apparatus 10. Examples of “cleaning surfaces” and “cleaning media” include, but are not limited to, carpets, floors (including floors fabricated from hardwood, linoleum, ceramic, marble and other complementary and equivalent materials), mattresses (including mattresses for humans and pets), furniture (including fully or partially upholstered furniture, wooden furniture, metal furniture, patio and sunroom furniture and the like), accessories (including textile accessories such as pillows, throw pillows and seat cushions), drapery, walls and ceilings (including walls and ceiling made from drywall, having textured and/or painted surfaces, incorporating wainscoting and having a covering secured thereon), stuffed animals, textiles and other surfaces and media. The term “carpet” as used herein includes all textile floor coverings, including but not limited to those having fibers (e.g., whether looped, tufted, hooked, needlefelt, woven or of other design), indoor or outdoor, of natural or synthetic materials, wall-to-wall textiles or roll goods.

One or more visual, tactile, audio and other indices may be provided with power button 18 (and/or any other actuator provided on handle 16) not only to help a user identify the power source activation means for cleaning apparatus 10, but also to indicate a current state of cleaning apparatus 10 (e.g., “on” or “off”). Such indices may include visual indices, such as one or more LED lights or other illumination means provided proximate power button 18. Other visual indices may include one or more letters, numbers, symbols and combinations that readily identify power button 18. Still other indices may include raised protrusions (or indentations) providing tactile guidance of the activation source for cleaning apparatus 10.

In some embodiments, handle 16 may include at least one cord retention member 20 that enables retention of power cord 19 thereby. Cord retention member 20 may be provided as a hook member as shown in the figures or alternatively provided as a retractable element extendable relative to handle 16. At least one supplementary cord retention member 20a may be incorporated anywhere along main body 12, and the disposition of such supplementary cord retention members is not limited to that illustrated herein (for example, a supplementary cord retention member may be disposed at or near a motor shroud 29 instead of, or in addition to, supplementary cord retention member 20a shown in FIGS. 1 and 1A). Overall, the various electrical components of cleaning apparatus 10 (including the motor thereof) can be powered by power cord 19, which is configured for receipt by a complementary electrical outlet or other suitable external power source. In addition to, or in place of external power sources, cleaning apparatus 10 may also be powered through the use of various battery pack systems as is known in the art, including but not limited to hybrid rechargeable power systems.

A hose connector 22 may be formed on at least a portion of main body 12 that communicates with a suction port 24 and facilitates removable fastening of an extendable hose 26. Main body 12 may have a hose carrier 28 provided thereon that permits storage of hose 26 when either the hose or the cleaning apparatus is not in use. At least one of hose connector 22 and hose carrier 28 may be integral with at least a portion of main body 12 or detachably mounted thereto by one or more fastening means as known in the art. Optional accessories for hose 26 may also be removably fastened to corresponding structure on main body 12, including but not limited, to, a brush 30, a crevice tool 32 and a hose wand 34 that permits a user to guide the hose for removal of particulates from a variety of cleaning surfaces. Additional tools may include one or more brushes, squeegees, beater bars, nozzles, etc. It is understood that the incorporation of accessories and tools as shown and described herein is purely optional and does not limit the scope of the presently disclosed invention.

Main body 12 is at least supportable by abuse suction unit 14 that may include fascia 40 having a leading edge 40a and one or more side edges 40b. One or more of fascia 40, leading edge 40a and side edges 40b may have one or more designs, colors, textures and/or embellishments incorporated therewith to enhance the aesthetic features of main body 12. Alternatively, one or more of fascia 40, leading edge 40a and side edges 40b may be fabricated from one or more materials having an antimicrobial additive for treatment of infestation agents during a cleaning operation. Such materials may alternatively, or also, incorporate additives that impart easy-clean characteristics to base suction unit 14.

Leading edge 40a may include a bumper 42 thereon (or integral therewith) to protect cleaning apparatus 10 and floor and wall surfaces from inadvertent marks and impacts. One or more of fascia 40, leading edge 40a, side edges 40b and bumper 42 may include optional indicia for indicating a steering direction of base suction unit 14. For example, one or more illumination means (such as LED or fiber optic lights, not shown) may be used to illuminate at least a portion of base suction unit 14 and thereby direct a path along which cleaning apparatus 10 may be guided. Illumination means may also be used to indicate a state of cleaning apparatus 10 (e.g., “on” or “off”, “carpet mode”, “floor mode”, “need to empty debris collection cup”, etc.).

Base suction unit 14 may support an agitation member such as a beater bar (not shown) for lifting debris from a surface being cleaned. Such a beater bar may be selected from numerous beater bar embodiments, including but not limited to those beater bar embodiments disclosed by co-owned U.S. Ser. No. 10/646,233, the entire disclosure of which is incorporated by reference herein. The beater bar may be positioned within base suction unit 14 and configured to rotate during a beater bar operational mode of cleaning apparatus 10. The beater bar (or equivalent agitation member) may be in operative communication with a drive motor (not shown), such as through a belt drive (not shown) to enable rotation of the beater bar. It is contemplated that an agitation member such as a beater bar can be configured to rotate with sufficient speed to effectively impact the cleaning surface on which cleaning apparatus 10 is employed. For example, one or more actuators may be incorporated with handle 16 (as described hereinabove to control the agitation member (or associated drive motor) for effective agitation of carpet fibers in both higher knap and lower knap carpeting.

Equivalent structure to a beater bar may be suitable for lifting debris from a cleaning surface for delivery of the lifted debris through a suction port (not shown) supported by base suction unit 14. In some embodiments, additional particulate removal features may complement the beater bar or agitation member. Such features may include, but are not limited to, one or more brushes (not shown) along an undercarriage of fascia 40. Such features may also include corrugations (not shown) provided along at least a portion of bumper 42 for disrupting particulates from a cleaning surface and eventual collection of the disrupted particulates in cleaning apparatus 10 (as further described herein).

In an embodiment where cleaning apparatus 10 is a steerable vacuum cleaner, a coupling may be provided between main body 12 and base suction unit 14. Wheels 46 can be disposed on (or in steerable communication with) the coupling to facilitate linear and non-linear travel paths that cleaning apparatus may traverse during use. In some embodiments, the coupling may comprise a yoke having wheels disposed thereon (an example of which is disclosed by co-owned U.S. Ser. No. 12/771,865, the entire disclosure of which is incorporated by reference herein). In some embodiments, the coupling may comprise a swivel joint (shown generally as swivel coupling 48 in FIG. 1A) at the junction of the base suction unit and the main body. In such embodiments, the swivel joint causes base suction unit 14 to turn right with a clockwise twist of the handle and turn left with a counter-clockwise twist of the handle. Cleaning apparatus 10 may therefore exhibit optional maneuverability such that base suction unit 14 is responsive to the user and achieves a turning effect, rather than a sliding effect, during use. In such a configuration, a user need only maneuver apparatus handle 16 to propel base suction unit 14 relative to the cleaning surface and thereby direct cleaning apparatus 10 as desired to optimize particulate suction over a cleaning surface.

Main body 12 incorporates a carapace 50 having a base extent 50a proximate base suction unit 14 (shown in FIGS. 1 and 1A). Base extent 50a may include structure for communicating engagement with base structure 14 as known in the art. Base extent 50a may include further housing structure for housing vacuum motor features therein as shown generally by motor shroud 29. Motor shroud 29 may optionally incorporate a filter access door 51 (see FIG. 1A) that permits access to an exhaust filter (not shown). Such exhaust filter may be a HEPA filter or any comparable or equivalent filtering means. One or more exhaust vents 53 may be incorporated in at least a portion of base extent 50a to facilitate egress of clean air from cleaning apparatus 10.

Carapace 50 also includes a handle extent 50b proximate handle member 16 (as shown in FIGS. 1 and 1A). Handle extent 50b may include structure for engagement with handle member 16 as shown herein (e.g., a ferrule that facilitates removable securement of handle member 16 with main body 12 by snap-tight engagement, snap-click engagement, thread-fit engagement and any complementary and equivalent engagement means amenable to practice of the presently disclosed cleaning apparatus). It is understood that structure for removable securement of handle member 16 with main body 12 may incorporate one or more complementary and equivalent fastening systems, either known or hereafter derived.

Referring further to FIGS. 2, 3, 3A and 3B an exemplary dual-stage cyclonic separator 200 is provided as an operative feature with a debris collection device 100 used with a cleaning apparatus 10. Debris collection apparatus 100 is removably mounted in a chamber in main body 12 during use or storage of cleaning apparatus 10. The chamber includes a seat that supports debris collection device 100 thereon, which seat may include optional engagement means for removable retention of debris collection device 100. It is contemplated that successful operation of cyclonic separator 200 is not limited to the debris collection device shown and that the presently disclosed separator is amenable for use with a plurality of debris collection device configurations.

Debris collection device 100 may include a device handle 102 that is readily grasped by a user for removal of the debris collection device from, and insertion of the debris collection device into, main body 12. Handle 102 may be an integral component or an assembly of interchangeable components that may be thrilled on or coupled with at least one of a debris collection canister 106 and a debris collection cover 107. In an embodiment where handle 102 is incorporated with cover 107, a user may grasp handle 102 to effect separation and coupling of the debris collection cover relative to canister 106 (e.g., via frictional fit, complementary threaded engagement and the like). Although debris collection device handle 102 is shown as a generally arcuate member, it is understood that such handle may assume any geometry amenable to practice of the presently disclosed invention.

A user may grasp handle 102 to remove debris collection device 100 from main body 12 and carry the debris collection device and its contents to another location (e.g., for disposal of accumulated debris into a disposal vessel such as a dustbin or trash receptacle). Debris collection device 100 (and therefore cyclonic separator 200) may alternatively be carried and inserted into a chamber of another cleaning apparatus that operatively receives debris collection device 100 (and therefore separator 200) thereby. In exemplary embodiments where debris collection device 100 is removably secured with complementary engagement structure (e.g., one or more engagement teeth), a user may remove debris collection device 100 from main body 12 simply by grasping debris collection device handle 102 and applying a pulling force sufficient to overcome the retention force between the engagement structure and the debris collection device. Instead of, or in addition to, engagement structure that releasably secures debris collection device 100 in main body 12, handle 102 may include one or more retractable pins (not shown) that cooperate with corresponding recesses (not shown) in a chamber wall of main body 12 Such pins retract from their corresponding recesses upon depression of one or more optional actuators, such as an optional actuator button 104 provided on handle 102.

Further referring to FIG. 2, debris collection device 100 includes a canister 106 having a top extent opening 106a, a bottom extent opening 106b and a coextensive side wall 106c. Canister side wall 106c includes an outer surface 106c′ and an inner surface 106c″ with a predetermined thickness delineated therebetween. Cyclonic separator 200 is disposed in a recess defined by inner canister surface 106c″. Although an exemplary debris collection device is shown and described herein, it is contemplated that a plurality of exemplary debris collection configurations are amenable for use with the presently disclosed cyclonic separator.

At least one air ingress 105 (see FIGS. 6 and 7) may be provided that depends generally normally relative to canister side wall 106c and defines a lumen therethrough. The lumen of air ingress 105 may facilitate communication of dirty air from a conduit (such as hose 26 shown in FIG. 1A) to debris collection device 100. Air ingress 105 may communicate with hose 26 that is in fluid communication with a suction source (not shown) as generally known for delivering suction to a cleaning surface. Debris-laden air is delivered through the air ingress and tangentially impinges separator 200 (as further described herein). The debris is thereby subject to a dual-stage centrifugal separation, such that the particles separate from the air and accumulate in debris collection device 100, as further described herein.

Referring additionally to FIGS. 3, 3A and 3B, cyclonic separator 200 includes a cyclonic frustum 208 that exhibits a generally frustoconical wall 208a. Frustum wall 208a has an outer wall surface 208a′ for directing a preliminary centrifugal airflow thereabout. Frustum wall 208a also includes an inner wall surface 208a″ for directing an ultimate centrifugal airflow in a region 209 delineated by the inner wall surface. Frustum wall 208a tapers generally inwardly from a frustum extent 208b disposed adjacent a frustum extent opening 208c and toward an opposed frustum extent 208d disposed adjacent a frustum egress 208e. As shown herein, cyclonic frustum 208 further incorporates a cylindrical wall 208f depending upwardly from an interface 208g with frustum extent opening 208c and terminating in a cylindrical ingress 208h. Frustum wall 208a and cylindrical wall 208f together exhibit a collective frustum height H.

Cyclonic separator 200 also includes an airflow turret 212, the details of which are further shown in FIGS. 4 and 4A. Airflow turret 212 facilitates transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow (as further described herein). Airflow turret 212, which is provided in a region proximate cylindrical ingress 208h, includes two or more similarly configured and evenly spaced sails 214 that are circumferentially arranged relative to cylindrical ingress 208h. As presently shown herein, a preferred embodiment of airflow turret 212 incorporates five sails 214 to effect the transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow. It is contemplated that an alternative number of sails may be employed that accommodate the dual-stage separation of coarse and fine particles. When an alternative number of sails are utilized, each sail should incorporate the additional features presented herein and shown in further detail in FIGS. 4 and 4A.

Each sail 214 includes a guide surface 214a to guide incoming air from the preliminary centrifugal airflow toward cylindrical ingress 208h. Guide surface 214a of each sail 214 includes an impact surface 214a′ of predetermined concavity against which the incoming air strikes (for example, as shown by arrows I in FIG. 4A). Each guide surface 214a also includes a terminal restraining edge 214a″ for piloting the incoming air toward cylindrical ingress 208h. In an exemplary embodiment, each guide surface 214a exhibits a generally radial profile which is particularly suitable for accelerating the incoming air during the transition from the preliminary centrifugal airflow to the ultimate centrifugal airflow. In some embodiments, such a radial profile exhibits a radius of about 38°.

Each terminal restraining edge 214a″ includes a lead surface 214b that leads the incoming air (for example, in the direction of arrows I′ shown in FIG. 4) toward impact surface 214a′. In some embodiments, each lead surface 214b exhibits a radius of about 14°. A trail surface 214c opposed to lead surface 214b pilots the incoming air toward cylindrical ingress 208h (for example, in the direction of arrow II in FIG. 4) during the transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow. In some embodiments, each trail surface 214c exhibits a radius of about 14°. Lead surface 214b of terminal restraining edge 214a″ leads the incoming air that enters through an adjacent velocity slot 216 provided between adjacent sails 214. In a preferred embodiment, each velocity slot exhibits a cross-sectional area in a range from about 120 mm² to about 130 mm².

Each velocity slot 216 conveys the incoming air that is delivered along an entry ramp 218 of predetermined camber. In some embodiments, each entry ramp 218 exhibits a grade of about 48°. Each entry ramp 218 is configured to deliver the preliminary centrifugal airflow from a coarse debris collection area 300 (shown in FIGS. 2 and 5 and further described herein) toward cylindrical ingress 208h. In some embodiments, entry ramp 218 at least partially envelops an airflow conduit through which the incoming airflow traverses for delivery to airflow turret 212 via velocity slot 216. In some embodiments, the airflow conduit provides an airflow path through a turret seating flange 225 having an upper turret seat 225a and a lower turret seat 225b (see FIG. 3A).

Referring again to FIGS. 2, 3, 3A and 3B, a cyclonic sieve 228 incorporated in cyclonic separator 200 is slidingly positioned relative to outer frustum wall surface 208a′ so that a sieve wall 228a coextensive with a turret extent 228b is placed adjacent airflow turret 212. A sieve seating flange 230 having an upper sieve seat 230a and a lower sieve seat 230b may be provided at or near turret extent 228b such that cyclonic sieve 228 is positionable relative to cyclonic frustum 208 with upper sieve seat 230a disposed adjacent lower turret seat 225b.

At least a portion of sieve wall 228a is a continuous portion 228a′ (i.e., having no apertures therein) for directing the preliminary centrifugal airflow about frustum wall 208a and depositing debris into coarse debris collection area 300. When sieve wall 228a is positioned in debris collection device 100, continuous portion 228a′ is disposed relative to air ingress 105 such that dirty air entering the debris collection device tangentially impinges the continuous portion of the sieve wall. This striking trajectory initiates the preliminary centrifugal airflow along outer frustum wall 208a that carries unseparated debris and air and deposits debris in coarse debris collection area 300.

Sieve wall 228a includes an opposed debris restriction extent 228d at which a debris restriction flange 233 is electively provided to deflect debris in the preliminary centrifugal airflow into course debris collection area 300. Debris restriction flange 233 may be integral with frustum wall 208a or sieve wall 228a and have a flange lip 233a that helps to deflect debris into course debris collection area 300. Flange lip 233a may be rounded along a periphery thereof to guide debris into course debris collection area 300 after impingement against continuous portion 228a′ of sieve wall 228a. Debris that remains unseparated from the preliminary centrifugal airflow strikes a deflection surface 233b of debris restriction flange 233 for deflection into coarse debris collection area 300. A predetermined clearance 235 between flange lip 233a and inner canister wall surface 106c″ (see FIG. 2) inhibits delivery of residual coarse particulates from coarse debris collection area 300 while permitting unimpeded airflow toward sieve 228.

A remaining louvered portion 228a′ of sieve wall 228a incorporates a plurality of apertures 240 for delivering airflow to toward airflow turret 212. Each aperture 240 includes a rounded upstream edge 240a and a rounded downstream edge 240b past which the preliminary centrifugal airflow is generally directed toward each airflow entrance 216. In some embodiments, sieve wall 228a exhibits a generally frustoconical geometry along which apertures 240 are provided in a predetermined pattern along louvered portion 228a″. In an exemplary embodiment as shown in FIG. 3, multiple sets of apertures 240 are provided in which each set comprises a pair of aperture rows having equal numbers of apertures 240. One or more apertures 241 may be provided at a predetermined inclination (see FIG. 3) as determined to effectively transition the preliminary centrifugal airflow to the ultimate centrifugal airflow.

In some embodiments, locking structure is provided along or near debris restriction extent 228d for engagement with corresponding locking structure presented along frustum wall 208a, such locking structure may include one or more locking teeth (not shown) provided as diametrically opposed members that engage at least a portion of a securement flange 245 provided around at least a portion of frustum outer wall 208a′. In such embodiments, a gap may remain when cyclonic sieve 228 and cyclonic frustum 208 are in locking engagement that permits an additional opportunity for the deposit of debris into coarse debris collection area 300 prior to transition to the secondary centrifugal airflow.

Cyclonic separator 200 additionally includes a debris collection cup 250 that collects debris remaining after the preliminary and ultimate centrifugal airflows. Debris collection cup 250 includes a generally frustoconical or annular cup wall 250a having an outer wall surface 250a′ that, together with debris collection device 100 and outer frustum wall surface 208a′, provides coarse debris collection area 300 within which debris is deposited by the preliminary centrifugal airflow. Debris collection cup wall 250a also includes an inner wall surface 250a″ within which debris is deposited by the ultimate centrifugal airflow in a fine debris collection area 350.

A frustum extent 250a of debris collection cup wall 250a has an aperture 252 that accommodates removable insertion of at least a portion of opposed frustum extent 208d therein. As shown in FIG. 3B, opposed frustum extent 208d depends inwardly into debris collection cup 250 such that frustum egress 208e is enveloped by inner cup wall surface 250a″. An optional sifter 255 may be disposed a predetermined distance from frustum egress 208e so as to direct the ultimate centrifugal airflow (and any fine debris therein) from region 209 directly into fine debris collection area 350. Sifter 255 is depicted as a generally frustoconical element having an axis generally coincident with the longitudinal axes of cyclone frustum 208 and debris collection cup 250 to ensure that the ultimate centrifugal airflow deposits debris directly within fine debris collection area 350. It is contemplated that sifter 255 may incorporate various other geometries that facilitate deposit of captured particulates to fine debris collection area 350. An optional gasket 259 may be provided at or near a support extent 250c of debris collection cup 250 for sealing fine debris collection area 350 until release of accumulated debris therefrom.

Securement structure may be selectively provided on at least one or both of debris collection cup 250 and cyclonic frustum 208 to preserve both portions of the centrifugal airflow during operation of cleaning apparatus 10. Such securement structure may include diametrically opposed locking slots (not shown) disposed at or near aperture 252 of debris cup wall 250a. Such locking slots engage corresponding locking tabs 265 disposed at or near frustum egress 208e at a predetermined distance above optional sifter 255. A circumferential seating flange 267 may be provided at or near locking tabs 265 that engages a complementary frustum seat 269 provided at a periphery of aperture 252. When seating flange 267 is positioned adjacent frustum seat 267, locking tabs 265 may contact a locking guide groove in debris collection cup 250 that guides locking tabs 265 into engagement with the corresponding locking slots. Additional indicia, including but not limited to visual indicia (e.g., arrows 275 in FIG. 3A) may be provided to indicate the proper alignment of cyclonic frustum 208 and debris collection cup 250.

Debris collection device 100 includes a platform that supports debris collection cup 250 and provides at least a partial boundary for each of coarse debris collection area 300 and fine debris collection area 350. Such a platform can help control the collective release of debris from both collection areas through a collective release outlet 375 at open canister extent 106b. An exemplary platform may be a flapper 380 rotatably coupled with debris collection canister 208 (see FIG. 2). An exemplary embodiment of debris collection device 100 and a flapper used therewith to control the release of debris through a collective debris release outlet is shown and described in co-owned and co-pending U.S. Ser. No. ______, entitled DEBRIS COLLECTION DEVICE FOR BAGLESS VACUUM CLEANERS, the entire disclosure of which is incorporated by reference herein.

Cyclonic separator 200 includes an airflow outlet 400 configured to deliver air from debris collection device 100 after depositing debris in fine debris collection area 350. Airflow outlet 400 may be provided as a duct or conduit in a support member 402 that is disposed adjacent upper turret seat 230a. Support member 402 is configured to direct outgoing air from cyclonic separator 200 and includes one or more optional gaskets 404, 406 positioned in sealing relationship therewith. Support member 402 may incorporate a finger grip 403 (see FIG. 3) or similar structure to facilitate removal of the support structure by a user (for example, to remove and clean cyclonic separator 200). Support member 402 may optionally support a filter 410 thereon that is housed intermediate canister 106 and debris collection cup cover 107. Air that has travelled through canister 106 and has deposited debris in course debris collection area 300 and fine debris collection area 350 can also be subject to additional filtering by filter 410. The resulting clean and filtered airflow departs debris collection device 100 through an airflow egress 412 (see FIGS. 6 and 7) provided in cover 107, which cover may include an optional bleed valve 415 as known in the art.

During operation of cleaning device 10, cyclonic separator 200 is housed in debris collection device 100 that is supported within main body 12. Upon actuation of cleaning apparatus 10, a suction source inhales a combination of air and debris (“dirty air”) into an intake conduit (not shown) for delivery through air ingress 105. Referring to FIG. 5, dirty air departing the lumen of air ingress 105 tangentially impinges continuous portion 228a′ of sieve wall (see arrow A of FIG. 5), thereby forcing the air downward along a generally centrifugal path about outer frustum wall surface 208a′ (see arrows B in FIG. 5). During this preliminary centrifugal airflow, air speed increases with the tapering of frustum wall 208a. Coarse particulates and debris that lose momentum toward opposed frustum extent 208d are deposited into coarse debris collection area 300 (see arrows C in FIG. 5). Deposit of debris is at least partially assisted by flange lip 233a. With the continuing preliminary centrifugal airflow, the once-separated air is directed toward cyclonic sieve 228 (see arrow D in FIG. 5). Debris in the continuing airflow that has not been deposited in coarse debris collection area 300 strikes deflection surface 233b of debris restriction flange 233 for deflection back into coarse debris collection area 300.

Separated air thereafter traverses clearance 235 for delivery through apertures 240 of louvered portion 228a″ (see arrow E of FIG. 5). This continuing preliminary centrifugal airflow traverses rounded edges 240a, 240b of apertures 240 toward entry ramps 218 of airflow turret 212. Each entry ramp 218 has a predetermined camber that ensures unimpeded delivery of incoming airflow through corresponding velocity slots 216 disposed between adjacent sails 214. As shown in the exemplary embodiment herein, incoming air is delivered through five separate entrances 216 and undergoes a transition to the ultimate centrifugal airflow upon striking impact surface 214a′ of each sail. As delivery of incoming air continues through velocity slots 216, terminal restraining edges 214a″, including lead surfaces 214b, continue to lead the incoming air toward impact surfaces 214a′.

Lead surfaces 214b guide the incoming air that enters through an adjacent velocity slot 216 toward cylindrical ingress 208h. The ultimate centrifugal airflow is piloted from cylindrical ingress 208h in region 209 along inner frustum wall surface 208a″. The ultimate centrifugal airflow is generally a vortex that rotates through region 209 and thereby accelerates any residual debris for delivery through frustum egress 208e and eventual deposit in fine debris collection area 350. Thus, debris that is not deposited in coarse debris collection area 300 by the preliminary centrifugation airflow is deposited by the ultimate centrifugal airflow into fine debris collection area 350 through the frustum egress.

As the ultimate centrifugal airflow continues to accelerate along inner frustum wall surface 208a″ (see arrow F of FIG. 5), the airflow impacts a shelf (e.g., sifter 255 or any comparable or equivalent structure) and travels along a return path through region 209 toward cylindrical ingress 208h (see arrow G of FIG. 5). Air departs separator 200 through airflow outlet 400 of support member 402 for eventual delivery through optional filter 410 and expulsion of twice-separated and filtered air through air egress 412. In some embodiments, a baffle (not shown) may be incorporated in the airflow outlet to aid the reduction of air speed and rotation as the ultimate centrifugal airflow expires.

When disposal of the accumulated debris within debris collection device 100 is needed, a user may execute an operation by which at least a portion of the accumulated debris is released through collective debris release outlet 375. Referring to FIG. 6, such an operation is depicted with respect to some embodiments, in which a user lifts a pull lever body 500 in the direction of arrow III. Actuation of pull lever body 500 places flapper 380 in an articulation state, the initiation of which results in at least the partial release of accumulated debris 600 from coarse debris collection area 300 and fine debris collection area 350. Referring to FIG. 7, further actuation of pull lever body 500 articulates flapper 380 into a release state in which all or almost all of accumulated debris 600 is released through collective debris release outlet 375. Lowering of pull lever body 500 in the direction of arrow III′ will correspondingly return flapper 380 to a stationary state whereby the flapper obstructs collective debris release outlet 375. Upon disposal of debris 600, cyclonic separator 200 is easily removed from canister 106 and cleaned as needed without the need for the user to contact either the flapper or the debris.

One or more of cyclonic frustum 208, cyclonic sieve 228 and debris collection cup 250 may be fabricated from materials that are amenable to repeated use and also to related assembly and disassembly. Such materials should also be amenable to being held and cleaned by users. Such materials may be selected from a variety of materials, including but not limited to plastics and composites that are well known for use in temporally and fiscally efficient manufacturing processes

As used herein, a “user” or an “operator” may be a single user or operator or multiple users and operators (for example, multiple users within a shared residence or multiple members of a cleaning service sharing use of one or more devices incorporating the presently disclosed invention). As used herein, the term “process” or “method” may include one or more steps performed at least by one user or operator. Any sequence of steps is exemplary and is not intended to limit methods described herein to any particular sequence, nor is it intended to preclude adding steps, omitting steps, repeating steps, or performing steps simultaneously.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value as well as equivalent units of that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm” as well as “1.58 inches”. The disclosure of such dimensions and values, however, shall not preclude use of any of disclosed devices having dimensions and values outside of the prescribed ranges.

Every document cited herein, including any cross-referenced or related patent or application is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While the presently disclosed invention has been described in a preferred form, it will be understood that changes, additions, and modifications may be made to the respective articles forming the invention. Accordingly, no limitation should be imposed on the scope of this invention, except as set forth in the accompanying claims.

Claims

1. A dual-stage cyclonic separator for separating debris from air in a bagless surface cleaning apparatus, comprising:

a cyclonic frustum comprising: a frustum wall having an outer frustum wall for directing a preliminary centrifugal airflow thereabout and an inner frustum wall for directing a ultimate centrifugal airflow therein, with the frustum wall tapering generally inwardly from a frustum extent disposed adjacent a frustum extent opening toward an opposed frustum extent disposed adjacent a frustum egress; a cylindrical wall depending upwardly from an interface with the frustum extent opening and terminating in a cylindrical ingress; and an airflow turret provided at the cylindrical ingress that facilitates transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow;

a debris collection cup comprising: a cup wall having an outer cup wall that, together with a debris collection device and the outer frustum wall, provides a coarse debris collection area within which debris is deposited by the preliminary centrifugal airflow, and an inner cup wall that provides a fine debris collection area within which debris is deposited by the ultimate centrifugal airflow, with at least a portion of the opposed frustum extent depending inwardly into the debris collection cup such that the ultimate centrifugal airflow deposits debris directly within the fine debris collection area;

a cyclonic sieve having a sieve wall coextensive with a turret extent for placement adjacent the airflow turret and an opposed debris restriction extent, with the sieve wall having a continuous portion for directing the preliminary centrifugal airflow about the frustum wall and a louvered portion for delivering airflow to the airflow turret, and with the louvered portion including a plurality of apertures; and

an airflow outlet configured to deliver air from the debris collection device after depositing debris in the fine debris collection area.

2. The cyclonic separator of claim 1, wherein the airflow turret comprises at least two similarly configured and evenly spaced sails that are circumferentially arranged relative to the cylindrical ingress, with each sail having a guide surface to guide incoming air from the preliminary centrifugal airflow toward the cylindrical ingress.

3. The cyclonic separator of claim 2, wherein the airflow turret comprises five sails and the guide surface of each sail exhibits a generally radial profile that includes an impact surface of predetermined concavity against which the incoming air strikes and a terminal restraining edge for piloting the incoming air toward the cylindrical ingress.

4. The cyclonic separator of claim 3, wherein the terminal restraining edge includes a lead surface that leads the incoming air toward the impact surface, and a trail surface that pilots the incoming air toward the cylindrical ingress during the transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow.

5. The cyclonic separator of claim 4, wherein the lead surface of the terminal restraining edge leads the incoming air that enters through an adjacent velocity slot provided between adjacent sails, with the velocity slot including an entry ramp of predetermined camber configured to deliver the preliminary centrifugal airflow from the coarse debris collection area toward the cylindrical ingress.

6. The cyclonic separator of claim 5, wherein the airflow turret includes a turret seating flange having an upper turret seat and a lower turret seat, and the cyclonic sieve includes a sieve seating flange having an upper sieve seat and a lower sieve seat, with the cyclonic sieve positioned relative to the cyclonic frustum such that the upper sieve seat is disposed adjacent the lower turret seat.

7. The cyclonic separator of claim 5, wherein the sieve wall is positioned relative to the debris collection device such that dirty air that enters the debris collection device tangentially impinges the continuous portion of the sieve wall.

8. The cyclonic separator of claim 7, wherein:

each guide surface exhibit s a radius of about 38°;

each lead surface exhibits a radius of about 14°;

each trail surface exhibits a radius of about 14°;

each velocity slot exhibits a cross-sectional area in a range from about 120 mm2 to about 130 mm2; and

each entry ramp exhibits a grade of about 48°.

9. The cyclonic separator of claim 8, wherein at east one of the apertures in the louvered portion of the sieve wall has at least one of a rounded upstream edge and a rounded downstream edge past which the preliminary centrifugal airflow is delivered to the velocity slot.

10. The cyclonic separator of claim 9, wherein the sieve wall exhibits a generally frustoconical geometry and the apertures are provided in a predetermined pattern along the louvered portion thereof.

11. The cyclonic separator of claim 8, wherein debris that is not deposited in the coarse debris collection area by the preliminary centrifugation airflow is deposited by the ultimate centrifugal airflow into the fine debris collection area through the frustum egress.

12. The cyclonic separator of claim 11, wherein an optional sifter is disposed near the frustum egress and configured to direct debris that is deposited from the frustum through the frustum egress into the fine debris collection area.

13. The cyclonic separator of claim 8, wherein the airflow outlet is provided in a support member that is disposed adjacent the upper turret seat and configured to direct outgoing air from the cyclonic separator.

14. The cyclonic separator of claim 8, further comprising a debris restriction flange provided adjacent the debris restriction extent of the cyclonic sieve and configured to deflect debris in the preliminary centrifugal airflow into the course debris collection area.

15. A bagless surface cleaning apparatus, comprising:

a base suction unit;

an apparatus handle; and

a main body provided intermediate the base suction unit and the apparatus handle and operably supporting a debris collection device thereby; and

the cyclonic separation system of claim 1 with the sieve wall positioned relative to the debris collection device such that dirty air that enters the debris collection device tangentially impinges the continuous portion of the sieve wall.

16. The bagless surface cleaning apparatus of claim 15, wherein at least two similarly configured and evenly spaced sails are provided in the turret, with each sail comprising:

a guide surface to guide incoming air from the preliminary centrifugal airflow toward the cylindrical ingress, with the guide surface of each sail including an impact surface of predetermined concavity against which the incoming air strikes and a terminal restraining edge for piloting the incoming air toward the cylindrical ingress, and with the terminal restraining edge including a lead surface that leads the incoming air toward the impact surface, and a trail surface that pilots the incoming air toward the cylindrical ingress during the transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow.

17. The bagless surface cleaning apparatus of claim 16, wherein the lead surface of the terminal restraining edge leads the incoming air that enters through an adjacent velocity slot provided between adjacent sails, with the velocity slot including an entry ramp of predetermined camber configured to deliver the preliminary centrifugal airflow from the coarse debris collection area toward the cylindrical ingress.

18. A debris collection device used with a bagless surface cleaning apparatus to separate debris from air, comprising:

a debris collection canister;

a debris collection cover coupled with the debris collection canister;

a centrifugal separation system according to claim 1

19. The debris collection device of claim 18, further comprising at least one of:

a handle formed on at least one of the debris collection canister and the debris collection cover, with the handle configured to be grasped by a user for removal of the debris collection device from, and replacement of the debris collection device in, the cleaning apparatus and for carrying the debris collection device upon removal from the cleaning apparatus;

an actuatable flapper provided at or adjacent a collective debris release outlet from which accumulated debris is released from the course debris collection area and the fine debris collection area; and

a controlled tension apparatus that controls an angular range of movement of the flapper for controllable release of accumulated debris from the collective debris release outlet.

20. A method of separating debris from air using a bagless surface cleaning apparatus, comprising:

providing the cyclonic separator of claim 1 in a debris collection device operably mounted in the cleaning apparatus;

positioning the cyclonic separator so that dirty air that enters the debris collection device tangentially impinges the continuous portion of the sieve wall;

positioning the cyclonic sieve so that the preliminary centrifugal airflow traverses the louvered portion of the sieve wall toward the cylindrical ingress during the transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow; and

configuring the airflow outlet to direct separated air from the cyclonic separator.