Cyclonic separator

Abstract

In one aspect, a cyclonic separator including a body at least partially defining a cleaning chamber having a first cleaning chamber diameter, where the body defines a body axis, an air inlet open to the cleaning chamber, an air outlet open to the cleaning chamber, and a debris outlet open to the cleaning chamber, where the debris outlet defines an average radial width, and wherein the ratio of the cleaning chamber diameter to the average radial width is between 12.5:1 and 6.7:1.

Description

RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 780,153, filed on Mar. 28, 2025 and Provisional Application No. 63 / 782,367, filed on Apr. 2, 2025. The entire contents of both is hereby incorporated by reference.FIELD

[0002] The present disclosure relates generally to cyclonic separators, and more specifically to cyclonic separators having improved ingestion rates.BACKGROUND

[0003] Cyclonic separators generally include a debris outlet opening through which dust and debris may be ejected into a dust container.SUMMARY

[0004] In one aspect, a cyclonic separator including a body at least partially defining a cleaning chamber having a first cleaning chamber diameter, where the body defines a body axis, an air inlet open to the cleaning chamber, an air outlet open to the cleaning chamber, and a debris outlet open to the cleaning chamber, where the debris outlet defines an average radial width, and wherein the ratio of the cleaning chamber diameter to the average radial width is between 12.5:1 and 6.7:1.

[0005] Alternatively or additionally, in any combination where the ratio of the cleaning chamber diameter to the average radial width is between 12.5:1 and 7:1.

[0006] Alternatively or additionally, in any combination where the ratio of the cleaning chamber diameter to the average radial width is 9:1.

[0007] Alternatively or additionally, in any combination where the debris outlet includes a first end portion, a second end portion, and an intermediate portion extending between the first end portion and the second end portion, and where the intermediate portion has a constant radial width.

[0008] Alternatively or additionally, in any combination where the intermediate portion extends circumferentially about the body axis for between 90 and 270 degrees.

[0009] Alternatively or additionally, in any combination where the intermediate portion extends circumferentially about the body axis for 180 degrees.

[0010] Alternatively or additionally, in any combination where the air inlet defines an angular zone with respect to the body axis, where the debris outlet includes a leading end, and where the leading end is positioned within the angular zone.

[0011] Alternatively or additionally, in any combination where the debris outlet extends between 90 degrees and 270 degrees circumferentially about the body axis.

[0012] Alternatively or additionally, in any combination where the body includes a perimeter wall extending circumferentially about the body axis, where the perimeter wall includes a first end, where the body includes a base plate enclosing at least a portion of the first end, and where the base plate at least partially defines the debris outlet.

[0013] Alternatively or additionally, in any combination where the debris outlet is a first debris outlet, and where the cyclonic separator further includes a second debris outlet.

[0014] Alternatively or additionally, in any combination where the second debris outlet has a leading end and a trailing end, where the second debris outlet defines a second outlet width at each point along its circumferential length, and where the second outlet width continuously increases as the second debris outlet extends from the leading end to the trailing end.

[0015] Alternatively or additionally, in any combination where the second outlet width is less than the average radial width of the first debris outlet at the leading end, and where the second outlet width is greater than the average radial width of the first debris outlet at the trailing end.

[0016] In another aspect, a cyclonic separator including a body at least partially defining a cleaning chamber having a first cleaning chamber diameter, where the body defines a body axis, an air inlet open to the cleaning chamber, an air outlet open to the cleaning chamber, and a debris outlet open to the cleaning chamber, where the debris outlet includes a first end portion, a second end portion, and an intermediate portion extending between the first end portion and the second end portion, where the radial width of the intermediate portion is between 5% to 15% of the first cleaning chamber diameter.

[0017] Alternatively or additionally, in any combination where the intermediate portion extends circumferentially about the body axis for between 45 degrees and 350 degrees.

[0018] Alternatively or additionally, in any combination where the intermediate portion extends circumferentially about the body axis for between 90 degrees and 350 degrees.

[0019] Alternatively or additionally, in any combination where the intermediate portion extends circumferentially about the body axis for between 150 degrees and 200 degrees.

[0020] Alternatively or additionally, in any combination where the radial width of the intermediate portion is between 8% to 14% of the first cleaning chamber diameter at all points.

[0021] Alternatively or additionally, in any combination where the radial width of the intermediate portion is constant.

[0022] Alternatively or additionally, in any combination where the debris outlet is a first debris outlet, the cyclonic separator further including a second debris outlet.

[0023] In another aspect, a cyclonic separator including a body at least partially defining a cleaning chamber, where the body defines a body axis, an air inlet open to the cleaning chamber, where the air inlet defines a first angular zone with respect to the body axis, an air outlet open to the cleaning chamber, and a debris outlet open to the cleaning chamber, where the debris outlet includes a leading end and a trailing edge, and where the leading end is positioned within the first angular zone.

[0024] Alternatively or additionally, in any combination where the debris outlet extends circumferentially about the body axis for 180 degrees.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is a schematic view of a vacuum assembly with a pre-separator incorporated therein.

[0026] FIG. 2 is a top perspective view of the pre-separator of FIG. 1.

[0027] FIG. 3 is a bottom perspective view of the pre-separator of FIG. 1.

[0028] FIG. 4 is a bottom view of the pre-separator of FIG. 1.

[0029] FIG. 5 is a detailed bottom view of the cyclonic separator of the pre-separator of FIG. 1.

[0030] FIG. 6 is a section view taken along line 6—6 of FIG. 3.

[0031] FIG. 7 is a section view taken along line 7—7 of FIG. 4.

[0032] FIG. 8 is a section view taken along line 8—8 of FIG. 4.DETAILED DESCRIPTION

[0033] Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,”“comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,”“connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include hydraulic or electrical connections or couplings, whether direct or indirect.

[0034] FIGS. 1-8 illustrate a cyclonic separator 1000 for use in a vacuum assembly 14. More specifically, the cyclonic separator 1000 is configured to be integrated into the operational flow path of the vacuum assembly 14 such that operation of the vacuum assembly 14 causes untreated air to enter the cyclonic separator 1000 where cyclonic action separates the dust and debris from the air flow to be deposited in a collection volume 26 of a collection container 22. The treated air may then exit the separator 1000 and continue through the vacuum assembly 14.

[0035] In the illustrated embodiment, the cyclonic separator 1000 is incorporated into a preseparator 10 that, in turn, is configured to be incorporated into the airflow path of the preexisting vacuum assembly 14 without the need for any dedicated hoses or external connections (see FIG. 1). More specifically, the pre-separator 10 may be installed (e.g., stacked) between the power head 18 and the collection container 22 of the vacuum assembly 14 such that the untreated air being drawn in by the power head 18 must first pass through and be processed by the preseparator 10 (e.g., via the cyclonic separator 1000) before passing through the filter 140 of the power head 18 and being exhausted back out into the atmosphere.

[0036] While the illustrated cyclonic separator 1000 is shown incorporated into the preseparator device 10, it is understood in other embodiments the cyclonic separator 1000 may be incorporated into other elements of a vacuum system 14 such as, but not limited to, the power head 18, the collection container 22, and the like. In such embodiments, the cyclonic separator 1000 may be installed in place of a traditional filter 140 or used to supplement a traditional filter 140. In still other embodiments, the cyclonic separator 1000 may be incorporated into other vacuum or air handling assemblies.

[0037] The vacuum assembly 14 of FIG. 4 is a form of wet / dry vacuum assembly including a collection vessel or container 22 defining a collection volume 26 therein, and a power head 18 couplable to the collection container 22.

[0038] The container 22 of the vacuum assembly 14 includes a body 30 at least partially defining the collection volume 26 therein. The body 30 includes a base wall 34, and a plurality of side walls 38 extending from the periphery of the base wall 34 to define an open end 42 opposite thereof. The resulting open end 42 provides access to the collection volume 26.

[0039] As shown in FIG. 1, the power head 18 of the vacuum assembly 14 includes a housing 82 at least partially defining a power head volume 86, a blower assembly 90 at least partially positioned within the power head volume 86, an inlet passage 94 open to the exterior of the housing 82, an outlet passage 100 open to the exterior of the housing 82, and a filter assembly 104.

[0040] The housing 82 of the power head 18 includes a series of walls positioned to at least partially enclose the power head volume 86 therein. More specifically, the housing 82 includes a bottom or base wall 108a, one or more side walls 108b extending from the base wall 108a, and a top wall 108c enclosing the side walls 108b opposite the base wall 108a. In some embodiments, the housing 82 may also forms one or more battery ports (not shown) into which rechargeable batteries may be inserted to power the blower assembly 90.

[0041] The inlet passage 94 of the power head 18 includes a fluid passage or channel configured to receive untreated air from a hose or other vacuum accessory and convey the untreated air to one of the container volume 26 and / or the pre-separator device 10. More specifically, the inlet passage 94 includes a first end 120 that is open to the exterior of the housing 82 to serve as a mounting point to which a hose or other vacuum accessory (not shown) may be releasably attached during use. The inlet passage 94 also includes second end 124 opposite the first end 120 that extends downwardly away from the base wall 108.

[0042] The outlet passage 100 of the power head 18 includes a fluid passageway configured to convey the exhausted air from the blower assembly 90 to the outside of the housing 82. More specifically, the outlet passage 100 includes a first end 132 open to the exterior of the housing 82 to serve as a mounting point for a hose or other vacuum accessory (e.g., for use when the vacuum is in a blower mode). While the illustrated outlet passage 100 is sized and shaped to connect with a hose or tube, it is understood that in other embodiments a filter or grate may be incorporated into the outlet passage 100 to minimize noise or external access to the passage 100.

[0043] The filter assembly 104 of the power head 18 includes a filter mounting point 136 formed into the base wall 108a to which a filter 140 may be releasably attached. When a filter 140 is attached to the mounting point 136, the filter 140 itself extends downwardly away from the base wall 108a of the housing 82.

[0044] The blower assembly 90 of the power head 18 includes a blower or fan configured to generate an airflow within the vacuum assembly 14. More specifically, the blower assembly 90 includes a blower inlet 92 that is in fluid communication with and draws air through the filter 140, and a blower outlet 96 that is open and exhausts air to the exterior of the housing 82 via the outlet passage 100. During operation, the blower assembly 90 is intended to draw power from a power source (e.g., rechargeable batteries and / or an outlet source).

[0045] As shown in FIGS. 2-4, the pre-separator 10 is configured to serve as an accessory for use with a pre-existing vacuum assembly 14 providing improved dirt and debris separating capabilities and extended intake filter 140 life. More specifically, the pre-separator 10 is intended to provide supplemental dust and debris separation capabilities using the cyclonic separator 1000 before the air reaches the filter 140 of the power head 18. By doing so, the load placed on the filter 140 is greatly reduced as the amount of dust and debris that actually reaches the filter 140 is reduced significantly.

[0046] The illustrated pre-separator 10 includes a housing 160 defining a pre-separator volume 164, a cyclonic separator 1000 at least partially positioned within the pre-separator volume 164, a filter casing 144 at least partially positioned within the pre-separator volume 164, a feed passageway 176 to convey air into the cyclonic separator 1000, and an intermediate passageway 180 to convey air from the cyclonic separator 1000 to the filter casing 144.

[0047] As shown in FIGS. 1, and 5-8 the cyclonic separator 1000 is configured to remove dust and debris from untreated air flowing therethrough. The cyclonic separator 1000 includes a body 1004 at least partially defining a cleaning chamber 1008 therein, an air inlet 1012, an air outlet 1016, and a debris outlet 1020. During operation, the cyclonic separator 1000 is configured to provide a high separation efficiency when the associated vacuum assembly 14 is operating in a high-ingestion rate condition. For example, the cyclonic separator 1000 is capable of greater than or equal to 90% separation efficiency when experiencing an ingestion rate of approximately 70 g / s. In other examples, the separator 1000 is capable of greater than or equal to 93% separation efficiency when experiencing an ingestion rate of approximately 70 g / s.

[0048] The body 1004 of the cyclonic separator 1000 defines a body axis 1028 and includes a series of walls or barriers that enclose the cleaning chamber 1008 therein. During operation, the size and shape of the body 1004 is generally configured so that untreated air introduced into the cleaning chamber 1008 (e.g., via the air inlet 1012) forms a cyclonic flow path or vortex therein. In some embodiments, the body 1004 is shaped so that the cyclonic flow path circulates about the body axis 1028. In the illustrated embodiment, the body 1004 is substantially cylindrical in shape enclosing a substantially toroidal cleaning chamber 1008 therein. However, in other embodiments, both the body 1004 and chamber 1008 may be cylindrical. In still other embodiments, different sizes and shapes of the body 1004 and cleaning chamber 1008 may be present. For example, in some embodiments the body 1004 and / or cleaning chamber 1008 may form an elliptical prism, an ovoidal prism, a polygonal prism, a shape of revolution (e.g., about the axis 1028), and the like.

[0049] As shown in FIG. 7, the illustrated body 1004 of the cyclonic separator 1000 includes a perimeter wall or barrier 1032 having a first or top end 1036 and a second or bottom end 1040 spaced axially from the first end 1036. The illustrated body 1004 also has a first end barrier 1044 at least partially enclosing the first end 1036 of the perimeter wall 1032, and a second end barrier or plate 1048 at least partially enclosing the second end 1040 of the perimeter wall 1032. Together, the perimeter wall 1032, the first end barrier 1044, and the plate 1048 define the cleaning chamber 1008. In some embodiments, the body 1004 of the cyclonic separator 1000 is mounted within the pre-separator 10 so that the body axis 1028 is in a substantially vertical orientation with the second end 1040 positioned vertically below the first end 1036.

[0050] The perimeter wall 1032 of the body 1004 extends circumferentially about the body axis 1028 forming an inner surface 1052 facing the cleaning chamber 1008 to define a first or cleaning chamber diameter 1056. In the illustrated embodiment, the perimeter wall 1032 is annular in shape such that the inner surface 1052 maintains a constant radial distance from the body axis 1028 along its entire circumferential length (see FIG. 6). In other embodiments, the inner surface 1052 may be elliptical, ovoidal, polygonal and / or other shapes where the radial distance between the inner surface 1052 and the axis 1028 varies as the perimeter wall 1032 extends circumferentially about the axis 1028. In some embodiments, the perimeter wall 1032 completely surrounds the body axis 1028.

[0051] In some embodiments, the first chamber diameter 1056 is approximately 180mm (±1%, ±2%, ±3%, ±5%, ±10%, ±15%). In other embodiments, the first chamber diameter 1056 is between 100mm and 200mm. In still other embodiments, the first chamber diameter 1056 is between 115mm and 200mm. In still other embodiments, the first chamber diameter 1056 is between 115mm and 180mm. In still other embodiments, the first chamber diameter 1056 is between 170mm and 190mm.

[0052] As shown in FIG. 7, the first end barrier 1044 of the body 1004 encloses the first end 1036 of the perimeter wall 1032 being integrally formed together therewith. In the illustrated embodiment, the first end barrier 1044 is substantially planar forming a disk-like structure oriented normal to the body axis 1028. In other embodiments, the first end barrier 1044 may include different shapes and / or contours to help guide the flow of air within the cleaning chamber 1008 during use. Furthermore, while the illustrated first end barrier 1044 is shown being formed integrally with the perimeter wall 1032, it is understood that in other embodiments the first end barrier 1044 may be formed separately from the perimeter wall 1032.

[0053] The first end barrier 1044 also includes an inlet extension 1058 extending axially from the first end barrier 1044 and into the cleaning chamber 1008 to define a distal end 1060. The distal end 1060, in turn, is open to form the air outlet 1016. In some embodiments, the inlet extension 148 is cylindrical in shape and oriented co-axial with the axis 1028. However, in other embodiments different sizes and shapes of extension 1058 may be present. As shown in FIG. 7, the inlet extension 1058 only extends a portion of the axial height of the chamber 1008 so that the distal end 1060 (e.g., the air outlet 1016) is positioned just above the plate 1048 with a gap formed therebetween. In still other embodiments, no inlet extension 1058 may be present. In such an embodiment, the air outlet 1016 may be formed into the first end barrier 1044 itself.

[0054] The second end barrier or base plate 1048 encloses the second end 1040 of the perimeter wall 1032. In the illustrated embodiment, the plate 1048 is substantially planar forming a disklike structure that is oriented normal to the body axis 1028. However, in other embodiments the second end barrier 1048 may incorporate different shapes and / or contours therein to help guide the flow of air within the cleaning chamber 1008 during use.

[0055] As shown in FIG. 5, the plate 1048 is formed separately from the remainder of the body 1004 (e.g., the perimeter wall 1032 and first end barrier 1044) and is movable with respect thereto. In such embodiments, the plate 1048 is movable with respect to the remainder of the body 1004 between a first or closed position, in which the plate 1048 at least partially encloses the second end 1040, and a second or open position, in which the plate 1048 does not enclose the second end 1040 so that a user may access the cleaning chamber 1008.

[0056] In some embodiments, the plate 1048 includes a hinge element 1064 to form a pivoting joint with the remainder of the body 1004 and a latching element 1068 opposite the hinge element 1064 to form a releasable connection with the remainder of the body 1004. Together, the hinge element 1064 and latch 1068 allow the plate 1048 to be pivoted between the first and second positions and be retained in the first position during use. In the illustrated embodiment, the latch element 1068 includes an elastically deformable latch configured to releasably capture and retain a pawl formed into the perimeter wall 1032. However, in other embodiments different types of hinge element 1064 and latch element 1068 may be used.

[0057] The air inlet 1012 of the cyclonic separator 1000 is configured to receive untreated air from a collection source (e.g., a collection hose, a powered brush head, a vacuum accessory, a power head, and the like) and introduce the untreated air into the cleaning chamber 1008. As shown in FIG. 6, the illustrated air inlet 1012 is formed into the perimeter wall 1032 such that untreated air is introduced into the cleaning chamber 1008 in a first flow direction F1. In some embodiments, the first flow direction F1 is tangential to the body axis 1028 (e.g., along the inner surface 1052 of the perimeter wall 1032) and offset toward the first end 1036 (see FIG. 6).

[0058] The air inlet 102 also defines a first inlet angular zone 1076 with respect to the body axis 1028. The first inlet angular zone 1076 generally includes the angular region over which the inlet 1012 is positioned taken relative to the body axis 1028 (see FIG. 6). The air inlet 102 also defines a second or expanded inlet angular zone generally including the angular region over which the inlet 1012 is positioned with an added ±1 degree, ±2 degrees, ±3 degrees, ±5 degrees, ±10 degrees, ±15 degrees, or ±20 degrees on either side thereof. The air inlet also defines a third or downstream angular zone generally including the angular region over which the inlet 1012 is positioned with an added ±1 degree, ±2 degrees, ±3 degrees, ±5 degrees, ±10 degrees, ±15 degrees, or ±20 degrees on the downstream side thereof (e.g., in the first flow direction F1).

[0059] The air outlet 1016 of the cyclonic separator 1000 is configured to convey treated or cleaned air out of the cleaning chamber 1008. In some embodiments, the air outlet 1016 extends between and is open to both the cleaning chamber 1008 and a blower assembly 90 so that the treated air CA is ultimately drawn in by and then discharged outside the vacuum assembly by the blower 90. In the illustrated embodiment, the air outlet 1016 is formed into the inlet extension 1058 (described above). In other embodiments, the air outlet 1016 may be formed into other structures of the body such as, but not limited to, the first end barrier 1044, the plate 1048, and the like. In some embodiments, the air outlet 1016 is positioned proximate to or co-axial with the body axis 1028.

[0060] The debris outlets 1020 of the cyclone separator 1000 are configured to allow dust and debris that has been separated from the circulating air flow during operation to be expelled from the cleaning chamber 1008. In some embodiments, the debris outlets 1020 may further direct the expelled dust and debris into a collection chamber 26 (see FIG. 1). In some embodiments, the debris outlets 1020 include apertures formed into or at least partially defined by the plate 1048. In still other embodiments, the debris outlets 1020 include notches formed into the perimeter of the plate 1048 so that the outlet 1020 itself is defined by both the perimeter of the plate 1048 and the second end 1040 of the perimeter wall 1032 (see FIG. 7). In some embodiments, the aperture forming each debris outlet 1020 is located on a reference plane 1120 oriented normal to the body axis 1028.

[0061] As shown in FIG. 5, the illustrated cyclone separator 1000 includes a first or upstream debris outlet 1020a and a second or downstream debris outlet 1020b. Together, the two outlets 1020a, 1020b are positioned angularly and sized radially to maximize the volume of dust and debris that can pass therethrough during high-ingestion operation. While the illustrated separator 1000 includes two outlets 1020a, 1020b, it is understood that in other embodiments more or fewer debris outlets 1020 may be present.

[0062] The first or upstream debris outlet 1020a includes an aperture defined by the second end 1040 of the perimeter wall 1032 and the outer perimeter of the plate 1048 (see FIG. 7). The debris outlet 1020a includes a leading or upstream end 1088 and a trailing or downstream end 1090 taken relative to the direction of flow F1. While the exterior shape of the illustrated outlet 1020a is defined by both the perimeter wall 1032 and the plate 1048, it is understood that in other embodiments the outlet 1020a may be completely defined by the plate 1048. In some embodiments, the outlet 1020a is at least partially positioned on the reference plate 1120 oriented normal to the body axis 1028. In the illustrated embodiment, the outlet 1020a is completely positioned on the reference plane 1120.

[0063] In some embodiments, the leading end 1088 of the first debris outlet 1020a is positioned within the first inlet angular zone 1076 (see FIG. 5). In other embodiments, the leading end 1088 is positioned within the second inlet angular zone. In still other embodiments, the leading end 1088 is positioned within the third inlet angular zone.

[0064] The first debris outlet 1020a also defines a circumferential or angular length 1108 measured as the angular distance between the upstream end 1088 and the downstream end 1090. The angular length 1108 of the first debris outlet 1020a further defines a first outlet angular zone 1112 (see FIG. 5). In some embodiments, the first debris outlet 1020a has an angular length 1108 of approximately 180 degrees (±1 degree, ±2 degrees, ±3 degrees, ±5 degrees, ±10 degrees, ±15 degrees, ±20 degrees). In other embodiments, the first debris outlet 1020a has an angular length 1108 between 45 degrees and 350 degrees. In still other embodiments, the first debris outlet 1020a has an angular length 1108 between 90 and 270 degrees. In still other embodiments, the first outlet angular zone 1112 overlaps with the first inlet angular zone 1076 (see FIG. 5).

[0065] The first debris outlet 1020a also defines a radial width 1116 at each point along the circumferential length thereof. The radial width 1116 of the first debris outlet 1020a also defines an average radial width. In some embodiments, the ratio of the first chamber diameter 1056 to the average radial width of the first debris outlet 1020a is between 12.5:1 and 6.7:1. In other embodiments, the ratio of the first chamber diameter 1056 to the average radial width is between 12.5:1 and 7:1. In still other embodiments, the ratio of the first chamber diameter 1056 to the average radial width of the first debris outlet 1020a is approximately 9:1 (±1%, ±2%, ±3%, ±5%, ±10%, ±15%).

[0066] The first debris outlet 1020a also includes a first end portion or transition portion 1094 proximate the upstream end 1088, a second end portion or transition portion 1100 proximate the downstream end 1090, and an intermediate portion 1104 extending circumferentially between the first end portion 1094 and the second end portion 1100. In some embodiments, the first and second end portions 1094, 1100 generally include the radiused or otherwise tapered end regions of the outlet 1020a.

[0067] As shown in FIG. 5, the intermediate portion 1104 of the first debris outlet 1020a defines an angular circumferential length that is approximately 170 degrees (±1 degree, ±2 degrees, ±3 degrees, ±5 degrees, ±10 degrees, ±15 degrees, ±20 degrees). In other embodiments, the intermediate portion 1104 of the first debris outlet 1020a has an angular length between 45 degrees and 350 degrees. In still other embodiments, the intermediate portion 1104 of the first debris outlet 1020a has an angular length 1108 between 90 and 270 degrees. In still other embodiments, the intermediate portion 1104 of the first debris outlet 1020a has an angular length 1108 between 150 and 200 degrees.

[0068] In some embodiments, radial width 1116 of the intermediate portion 1104 of the first debris outlet 1020a is approximately 20mm (±1%, ±2%, ±3%, ±5%, ±10%, ±15%). In other embodiments, the ratio of the first chamber diameter 1056 to the radial width 1116 of the intermediate portion 1104 of the first debris outlet 1020a is between 12.5:1 and 6.7:1. In still other embodiments, the ratio of the first chamber diameter 1056 to the radial width 1116 of the intermediate portion 1104 is between 12.5:1 and 7:1. In still other embodiments, the ratio of the first chamber diameter 1056 to the radial width 1116 of the intermediate portion 1104 of the first debris outlet 1020a is approximately 9:1 (±1%, ±2%, ±3%, ±5%, ±10%, ±15%). In still other embodiments, the intermediate portion 1104 of the first debris outlet 1020a has a constant radial width 1116. In still other embodiments, the radial width 1116 of the intermediate portion 1104 is between 5% to 15% of the first chamber diameter 1056. In still other embodiments, the radial width 1116 of the intermediate portion 1104 is between 8% to 14% of the first chamber diameter 1056. In still other embodiments, the radial width 1116 of the intermediate portion 1104 is between 4.5% to 16% of the first chamber diameter 1056. In still other embodiments, the radial width 1116 of the intermediate portion 1104 is approximately 11% of the first chamber diameter 1056 (±1%, ±2%, ±3%, ±5%, ±10%, ±15%).

[0069] In still other embodiments, the radial width 1116 of at least 50% of the first debris outlet 1020a is greater than or equal to 8% of the first chamber diameter 1056. In still other embodiments, the radial width 1116 of at least 75% of the first debris outlet 1020a is greater than or equal to 8% of the first chamber diameter 1056. In still other embodiments, the radial width 1116 of at least 80% of the first debris outlet 1020a is greater than or equal to 8% of the first chamber diameter 1056. In still other embodiments, the radial width 1116 of at least 50% of the first debris outlet 1020a is between 8% to 14% of the first chamber diameter 1056. In still other embodiments, the radial width 1116 of at least 75% of the first debris outlet 1020a is between 8% to 14% of the first chamber diameter 1056. In still other embodiments, the radial width 1116 of at least 80% of the first debris outlet 1020a is between 8% to 14% of the first chamber diameter 1056.

[0070] The second or downstream debris outlet 1020b includes an aperture defined by the second end 1040 of the perimeter wall 1032 and the outer perimeter of the plate 1048 (see FIG. 5). The debris outlet 1020b includes a leading or upstream end 1124 and a trailing or downstream end 1128 taken relative to the direction of flow F1. While the exterior shape of the illustrated outlet 1020b is defined by both the perimeter wall 1032 and the plate 1048, it is understood that in other embodiments the outlet 1020b may be completely defined by the plate 1048. In some embodiments, the outlet 1020b is at least partially positioned on the reference plate 1120 oriented normal to the body axis 1028. In the illustrated embodiment, the outlet 1020b is completely positioned on the reference plane 1120.

[0071] The second debris outlet 1020b also defines a circumferential or angular length 1132 measured as the angular distance between the upstream end 1124 and the downstream end 1128. The angular length 1132 of the second debris outlet 1020b further defines a second outlet angular zone 1136 (see FIG. 5). In some embodiments, the first debris outlet 1020b has an angular length 1132 of approximately 90 degrees (±1 degree, ±2 degrees, ±3 degrees, ±5 degrees, ±10 degrees, ±15 degrees, ±20 degrees). In other embodiments, the angular length 1132 of the second debris outlet 1020b is approximately 50% of the angular length 1108 of the first debris outlet 1020a (see FIG. 5). The second outlet angular zone 1136 does not overlap the first outlet angular zone 1112 nor the first inlet angular zone 1076.

[0072] The first debris outlet 1020a also defines a radial width 1140 at each point along the circumferential length thereof. The radial width 1140 of the second debris outlet 1020b is such that the radial width 1140 continuously increases as it extends circumferentially from the upstream end 1124 to the downstream end 1128. In the illustrated embodiment, the radial width 1140 of the second debris outlet 1020b at the upstream end 1124 is less than the average radial width of the first debris outlet 1020a while the radial width 1140 of the second debris outlet 1020b at the downstream end 1128 is greater than the average radial width of the first debris outlet 1020a.

[0073] During use, untreated air enters the cleaning chamber 1008 via the air inlet 1012 whereby the size, shape, and relative positioning of the inlet 1012 and body 1004 direct the air into a cyclonic flow path or vortex in the first flow direction F1. The resulting flow path then causes the relatively denser dust and debris particles to separate from the airflow (e.g., generally being forced radially outwardly and downwardly toward the second end 1040, discussed above). The separated debris particles then exit the chamber 1008 through both the first debris outlet 1020a and the second debris outlet 1020b.

[0074] In some embodiments, the presence of the relatively wide first outlet 1020a positioned in the immediate vicinity of the air inlet 1012 (e.g., when the leading end 1088 overlaps the first inlet angular zone 1076) allows for large volumes of dust and debris to immediately exit the cleaning chamber 1008. This, in turn, permits the separator 1000 to more efficiently separate debris in high ingestion situations. To the extent any particularly large rocks or debris are present in the air stream, the increasingly larger radial width 1140 of the second outlet 1020b allows for such items to also pass through and exit the chamber 1008.

[0075] With the dust and debris separated, the treated airflow can then exit the cleaning chamber 1008 via the air outlet 1016.

Claims

1. A cyclonic separator comprising:a body at least partially defining a cleaning chamber having a first cleaning chamber diameter, wherein the body defines a body axis;an air inlet open to the cleaning chamber;an air outlet open to the cleaning chamber; anda debris outlet open to the cleaning chamber, wherein the debris outlet defines an average radial width, and wherein the ratio of the cleaning chamber diameter to the average radial width is between 12.5:1 and 6.7:1.

2. The cyclonic separator of claim 1, wherein the ratio of the cleaning chamber diameter to the average radial width is between 12.5:1 and 7:1.

3. The cyclonic separator of claim 1, wherein the ratio of the cleaning chamber diameter to the average radial width is 9:1.

4. The cyclonic separator of claim 1, wherein the debris outlet includes a first end portion, a second end portion, and an intermediate portion extending between the first end portion and the second end portion, and wherein the intermediate portion has a constant radial width.

5. The cyclonic separator of claim 4, wherein the intermediate portion extends circumferentially about the body axis for between 90 and 270 degrees.

6. The cyclonic separator of claim 4, wherein the intermediate portion extends circumferentially about the body axis for 180 degrees.

7. The cyclonic separator of claim 1, wherein the air inlet defines an angular zone with respect to the body axis, wherein the debris outlet includes a leading end, and wherein the leading end is positioned within the angular zone.

8. The cyclonic separator of claim 1, wherein the debris outlet extends between 90 degrees and 270 degrees circumferentially about the body axis.

9. The cyclonic separator of claim 1, wherein the body includes a perimeter wall extending circumferentially about the body axis, wherein the perimeter wall includes a first end, wherein the body includes a base plate enclosing at least a portion of the first end, and wherein the base plate at least partially defines the debris outlet.

10. The cyclonic separator of claim 1, wherein the debris outlet is a first debris outlet, and wherein the cyclonic separator further includes a second debris outlet.

11. The cyclonic separator of claim 10, wherein the second debris outlet has a leading end and a trailing end, wherein the second debris outlet defines a second outlet width at each point along its circumferential length, and wherein the second outlet width continuously increases as the second debris outlet extends from the leading end to the trailing end.

12. The cyclonic separator of claim 11, wherein the second outlet width is less than the average radial width of the first debris outlet at the leading end, and wherein the second outlet width is greater than the average radial width of the first debris outlet at the trailing end.

13. A cyclonic separator comprising:a body at least partially defining a cleaning chamber having a first cleaning chamber diameter, wherein the body defines a body axis;an air inlet open to the cleaning chamber;an air outlet open to the cleaning chamber; anda debris outlet open to the cleaning chamber, wherein the debris outlet includes a first end portion, a second end portion, and an intermediate portion extending between the first end portion and the second end portion, wherein the radial width of the intermediate portion is between 5% to 15% of the first cleaning chamber diameter.

14. The cyclonic separator of claim 13, wherein the intermediate portion extends circumferentially about the body axis for between 45 degrees and 350 degrees.

15. The cyclonic separator of claim 13, wherein the intermediate portion extends circumferentially about the body axis for between 90 degrees and 350 degrees.

16. The cyclonic separator of claim 13, wherein the radial width of the intermediate portion is between 8% to 14% of the first cleaning chamber diameter.

17. The cyclonic separator of claim 13, wherein the radial width of the intermediate portion is constant.

18. The cyclonic separator of claim 13, wherein the debris outlet is a first debris outlet, the cyclonic separator further including a second debris outlet.

19. A cyclonic separator comprising:a body at least partially defining a cleaning chamber, wherein the body defines a body axis;an air inlet open to the cleaning chamber, wherein the air inlet defines a first angular zone with respect to the body axis;an air outlet open to the cleaning chamber; anda debris outlet open to the cleaning chamber, wherein the debris outlet includes a leading end and a trailing end, and wherein the leading end is positioned within the first angular zone.

20. The cyclonic separator of claim 19, wherein the debris outlet extends circumferentially about the body axis for 180 degrees.

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