Cyclonic Dirt Separator Layout for Shorter Airflow Paths

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing cyclonic dirt separators in vacuum cleaners often have tortuous air paths that lead to air leaks and reduced cleaning performance due to the vertical orientation of the suction source and obstructed views of the primary cyclone, which affects airflow efficiency and user visibility.

Innovation Solution

A cyclonic dirt separator design featuring a first cyclone with secondary cyclones arranged around it, forming gaps for unobstructed viewing and a translucent side wall, along with a dirt cup assembly and working air conduit that minimizes air path length and reduces pressure losses, incorporating vortex stabilizers in the secondary cyclones for enhanced separation efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If secondary cyclones are arranged directly above the upstream cyclone, then the cyclonic separator can be compact, but the unit becomes tall and obstructs the view of the first cyclone

Engineering Contradiction:

Improvecyclonic separator compactnessVSAvoiduser visibility of cyclone operation

Core Design Contradiction:

Volume of moving objectVSLoss of information

Solution Approach 1:

The secondary cyclones are arranged radially around the first cyclone in a horizontal plane rather than vertically above it, changing the spatial dimension of the arrangement. This radial configuration allows the secondary cyclones to be positioned at the same vertical level as the first cyclone, creating viewing gaps while maintaining compact overall dimensions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The cyclonic separator is divided into multiple functional zones: the first cyclone for primary separation, secondary cyclones for further separation, and a dirt cup assembly for collection. This segmentation allows each component to be optimally positioned - with viewing gaps strategically located between secondary cyclones - to achieve both compactness and visibility.

Inventive Principle:

Principle #1Segmentation

2Length of stationary object

If the suction source is placed vertically below the cyclone separator, then the air path can be shortened, but the air path becomes tortuous and requires multiple parts that allow air leaks

Engineering Contradiction:

Improveair path lengthVSAvoidair path seal integrity

Core Design Contradiction:

Length of stationary objectVSReliability

Solution Approach 1:

Instead of routing air vertically down through multiple components, the exhaust air path is inverted to flow horizontally through the dirt cup assembly and then directly into the suction source. This reversal of the air path direction eliminates tortuous routing and reduces the number of connection points where leaks could occur.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The dirt cup assembly is merged with the exhaust air path, allowing exhaust air to flow directly through the dirt cup and into the suction source. This integration eliminates separate air path components and connection points, reducing potential leak locations while maintaining a compact design.

Inventive Principle:

Principle #5Merging (Combining)

3Area of stationary object

If multiple cyclones are arranged in parallel vertically, then the separator can be compact, but the downstream cyclones are located above the upstream cyclone creating a tall unit

Engineering Contradiction:

Improvefootprint of cyclonic separatorVSAvoidheight of cyclonic separator

Core Design Contradiction:

Area of stationary objectVSLength of stationary object

Solution Approach 1:

The cyclones are arranged in a radial pattern around a central axis, transitioning from a vertical stacking configuration to a horizontal radial configuration. This dimensional change allows multiple cyclones to be positioned at the same vertical level, reducing the overall height while maintaining a compact footprint through efficient use of radial space.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design provides improved airflow efficiency, reduces pressure losses, allows for user visualization of the cyclone operation, and enhances debris collection, resulting in better cleaning performance and reduced clogging risks.

Implementation Method 1

cyclone separators...use high-speed rotational motion of the air/dirt to separate the dirt by centrifugal force

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

a first cyclone having a side wall defining a first cyclonic chamber for separating contaminants from an air stream

Methodology Applied

Scientific EffectCyclone separation: Cyclone Separation

Data Source

PatentUS7547336B2Vacuum cleaner with multiple cyclonic dirt separators and bottom discharge dirt cup

Publication Date: 2009.06.16 BISSELL INC

AI summary

A vacuum cleaner comprises a cyclonic separator having a first cyclone and a plurality of downstream secondary cyclones. The first cyclone comprises a side wall defining a first cyclonic chamber, and the secondary cyclones each comprise a side wall defining a second cyclonic chamber. A dirt cup assembly is mounted below the cyclonic separator to collect contaminants separated in the first and second cyclonic chambers. The secondary cyclones can be arranged around the first cyclone side wall and form a gap between adjacent secondary cyclones so that the first cyclone side wall is exposed at the gap. A working air conduit can extend through the first cyclone and the dirt cup assembly to couple the secondary cyclones to a suction source located below the dirt cup assembly. Furthermore, the secondary cyclones can have a vortex stabilizer.