Disc Stack Cyclone Separator With Forced Vortex Fine Dust Separation
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Solution Overview
Problem
Cyclone separators in vacuum cleaners struggle to completely separate fine dust due to low separation efficiency, requiring multiple layers and resulting in bulky designs, as they create free vortices with varying centrifugal forces that mix light and heavy phase fluids at the separation point.
Innovation Solution
A compact disc stack cyclone separator with a forced vortex and laminar swirling flow, utilizing a device with a transmission base and stacked truncated cones to generate a centrifugal acceleration gradient, separating fluids by density and size through a series of cones with narrow gaps, and employing the Coanda effect to guide fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional cyclone separator with tangential inlet is used, then the structure is simple, but the separation efficiency of fine dust is low
Solution Approach 1:
The cyclone separator is divided into multiple functional segments: a forced vortex generation section with specific inlet structure, a free vortex separation section with conical body, and a dust collection section. This segmentation allows each part to perform its specific function optimally, improving overall separation efficiency while keeping individual components relatively simple
Solution Approach 2:
The patent changes the flow pattern parameter from free vortex to forced vortex by designing a specific inlet structure with guide vanes or swirl generators. This parameter change creates a different centrifugal force distribution that improves fine dust separation efficiency without significantly complicating the overall structure
2Manufacturing precision
If multiple cyclone separators are placed in multiple layers to improve separation efficiency, then the separation efficiency increases, but the device becomes big and bulky
Solution Approach 1:
The patent merges the forced vortex generation function and free vortex separation function into a single integrated cyclone separator unit. The inlet structure generates forced vortex that transitions to free vortex within the same device, combining multiple separation mechanisms in one compact unit rather than requiring multiple separate cyclones
Solution Approach 2:
The patent utilizes the axial dimension within the cyclone separator to create a flow pattern transition from forced vortex at the inlet to free vortex toward the outlet. This dimensional utilization allows multiple vortex patterns to coexist in one device, improving separation efficiency without increasing the number of devices needed
3Manufacturing precision
If a free vortex is created by tangential inlet, then the structure is simple, but the centrifugal force is low at the outer circumference resulting in incomplete fine dust separation
Solution Approach 1:
The patent changes the vortex type parameter from free vortex to forced vortex by designing a specific inlet structure with guide vanes or swirl generators. This creates a velocity distribution where the outer circumference has higher velocity and centrifugal force, improving fine dust separation at the separation point
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
The separator achieves high separation efficiency with a compact design by ensuring heavy phase fluids are separated at the outer circumference and light phase fluids at the inner circumference, allowing for efficient separation of fine dust and maintaining a compact size suitable for portable vacuum cleaners and industrial applications.
Implementation Method 1
a device for generating a forced vortex with a laminar swirling flow, a vortex generating chamber
Implementation Method 2
the centrifugal force is varies proportional to the velocity of the vortex, therefore the centrifugal force of free vortex is low at the outer circumference of the vortex and it is high at the inner circumference of the vortex
Data Source
AI summary
A compact disc stack cyclone separator includes: a fluid inlet; a vortex generator which generates a forced vortex; a conical or cylindrical vortex generating chamber; a separation chamber which is a cavity formed by downstream open ends of stacked truncated cones; narrow gaps between the stacked truncated cones, a collecting channel for heavy phrase fluid from the gaps between the stacked truncated cones which installed about the outlets of the gaps at upstream open end of the stacked truncated cones to channel heavy phrase fluid to a storage chamber of heavy phrase fluid; and an outlet for heavy phrase fluid to flow out from the storage chamber of heavy phrase fluid, while the outlet of light phrase fluid is annexed to the downstream open end of the last stacked truncated cone which is the downstream open end of separation chamber.