Low-Profile Cyclonic Dust Separator Plate for Fine Particulate Capture

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Solution Overview

Problem

Conventional cyclonic dust separators are bulky and expensive, making them unsuitable for small workshops, and they often fail to capture fine particulates that pose health risks, necessitating a compact, high-efficiency solution for air purification.

Innovation Solution

A low-profile cyclonic dust separator utilizing centrifugal force and inertia to separate particulates, designed to be compatible with shop vacuums and capable of removing over 99% of debris and fine particles, featuring a unique shape that allows for efficient operation in confined spaces and various container sizes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional cyclonic dust separators are used, then dust separation function is provided, but the device becomes bulky and expensive

Engineering Contradiction:

Improvedust separation functionVSAvoiddevice size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent transitions from conventional three-dimensional cyclonic separators to a two-dimensional planar separator plate design. The separator plate with radially extending passages and openings provides dust separation functionality in a flattened, low-profile configuration that dramatically reduces device volume while maintaining separation effectiveness through the engineered passage geometry and centrifugal force distribution.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent extracts the essential dust separation function from the bulky three-dimensional cyclonic separator housing and concentrates it into a thin separator plate component. By isolating the active separation elements (passages and openings) from the surrounding structural volume, the design achieves high separation efficiency in a minimal space footprint.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If conventional cyclonic dust separators are used, then dust separation function is provided, but the device becomes expensive

Engineering Contradiction:

Improvedust separation functionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The separator plate is designed as an inexpensive, simple component that can be easily manufactured and replaced. The flat plate construction with molded or drilled passages eliminates the need for expensive three-dimensional cyclonic housing, making the separator economically viable for consumer applications where cost-effectiveness is paramount.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent replaces the complex mechanical three-dimensional cyclonic separator structure with a simplified two-dimensional plate-based system. This substitution maintains the essential centrifugal separation mechanism while eliminating costly structural components, fasteners, and assembly requirements associated with traditional cyclonic separators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If conventional cyclonic dust separators are used, then dust separation is achieved, but fine particulates are not captured

Engineering Contradiction:

Improvecoarse dust separationVSAvoidfine particulate capture efficiency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The separator plate incorporates regions of varying passage dimensions and opening sizes to address different particle sizes. Specific local areas feature narrower passages and smaller openings optimized for fine particulate capture, while other regions handle coarse dust. This spatial variation in geometric properties enables multi-size particle separation within a single integrated plate structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent varies key geometric parameters of the passages and openings along their length and across different radial positions. By changing passage width, height, and opening diameter as functions of position, the separator optimizes performance across the full spectrum of particle sizes, from fine dust to coarse debris, within the constraints of a thin plate geometry.

Inventive Principle:

Principle #35Parameter changes

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 solution provides a cost-effective, reliable, and efficient means to remove particulates and fine particles from dust-laden air, extending the time between filter cleanings and improving air quality, while being adaptable to different settings and scalable for industrial use.

Implementation Method 1

Devices which use centrifugal force as a primary means of separating debris from dust-laden air are commercially referred to as cyclonic or centrifugal particulate collectors or separators

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

A low-profile cyclonic dust separator utilizing centrifugal force and inertia to separate particulates

Methodology Applied

Scientific EffectInertia: Inertia

Data Source

PatentUS10857550B2Low profile dust separator

Publication Date: 2020.12.08 HUNTLEY THOMAS

AI summary

A dust separator including a top member having a top member having an inlet port arranged to supply dust-laden air and an outlet port arranged to remove clean air, the top member having a lower portion configured as a lip and having a radius which equals diameter of the inlet port, and a dust separator plate, housed within the lip, having a passage with at least one opening arranged to remove the dust from within the top member.