Nested Cyclone Dust-Air Separator to Reduce Component Count and Space
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Solution Overview
Problem
Conventional two-stage dust-air separation structures in dust collectors require numerous components, complex assembly processes, and suffer from air and dust leakage issues, leading to reduced performance and limited applicability to mini and portable dust collectors due to their large size and volume.
Innovation Solution
A two-stage dust-air separation structure incorporating a cyclone separator and a spiral dust-air separation device within a dust cup, where the cyclone separator performs first-stage separation and the spiral device enhances second-stage separation using centrifugal force, reducing component count and assembly complexity while minimizing space occupation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional two-stage cyclone structure with multiple cone bodies and partition plates is used, then dust-air separation function is achieved, but the number of components increases and assembly process becomes complicated
Solution Approach 1:
The patent combines multiple cone bodies and partition plates into a single integrated cyclone separator structure. The cyclone separator includes a conical body with integrated partition surfaces that perform both separation functions in one component, eliminating the need for multiple stacked cone bodies and separate partition plates, thus reducing component count and assembly complexity while maintaining separation effectiveness
Solution Approach 2:
The cyclone separator is designed as a multi-functional component that simultaneously performs first-stage and second-stage dust-air separation. The single structure incorporates multiple cyclone chambers and partition surfaces that handle different separation stages, making one component serve multiple functions that previously required several separate parts
2Reliability
If multiple layers of cone bodies and cyclone partition plates are axially stacked, then dust-air separation is achieved, but the filter structure occupies large space and reduces dust-collecting volume
Solution Approach 1:
The patent implements a nested configuration where the second cyclone separator is positioned inside the first cyclone separator, and the dust cup is integrated within the cyclone structure. This nesting arrangement allows the separation chambers to occupy the same radial space rather than requiring axial stacking, significantly reducing the overall height and volume occupied by the separation structure while maintaining both separation stages
Solution Approach 2:
The invention transitions from axial stacking (one-dimensional arrangement) to radial nesting (two-dimensional arrangement). By organizing the first and second cyclone separators concentrically in the radial direction rather than stacking them axially, the structure achieves compact space utilization and maximizes the dust-collecting volume of the dust cup
3Reliability
If conventional axial stacking of cone bodies is used, then separation function is achieved, but the dust cup requires high size and large volume, limiting applicability to mini and portable collectors
Solution Approach 1:
The nested configuration of the first and second cyclone separators within a compact dust cup structure enables the entire assembly to fit within small form factors. This nesting approach reduces the overall dimensions of the separation system, making it adaptable to mini and portable dust collectors while maintaining effective two-stage separation functionality
Solution Approach 2:
The integrated cyclone separator design with combined first and second separation stages creates a universal module that can be applied across different dust collector types and sizes. The compact, multi-functional structure adapts to various applications from portable to standard dust collectors without requiring redesign
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 configuration improves comprehensive performance, increases dust storage volume, and enhances dust collecting efficiency, making the structure applicable to various dust collector types and sizes while minimizing space and leakage issues.
Implementation Method 1
a cyclone separator comprises a cyclone housing for a first stage dust-air separation
Implementation Method 2
a spiral dust-air separation device is arranged at a barrel opening of the second-stage cyclone barrel and comprises a spiral impeller configured to generate a second-stage cyclone
Data Source
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AI summary
Disclosed is a two-stage dust-air separation structure, which comprises a wind cover dust barrel (210) and a spiral dust-air separation device (220), a first stage separation of dust and air is realized via a cyclone cover (211), a two-stage cyclone barrel (212) and the spiral dust-air separation device located at a barrel opening are provided in the cyclone cover; after the first stage separation, under the guidance of the spiral dust-air separation device, the dust and air form on an inner wall of the two-stage cyclone barrel an air flow rotating towards the barrel bottom, the dust in the air flow is driven by a centrifugal force to rotate downwardly to the barrel bottom and is collected in a two-stage dust collecting space, and the air in the rotating air flow is extracted by a negative pressure, such that a second stage of dust-air separation is realized. The two-stage dust-air separation structure has a small number of components, simplifies the assembly process, and is convenient to improve the comprehensive performance of the entire machine. At the same time, the structure has a small volume, which can effectively reduce the space of the dust cup occupied by a two-stage separation structure, realize the maximum dust storing volume and improve the dust collecting efficiency, and is applicable to various types and sizes of dust collectors.