US20090205161A1

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Publication number: US20090205161A1
Application number: US12/338,022
Authority: US
Inventors: Wayne Ernest Conrad
Original assignee: GDB CORP; GBD Corp
Current assignee: GBD Corp
Priority date: 2007-12-19
Filing date: 2008-12-18
Publication date: 2009-08-20
Also published as: US8640303B2; US7941895B2; US20190231158A1; EP2237891A1; US20130061568A1; US20090205160A1; EP2237891A4; US20090173365A1; CN104607326B; US12396604B2; CN101939110A; US8898857B2; CN101939110B; US10327612B2; US8034140B2; US20150121651A1; US11547259B2; CN104607326A; WO2009076774A1; US20130145575A1

Abstract

A cyclone separator useable in a surface cleaning apparatus comprises a cyclone casing defining a cyclone chamber and having first and second opposed ends and a sidewall extending between the first and second ends. A separated material collection chamber surrounds at least a portion of the cyclone chamber and is communication therewith via a separated material outlet. The separated material collection chamber is spaced at least about 0.5 inches from the cyclone chamber. In addition, the separated material collection chamber is spaced from the bottom of the cyclone by at least about 0.5 inches.

Description

FIELD

This invention relates to a cyclone separator. In a preferred embodiment, the invention relates to a cyclonic separator, or a plurality of cyclonic separators in parallel, utilized as a cleaning stage in a surface cleaning apparatus such as a vacuum cleaner.

BACKGROUND

Cyclonic separators, including those used in vacuum cleaners are known in the art. Typically, a cyclonic separator has an inlet for fluid (air, liquid or and air and liquid mix) to be treated and an outlet for treated fluid. Dirt may be collected either in the cyclone chamber itself (e.g. in the bottom) or in a collection chamber in fluid communication with the cyclone separator. Various such constructions are known in the art.

U.S. Pat. No. 7,086,119 (Go et al) discloses a dust-collecting unit for a vacuum cleaner. The dust-collecting unit includes a cyclone separator having a dirt collection chamber positioned adjacent one lateral side of the cyclone separator. A dirt outlet is provided in the upper wall of the cyclone such that dirt may enter the adjacent dirt collection chamber through the outlet in the upper wall of the cyclone separator. A second dirt collection chamber is positioned below the cyclone chamber and is accessed by an opening formed in a separating plate that separates the cyclone chamber and the second dirt collection chamber. An openable bottom is provided. However, when the bottom is opened, the cyclone chamber is still closed by the separating plate.

U.S. Pat. No. 7,160,346 (Park) discloses a cyclone for use in a vacuum cleaner having a dirt collection space positioned below the cyclone chamber. A dirt outlet is provided as an annular gap between the sidewall of the cyclone chamber and a separating plate for permitting dirt to travel downwardly from the cyclone into the dirt collection chamber. Accordingly, the dirt collection chamber is not exterior to the cyclone casing but is within the casing.

SUMMARY

In accordance with this invention, a cyclone separator is provided that comprises a fluid inlet provided in a first portion, a separated material outlet provided in a spaced apart, opposed second portion and being in communication with a separated material collection chamber and a side wall. The separated material collection chamber is spaced a sufficient distance from the cyclone casing (at least portions of the side and the opposed second portion) to enhance the separation efficiency of the cyclone separator. In particular, the separated material collection chamber is spaced from at least some of the cyclone casing by at least 0.5 inches.

The separated material collection chamber may surround all or a portion of the cyclone casing and is exterior to the portion of the cyclone casing having the separated material outlet. The sidewall of the cyclone casing has an inlet section and a second section and the fluid inlet is provided on the inlet section. Accordingly, the sidewall of the separated material collection chamber facing the sidewall of the second section of the cyclone casing is spaced apart by at least about 0.5 inches and, the separated material collection chamber has an opposed surface facing the second portion of the cyclone casing by at least about 0.5 inches.

Surprising, it has been determined that such positioning of the separated material collection chamber enhances the separation efficiency of the cyclone separator.

The separated material collection chamber (e.g., a dirt collection chamber) may extend completely around the cyclone casing. Accordingly, fluid will enter a cyclone chamber through the fluid inlet at one end and travel towards the distal end wall of the cyclone chamber. As the fluid travels through the cyclone chamber, it will rotate and heavier material (e.g. particulate matter) will exit the cyclone chamber via the separated material outlet. The fluid will then reverse direction and exit the cyclone chamber through the fluid outlet.

Preferably, the cyclone separator is provided with an inwardly directed transition member that extends between the sidewall of the cyclone casing and an end wall of the cyclone casing. The transition member may extend at an angle or may be curved inwardly. If the cyclone separator is oriented in an upright fashion, then the fluid inlet is provided adjacent the upper end of the cyclone and the fluid exit may also be provided adjacent the upper end of the cyclone. Accordingly, the transition member would extend downwardly and inwardly from the sidewall to the lower end wall that is positioned distal to the fluid inlet. It will be appreciated that if the cyclone separator were to be inverted, then the fluid inlet would be positioned on the bottom and the end wall would be positioned above the inlet (e.g., the end wall would be an upper end wall). In such an orientation, the transition member will extend upwardly and inwardly from the sidewall to the end wall. It will also be appreciated that the cyclone separator could also be oriented horizontally, or at any other angle.

Preferably, the separated material outlet is provided adjacent the end wall distal to the fluid inlet and, more preferably, the dirt outlet is provided at least partially in the transition member. Most preferably, the dirt outlet is provided in the transition member.

In accordance with an aspect of the present invention, there is provided a cyclone separator comprising:

- (a) a cyclone casing defining a cyclone chamber and having first and second spaced apart portions, a sidewall, a fluid inlet, a fluid outlet and a separated material outlet, the first portion including a first end and the second portion including an opposed second end;
- (b) the fluid inlet provided in the first portion;
- (c) the separated material outlet provided in the second portion and being in communication with a separated material collection chamber;
- (d) the sidewall having an inlet section and a second section, the fluid inlet provided on the inlet section;
- (e) the separated material collection chamber having a sidewall and surrounding at least a portion of the cyclone chamber wherein the sidewall of the separated material collection chamber facing the sidewall of the second section of the cyclone casing is spaced apart by at least about 0.5 inches; and,
- (f) the separated material collection chamber has an opposed surface facing the second end and spaced from the second end by at least about 0.5 inches.

It will be appreciated by those skilled in the art that the cyclone separator disclosed herein may be utilized with any fluid stream (e.g. liquid and/or gas). In addition, it will be appreciated by those skilled in the art that the cyclone separator may be used in any consumer appliance and, preferably, is utilized in a surface cleaning apparatus or an air cleaner. The surface cleaning apparatus may be a vacuum cleaner, including an upright vacuum cleaner, a stick vacuum cleaner, a canister vacuum cleaner, a back pack vacuum cleaner, a strap carriable vacuum cleaner or a portable vacuum cleaner; a carpet extractor, a bare floor cleaner or the like.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective vertical section through a cyclone separator according to a first embodiment of this invention wherein the cyclone separator is oriented in an upright fashion;

FIG. 1ais a vertical section through the cyclone separator ofFIG. 1;

FIG. 1bis a perspective vertical section looking downwardly through the cyclone separator ofFIG. 1;

FIG. 2 is a vertical perspective view as shown inFIG. 1 including the air flow and dirt flow path through the cyclone separator;

FIG. 3 is a side view of the vertical section ofFIG. 1;

FIG. 4 is an exploded view of the cyclone separator ofFIG. 1;

FIG. 5 is a vertical section through the exploded view ofFIG. 4;

FIG. 6 is a perspective view showing an optional embodiment that permits the cyclone separator to be opened to permit emptying;

FIG. 7 is an end view of the opened cyclone separator shown inFIG. 6;

FIG. 8 is a vertical section through a cyclone separator according to a second embodiment of this invention wherein the cyclone separator is inverted;

FIG. 9 is a side view of the cyclone separator ofFIG. 8 shown encased in a housing;

FIG. 10 is an exploded view of the second embodiment ofFIG. 8;

FIG. 11 is a perspective view from below of the cyclone separator ofFIG. 8 showing an optional embodiment that permits the cyclone separator to be opened to permit emptying;

FIG. 12 is an end view of the opened cyclone separator shown inFIG. 11;

FIG. 13 is a vertical section through a third embodiment of a cyclonic cleaning stage according to this invention wherein a plurality of cyclone separators are connected in parallel;

FIG. 14 is a front view of the vertical section of the cyclonic cleaning stage ofFIG. 13;

FIG. 15 is a front view of a vertical section of a cyclonic cleaning stage according to a fourth embodiment of this invention wherein the transition member is angled;

FIG. 16 is a front view of a vertical section of a cyclonic cleaning stage according to a fifth embodiment of this invention wherein the transition member is angled and the cyclonic cleaning stage comprises a single cyclone;

FIG. 17 is a front view of a vertical section of a cyclonic cleaning stage according to a sixth embodiment of this invention wherein the transition member is rounded, the cyclonic cleaning stage comprises a single cyclone and the separated material outlet extends above the transition member and is positioned about 270° around the cyclone casing in a flow direction from the fluid inlet;

FIG. 18 is a front view of a vertical section of a cyclonic cleaning stage according to an seventh embodiment of this invention wherein the transition member is rounded, the cyclonic cleaning stage comprises a single cyclone and the separated material outlet extends above the transition member and is positioned opposed to the air inlet;

FIG. 19 is a front view of a vertical section of a cyclonic cleaning stage according to a eighth embodiment of this invention wherein the cyclone chamber is openable with the dirt collection chamber, showing the dirt collection chamber and the cyclone chamber in the closed position; and,

FIG. 20 is a front view of a vertical section of a cyclonic cleaning stage according to a eighth embodiment of this invention wherein the cyclone chamber is openable with the dirt collection chamber, showing the dirt collection chamber and the cyclone chamber in the open position;

FIG. 21 is a top plan view of a cyclone chamber and a dirt collection chamber according to a ninth embodiment of this invention; and,

FIG. 22 is a perspective view of a surface cleaning apparatus utilizing a cyclone separator assembly as setout herein

DETAILED DESCRIPTION

In the following description of the preferred embodiment, the cyclone separator is described as used in a vacuum cleaner of any particular design. As exemplified inFIG. 22,surface cleaning apparatus120 may be an upright vacuum cleaner having asurface cleaning head122 and avacuum cleaner body124 pivotally mounted thereto. Handle126 may be provided for movingsurface cleaning apparatus120.Surface cleaning apparatus120 has a firstcyclonic cleaning stage128 and a secondcyclonic cleaning stage130. However, it will be appreciated that the description set out herein is not confined to such uses as may be used for any other application referred to herein or known in the art.

As exemplified inFIGS. 1-5, acyclone separator assembly10 comprises a cyclone casing defining acyclone chamber26 and comprising asidewall12, air orfluid inlet18, air orfluid outlet20,optional transition member22 and a dirt or separatedmaterial outlet24. The cyclone casing has first and second spaced apart portions. The first portion comprisesfirst end wall14 and the second portion comprises an opposedsecond end wall16. A separated material collection chamber ordirt collection chamber32 is provided exterior tocyclone chamber26.

First and

second end walls

14 and16 are spaced apart and are positioned opposite each other. Preferably, as exemplified,air inlet18 is provided insidewall14 and, more preferably, adjacent first orupper end14. In addition,air outlet20 is preferably provided in upperfirst end14 and, preferably, is centrally located therein. As exemplified inFIG. 14, the lower end ofoutlet20 is preferably positioned above the top ofdirt outlet24. Accordingly, as exemplified in a vertical orientation inFIG. 2, air entering the cyclone casing will travel in a cyclonic fashion downwardly towards secondlower end wall16. Heavier material, e.g. particulate material, will exitcyclone chamber26 viadirt outlet24. The air at some point reverses direction and travels upwardly throughoutlet20 to exitcyclone chamber26.

As shown inFIG. 1, sidewalls18 preferably extend linearly (i.e. it is straight) and, in the orientation shown inFIG. 1, vertically. Preferably,sidewall18 meetsupper end wall14 at about 90° such that upperfirst end wall14 is essentially perpendicular tosidewall18. In addition, lowersecond end wall16 is preferably parallel tofirst end wall14. Accordingly, but fortransition member22, the cyclone casing is exemplified as being cylindrical. It will be appreciated that whilecyclone separator10 is preferably generally cylindrical, it may have other shapes. For example, it may be frustoconical as is also known in the art. In addition,air inlet18 andair outlet20 may be of any construction and positioning known in the art.

Transition member

12 is provided adjacentlower end wall16 and preferable is immediately adjacentlower end wall16. Accordingly,transition member22 may linksidewall18 andlower end wall16. For example, as exemplified inFIG. 1,transition member22 extends betweenlower end28 ofsidewall18 andouter end30 oflower end wall16. If the cyclone separator is oriented as shown inFIG. 1 (it is in an upright orientation), then transitionmember22 extends downwardly and inwardly.

It will be appreciated thattransition member22 may have a variety of configurations. For example,transition member22 may be a single surface that extends at an angle fromlower end28 ofsidewall18 toouter end30 of lower end wall16 (see for exampleFIGS. 15 and 16). As exemplified,sidewall18 extends between thefirst end14 andtransition member22 in a first direction (vertically),second end16 extends in a second direction (horizontally), andtransition member22 extends in at least one third direction fromsidewall18 to thesecond end16. Accordingly, it will be appreciated that the transition member extends in a third direction (other than the direction ofsidewall18 and the direction of end wall16). Accordingly,transition member22 may be at an angle to the longitudinal axis ofsidewall18, at an angle to the longitudinal axis A of the cyclone separator itself and at an angle to the plane of lower end16 (the horizontal plane as exemplified inFIGS. 15 and 16).

Alternately, a plurality of angled surfaces may be provided. Alternately, and preferably,transition member22 may be curved and, more preferably, is radiused. In a particularly preferred embodiment,transition member22 describes part of an arc of a circle which may have a radius from 0.125 inches to 2 inches, more preferably from 0.25 to 1 inch, even more preferably from about 0.375 to 0.75 inches and most preferably about 0.5 inches.

Preferably,dirt outlet24 is provided in a lower portion of the cyclone separator. Preferably, iftransition member22 is provided, at least a portion ofdirt outlet24 is provided intransition member22. For example, as exemplified inFIGS. 17 and 18,dirt outlet24 may extend abovetransition member22. Preferably, as exemplified inFIG. 1,dirt outlet24 is positioned completely withintransition member22. For example, as exemplified inFIG. 14,dirt outlet24 extends to the juncture oftransition member22 andsidewall18. Alternately, as exemplified inFIG. 15,dirt outlet24 may terminate at a position below the juncture oftransition member22 andsidewall18.

One ormore dirt outlets24 may be provided for asingle cyclone chamber26. Preferably, asingle dirt outlet24 is provided, as exemplified inFIG. 1. The one ormore dirt outlets24 may be positioned at any angular displacement B with respect to inlet18 (see for exampleFIG. 21). Dirt outlet may be displaced from about 90 to about 330 degrees, preferably from about 180 to about 300 degrees, more preferably from about 240 to about 300 degrees and most preferably about 270 degrees in the flow direction fromair inlet18. For example, as shown inFIGS. 12 and 18,dirt outlet24 may be displaced about 180 degrees in the flow direction aroundcyclone chamber26 from inlet18 (i.e.,dirt outlet24 is generally opposed to air inlet18). Alternately, as exemplified inFIG. 17, dirt outlet may be displaced about 90 degrees in the flow direction aroundcyclone chamber26 frominlet18. It is preferred thatoutlet24 having such an angular positioning is provided in a lower portion of the cyclone casing as discussed herein.

As shown inFIG. 1, the cyclone chamber has a height H (i.e., the distance between first and secondopposed end walls14 and16) and a diameter D (i.e. the diameter of sidewall12). Accordingly, height H is the combined height ofsidewall18 andtransition member22. In a broad aspect of this invention, height H and diameter D may be any of those known in the art. Preferably, height H is less than diameter D and, more preferably, height H is less than half of the diameter D.

It will be appreciated thattransition member22 may have any desired length. Accordingly,transition member22 may extend fromend wall16 toinlet18. However, it is preferred that a portion ofsidewall12 is provided betweeninlet18 andtransition member24. For example, as shown inFIG. 1,sidewall12 has a portion having a distance d that extends from bottom13 ofinlet18 tolower end28 ofsidewall18. Preferably, this section of sidewall is straight and, more preferably parallel to axis A (e.g., vertical as exemplified inFIG. 1 wherein the cyclone separator is oriented with the longitudinal axis A of the cyclone extending vertically). In particular, it is preferred that the section of sidewall having a length d is parallel to the longitudinal axis A ofcyclone chamber26.Lower end13 ofinlet12 is preferably closer to secondlower end16 than firstupper end14. Accordingly, distance d may be less than the vertical height of theinlet12.

Dirt collection chamber or separatedmaterial collection chamber32 is positioned in fluid flow communication withdirt outlet24 and exterior tocyclone chamber26.Dirt outlet24 is a lateral outlet, i.e., the outlet is provided insidewall18 ortransition member22 so that the separated material travels at least partially laterally as it exitscyclone chamber26. In the embodiment ofFIG. 8 wherein the cyclone is inverted, the upper end (second end16) may be open. In such a case, the open end would function as the dirt outlet.

Dirt collection chamber

32 may be of any shape. As shown inFIG. 2, dirt or other heavy material will exitcyclone chamber26 laterally viaoutlet24 and then travel downwardly to accumulate oncollection surface34. As exemplified,dirt collection chamber32 has acollection surface34,sidewall36 and atop wall38.

Dirt collection chamber

32 surrounds at least a portion of the cyclone casing. Preferably,dirt collection chamber32 surrounds the portions of the sidewall of the cyclone casing that are not provided withinlet18. Alternately, as exemplified inFIG. 21, it may surround all ofsidewall12. The sidewalls of the cyclone casing and the collection chamber are spaced apart so as to define a gap, that may be an annular gap G if it fully surrounds the cyclone casing, that has a width D. Accordingly, the cyclone casing may be positioned fully withindirt collection chamber32 as exemplified inFIG. 1.

In addition, the surface ofcollection chamber32 opposed to and facing second end16 (collection surface34 in the cyclone is oriented upright and opposedsurface33 if the cyclone is inverted) is spaced fromend16 of the cyclone casing. Preferably,collection surface34 is an opposed surface facing thesecond end16 and spaced from the secondlower end16 by at least about 0.5 inches.

Preferably,sidewall12 may have an inlet section and a second section, andfluid inlet18 is provided on the inlet section and the portion ofsidewall36 of separatedmaterial collection chamber32 facing the second section ofsidewall12 of the cyclone casing is spaced apart by at least about 0.5 inches. As exemplified a gap having a width D_g1may be provided around the second section ofsidewall12. Distance D_g1is at least 0.5 inches. It will be appreciated that the annular gap D_g1may be larger and need not have a uniform width. Further, a gap having a width D_g2may be provided around the inlet section ofsidewall12. It will be appreciated that width D_g2may be less than 0.5 and may be zero such thatwall69 ofpassage68 merges withsidewall36 of collection chamber32 (see for example the embodiment ofFIG. 14).

It will be appreciated that if the cyclone casing is positioned completely within dirt collection chamber32 (i.e.dirt collection chamber32 extends completely around the cyclone separator as exemplified inFIG. 21) then,top wall38 ofdirt collection chamber32 may be annular in shape (i.e., extend betweensidewall12 of the cyclone andsidewall36 of the dirt collection chamber32).

As exemplified inFIG. 4,top wall38 ofdirt collection chamber32 and upperfirst end wall14 ofcyclone chamber36 may be connected together and are preferably integrally molded as acontinuous plate40. Preferably,air outlet24 may be provided as part ofplate40 and may be integrally molded therewith.

As exemplified inFIGS. 1 and 22,cyclone separator assembly10 may be provided as a secondcyclonic stage130. Accordingly,cyclone separator assembly10 preferably has provided as part thereof the air outlet orvortex finder42 of an upstream cyclonic stage128 (which is preferably a single cyclone but, as will be appreciated, could be a plurality of cyclones in parallel wherein the vortex finder of each is secured to, and removable with, cyclone separator assembly10). Preferably,outlet42 comprises a tubularmember having sidewalls44 whereinapertures46 may be provided in a lower end thereof. Alternately, it will be appreciated that any air outlet or vortex finder of a cyclone known in the art may be utilized, and need not be provided as part ofcyclone separator assembly10.Vortex finder42 is preferably attached to the bottom ofcyclone separator assembly10, e.g.,bottom panel50, and may be molded as part ofbottom panel50.

If the cyclone is downstream from another filtration member or air treatment member, thenair inlet18 may be in airflow communication therewith by any means known in the art. In a particularly preferred embodiment as illustrated inFIGS. 1-5,cyclone separator assembly10 may incorporate an airflow passage from an upstream filtration stage toinlet18. As illustrated therein,outlet42 is in airflow communication withheader48.Header48 is positioned betweenbottom panel50 having anupper surface52 and alower surface54 ofcollection surface34.

Ifbottom panel50 is openably, then in order to provide an airtight seal forbottom panel50, a sealinggasket66, O-ring or other sealing member known in the art may be provided.Gasket66 may be mounted to, or removably mounted to, pivotingbottom50. In such a case,header48 may be positioned betweengasket66 andlower surface54 ofcollection surface34. Fromheader48, the air travels upwardly trough side air passage56 (seeFIGS. 3,4 and5). It will be appreciated thatair passage56 may be of any configuration known in the art. The airflow path is exemplified inFIG. 2.

In order to permitdirt collection chamber32 to be emptied,bottom panel50 may be pivotally attached tocyclone separator assembly10. For example,flange58 may be provided onbottom panel50. A mating flange may be affixed to sidewall36 (seeFIG. 7). The flanges may be pivotally connected by any means known in the art. A latch may be provided onsidewall36, which engagesflange60, which is provided onbottom panel50. Accordingly, when in the closed position (shown inFIG. 1), the latch may engageflange60, thereby securingbottom panel50 in position. When released,bottom panel50 may pivot to an open position (as shown inFIG. 7) permitting dirt collected incollection chamber32 to be emptied. In such a case, a sealinggasket66 or the like is preferably provided, e.g., mounted toupper surface52 ofpanel50, so as to open withpanel50. Any sealing member known in the art may be used.

In order to permitdirt collection chamber32 to be emptied, an opening is provided to access the interior ofdirt collection chamber32. Accordingly,collection surface34 may be moveably or removable mounted or a door provided to permit access todirt collection chamber32. For example,collection surface34 may be removable, as exemplified inFIG. 6. Alternately, or in addition,collection surface34 may be pivotally mounted. For example, as exemplified inFIGS. 19 and 20,collection surface34 is pivotally mounted tosidewall36 bypivot pin78. See also for example, the embodiment ofFIG. 9.

It will be appreciated that larger particulate matter may be collected incyclone chamber26. Accordingly, in any embodiment disclosed herein, access may be provided to the interior ofcyclone chamber26 as well. For example,cyclone chamber26 may be opened independently ofcollection chamber32. Alternately,cyclone chamber26 may be opened whendirt collection chamber32 is opened so thatcyclone chamber26 andcollection chamber32 may be emptied concurrently.

Accordingly, it will be appreciated that it is preferred thatcyclone chamber26 andcollection chamber32 are each openable. For example,lower end16 andcollection surface34 may be each moveably mounted and may be joined together so thatcyclone chamber26 andcollection chamber32 are concurrently opened. As exemplified inFIGS. 19 and 20, bottom orsecond end wall16 ofcyclone chamber26 may be secured or joined tocollection surface34, such as byribs104 and constructed to be openable withcollection surface34. The openable portion of each ofcyclone chamber26 andcollection chamber32 may be moveably mounted by any means known in the art. For example, they may be slideably or translatably mounted. Preferably, they are pivotally mounted. Alternately, they may be removably mounted, such as by means of a screw mount, a bayonet mount or securing members such as wing nuts.

As exemplified, cyclone chamber is openable at the juncture oftransition member22 andsidewall12. Accordingly, when a latch or lock is released,collection surface34 may be moved to the open position shown inFIG. 20 and accordingly, bottom16 andtransition member22 are concurrently moved to the open position.

In an alternate embodiment,cyclone chamber26 may be inverted. In such a case, as exemplified inFIGS. 8-12,collection surface34 is spaced from opposedsurface33.Collection surface34 and the first portion of the cyclone casing are openable and, preferably concurrently openable. For example, they may be moveably mounted and connected together. They may be moveably mounted by any means known in the art. For example, they may be slideably or translatably mounted. Preferably, they are pivotally mounted. Alternately, they may be removably mounted, such as by means of a screw mount, a bayonet mount or securing members such as wing nuts. For example, as exemplified inFIGS. 11 and 12, the bottom of the cyclone chamber (when the cyclone chamber is in an inverted orientation) and the collection chamber may both be emptied at the same time by the cyclone chamber and the dirt collection chamber having a bottom panel that are adjacent (e.g., lie in a common plane) and are preferably integrally formed.

It will be appreciated that bottom16 may be constructed to be opened subsequently to collection chamber32 (e.g., bottom16 may not be secured to collection surface34).

Ifside air passage56 is provided, thencollection surface34 may incorporate a cut out62, which meets, preferably in an airtight manner, withbottom64 ofside air passage56.

An alternate embodiment is shown inFIGS. 8-12. In this alternate embodiment, the cyclone is inverted. Accordingly,air inlet18 andair outlet20 are provided infirst end14, which comprises the lower end of thecyclone separator apparatus10. Accordingly, in operation, air will enterinlet18 via, e.g.,tangential passage68. The air will then travel upwardly in a cyclonic fashion incyclone chamber26 prior to exiting throughoutlet20, which is preferably provided infirst end16. Heavier material (e.g. particulate material) will exitoutlet24 provided, preferably, intransition member22 and accumulate in the separatedmaterial collection chamber32. If a sealinggasket66 is optionally provided as exemplified inFIG. 10, then the upper surface ofgasket66 functions ascollection surface34.

In order to emptycyclone separator assembly10, alatch72 may be provided. For example,button70 oflatch72 may be pressed movingarm74 outwardly thereby disengagingarm74 fromflange60, thereby permittingbottom panel50 to pivot downwardly (as shown inFIGS. 11 and 12) to permit theinterior cyclone chamber26 andcollection area22 to be emptied.Bottom panel50 may be pivotally mounted to sidewall36 ofcasing76 such as bypivot pin78 extending transversely to connectflange58 ofbottom panel50 withflange80 affixed tosidewall36.

Accordingly, by openingbottom panel50, preferably over a garbage can or the like, material collected insidecyclone chamber26 andcollection chamber32 may be emptied. In this embodiment, thecollection surface34 andsecond end16 are integrally formed (i.e. they are defined by bottom panel50). Accordingly, both chambers may be emptied concurrently. In an alternate design they may be separately opened (e.g., ifcollection surface34 andsecond end16 are separate members).

In a particularly preferred embodiment,cyclone separator apparatus10 comprises an upper portion of an upright vacuum cleaner. Accordingly,housing76 may be provided with ahandle82 which may be connected tocyclone separator apparatus10 by any means known in the art.Air inlet18 may be in airflow communication with a dirty air inlet or the like of a vacuum cleaner, as a first or subsequent cleaning stage, via opening84 inpanel50 andopening86 inoptional gasket66.

Further alternate embodiments are exemplified inFIGS. 13-15. In these alternate embodiments, a plurality of thecyclone separators10 is provided. Preferably, the plurality ofcyclone separators10 is provided in parallel. More preferably, the plurality ofcyclone separators10 is provided as a second cleaning stage, more preferably a second cyclonic cleaning stage and most preferably a second cyclonic cleaning stage of parallel cyclones in a surface cleaning apparatus. Any number ofcyclone separator apparatus10 may be provided.

Each cyclone chamber has its owndirt collection chamber32 that is isolated from thecollection chambers32 of theother cyclone separators10. For example, as shown, dividingwalls106

separate collection chambers

32. It will be appreciated that, in alternate embodiments,collection chambers32 need not have common walls. Dividingwalls106 may be secured toextension112 ofsidewall12 of16 of cyclone chamber26 (see for example,FIG. 14) so as to function as arib104, such thatsecond end16 andcollection34 open concurrently. Alternately, dividingwalls106 may be removable from engagement withextension112 such thatcollection chamber32 may be emptied independent ofcyclone chamber26.Cyclone chamber26 may be separately openable or may not be openable.

As exemplified,outlets20 ofcyclone separators10 are in airflow communication with aheader108 having, preferably, asingle outlet110. Accordingly, a single flow passage may be provided downstream from the cyclonic cleaning stage exemplified inFIGS. 13-15.

As exemplified, optionally inlets18 ofcyclone separators10 may be positioned adjacent each other (e.g., side by side). See alsoFIG. 14. In such a case,collection chamber32 may surround only the second section, and not the inlet section, ofsidewall12.

It will be appreciated that any of the alternate or optional configurations or features may be used single or in any particular combination or sub-combination with other configurations or features disclosed herein.

It will be appreciated by those skilled in the art that various modifications and additions may be made in each or within the scope of the following claims. In particular, it will be appreciated that one or more cyclones as disclosed herein may be provided in an appliance, preferably in a surface cleaning appliance and, more preferably in a vacuum cleaner. The cyclones may be provided at any orientation and are preferably either inverted or in an upright orientation.