Low Profile Bucket Lid and Dust Cyclone

Abstract

A low-profile dust collector assembly incorporates a low-profile cyclonic separator into a lid for a dust collection bucket. An outer lid ring can be formed of coffers that add strength to the lid and also reduce swirl in the air below the lid. The cyclonic separator has a shell rising from an inner circumference of the lid ring and has a horizontal inlet tube and central vertical outlet tube. A baffle for the separator includes a baffle plate fitted within the inner circumference and a turret of vertical members arranged with a top ring that fits onto the outlet tube. This compact arrangement has improved performance in airflow and dust separation. A spring clamp assists in fitting onto buckets over a range of diameters, and a pair of circumferential gaskets at right angles to one another form an air-tight seal.

Claims

1. A combined lid for a dust collection bucket and a low-profile cyclonic dust separator, comprising a lid ring having a center axis and having an outer edge adapted to conform with and fit onto an upper rim of said dust collector bucket, with an annular channel at said outer edge adapted to secure sealably onto said upper rim; and an inner generally circular inner circumferential edge concentric with said outer edge; a low profile cyclonic separator centered on said lid ring and rising from said inner edge thereof; the low profile cyclonic separator having a generally horizontal inlet tube adapted for accepting an inlet hose connecting to a source of said dust and air flow in which said dust is entrained; a vertical outlet tube at a center axis of said separator adapted for connecting to a vacuum source; a shell having a rounded wall that is affixed onto the lid ring substantially at the inner edge thereof, and defining within it a cyclonic chamber creating an air flow direction from said inlet tube around the interior of the shell to a vertical outlet tube substantially at the center axis; the shell having a shape that spirals from the outlet tube around said center axis in a downward direction; a baffle assembly within said chamber disposed at the center axis and including a baffle plate having an outer circumference positioned substantially at said inner generally circular edge and spaced therefrom over a major portion of the outer circumference thereof, to define an exit slot permitting separated dust to drop therethrough into the bucket; the slot having a gap that increases in the direction of air flow.

2. The combined lid and low-profile cyclonic dust separator according to claim 1, wherein said lid ring is formed of an array of coffers, each coffer being an annular segment with a sloping surface, and each joined to a next thereof by a radially extending vertical step member.

3. The combined lid and low-profile cyclonic dust separator according to claim 1 wherein said baffle assembly further includes a vane turret that is formed of a circular array of vertical vanes rising from a center of said baffle plate to said outlet tube.

4. The combined lid and low-profile cyclonic dust separator according to claim 3, wherein said vane turret has a turret ring at an upper end thereof fitted to the outlet tube.

5. The combined lid and low-profile cyclonic dust separator according to claim 3, wherein said baffle plate has a center opening at a central portion thereof, and said vertical vanes rise from around said center opening.

6. The combined lid and low-profile cyclonic dust separator according to claim 5 comprising a baffle dome insert fitting into said center opening, and having a pressure equalizing opening for equalizing the pressure between the interior of the vane turret and air in the dust collection bucket.

7. The combined lid and low-profile cyclonic dust separator according to claim 5, wherein said shell is formed to have a rounded wall rising from said lid ring and a shape that spirals downwardly from said inlet tube and around said center axis to said outlet tube.

8. Combined lid for a dust collection bucket and low-profile cyclonic dust separator, comprising a lid ring having a center axis and having an outer edge adapted for fitting said dust collection bucket, and an inner generally circular edge; a low-profile cyclonic separator centered on said lid ring, and rising from the inner edge of said lid ring; the cyclonic separator including an inlet tube adapted for accepting a hose that provides a flow of air with entrained dust; a shell having an outer wall affixed onto the lid ring, substantially at the inner edge thereof and incorporating said inlet tube, the shell defining within it a cyclonic chamber in which a cyclonic air flow is created for the flow of air received from said inlet tube, in an airflow direction spiraling from said inlet tube to a vertical outlet tube at said center axis; and a baffle assembly at a lower part of said cyclonic chamber and having a baffle plate disposed at said inner generally circular edge, and an open turret rising from the baffle plate and having an upper end fitting onto said outlet tube.

9. The combined lid and low-profile dust collector according to claim 8, wherein said lid ring has a plurality of sloping segments formed therein.

10. The combined lid and low-profile dust collector according to claim 9, further including radial step members connecting the end of each said sloping segment with and adjoining edge of a next segment.

11. The combined lid and low-profile according to claim 8 wherein said shell is formed as a rounded wall rising from said lid rim, and with a shape that spirals downwardly from said inlet tube and around said center axis to said outlet tube.

12. The combined lid and low-profile dust collector according to claim 8 wherein said open turret is formed of a circular array of vanes around said center axis, and rises from an opening in said baffle plate.

13. The combined lid and low-profile dust collector according to claim 12 wherein the vanes of said circular array each are separated from one another to define open spacings between them configured to face in the direction opposite to said air flow.

14. The combined lid and low-profile dust collector according to claim 13 wherein said turret ring joins upper ends of the vanes of said turret to said outlet tube.

15. The combined lid and low-profile dust collector according to claim 13, wherein said baffle assembly further includes a baffle dome fitting into a lower end of said turret and having a center opening aligned with said center axis, and operative for equalizing air pressure between the interior of said turret and air within the dust collection bucket.

Description

BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0024] FIG. 1 is a perspective view of the low-profile cyclonic separator and lid, here seated upon a standard five-gallon pail or bucket, according to an embodiment of our invention.

[0025] FIG. 2 is an assembly view showing the combined lid and separator shell, the combined baffle plate and vane turret, the baffle domed insert, and a pair of flexible clamps mounted on the rim of the lid.

[0026] FIG. 3 is a top plan view of the low-profile separator and lid.

[0027] FIG. 4 is a side elevation thereof.

[0028] FIG. 5 is a bottom plan view of the low-profile separator and lid.

[0029] FIG. 6 is a perspective view from below featuring the bottom side of the lid ring and the baffle.

[0030] FIG. 7 is an assembly view from below featuring the combined lid ring and separator shell, the combined baffle plate and vane turret, and the baffle insert.

[0031] FIG. 8 is a perspective view of the low profile separator and lid, with the baffle elements visible through the separator shell which here is formed of a transparent plastic resin material.

[0032] FIG. 9 is a top plan view of the low-profile separator and lid of FIG. 8.

[0033] FIG. 10 is a perspective view of the bucket and lid-separator, showing also the improved spring clamps or latches.

[0034] FIG. 11 is a top plan view thereof.

[0035] FIG. 12 is an exploded elevation showing the components and placement thereof for the improved clamp or latch.

[0036] FIG. 13 is an elevation showing the pem stud component relative to the associated rim ring and the receptacle for the clamp or latch.

[0037] FIG. 14 is an assortment view of the components of the clamp or latch.

[0038] FIG. 15 is a partial perspective view featuring the improved clamp as installed on the rim ring.

[0039] FIG. 16 is a bottom plan of the lid and cyclonic separator of this invention featuring the improved seal.

[0040] FIG. 17 is a partial bottom perspective view thereof.

[0041] FIG. 18 is a partial cross-section thereof.

[0042] FIG. 19 shows a supply of conductive tape for forming an anti-static arrangement on the low-profile cyclonic separator and lid.

[0043] For embodiments where the separator shell is made of an opaque material, the construction would be identical or similar, and is not separately shown or described.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)

[0044] With reference to the Drawing Figures, and initially to FIG. 1, a low profile cyclonic dust separator arrangement is with a standard five-gallon bucket 10, on which the combination lid-and-cyclonic-separator 12 is seated. The arrangement receives a flow of dust laden air from a tool or other dust producing device (not shown), and separates out the dust from the air flow and deposits the dust into the bucket 10 below.

[0045] The bucket is shown here as a standard-size 5-gallon utility pail, frequently used to hold drywall compound or other materials, and often sold empty as a utility pail. Here the bucket 10 has a bail handle 14 and a top rim 16 that is designed to mate with the rim of an associated lid.

[0046] In this embodiment, the combination lid-and-cyclonic-separator 12 is constructed with a lid ring 20 at its radially outer regions and a separator module 22 at a center portion of thereof.

[0047] The separator module 22 rises from a radially inner edge or circumference of the lid ring 20, and is formed of an outer shell 24 of a generally coiled or spiral shape. A generally horizontal inlet tube 26 is joined to an upper end of the shell 24, and a generally vertical outlet tube 28 is disposed at a center axis of the module 22. Here, the inlet tube serves as a female fitting to which the male end of a hose is inserted, to supply the dust-laden air which travels in a spiral path within the shell and exits via the central vertical outlet tube 28 as air from which the large majority of dust has been removed. The outlet tube 28 serves as a female fitting to which is fitted a vacuum hose (not shown) leading to a not-shown dust extractor or shop vacuum.

[0048] Now, with further reference to FIG. 2, the lid ring 20 of this embodiment has a rim 30 at its outer circumference adapted to fit onto the top rim 16 of the bucket 10. Radially inside the rim 30 there is an annular series of coffers 32. Each coffer is formed of an arcuate segment 34 that slopes upward along the curve of the rim ring. End walls or steps 36 each join the upper end of each arcuate segment 34 with the lower end of the next. Favorably, this is in the general direction of air flow in the unit, so that the geometry of the series of coffers 32 blocks any swirl of the air beneath the lid ring and prevents any unwanted air movement from forming. The coffers with the sloping segments and vertical steps 36 also serves to reinforce the rim ring 30 to help support the separator module 22 when the unit is in use.

[0049] At two or more locations along the rim 30 are located flexible plastic clamps 40 that serve to hold the rim 30 removably against the top rim 16 of the pail or bucket. At the same time there are drilled holes at locations along the rim 30 so that screws may be used to fasten the rim 30 to the top rim of the bucket, if a more permanent fitting is desired.

[0050] Shown below the lid ring and shell in this assembly view is a baffle assembly that is positioned at the radial axis of the separator module 22 inside the shell 24. At its base, the assembly includes a baffle plate 44 configured to fit within the inner rim or inner circumference of the lid ring 20. A portion 46 of the baffle plate 44 is curved to match the curvature of the inner circumference and may have prongs or teeth 46 as shown to fit into the rim ring 30 or into the base of the separator shell 24. The remainder of the edge of the baffle plate is set in from the inner circumference so as to define a narrow circumferential slot or space. As shown in FIG. 2, there is a circular array of vanes, i.e., a vane turret 48, rising from the center portion of the baffle plate 44 and extending upwards to a vane turret ring 62, which interfits the outlet tube 28. The portion of the baffle plate inside the turret is open, and this opening is fitted with a baffle plug or insert 50. The plug closes off the base of the baffle assembly, at the base of the vane turret 48, except for a small vent hole that serves to equalize the air pressure between the inside of the turret 48 and the dust repository in the bucket below the lid and cyclonic separator 12, so that the air around the collected dust remains quiet.

[0051] FIGS. 3 and 4 show this embodiment in a top plan view and a right side elevation. In this embodiment the entering air stream goes through the inlet tube 26 into the shell 24 so that the air flow direction within the shell 24 is in a counter-clockwise (CCW) direction and then circles in a radially inward direction to exit through the outlet tube 28. Also shown here, the two flexible rubber clamps 50 are disposed opposite one another, i.e., 180 degrees apart. More clamps could be used if desired. FIG. 4 shows the upward angle of the coffers 32, that is, upward in the direction of air flow.

[0052] FIG. 5 shows a bottom plan view of the combination lid-and-cyclonic-separator 12. There is a space or circumferential slot 56 proceeding over a majority of the circumference of the baffle plate 44. The slot proceeds in the airflow direction (which is counter clockwise looking down as in the previous views, but thus clockwise in this view looking upwards). The slot 56 gradually increases in gap width until it reaches a wide opening 58. This configuration prevents chunks from becoming jammed in the slot and blocking dust flow. Larger particles continue around until they drop through. Chunks can easily pass through the wide gap 58 at the end.

[0053] The circumferential rim channel 54 is shown at the outer perimeter of the lid ring 30. This channel 54 may have a foam gasket to help seal against air leakage between the rim channel 54 and the bucket top rim 16.

[0054] As this view is upwards from below, whereas the air flow direction is counter-clockwise (CCW) when viewed from above in FIG. 3, and the airflow is CCW above the baffle plate, the airflow direction is clockwise (CW) on the opposite side of the baffle plate as in the view of FIG. 5. Thus this view illustrates the increase in slot width of slot 56, in the airflow direction. The very wide space 58 is shown at the end of the slot 56, in the airflow direction. The geometry of the circumferential slot 56 allows dust that separates from the air stream to fall through the slot, and any solid chunks and debris continue around and fall through the slot or though the wide opening 58, not clogging or jamming the slot.

[0055] This view also illustrates the arcuate segments 34 that constitute the coffers of the lid ring.

[0056] The perspective view of FIG. 6 and the exploded or assembly perspective of FIG. 7 further illustrate the various components discussed in the previous several paragraphs with some details of their shape and how they interfit with other components. In this embodiment, for each of the flexible rubber clamps 40 there is a receptacle 60 molded into the outer edge of the lid ring.

[0057] FIG. 7 also shows latch receptacles 60 formed or molded onto the rim 30 for locating and assisting the snap action of the associated flexible latches 40.

[0058] FIGS. 8 and 9 are a perspective view and a plan view of a related embodiment, which has the same constituents as the first-described embodiment, except that the shell 24A, including inlet tube 26A and outlet tube 28A are formed of a transparent material, so that interior components such as the baffle plate 44 and vane turret 48 are visible through the shell of the dust separator. In operation, the separated dust that cycles around the interior of the shell will also be visible. Thus any blockage or other irregularity in the flow of air and dust through the shell will be noticeable, and can be addressed.

[0059] In these views, the vane turret 48 is shown as having eight vanes each extending vertically from the baffle plate and configured such that there is a spacing between successive vanes, and an opening at the outer end of the vanes to permit air flow from the outer portion of the shell, through the vanes into the core of the turret, and out through the outlet tube. The CCW air flow within the separator module 22 has to change directions and make a sharp bend when it enters the spaces between the vanes. This sharp change of airflow direction accelerates any entrained particulate at this point so that the particulate solids are flung out towards the circumferential dust slot 56, optimizing their separation.

[0060] The number of vanes depends on the size and geometry of the separator module, and a practical vane turret may instead have seven vanes, arranged in a cylindrical fashion, but with the outer edges of the vanes placed against the flow direction, so that the airflow makes a sharp turn when entering into vane turret.

[0061] The vane turret dome 50, i.e., plug or insert is fitted into the bottom end of the vane turret 48. In this embodiment the dome base has a shape of an eight-pointed star that matches the arrangement of vanes at the foot of the turret. The vane ring 62 is fused to the upper end of the vanes in the turret, and ensures that the separated air flows out from the core of the turret and up through the outlet tube 28. Of course, if the shell is formed of an opaque material, the inner components, i.e., the baffle plate and turret, as well as the spiraling separated dust, would not be visible.

[0062] Now, as shown in FIG. 10 and the ensuing drawing FIGS. 11 to 15, a spring clamp 140 is shown to be employed on the lid rim 30 rather than the all-plastic latch or clamp 40 described earlier. This clamp 140 provides a secure, but adjustable attachment to the top rim of the bucket or pail 10. Preferably there are a pair of these spring latches 140 disposed on opposite sides of the cyclonic separator 22, as seen in FIG. 11, and these may be positioned at the two receptacles 60 described earlier (see FIG. 7).

[0063] The set of components of the spring clamp or latch 140 are illustrated in FIGS. 12 and 14. A generally C-shaped flexible plastic latch member 141 is shown there, which included a finger grip or pull handle 142 affixed onto its lower limb. A pem stud 143 is used to secure the latch member 141 onto the lid rim 130 (see FIGS. 12 and 13), as well as to hold down the remaining components. A pem stud is a self-clinching stud, i.e., male threaded rod with a head, where the rod side of the head is configured so that the action of an associated nut squeezed the head into the plastic material of the rim ring until the pem stud head is flush (with the underside of the rim ring). A spring clip 144 fits over the plastic latch member 141 and these are secured in place (on the receptacle 60), by a washer 145 and wing nut 146 onto the pem stud 143 (FIG. 15). Once this spring clamp 140 is installed, it can be adjusted by loosening the wing nut 146 and by pulling on the finger grip 142, moving the position of the spring clip out or in to match the top rim of the pail or bucket (which may vary in diameter from one to another). The receptacles 60 are configured to permit at least some radial adjustment for the spring latches 140.

[0064] The wing nut 146 and washer 145 can also be used to assist in grounding an associated anti-static arrangement as explained later.

[0065] As shown in FIGS. 16, 17 and 18, an annular foam sealing gasket 160 is favorably installed within the channel member formed at the underside of the rim ring 30. A first ? inch wide foam gasket member 161 is placed flat along the underside of the ring rim, with ends overlapping around the circumference, and firmly pressing against itself at the overlap to avoid air leaks. A second ? inch gasket member 162 is then installed along the inner lip of the rim ring and perpendicular to the ? inch gasket member 161. This gasket member 162 should also overlap around the circumference to avoid any air leaks. This arrangement, properly installed, forms a secure, complete seal between the lid ring and the bucket so there are no air leaks.

[0066] Finally, as shown in FIG. 19, a conductive tape 170 is provided which can be installed so that it connects the inlet tube 26 and outlet tube 28 while wrapping at least partly around the shell 26 of the separator module, with at least about ? inch extending into each of the inlet and outlet tubes, wrapping around the edge of each opening. Favorably, a section of the tape 170 can also extend to one of the latch receptacles and fit over the associated pem stud. At that point a grounding wire can be attached, with a metallic member connected there and held in place by the wing nut and washer, and of sufficient length so that a washer affixed to its far end can lie on the workshop floor. Static-conductive elbows and couplers may be used at the inlet and outlet tubes to connect with the respective vacuum hoses, and these assist in static dissipation.

[0067] Although not shown here, there may be casters affixed on to the lower part of the pail or bucket 10, favorably four casters at 90-degree intervals, to assist in mobility of the bucket and associated lid-separator. One or another of the casters may be provided with a tether to attach to the shop vacuum, dust extractor, or other vacuum source. Alternatively, a four-caster dolly fitting the base of the bucket may be used.

[0068] The inventors have run a comparison test, employing an embodiment of this invention and also employing versions of the prior dust separation equipment to study their performance in a realistic setting. This made it possible to conduct a performance analysis as between (a) the low profile bucket lid and separator of this invention, (b) a conic cyclone dust separator arrangement Dust Deputy (see U.S. Pat. No. 7,202,074) mounted on a supporting bucket lid (See U.S. Pat. No. 11,419,467); and (c) an available cyclonic dust separator made according to Huntley U.S. Pat. No. 10,857,550 (Dec. 8, 2020) (Huntley) in which a low-profile separator with a concave top is fitted onto a dust collection bucket. In each case these were installed between the same source of process dust, and the same shop vacuum serving as a dust extractor or vacuum source. The results are displayed in the following table. In the case of the Huntley, the dust separator had to be taped around the fitting for the bucket to reduce the air leakage at the rim.

The results are tabulated as follows:

TABLE-US-00001 Dust This Parameter Deputy Huntley embodiment Velocity (Ft/Min) 4,868 3,319 4,675 Flow (CFM) 134.4 91.6 129.0 Static Pressure (inches H.sub.2O) ?2.663 ?1.303 ?2.90 Maximum Static Pressure ?43.9 ?41.2 ?42.8 (blocked flow) (inches H.sub.2O)

[0069] These results of this performance comparison show a significantly better performance of the low profile dust collector embodying this invention as compared with the Huntley low profile separator, in terms of better airflow velocity and volume, with this low-profile dust collector achieving a better static pressure, when compared with the Huntley low-profile unit, and exhibiting performance that is comparable with the Dust Deputy tall conic dust separator. In the unit of this invention, the smaller diameter dust separator chamber, as compared with the Huntley unit, increases the air velocity, and the radial space between the circumferential slot and bucket rim, creates room for eddying in the bucket while reducing re-uptake of the collected dust. The decreased diameter of the dust separation chamber, and the addition of deflector vanes, i.e., the vane turret 48 around the center axis, helps achieve the increased performance. The venting of the top opening in the turret plug or insert 50 evens the pressure between the interior of the turret and the dust collection regions of the bucket, helping avoid re-uptake of dust. Also, as discussed earlier, the vertical tangential vanes improve separation by forcing the air to make a 180 degree turn, which causes an outward increase in momentum of the dust particles in the direction toward the dust slot. Also the vane ring 62 connects the vane turret to the outlet tube assisting in air flow out of the cyclonic chamber of the unit.

[0070] Finally the flexible and adjustable latches 40 on the lid ring assist in fitting the lid-separator onto a wider variety of buckets and pails. The one-piece latch design, favorably of Sanoprene TPE or similar material, is flexible and can be adjusted by the user inward and outward. This helps accommodate the various pails and buckets which may differ in diameter one to another by as much as two inches at the top rim.

[0071] The above and many other objects and features of this invention are achieved the aforedescribed embodiment, and in variations thereto, without departing from the scope and spirit of this invention, which is to be measured by the attached claims.