Abstract:
The present invention relates to a cyclonic separating apparatus and a vortex finder plate for use in a cyclonic separating apparatus, the vortex finder plate including a support structure and a plurality of vortex finder support flaps extending from the support structure, each vortex finder support flap comprising a vortex finder. At least one of the vortex finder support flaps is connected to the support structure by a hinge.

Description:
REFERENCE TO RELATED APPLICATIONS 
     This application claims the priority of United Kingdom Application No. 1003284.5, filed Feb. 26, 2010, the entire contents of which are incorporated herein by reference. 
     FIELD OF THE INVENTION 
     The present invention relates to a cyclonic separating apparatus and a vortex finder plate for use in a cyclonic separating apparatus. 
     BACKGROUND OF THE INVENTION 
     Vacuum cleaners are often made from parts which can be complicated and expensive to manufacture. 
     One such part is known as a “vortex finder plate”. An exploded view of a prior art cyclonic separating apparatus comprising a vortex finder plate is shown in  FIG. 1   a . A perspective view of the vortex finder plate itself can be seen in  FIG. 1   b  and a section through the vortex finder plate can be seen in  FIG. 1   c.    
     It can be seen that the cyclonic separating apparatus  1  comprises a plurality of cyclones  2  which are arranged in parallel in terms of airflow passing through the cyclones  2 . Each cyclone  2  has an air inlet  4  and an air outlet  6 . The air outlets  6  are in the form of so called “vortex finders”  8  which protrude through vortex finder apertures in a seal  9  into a top end of each cyclone  2 . It can be seen that the vortex finders  8  are an integral part of the vortex finder plate  10 . 
     As can be seen from  FIG. 1   a  each of the plurality of cyclones  2  is angled such that their lower ends  12  point towards a central axis A of the cyclonic separating apparatus  1 . This angling of the cyclones  2  is often done to minimize the overall size of the cyclonic separating apparatus  1 . This angling of the cyclones  2  however has to be mirrored in the vortex finder plate  10  and vortex finders  8  so that a tight seal can be formed between the upper edges  14  of the cyclones  2  and the vortex finder plate  10 . In order to achieve this and as can be seen in  FIGS. 1   a  and  1   b  the vortex finder plate  10  is not flat, instead it is sloped towards its outer edge  16  in all directions. Each of the vortex finders  8  are also angled towards axis A. This means that the vortex finders  8  on the vortex finder plate  10  are all arranged at different angles to each other. 
     The manufacture of such a vortex finder plate  10  therefore poses a problem because each vortex finder  8  is pointing in a different direction and there is an undercut  18  between the lower surface  20  of the vortex finder plate  10  and each of the vortex finders  8 . The tool  22  that is currently used to produce such vortex finder plates  10  is shown schematically in  FIGS. 2   a  to  2   f.    
       FIG. 2   a  shows an exploded view of a section through the tool  22  with the component parts moved into the open position. It can be seen that the tool  22  is very complex, comprising a lower core  24  having a plurality of separate lower core pins  26  which are used to form the inner surfaces of at least some of the vortex finders  8 . The tool  22  also comprises a lifter section  28  which is necessary to deal with the undercuts  18  between the lower surface  20  of the vortex finder plate  10  and the vortex finders  8 . This lifter section  28  will be explained in more detail later. 
     The tool  22  also comprises an upper cavity part  30  and a plurality of separate upper core pins  32 . 
     To manufacture a vortex finder plate  10 , all of the parts of the tool  22  are brought together to form a cavity  34  formed between the parts; this is the position shown in section in  FIG. 2   b . A molten plastics material is forced into the cavity  34 , for example by injection molding. The molten plastics material is left to solidify to form the vortex finder plate  10 . Once the vortex finder plate  10  has solidified within the cavity  34 , it then has to be removed from the tool  22 . 
     The sequence of movements of the parts of the tool  22 , necessary for removal of the formed vortex finder plate  10 , is shown in  FIGS. 2   c  to  2   f . For clarity the formed vortex finder plate  10  is not shown. 
     In  FIG. 2   c  it can be seen that the first action needed to remove the formed vortex finder plate  10  is to lift the upper core pins  32  such that their lower ends  36  are freed from their position inside the newly formed vortex finders  8 . Since each vortex finder  8  is at a different angle the upper core pins  32  cannot simply be moved upwardly, instead each upper core pin  32  has to be removed upwardly and outwardly. It is for this reason that the upper core pins  32  have to be separate from each other and from the upper cavity part  30 . 
     After the upper core pins  32  have been moved, the upper cavity part  30  is lifted from the lower core part  24  as shown in  FIG. 2   d . The next step is shown in  FIG. 2   e  and comprises lowering the lower core pins  26 . Again because each vortex finder  8  is at a different angle the lower core pins  26  cannot simply be moved downwardly, instead each lower core pin  26  has to be removed downwardly and inwardly. Again it is for this reason that the lower core pins  26  have to be separate from each other and from the lower core part  24 . 
     After the lower core pins  26  have been moved it is then necessary to move the lifter sections  28  in an upward and inward direction so that the formed vortex finder plate  10  can be released from the tool  22 . These lifter sections  28  are necessary because of the undercut  18  formed between each of the vortex finders  8  and the lower surface  20  of the vortex finder plate  10 . This problem can be visualized best in  FIG. 2   e  where the formed vortex finder plate  10  would be positioned on the upper surface  44  of the lower core part  24  with the vortex finders  8  located in the cavities  38 . As can be seen in  FIG. 2   e  if the lower central part of the tool  22 , which is formed from the lifter sections  28  and a lower central core part  40 , was formed in one piece it would be trapped between the inwardly pointing vortex finders  8  and therefore it would be impossible to remove the formed vortex finder plate  10  from the lower core part  24 . 
     As shown in  FIG. 2   f  the solution to this problem is to use the lifter sections  28  which are arranged to be moveable in an upwardly and inwardly direction. The lifter sections  28  are normally moved using mechanical arms which for clarity are not shown in the Figures but they could be moved by any suitable means. Moving the lifter sections  28  upwardly and inwardly to the position shown in  FIG. 2   f  will cause the vortex finder plate  10  to lift off from the upper surface  44  of the lower core part  24  and the lifter sections  28  to move out of the undercuts  18 . The vortex finder plate  10  would then be free from the tool  22 . 
     Such a tool  22  is therefore expensive to make and the process for making each vortex finder plate  10  using the tool  22  is complex. Alternative vortex finder plates which could be manufactured more easily would therefore be desirable. 
     The problems associated with making a vortex finder plate can become even more complex if it is desired to integrate other components of a cyclonic separating apparatus with the vortex finder plate. 
     SUMMARY OF THE INVENTION 
     A first aspect of the present invention provides a vortex finder plate for use in a cyclonic separating apparatus comprising a support structure and a plurality of vortex finder support flaps extending from the support structure, each vortex finder support flap comprising a vortex finder, characterized in that at least one vortex finder support flap is connected to the support structure by a hinge. 
     Advantageously such a vortex finder plate can be manufactured in a first position where the vortex finder support flap is in the same or substantially the same plane as the support structure and the vortex finder is at or substantially at 90 degrees to the support structure. After manufacture the vortex finder support flap can be moved into a second position where the vortex finder support flap is bent about its hinge and the vortex finder is angled towards a central axis of the vortex finder plate. 
     This means that there is no undercut to deal with during manufacture making production of the vortex finder plate simpler and cheaper. 
     In a preferred embodiment each vortex finder support flap may be connected to the support structure by a hinge. In such an embodiment the tool used to make the vortex finder plate does not require any lifter sections. 
     At least one hinge may be in the form of an area of reduced thickness between a vortex finder support flap and the support structure. Alternatively at least one hinge may be in the form of a scored line between a vortex finder support flap and the support structure. Preferably the vortex finder support flaps may be able to independently move about their hinges between the first and second positions. 
     In a particular embodiment the vortex finder plate may further comprise an air duct. The air duct may, for example, extend downwardly from the center of the support structure. 
     Preferably one or more of the following components may be formed integrally as one piece, the vortex finder flaps, the support structure, the hinge(s), the vortex finders and the air duct. In a preferred embodiment the vortex finder plate may be formed from a rigid material such that the vortex finder support flaps can only flex about the hinge(s). 
     In a preferred embodiment the plurality of vortex finder support flaps may extend outwardly from the support structure. Alternatively they may extend inwardly from the support structure. 
     A second aspect of the present invention provides a cyclonic separating apparatus comprising, a plurality of cyclones arranged in parallel, each cyclone comprising an air inlet and an air outlet, a vortex finder plate comprising a support structure and a plurality of vortex finder support flaps extending from the support structure, each vortex finder support flap supporting a downwardly extending vortex finder, the vortex finder plate being arranged such that an end of each cyclone is covered by a vortex finder support flap such that a vortex finder protrudes into each cyclone forming the air outlet of the cyclone, characterized in that at least one vortex finder support flap is connected to the support structure by a hinge. 
     When used in relation to the cyclones the term “in parallel” shall be taken to mean in terms of airflow passing through the cyclones. 
     Preferred aspects of the vortex finder plate may be as described in relation to the first aspect of the present invention. 
     A seal may be arranged between the plurality of cyclones and the vortex finder plate. Additionally or alternatively an exhaust manifold may be positioned above the vortex finder plate such that the vortex finder plate is sandwiched between the plurality of cyclones and the exhaust manifold. 
     The plurality of cyclones may be angled towards a longitudinal axis of the cyclonic separating apparatus. In such an embodiment the vortex finder support flaps may be bent about their hinges. 
     The plurality of cyclones may be arranged around an air duct in the cyclonic separating apparatus. The air duct may contain at least one filter, for example a sock filter, elongate filter or electrostatic filter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Preferred embodiments of a surface treating appliance and vortex finder plates according to the present invention will now be described in detail with reference to the accompanying drawings in which: 
         FIG. 1   a  shows an exploded section through a prior art cyclonic separating apparatus comprising a vortex finder plate; 
         FIG. 1   b  shows a perspective view of the vortex finder plate shown in  FIG. 1   a;    
         FIG. 1   c  shows a section through the vortex finder plate shown in  FIGS. 1   a  and  1   b;    
         FIG. 2   a  shows an exploded schematic section through a tool for manufacturing the vortex finder plate shown in  FIGS. 1   a  to  1   c;    
         FIG. 2   b  shows a section through the tool shown in  FIG. 2   a  in the closed position; 
         FIGS. 2   c  to  2   f  show the sequence of positions through which the tool must move to release a newly manufactured vortex finder plate as shown in  FIG. 1   b;    
         FIG. 3   a  shows a first embodiment of a vortex finder plate according the present invention, in its first position; 
         FIG. 3   b  shows the vortex finder plate shown in  FIG. 3   a  in its second position; 
         FIG. 4   a  shows an exploded schematic section through a tool for manufacturing the vortex finder plate shown in  FIGS. 3   a  and  3   b;    
         FIGS. 4   b  and  4   c  show the sequence of positions through which the tool must move to release a newly manufactured vortex finder plate as shown in  FIGS. 3   a  and  3   b;    
         FIG. 5   a  shows a second embodiment of a vortex finder plate according the present invention, in its first position; 
         FIG. 5   b  shows a section through the vortex finder plate shown in  FIG. 5   a;    
         FIG. 5   c  shows the vortex finder plate shown in  FIGS. 5   a  and  5   b  in its second position; 
         FIG. 5   d  shows a section through the vortex finder plate shown in  FIG. 5   c;    
         FIG. 6   a  shows a partial section through the parallel cyclones of a cyclonic separating apparatus; 
         FIGS. 6   b  to  6   d  show the steps fitting the vortex finder plate shown in  FIGS. 5   a  to  5   d  to the cyclones shown in  FIG. 6   a;    
         FIG. 7   a  shows an exploded schematic section through a tool for manufacturing the vortex finder plate shown in  FIGS. 5   a  to  5   d ; and 
         FIGS. 7   b  and  7   c  show the sequence of positions through which the tool must move to release a newly manufactured vortex finder plate as shown in  FIGS. 5   a  to  5   d.    
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to  FIGS. 3   a  and  3   b  the structure of a vortex finder plate  10  according to a first embodiment of the present invention is shown. The vortex finder plate  10  comprises a support structure  46  and a plurality of vortex finder support flaps  48 . A single vortex finder  8  projects downwardly from each vortex finder support flap  48 . A hinge  50  in the form of an area or line of reduced thickness is provided between the support structure  46  and each of the vortex finder support flaps  48 . The vortex finder support flaps  48  are not connected to each other. There may, for example, be a split line or a gap  52  between adjacent vortex finder support flaps  48 . This arrangement allows the vortex finder support flaps  48  to move or flex about their hinges  50  such that the vortex finder plate  10  can be manufactured in the first position shown in  FIG. 3   a  and then after manufacture the vortex finder support flaps  48  can be moved about their respective hinges  50  into the second position shown in  FIG. 3   b . In  FIG. 3   b  it can be seen that the vortex finders  8  are angled inwardly and each vortex finder support flap  48  is inclined downwardly. The vortex finder plate  10 , in its second position, is therefore arranged such that it would fit onto a set of angled cyclones  2  such as those shown in  FIG. 1   a.    
     Such a vortex finder plate  10  is very advantageous as it is much easier to manufacture than previous vortex finder plates.  FIGS. 4   a  to  4   c  illustrate an example of a tool  22  which could be used to make the vortex finder plate  10  shown in  FIGS. 3   a  and  3   b .  FIG. 4   a  shows an exploded view of the tool  22  which can be seen to comprise a lower core part  24  and an upper cavity part  30 . The upper cavity part  30  can be seen to comprise integral upper core pins  32 . The vortex finder plate  10  can therefore be made from simple up and down movements of these parts without the need for any separate core pins or lifter sections. 
     To manufacture this vortex finder plate  10 , the lower core part  24  and the upper cavity part  30  are brought together to form a cavity  34  between the parts, this is the position shown in section in  FIG. 4   b . A molten plastics material is forced into the cavity  34 , for example by injection molding. The molten plastics material is left to solidify to form the vortex finder plate  10 . Once the vortex finder plate  10  has solidified within the cavity  34 , it then has to be removed from the tool  22 . 
     Unlike in the prior art where a complex sequence of movements is required to remove the vortex finder plate  10 , the removal of this new vortex finder plate  10  is very simple. As can be seen in  FIG. 4   c  the lower core part  24  and the upper cavity part  30  are simply pulled apart to release the vortex finder plate  10 . 
       FIGS. 5   a  to  5   d  show a second embodiment of vortex finder plate  10  according to the present invention. It can be seen that the vortex finder plate  10  comprises a ring shaped support structure  46 , a plurality vortex finder support flaps  48  and a downwardly extending air duct  54 . A single vortex finder  8  projects downwardly from each vortex finder support flap  48 . A hinge  50  in the form of an area or line of reduced thickness is provided between the support structure  46  and each of the vortex finder support flaps  48 . The vortex finder support flaps  48  are not connected to each other. There may therefore be a split or gap  52  between adjacent vortex finder support flaps  48 . This arrangement allows the vortex finder support flaps  48  to move or flex about their hinges  50  such that the vortex finder plate  10  can be manufactured in the first position shown in  FIGS. 5   a  and  5   b , and then after manufacture the vortex finder support flaps  48  can be moved about their respective hinges  50  into the second position shown in  FIGS. 5   c  and  5   d . It can be seen in  FIGS. 5   c  and  5   d  that the vortex finders  8  are now angled such that they would fit onto a set of angled cyclones  2 , such as those shown in  FIGS. 6   a  to  6   d.    
       FIGS. 6   a  to  6   d  show part of a construction sequence for a cyclonic separating apparatus having a plurality of angled cyclones  2 . A vortex finder plate  10  as shown in  FIGS. 5   a  and  5   b  is used in the construction. As can be seen in  FIG. 6   a  the cyclonic separating apparatus  1  comprises a plurality of inclined cyclones  2  which are arranged in a circle. The first step in the construction of the cyclonic separating apparatus  1  is to take the plurality of cyclones as shown in  FIG. 6   a  and place on the upper edges  14  of the cyclones  2  a seal  9 . The seal  9  is shown in  FIG. 6   b  and can be seen to comprise a plurality of vortex finder apertures  56  surrounding a central air duct aperture  58 . The vortex finder apertures  56  are arranged such that one lies centrally above each cyclone  2  and the central air duct aperture  58  is arranged centrally of the cyclonic separating apparatus  1 . The outer edge  60  of the seal  9  is shaped to match the outer edges  62  of the cyclones  2 . 
     In the next step, as shown in  FIG. 6   c  the vortex finder plate  10  is placed on top of the seal  9  such that the vortex finders  8  protrude through the vortex finder apertures  56  and the air duct  54  protrudes through the central air duct aperture  58 . It can be seen that in this position because the vortex finder plate  10  is flat it is not completely in contact with the upper edges  14  of the cyclones  2 . 
     The next stage of the construction is shown in  FIG. 6   d  and comprises placing an exhaust manifold  64  on top of the vortex finder plate  10 . When the exhaust manifold  64  is placed on top of and is then fixed onto the remainder of the cyclonic separating apparatus  1  it causes the vortex finder support flaps  48  to flex about their hinges  50  until the vortex finder plate  10  makes a proper contact with and seals against the upper edges  14  of the cyclones  2 . This vortex finder plate  10  is therefore very useful because it is very simple to manufacture and yet can still be used on inclined cyclones  2 ) 
     A tool  22  for making the second embodiment of the vortex finder plate  10  is shown in  FIGS. 7   a  to  7   c.    
       FIG. 7   a  shows an exploded view of the tool  22  which can be seen to comprise a lower core part  24  and an upper cavity part  30 . The upper cavity part  30  comprises integral upper core pins  32  and an integral air duct forming portion  68 . The vortex finder plate  10  can be made from simple up and down movements of these parts without the need for any separate core pins or lifter sections. 
     To manufacture this vortex finder plate  10 , the lower core part  24  and the upper cavity part  30  are brought together to form a cavity  34  formed between the parts, this is the position shown in section in  FIG. 7   b . A molten plastics material is forced into the cavity  34 , for example by injection molding. The molten plastics material is left to solidify to form the vortex finder plate  10 . Once the vortex finder plate  10  has solidified within the cavity  34 , it then has to be removed from the tool  22 . 
     Unlike in the prior art where a complex sequence of movements is required to remove the vortex finder plate  10  the removal of this new vortex finder plate  10  is very simple. As can be seen in  FIG. 7   c  the lower core part  24  and the upper cavity part  30  are simply pulled apart to release the vortex finder plate  10 .