Patent Publication Number: US-2015059810-A1

Title: Cyclonic debris removal apparatuses and associated methods

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     None 
     BACKGROUND 
     When manufacture of components (e.g., a plastic tube) involves a cutting process (e.g., by a drum cutter), dust and debris can be statically energized and cling to these components. A conventional way to remove undesirable dust or debris is applying suitable airflow to these components individually. The undesirable dust or debris can be moved and carried away by suitable airflow. However, the conventional way of removing undesirable dust or debris can be extremely time consuming and thus inefficient. Therefore, improved apparatuses, systems, or methods for removing dust or debris from manufactured components are desirable. 
     SUMMARY 
     The technology of the present application is directed to an improved apparatus, system, and associated method for removing debris from lightweight components. The improved apparatus can include an air mover, a cyclonic chamber in fluid communication with the air mover, an enclosure component operably attached with the cyclonic chamber, and a debris collection component in fluid communication with the cyclonic chamber. The lightweight components positioned inside the cyclonic chamber can be moved, rotated, or carried by cyclonic airflow, causing the lightweight components to hit against one another or against the sidewall, so as to separate the debris clung thereto. 
     The technology of the present application also discloses a method of removing debris from lightweight components. The method can include: positioning the lightweight components in a cyclonic chamber; providing an incoming airflow path to the cyclonic chamber along a substantial tangential direction; generating cyclonic airflow in the cyclonic chamber; carrying, moving, or rotating the lightweight components by the cyclonic airflow; removing debris attached with the lightweight components at least by causing the lightweight components to hit against one another or against an inner surface of the cyclonic chamber; and collecting the separated debris by a debris collection component. 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary, and the foregoing Background, is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter. 
     These and other aspects of the present technology will be apparent after consideration of the Detailed Description and Drawings herein. 
    
    
     
       DRAWINGS 
       Non-limiting and non-exhaustive embodiments of the present technology, including the preferred embodiment, are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
         FIG. 1  illustrates a system for removing debris in accordance with an exemplary embodiment of the present technology. 
         FIG. 2  illustrates a system for removing debris in accordance with another exemplary embodiment of the present technology. 
         FIG. 3  illustrates a cyclonic chamber in accordance with an exemplary embodiment of the present technology. 
         FIG. 4  illustrates a cyclonic chamber in accordance with another exemplary embodiment of the present technology. 
         FIG. 5  is a schematic top view of a cyclonic chamber in accordance with an exemplary embodiment of the present technology. 
         FIG. 6  is a schematic top view of a cyclonic chamber in accordance with another exemplary embodiment of the present technology. 
         FIG. 7  is a schematic side view of a cyclonic chamber in accordance with an exemplary embodiment of the present technology. 
         FIG. 8  is a flowchart depicting a method in accordance with an exemplary embodiment of the present technology. 
     
    
    
     DETAILED DESCRIPTION 
     The technology of the present application is described with specific reference to an apparatus for removing debris clung to a plurality of lightweight components. The term “lightweight component” can be defined as components that can be moved, rotated, or carried by suitable airflow. As, as used herein, the terms “debris”, “dust”, “dirt”, or the like are used relatively interchangeably to mean any unwanted particle remaining on the lightweight components subsequent to processing whether the particle remains on the lightweight component due to static electric energy or other adhesion. Moreover, the technology of the present application will be described with relation to exemplary embodiments. The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Additionally, unless specifically identified otherwise, all embodiments described herein should be considered exemplary. 
       FIG. 1  illustrates a system  100  in accordance with an exemplary embodiment of the present technology. The system  100  can be used to remove debris or dust from lightweight components whose manufacturing processes involve cutting. For example, the lightweight components can be plastic tubes, other plastic components, or other hollow components. As shown in  FIG. 1 , the system  100  can include an air mover  101 , a cyclonic chamber  102 , a debris collection component  103 , and a controller  104 . The air mover  101  can be configured to generate airflow for moving, rotating, or carry lightweight components positioned in the cyclonic chamber  102 . The air mover  101  in certain aspects may be a compressor, pump, or the like. In still other aspects, the air mover  101  may be a pressurized reservoir. Also, while describes as an air mover  101 , it will be appreciated by a person of ordinary skill in the art that air mover  101  could supply other gases, such as, for example, helium, nitrogen, argon, etc. The cyclonic chamber  102  is in fluid communication with the air mover  101  and can accommodate the lightweight components to be cleaned. In some embodiments, the cyclonic chamber  102  can have a cylindrical shape. In other embodiments, the cyclonic chamber  102  can have a bucket shape. In other embodiments, the cyclonic chamber  102  can have other suitable shapes, such as an elliptic cylinder, a portion of a cone, an oblique elliptic cone, or shapes that can facilitate creating cyclonic airflow therein. 
     The cyclonic chamber  102  can have an air inlet, an air outlet, and a sidewall. The airflow generated by the air mover  101  can be directed into the cyclonic chamber  102  via the air inlet. The air inlet can be positioned on the sidewall, so as to allow the directed airflow to generate cyclonic (or spiral) airflow inside the cyclonic chamber  102 . The cyclonic airflow generated inside the cyclonic chamber  102  can cause lightweight components positioned in the cyclonic chamber  102  to hit against one another or against the sidewall, so as to separate the debris clung thereto. 
     In one exemplary embodiment, the cyclonic chamber  102  can have a bucker shape whose volume is around 5 gallons. An exemplary operating time of separating or removing debris, for example, can be 30 seconds. An exemplary number of lightweight components that can be position in the cyclonic chamber at one time can range up to about 200 to 225 parts. In other embodiments, the volume of the cyclonic chamber  102 , the operating time of separating or removing debris, and the number of lightweight components can vary depending on multiple factors, such as the sizes and/or materials of the lightweight components, efficiency of the air mover  101 , the size and/or shape of the cyclonic chamber  102 , or required cleaning results. 
     The debris collection component  103  is in fluid communication with the cyclonic chamber  102  via the air outlet. The separated debris can be carried by airflow leaving the cyclonic chamber  102  and then can be collected by the debris collection component  103 . In some embodiments, the debris collection component  103  can be a debris collection chamber (or a catch box) that can collect debris carried by passing airflow. For example, the debris can be collected by deposition, screening, meshing, or other suitable means. In other embodiments, the debris collection component  103  can be a filter designed to remove the carried debris. In still other applications, the debris collection component  103  is optional and the system may exhaust to atmosphere. 
     The controller  104  can be coupled to the air mover  101 , the cyclonic chamber  102 , and the debris collection component  103 . The controller  104  can include a processor and a memory. In some embodiments, the controller  104  can monitor the statuses of the air mover  101 , the cyclonic chamber  102 , and the debris collection component  103  by receiving signals from suitable sensors. In other embodiments, the controller  104  can adjust the operation of the air mover  101 , the cyclonic chamber  102 , and the debris collection component  103  based on the received signals. For example, the controller  104  can increase the airflow generated by the air mover  101  when the controller  104  detects that the cyclonic airflow in the cyclonic chamber  102  is insufficient to move, rotate, or carry the lightweight components positioned therein. In another example, the controller  104  can decrease the airflow generated by the air mover  101  when the controller  104  detects that a debris-removing efficiency of the debris collection component  103  is below a certain threshold (e.g., providing more time for the debris collection component  103  to collect the separated debris). 
       FIG. 2  illustrates a system  200  for removing debris in accordance with another exemplary embodiment of the present technology. As shown in  FIG. 2 , the system  200  can include an air mover  203 , a cyclonic chamber  201 , a debris collection component  202 , and a controller  204 . The air mover  203 , the cyclonic chamber  201 , the debris collection component  202 , and the controller  204  can have similar functions as the air mover  101 , the cyclonic chamber  102 , the debris collection component  103 , and the controller  104  described above with reference to  FIG. 1 . Unlike the embodiment described in  FIG. 1  (i.e., the air mover  101  is positioned upstream of the cyclonic chamber  102 ), the air mover  203  can be positioned downstream of the cyclonic chamber  201 . In the illustrated embodiment, the air mover  203  also can be positioned downstream of the debris collection component  202 . In other embodiments (not shown), the air mover  203  can be positioned downstream of the cyclonic chamber  201  and upstream of the debris collection component  202 . 
       FIG. 3  illustrates a cyclonic chamber  300  in accordance with an exemplary embodiment of the present technology. As shown in  FIG. 3 , the cyclonic chamber  300  can include a top surface  301 , a bottom surface  302 , and a sidewall  303 . In some embodiments, the cyclonic chamber  300  can include an enclosure component  306  operably attached with the cyclonic chamber  300 . In some embodiments, the enclosure component  306  can be an operably detachable cap or lid positioned on the top surface  301 . When the enclosure component  306  is open, a user can position lightweight components to be cleaned (e.g., lightweight components with undesirable debris clung thereto) in the cyclonic chamber  300 . Once finished, the enclosure component  306  can be closed and secured so as to keep the lightweight components inside the cyclonic chamber  300 . In some embodiments, the enclosure component  306  can facilitate to maintain a substantially airtight condition of the cyclonic chamber  300 . In some embodiments, the cyclonic chamber  300  can only have the sidewall  303  with either the top surface  301  (e.g., an inverted cone shape) or the bottom surface  302  (e.g., a cone shape). In these embodiments, the enclosure component  306  can be positioned on either the top surface  301  (e.g., the inverted cone shape) or the bottom surface  302  (e.g., the cone shape). 
     In the illustrated embodiment, the cyclonic chamber  300  can include an air inlet  304  and an air outlet  305  both positioned on the sidewall  303 . The air inlet  304  can be positioned at a first height H1 of the sidewall  303 , and the air outlet  305  can be positioned at a second height H2 of the sidewall  303 . In the illustrated embodiment, the first height H1 is lower than the second height H2. In some embodiment, the first height H1 can be higher than the second height H2. In other embodiments, the first height H1 and the second height H2 can be substantially the same. Also, while shown in the sidewall  303 , the air inlet  304  and air outlet  305  may be positioned on either the top or bottom surfaces  301 ,  302 . 
     In the illustrated embodiment, the air inlet  304  can be a rectangular opening, while the air outlet  305  can be a slot. The slot can have a width less than the dimension of individual lightweight components, so as to prevent individual lightweight components from leaving the cyclonic chamber  300  through the slot. In other embodiments, the air inlet  304  and the air outlet  305  can be in other suitable shapes, such as circles or polygons. Also, rather than a simple opening, the air inlet  304  may include a nozzle, jet, filter, perforations, or the like. Similarly, the air outlet  305  may include a screen, mesh, cover, flap, or the like. 
     With reference to  FIG. 3 , an air airflow path can be defined by an air mover (e.g., the air mover  101  or  203 ), the cyclonic chamber  300 , and a debris collection component (e.g., the debris collection component  103  or  202 ). The airflow path can include an incoming airflow path A1, a cyclonic airflow path A2, and an exhaust airflow path A3. The incoming airflow path A1 may start from ambient air to the air inlet  304  of the cyclonic chamber  300 . In certain aspects, the incoming airflow may originate at a source of air, such as a tank or bottle. In some embodiments, the air mover can be positioned in the incoming airflow path A1 (e.g., as embodiments described in  FIG. 1 ). In other embodiments, the air mover can be positioned in the exhaust airflow path A3 (e.g., as embodiments described in  FIG. 2 ). 
     The cyclonic airflow path A2 can travel inside the cyclonic chamber  300  from the air inlet  304  to the air outlet  305 . In the illustrated embodiment, the cyclonic airflow path A2 can include an upward-spiral airflow path (as oriented and view on  FIG. 3 ). In other embodiments, the cyclonic airflow path A2 can include linear, non-linear, circular, or irregular (e.g., turbulent) airflow paths. The lightweight components positioned in the cyclonic chamber  300  can be moved, rotated, or carried along the cyclonic airflow path A2, causing the lightweight components to hit against one another or against the sidewall  303 , so as to separate undesirable debris from the lightweight components. 
     The exhaust airflow path A3 can start from the air outlet  305  of the cyclonic chamber  300  to ambient air, passing through the debris collection component (e.g., the debris collection component  103  or  202 ). The separated debris can be carried away along the exhaust airflow path A3 and collected by the debris collection component. The debris collection component can be a filter, collection chamber, catch box, or any other suitable means. 
       FIG. 4  illustrates a cyclonic chamber  400  in accordance with another exemplary embodiment of the present technology. As shown in  FIG. 4 , the cyclonic chamber  400  can include a top surface  401 , a bottom surface  402 , and a sidewall  403 . In some embodiments, the cyclonic chamber  400  can include an operably detachable cap or lid  406  positioned on the top surface  401 , allowing a user to position the lightweight components to be cleaned in the cyclonic chamber  400 , and/or remove the same therefrom. 
     In the illustrated embodiment, the cyclonic chamber  400  can include an air inlet  404  and an air outlet  405 . The air inlet  404  can be positioned on the sidewall  403 . The cyclonic chamber  400  can include a wire mesh  407  positioned at the air outlet  405  on the bottom surface  402  of the cyclonic chamber  400 . The wire mesh  407  can facilitate retaining the lightweight components in the cyclonic chamber  400 . In other words, only separated debris can be carried by airflow passing through the wire mesh  407 . In other embodiments, the wire mesh  407  can be replaced by a screen, sieve, strainer, sifter, or the like. 
     Similar to the embodiments described in  FIG. 3  above, an air airflow path can be defined by an air mover, the cyclonic chamber  400 , and a debris collection component. With reference to  FIG. 4 , the airflow path can include an incoming airflow path B1, a cyclonic airflow path B2, and an exhaust airflow path B3. The incoming airflow path B1 can start from ambient air to the air inlet  404  of the cyclonic chamber  400 . The cyclonic airflow path B2 can travel inside the cyclonic chamber  400  from the air inlet  404  to the air outlet  405 . In the illustrated embodiment, the cyclonic airflow path B2 can include a downward-spiral airflow path (as oriented and view on  FIG. 4 ). In other embodiments, the cyclonic airflow path B2 can include linear, non-linear, circular, or irregular (e.g., turbulent) airflow paths. The lightweight components positioned in the cyclonic chamber  400  can be moved, rotated, or carried along the cyclonic airflow path B2, causing the lightweight components to hit against one another or against the sidewall  403 , so as to separate undesirable debris from the lightweight components. The exhaust airflow path B3 starts from the air outlet  404  of the cyclonic chamber  400  to ambient air, passing through the debris collection component. The separated debris can be carried away along the exhaust airflow path B3 and collected by the debris collection component. 
       FIG. 5  is a schematic top view of a cyclonic chamber  500  in accordance with an exemplary embodiment of the present technology. As shown in  FIG. 5 , the cyclonic chamber  500  can include an air inlet  501  positioned on a sidewall  502 . The cyclonic chamber  500  can further include an air-guiding component  503  positioned adjacent to the air inlet  501 . In the illustrated embodiment, the air-guiding component  503  can be a guide plate. In other embodiments, the air-guiding component  503  can be a guide board, baffle, duct, pipe, nozzle, jet, or other suitable means for directing air flow. As shown in  FIG. 5 , the air-guiding component  503  defines an incoming airflow path C1 entering into the cyclonic chamber  500  in a substantively tangential direction (e.g., ±15 degrees relative to the tangential direction of the cyclonic chamber  500 ). This arrangement facilitates forming a cyclonic airflow path C2 inside the cyclonic chamber  500 . 
       FIG. 6  is a schematic top view of a cyclonic chamber  600  in accordance with another exemplary embodiment of the present technology. As shown in  FIG. 6 , the cyclonic chamber  600  can include an air inlet  601  positioned on a sidewall  602 . The cyclonic chamber  600  can further include an air-guiding component  603  positioned adjacent to the air inlet  601 . In the illustrated embodiment, the air-guiding component  603  can be a guide plate. In other embodiments, the air-guiding component  603  can be a guide board, baffle, duct, pipe, nozzle, jet or other suitable means for directing air flow. As shown in  FIG. 6 , the air-guiding component  603  defines an incoming airflow path D1 entering into the cyclonic chamber  600  in a direction that forms an angle θ with the tangential direction of the cyclonic chamber  600 . The angle θ can be an acute angle ranging from 15 to 85 degrees. This arrangement facilitates forming a cyclonic airflow path D2 inside the cyclonic chamber  600 . 
       FIG. 7  is a schematic side view of a cyclonic chamber  700  in accordance with an exemplary embodiment of the present technology. As shown in  FIG. 7 , the cyclonic chamber  700  is in fluid communication with an air mover  701  via an air-guiding component  702 . The air-guiding component  702  can be connected with the cyclonic chamber  700  at an air inlet  703  on a sidewall  704  of the cyclonic chamber  700 . The air-guiding component  702  can be used to adjust the direction or the flow velocity of the airflow generated by the air mover  701 , before it flows into the cyclonic chamber  700 . In the illustrated embodiment, the air-guiding component  702  can be an asymmetric air duct with a convergent portion  705 . The convergent portion  705  can be used to accelerate the flow speed of incoming airflow E1. In various embodiments, the flow speed of the incoming airflow E1 can be determined based on various factors, such as the types of the air mover  701 , the sizes and/or materials of the lightweight components positioned in the cyclonic chamber  700 , the size and/or shape of the cyclonic chamber  700 , or required cleaning results. In other embodiments, the air-guiding component  702  can have a symmetric shape (e.g., a portion of the Venturi device). 
       FIG. 8  is a flowchart depicting a method  800  in accordance with an exemplary embodiment of the present technology. The method  800  relates to removing debris from a plurality of lightweight components. With reference to  FIG. 8 , the method  800  can start at block  801  by positioning the plurality of lightweight components in a cyclonic chamber (such as the cyclonic chamber  102 ,  201 ,  300 ,  400 ,  500 ,  600 , or  700  described above). In some embodiments, the lightweight components can be placed in the cyclonic chamber by suitable delivery systems (e.g., a belt conveyer). In other embodiments, the lightweight components can be placed in the cyclonic chamber manually. 
     The method can continue at block  802  by providing an incoming airflow path to the cyclonic chamber along a substantial tangential direction (e.g., arrow C1 in  FIG. 5 ). In other embodiments, the incoming airflow path can enter into the cyclonic chamber in a direction that forms an angle θ with the tangential direction of the cyclonic chamber (e.g., arrow D1 in  FIG. 6 ). In the illustrated embodiment, the incoming airflow path can be at least partially defined by an air-guiding component. The air-guiding component can be a guide plate/board, baffle, duct, pipe, nozzle, jet, or other suitable means. 
     At block  803 , the method  800  can proceed by generating cyclonic airflow in the cyclonic chamber. The cyclonic airflow can include an upward-spiral airflow path (e.g., A2 in  FIG. 3 ) or a downward-spiral airflow path (e.g., B2 in  FIG. 4 ). In some embodiments, the cyclonic airflow can include linear, non-linear, circular, or irregular (e.g., turbulent) airflow paths. In some embodiments, the cyclonic airflow can be generated by an air mover (e.g., the air mover  101 ,  203 , or  701 ). In some embodiments, the cyclonic airflow can be generated at least partially by mechanically and/or manually rotating the cyclonic chamber. 
     At block  804 , the method  800  can proceed by carrying, moving, or rotating the plurality of lightweight components by the cyclonic airflow. The lightweight components positioned in the cyclonic chamber can be moved, rotated, or carried by the cyclonic airflow along the cyclonic airflow path. At block  805 , the method  800  can continue by removing debris attached with the plurality of lightweight components at least by causing the plurality of lightweight components to hit against one another or against an inner surface of the cyclonic chamber. Vibration caused by the impact or clash among the lightweight components can effectively remove or separate undesirable debris attached therewith. 
     At block  806 , the method  800  can end by collecting the removed debris by a debris collection component. Once the debris is separated, it will be transported outside the cyclonic chamber by exhaust airflow (e.g., A3 in  FIG. 3  or B3 in  FIG. 4 ). The exhaust airflow can direct the separated debris to the debris collection component. The debris collection component can be a debris collection chamber (or a catch box) or a filter. In some embodiments, the method  800  can further include a step of directing the cyclonic airflow to leave the cyclonic chamber via a slot. The slot, as an air outlet of the cyclonic chamber, can have a width less than the dimension of the individual lightweight component, so as to prevent the individual lightweight component from leaving the cyclonic chamber through the slot. 
     The technology of the present application will now be described more fully below with reference to the accompanying figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the technology of the present application. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense. 
     Although the technology has been described in language that is specific to certain structures and materials, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific structures and materials described. Rather, the specific aspects are described as forms of implementing the claimed invention. Because many embodiments of the invention can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, etc. used in the specification (other than the claims) are understood as modified in all instances by the term “approximately.” At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the claims, each numerical parameter recited in the specification or claims which is modified by the term “approximately” should at least be construed in light of the number of recited significant digits and by applying ordinary rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass and provide support for claims that recite any and all subranges or any and all individual values subsumed therein. For example, a stated range of 1 to 10 should be considered to include and provide support for claims that recite any and all subranges or individual values that are between and/or inclusive of the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).