Patent Publication Number: US-2016236210-A1

Title: System and method for air filtration via cyclone separators enclosed within exterior walls

Description:
REFERENCES TO PRIOR APPLICATIONS 
     This application is a continuation of co-pending non-provisional application, reference Ser. No. 13/998,597 filed Nov. 15, 2013, entitled SYSTEM AND METHOD FOR AIR FILTRATION VIA CYCLONE SEPARATORS ENCLOSED WITHIN EXTERIOR WALLS, and claims benefit thereof. Non-provisional application Ser. No. 13/998,597 is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The invention relates to the design and structure of air filtration systems for buildings and architectural structures. More specifically, the invention relates to a system of interconnected cyclone separators built into exterior wall structures of buildings. 
     Filtration of breathing air has become important for the comfort, health, and safety of people living inside modern buildings and domestic structures. Commercial structures such as office buildings often have HVAC (heating, ventilation, and air conditioning) systems that pull in air from outside the building, and filter it to remove harmful particulates before adding this air to the re-circulated air inside the building. These systems are expensive and use a considerable amount of energy. Most single family homes and many apartment buildings have no such air filtration system, as outside air is introduced mainly through open windows. This method of “fresh” air infusion has only a minimum of particle filtration, consisting typically of insect screens. These screens do little to block the introduction of particulates into the home. As a result the homeowner may be exposed to allergy causing dust, pollen, soot, and other harmful particulates. This contamination results in the homeowner spending many hours trying to remove (dusting, vacuuming) these particulates from inside the home. Once introduced, the smaller particulates are extremely hard to remove due to their strong attraction to surfaces. Homeowners often employ expensive filtration units placed within the home to reduce airborne particle counts, particularly if a household member has allergies, asthma, or other respiratory ailments. 
     While the use of modern HVAC systems could be employed in single family homes and small apartment buildings, their capital cost is prohibitive to all but the most expensive high end homes and apartments. What is needed is a more cost effective air filtration system for single family dwellings. 
     Cyclone separators have been employed by modern industry for many years to separate solid particulates from gasses. Typically, they require moderately high gas velocities (or pressure drops) provided by compressors or fans. Rarely, if ever, are they employed in the filtration of air for domestic dwellings, particularly single family homes. Air filtration for domestic dwellings is typically carried out by pleated “flow through” filter systems. 
     Trudell, in a Masters degree thesis document submitted to the graduate faculty of Rensselaer Polytechnic Institute, published August 2012, suggests the incorporation of single cyclone separators fashioned within solid masonry wall construction blocks. These would utilize the pressure drop created by wind pressure outside the building to force contaminated air into the cyclone separator&#39;s inlet. The reverse flow cyclonic separation would create a particulate stream leaving the bottom of the cyclone and clean air leaving the exhaust at the top, which is directed into the interior of the building. 
     There are a number of difficulties with the approach suggested by Trudell. The entire cyclone structure must be fabricated within the body of each solid block, which requires rather precise masonry molding techniques due to the specific geometries required by the cyclone separators. This requirement increases the cost of the construction blocks, which may be prohibitive for low cost housing or for use in third world countries. Furthermore, the use of solid molded blocks limits the use of reinforcing steel (or re-bar), commonly used within masonry walls. 
     These and other limitations of the prior art will become apparent to those of skill in the art upon a reading of the following descriptions and a study of the several figures of the drawing. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a system for air filtration including: a first cyclone separator chamber having a cylindrically shaped portion disposed above a conically shaped portion, the conically shaped portion of the first cyclone separator chamber having a first gas flow circulating within; a second cyclone separator chamber having a cylindrically shaped portion disposed above a conically shaped portion, the conically shaped portion of the second cyclone separator chamber having a second gas flow circulating within, a port fashioned within a wall of the cylindrically shaped portion of the second cyclone separator chamber; and a cyclone separator coupler disposed between the conically shaped portion of the first cyclone separator chamber and the cylindrically shaped portion of the second cyclone separator chamber, the cyclone separator coupler operative to isolate the first gas flow from the second gas flow, wherein the cyclone separator coupler has an input on a top surface for particulates leaving the bottom of the first cyclone separator chamber, an unfiltered air inlet directing air through the port of said second cyclone separator chamber, and a baffle to introduce rotary air motion within the second cyclone separator chamber. 
     These and other embodiments, features and advantages will become apparent to those of skill in the art upon a reading of the following descriptions and a study of the several figures of the drawing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Several example embodiments will now be described with reference to the drawings, wherein like components are provided with like reference numerals. The example embodiments are intended to illustrate, but not to limit, the invention. The drawings include the following figures: 
         FIG. 1 a    is a perspective view of cyclone separator coupler mounted between two cyclone chambers in accordance with an example embodiment of the present invention; 
         FIG. 1 b    is a perspective view of a cyclone separator coupler in accordance with an example embodiment of the present invention; 
         FIG. 2  is a top view of a cyclone separator coupler in accordance with an example embodiment of the present invention; 
         FIG. 3  is a front view of a cyclone separator coupler in accordance with an example embodiment of the present invention; 
         FIG. 4  is a rear view of a cyclone separator coupler in accordance with an example embodiment of the present invention; 
         FIG. 5  is a bottom view of a cyclone separator coupler in accordance with an example embodiment of the present invention; 
         FIG. 6  is a side view of a cyclone separator coupler in accordance with an example embodiment of the present invention; 
         FIG. 7  is a partial cross section view through section B-B of  FIG. 2 , of a cyclone separator coupler in accordance with an example embodiment of the present invention; 
         FIG. 8  is a partial cross section view through section A-A of  FIG. 2 , of a cyclone separator coupler in accordance with an example embodiment of the present invention; 
         FIG. 9  is a front view of a cyclone separator coupler mounted between two cyclone separator chambers, in accordance with an example embodiment of the present invention; 
         FIG. 10  is a partial cross section side view of a cyclone separator coupler mounted between two cyclone separator chambers showing air flow paths, in accordance with an example embodiment of the present invention; 
         FIG. 11  is a partial cross section side view of a cyclone separator coupler mounted between two cyclone separator chambers showing particulate flow paths, in accordance with an example embodiment of the present invention; 
         FIG. 12  is a top view of a construction block having molded cyclone separator cavities, in accordance with an example embodiment of the present invention; 
         FIG. 13  is a cross section view through section C-C of  FIG. 12 , in accordance with an example embodiment of the present invention; 
         FIG. 14  is a cross section view of two stacked construction blocks of  FIGS. 12,13 , in accordance with an example embodiment of the present invention; 
         FIG. 15  is a top view of a hollow construction block having a cyclone separator coupler mounted within one hollow chamber, in accordance with an example embodiment of the present invention; 
         FIG. 16  is a top view of a hollow construction block having a cyclone separator coupler mounted within one hollow chamber, the construction block being filled with grout and re-bar, in accordance with an example embodiment of the present invention; 
         FIG. 17  is a partial cut-away side view of two stacked construction blocks of  FIG. 16 , in accordance with an example embodiment of the present invention; 
         FIG. 18  is a top view of a cyclone separator coupler mounted within a gasket for mounting between stacked hollow construction blocks, in accordance with an example embodiment of the present invention; 
         FIG. 19  is a partial cross section side view though section D-D of  FIG. 18 , in accordance with an example embodiment of the present invention; 
         FIG. 20  is a top view of a cyclone separator coupler mounted within a gasket for mounting between stacked hollow construction blocks, in accordance with an example embodiment of the present invention; and 
         FIG. 21  is a top view of a cyclone separator coupler mounted within a gasket for mounting between stacked hollow construction blocks, in accordance with an example embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     While the incorporation of cyclone separators within external walls of a dwelling has clear advantages over conventional HVAC air filtration techniques, the heretofore proposed implementation structures leave much to be desired. Casting of the complex cyclone structures within a fully enclosed masonry block proves to be difficult and expensive. Furthermore, since the individual intake and exhaust ports of each cyclone separator are isolated, control of how much air is introduced into the home is difficult without the addition of other baffle or wall structures. Embodiments of the present invention serve to significantly improve upon the basic concept, lowering costs while improving flexibility. Embodiments of the present invention allow for the incorporation of interconnected cyclone separators within a network of conventional “cinder” masonry blocks. Such a network allows for various air flow scenarios, including the feeding and exhausting of all cyclone separator units within passages fashioned within the walls themselves. If desired, a central air feed and central filtered air exhaust can be provided, allowing for flow control, insect control, and centralized feed to a conventional heating/air conditioning system. 
     Central to the embodiments of the present invention is a modified structure of the cyclone separator comprising a coupler and a cyclone chamber. The coupler is provided with the dirty air inlet, the clean air outlet, and the required internal baffling to induce the required directional airflows in the cyclone chamber to which the coupler is attached. The coupler further provides for connection to another cyclone chamber mounted above it, having a built in flow passage for disposing of the particle stream exiting the above mounted cyclone chamber. 
       FIG. 1 a    is a perspective view of cyclone separator coupler  100  mounted between two cyclone chambers  101   a ,  101   b  in accordance with an example embodiment of the present invention.  FIG. 1 b    is a perspective view of a cyclone separator coupler  100 . Cyclone separator coupler  100  has a dirty air inlet  102 , a filtered air outlet  110 , waste particle inlet  104 , and waste particle chute  106 . Baffle  108  serves to direct inlet air flow to induce centripetal motion in cyclone chamber  101   b , while at the same time directing clean air from cyclone chamber  101   b  to the filtered air outlet  110 . Although a single coupler  100  connecting two cyclone chambers  101  is shown in  FIG. 1 , it will be evident to those skilled in the art that numerous cyclone chambers can be interconnected by a plurality of couplers in a similar manner. The coupler has the distinct advantage in that it incorporates all the complex air flow (and waste particle flow) baffling, and can be manufactured as a stand alone part, separate from the cyclone chambers. It can be molded, cast, or machined from metals or plastics, depending on the required durability and cost of the intended application. The cyclone chambers can be provided as stand alone components (which attach to the couplers), or molded cavities within the masonry construction block. For details please refer to the example embodiments described below. 
       FIG. 2  is a top view  200  of a cyclone separator coupler  100  in accordance with an example embodiment of the present invention.  FIG. 3  is a front view  300  of cyclone separator coupler  100 .  FIG. 4  is a rear view  400  of cyclone separator coupler  100 . Inlet air passage  302  directs unfiltered air around baffle  108  into cyclone chamber (not shown). Filtered air from the base of the cyclone chamber (not shown) is directed through the center of baffle  108 , through passage  402 .  FIG. 5  is a bottom view  500  of cyclone separator coupler  100 . Broken line  502  represents the outer perimeter of a cyclone chamber mounted below coupler  100 .  FIG. 6  is a side view  600  of cyclone separator coupler  100 . Passage  602  provides for the transport of waste particles through chute  106 . 
       FIG. 7  is a partial cross section view  700  through section B-B of  FIG. 2 , of a cyclone separator coupler  100  in accordance with an example embodiment of the present invention.  FIG. 8  is a partial cross section view  800  through section A-A of  FIG. 2 , of a cyclone separator coupler  100 .  FIGS. 7 and 8  illustrate how the coupler  100  routes waste particles from the cyclone chamber above the coupler (not shown) via inlet  104  through passage  602  within waste chute  106 , while simultaneously directing clean filtered air from the cyclone chamber mounted below coupler  100  (not shown) through passage  402  to clean air outlet  110   
       FIG. 9  is a front view  900  of a cyclone separator coupler  100  mounted between two cyclone separator chambers  101   a ,  101   b , in accordance with an example embodiment of the present invention. 
       FIG. 10  is a partial cross section side view  1000  of a cyclone separator coupler  100  mounted between two cyclone separator chambers  101   a ,  101   b , showing air flow paths, in accordance with an example embodiment of the present invention. Cyclone separator chambers  101   a  and  101   b  have an aperture  1002  fashioned within the outer wall to accommodate the feed of unfiltered air from coupler  100  into the chambers. Unfiltered inlet air is directed via passage  302  around baffle  108 , which induces a circular swirling motion to within cyclone chamber  101   b . As the particle laden air follows the wall contours of chamber  101   b , it increases in velocity in the conical section where the diameter decreases. The centripetal forces separate the particles from the air, and the filtered air exits up through the swirling air at the outer walls of chamber  101   b  through passage  402  within baffle  108 . 
       FIG. 11  is a partial cross section side view  1100  of a cyclone separator coupler  100  mounted between two cyclone separator chambers  101   a ,  101   b  showing particulate flow paths, in accordance with an example embodiment of the present invention. Particles accumulating at the base of cyclone chamber  101   a , for example, are directed via passage  602  to particle waste chute. 
       FIG. 12  is a top view  1200  of a construction block  1202  having molded cyclone separator cavities  1204 - 1212 , in accordance with an example embodiment of the present invention. In this example embodiment, the cyclone separator coupler  100  (not shown) is utilized with molded cavities in a solid masonry block. Since the complex flow passages of the cyclone separator are already incorporated within the coupler, the molded cavities only need reproduce the shape of the cyclone chamber cavity  1210 , and the outer envelope of the coupler itself, cavity sections  1206 ,  1208 , and  1212 . Additionally, passages  1204  for waste particle disposal need be included. Cavities  1204 - 1212  are relatively easy to fabricate as they may be, for example, formed by solid mold inserts than can be removed from the top surface of the masonry block  1202  subsequent to curing. Subsequent to fabrication, a cyclone separator coupler  100  (not show) can be inserted into cavities  1206 ,  1208 , and  1212  to form the completed cyclone separator. Blocks containing other cyclone separators can be stacked vertically, after aligning the waste particle passages  1204  and the waste particle outlet of the cyclone chamber with the particle inlet  104  of the coupler mounted below (see  FIGS. 13,14 ). 
       FIG. 13  is a cross section view  1300  through section C-C of  FIG. 12 , in accordance with an example embodiment of the present invention.  FIG. 14  is a cross section view  1400  of two stacked construction blocks of  FIGS. 12,13 , in accordance with an example embodiment of the present invention. Mortar layer  1402  joins blocks  1202   a  and  1202   b , and is interrupted in the location where particle waste disposal passages  1204   a  and  1204   b  join, so that waste particles can flow freely down through the construction blocks. Particle inlet  106   a  of coupler  100   a , as an example, extends through mortar layer  1402  to index with cyclone chamber cavity  1210   a.    
     While the forgoing example embodiments illustrate how costs can be reduced by combining a cyclone separator coupler with cast cavities in construction blocks, an even more cost effective solution can be obtained by utilizing standard “cinder” blocks, or construction blocks having hollow cells. The hollow cells are typically filled with grout and re-bar (reinforcing steel bar) as the wall or structure is being constructed. They save shipping costs to the construction site because they are hollow and are considerably lighter than solid blocks. 
       FIG. 15  is a top view  1500  of a hollow construction block  1502  having a cyclone separator coupler  100  mounted within one hollow chamber, in accordance with an example embodiment of the present invention. In this particular example embodiment, the unfiltered air inlet  102  is being fed by air within open chamber  1508 . Coupler  100  is mounted adjacent to the separating internal wall  1510 . This may be done, for example, by notching the wall  1510  or by placing a hooking surface underneath the unfiltered air intake duct  102  (not shown) such that the coupler  100  is “hung” on the upper wall surface. The filtered air is exhausted into the second open chamber  1506 . Particles are deposited into plenum duct  1504 , which is sealed to prevent contamination or the filtered air. Typically, plenum duct  1504  is terminated at a hopper at the base of the wall so that accumulated particulates can be removed. In this example embodiment, the hollow chambers  1506 ,  1508  are not filled with grout or rebar. For a single vertical column of blocks, or even an array of columns placed within a wall, this may not prove to be limiting, as all the other block members within the wall would be filled with grout and re-bar if required. This example embodiment has some significant advantages. The unfiltered air intake for all cyclone separators in a vertical array becomes the plenum formed by empty cinder block chambers  1508 . Intake ducts can be fashioned to feed this plenum without any additional HVAC ducting, as the wall structure actually provides it. The requirement of air flowing down this feed duct to change direction to feed each individual cyclone separator provides another level of separation. Intake ducts (mounted at the top or bottom of the wall) can contain boost fans and insect screens to further enhance separation of the cyclones. The cyclones are completely installed within the wall, reducing the probability of intake fouling with insects or leaves and plant matter. Intake ducts can also be equipped with dampers or throttling devices to control the amount of air entering the home. In a similar manner, a single duct or network of ducts coupled to a plurality of chambers  1506  allows connection of filtered air to a central HVAC system, or direct feed into rooms within the home. In one example of this embodiment, a single cyclone separator (coupler plus chamber) is sized to fit within the height of a single cinder block row. However, as can be appreciated by those skilled in the art, this is not a rigid requirement. If longer cyclone chambers are required, then a single cyclone separator having a height of two cinder blocks (or ultimately n integer cinder blocks) may also be utilized. In yet another example embodiment, cyclone chambers may be connected to couplers via hollow tubing or ducting, to allow spacing of a small number of cyclone separators within tall wall structures. 
       FIG. 16  is a top view  1600  of a hollow construction block  1602  having a cyclone separator coupler  100  mounted within one hollow chamber  1606 , the construction block  1602  being filled with concrete and re-bar  1610 , in accordance with an example embodiment of the present invention. For the case where unfilled hollow construction blocks are not suitable due to structural considerations, the example embodiment illustrated in  FIG. 16  may be employed. Unfiltered air is supplied by duct  1612  which extends vertically through the wall. Duct  1612  may be connected to intake ducts having fans, screens, or throttling devices as previously described above. In this example embodiment, filtered air is directed through the construction block wall via extension duct  1614 . In another example embodiment, filtered air can be directed to another internal vertical duct, similar to duct  1612  (not shown). After installation of the array of cyclone separators, concrete and re-bar can be filled within the open chambers  1606 ,  1608  to meet structural requirements. 
       FIG. 17  is a partial cut-away side view  1700  of two stacked construction blocks of  FIG. 16 , in accordance with an example embodiment of the present invention. Stacked construction blocks  1602   a ,  1602   b  are cemented together with mortar layer  1702  and filled with grout. Cyclone separator coupler  100  is connected to two cyclone separator chambers  1704   a  and  1704   b , as shown in the cut away section. 
       FIG. 18  is a top view  1800  of a cyclone separator coupler  100  mounted within a gasket  1804  for mounting between stacked hollow construction blocks, in accordance with an example embodiment of the present invention.  FIG. 19  is a partial cross section side view  1900  though section D-D of  FIG. 18 . This example embodiment reduces assembly costs even further by incorporating the cyclone separator coupler  100  within a gasket that is approximately the thickness of a typical mortar layer. The gasket seals the interior of the hollow construction blocks its mounted between from the elements, while serving as a mounting platform for coupler  100 . In the example embodiment of  FIGS. 18 and 19 , the unfiltered air intake  102  extends through an exterior facing wall and the filtered air outlet  1802  extends through an interior wall. Cyclone separator chambers (not shown) would be attached to coupler  100  as the wall is being constructed, as well as a particle removal duct (not shown) such as  1504  in  FIGS. 15 and 16 . The gasket mounting has the distinct advantage of not requiring notching or modification of the construction blocks during assembly of the cyclone separator system. 
       FIGS. 20 and 21  are top views  2000 ,  2100  of cyclone separator couplers  100  mounted within a gasket for mounting between stacked hollow construction blocks, in accordance with example embodiments of the present invention. The example embodiment of  FIG. 20  is similar to that depicted in  FIG. 16 , except that coupler  100  is mounted within a gasket. Ducts  1504  and  1612  are not shown, but would be added during assembly of gasket  2002  between rows of hollow construction blocks, if needed (along with the cyclone separator chambers). The example embodiment of  FIG. 21  is similar to that depicted in  FIG. 15 , except that coupler  100  is mounted within gasket  2102 . 
     Although various embodiments have been described using specific terms and devices, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or the scope of various inventions supported by the written disclosure and the drawings. In addition, it should be understood that aspects of various other embodiments may be interchanged either in whole or in part. It is therefore intended that the claims be interpreted in accordance with the true spirit and scope of the invention without limitation or estoppel.