Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of prior International Application No. PCT/KR2008/001947, filed Apr. 7, 2008, which claims priority to Korean Patent Application No. 10-2007-0043974, filed on Jul. 5, 2007, all of which are herein incorporated by reference in their entireties. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to a dust separator of a vacuum cleaner, and, more particularly, to a dust separator of a vacuum cleaner having a body including an air inlet formed in the body configured to receive an air flow containing dust, and a dust outlet formed to discharge dust separated in the body. 
         [0004]    2. Description of Related Art 
         [0005]    In general, a vacuum cleaner is an apparatus that uses suctioning force imparted by a suction motor installed in a main body to suction air including dust and filter the dust within the main body. Such vacuum cleaners can largely be divided into canister vacuum cleaners that have a suctioning nozzle provided separately from and connected with a main body, and upright vacuum cleaners that have a suctioning nozzle coupled to the main body. 
         [0006]    A related art vacuum cleaner includes a vacuum cleaner main body, and a dust separator installed in the vacuum cleaner main body for separating dust from air. The dust separator is generally configured to separate dust using a cyclone principle. Because performance of this these vacuum cleaners can be rated based on the fluctuating range of their dust separating performance, dust separators for vacuum cleaners have continuously been developed to provide improved dust separating performance. 
         [0007]    Also, from a user&#39;s perspective, dust separators for vacuum cleaners that can be easily separated from the vacuum cleaner main body, and that enable dust to easily be emptied, are desired. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    An object of the present invention is to provide a dust separator of a vacuum cleaner with improved dust separating performance. 
         [0009]    Another object of the present invention is to provide a dust separator of a vacuum cleaner having a dust container with a simplified configuration to allow a user to easily empty dust. 
         [0010]    A further object of the present invention is to provide a dust separator of a vacuum cleaner that allows a user to use minimal exertion to handle a dust container. 
         [0011]    According to one aspect of the present invention, a dust separator for a vacuum cleaner including a body having a pair of spaced apart ends, a first air inlet formed in the body and being configured to receive an air flow containing dust, and a dust outlet formed inwardly of the spaced apart ends and apart from the first air inlet to discharge dust separated in the body, is provided. In addition, a cross-sectional area of the body at the dust outlet is greater than a cross-sectional area of the body at the first air inlet. 
         [0012]    In accordance with another aspect of the present invention, a dust separator for a vacuum cleaner including a body having a first air inlet formed therein, the first air inlet being configured to receive an airflow containing dust, a first air outlet, and a dust outlet to discharge dust separated in the body, is provided. In addition, a cross-sectional area of the dust separator at the dust outlet is greater than a cross-sectional area of the dust separator at the first air outlet. 
         [0013]    In accordance with another aspect of the present invention, a vacuum cleaner is also provided. The vacuum cleaner includes a dust separator as described above, a dust container to collect dust discharged through the dust outlet, and a suction motor in communication with the dust separator. 
         [0014]    Further scope of applicability of the present application will become more apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from the detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention and wherein: 
           [0016]      FIG. 1  is a front perspective view of a dust separator of a vacuum cleaner according to a first exemplary embodiment of the present disclosure; 
           [0017]      FIG. 2  is a rear perspective view of the dust separator of  FIG. 1 ; 
           [0018]      FIG. 3  is a disassembled perspective view of the dust separator of  FIG. 1 ; 
           [0019]      FIG. 4  is a sectional view taken along line IV-IV of  FIG. 1 ; 
           [0020]      FIG. 5  is a sectional view taken along line V-V of  FIG. 1 ; 
           [0021]      FIG. 6  is a schematic view similar to  FIG. 4  showing airflow within the dust separator of  FIG. 1 ; 
           [0022]      FIG. 7  is a schematic view similar to  FIG. 5  showing airflow within the dust separator of  FIG. 1 ; 
           [0023]      FIG. 8  is a perspective view of a dust separator according to a second exemplary embodiment of the present disclosure; 
           [0024]      FIG. 9  is a sectional view taken along line IX-IX of  FIG. 8 ; 
           [0025]      FIG. 10  is a perspective view of a dust separator according to a third exemplary embodiment of the present disclosure; and 
           [0026]      FIG. 11  is a sectional view taken along line XI-XI of  FIG. 10 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    Below, detailed descriptions of exemplary embodiments of the present invention will be provided with reference to the drawings. 
         [0028]    Referring to  FIGS. 1 to 3 , a dust separator  1  of a vacuum cleaner according to a first exemplary embodiment of the present invention includes a dust separating unit  10  that separates dust from suctioned air, a dust container  20  for storing dust separated by the dust separating unit  10 , a suctioning guide  30  that guides the flow of air including dust toward the dust separating unit  10 , and a distribution unit  40  for distributing the air in the suctioning guide  30  to the dust separating unit  10 . 
         [0029]    In detail, air suctioned through a suctioning nozzle (not shown) flows to the suctioning guide  30 . The suctioning guide  30  is provided inside the vacuum cleaner, and is disposed below the dust container  20 . The suctioning guide  30  has the distribution unit  40  connected thereto. The dust separating unit  10  separates dust from air supplied from the distribution unit  40 . The dust separating unit  10  uses the cyclone principle to separate dust from air, and includes a cyclone  110  for this purpose. The cyclone  110  is formed to have a diameter greater at its middle than at either end thereof. The axis of the cyclone  110  extends in a horizontal direction. Thus, the air within the cyclone  110  rotates in a vertical direction. 
         [0030]    A pair of air inlets  120  is formed (one on either side) at the cyclone  110  and are arranged to suction air. The pair of air inlets  120  may be formed in tangential directions with respect to the cyclone  110  in order to generate cyclone airflows within the cyclone  110 . The pair of air inlets  120  provides suctioning passages for air entering the cyclone  110 . Each air inlet  120  is connected at opposite sides of the distribution unit  40 . Therefore, the air that flows through the suctioning guide  30  is branched at either side at the distribution unit  40 , and the branched air rises along the respective air inlets  120  to be suctioned into the cyclone  110 . 
         [0031]    A dust outlet  130  that exhausts dust separated within the cyclone  110  is formed at the center of the cyclone  110 . 
         [0032]    Accordingly, the dust separated from air suctioned through each air inlet  120  at either side of the cyclone  110  moves to the center of the cyclone  110 . Next, the dust that flows to the center of the cyclone passes through the dust outlet  130  and is discharged to the dust container  20 . In this first exemplary embodiment, the dust outlet  130  is formed tangentially with respect to the cyclone  110  to allow easy discharging of dust. Thus, the dust separated in the cyclone  110  is discharged tangentially with respect to the cyclone  110 —that is, in the same direction in which the dust has been rotating—allowing easy discharging of not only dust with higher density, but also easy discharging of dust with lower density from the cyclone  110 . Because dust with lower density can easily be discharged, less dust with lower density will accumulate on a filter member (to be described below), thereby facilitating flow of air and improving dust separating performance. 
         [0033]    Also, air outlets  140  are formed on opposite sides of the cyclone  110  and are configured to discharge air separated from dust in the cyclone  110 . The air discharged through the air outlets  140  converges at a converging passage  142  and enters the main body of the vacuum cleaner (not shown). 
         [0034]    The dust container  20  stores dust separated in the dust separating unit  10 . Because the dust container  20  is installed on the vacuum cleaner main body, the dust container  20  communicates with the dust separating unit  10 . Specifically, when the dust container  20  is installed on the vacuum cleaner main body, the dust container  20  is disposed below the dust separating unit  10 . Thus, a dust inlet  210  is formed in the upper side of the dust container  20 . Also, the dust outlet  130  extends downward from the cyclone  110  toward the dust inlet  210 . Accordingly, the dust separated in the cyclone  110  moves downward along the dust outlet  130 , and the separated dust can easily enter the dust container  20 . 
         [0035]    A cover member  220  is coupled at the bottom of the dust container  20  to discharge dust stored within. The cover member  220  may be pivotably coupled to the dust container  20 , and may be detachably coupled thereto, as well. The coupling method of the cover member  220  in the first exemplary embodiment is not restricted to any particular methods. Thus, the dust container  20  is provided as a separate component to the dust separating unit  10 , and is configured to be selectively communicable with the dust separating unit  10 . Accordingly, a user can separate only the dust container  20  from the vacuum cleaner main body to empty dust stored in the dust container  20 . 
         [0036]    Because a structure for separating dust within the dust container  20  is not provided, the structure of the dust container  20  is simplified and the weight of the dust container  20  can be minimized. By minimizing the weight of the dust container  20 , a user can easily carry and handle the dust container  20 , and because the internal structure of the dust container  20  is simple, dust can easily be emptied, and a user can easily clean the inside of the dust container  20 . 
         [0037]    Having described the dust separator  1  according to the first exemplary embodiment generally, a more specific description is provided with reference to  FIGS. 4 and 5 . Referring to  FIGS. 4 and 5 , the cyclone  110  includes a body  111  for generating cyclone airflow, and a pair of sides  115 , each constituting opposite sides of the body  111 . The sides  115  extend parallel to one another. 
         [0038]    An air inlet  120  is formed on opposite side of the body  111 , respectively. Each air inlet  120  is formed tangentially with respect to the cyclone  110 . Thus, the air suctioned through each air inlet  120  forms one of two cyclone airflows within the cyclone  110  and the cyclone airflows circulate along the inner surface of the body  111 . Thus, when a pair of cyclone airflows is generated within a single space, the flow volume of air is increased, loss of airflow is reduced, and separating performance can be improved and the cyclone can be formed smaller than with a single cyclone airflow generated in a single space. 
         [0039]    In this first exemplary embodiment, even if the cyclone  110  is formed smaller than in the related art, the centrifugal force generated at the air inlets  120  is greater than in the related art, thus improving dust separating performance. Also, when a pair of cyclone airflows is generated in a single space, the same level of dust separating performance as in a structure where air passes through a plurality of dust separating units can be realized. Thus, additional dust separating units for separating dust from air discharged from the dust separating unit are not required. However, additional dust separating units incorporating features of this first exemplary embodiment may be provided. 
         [0040]    Furthermore, when a pair of cyclone airflows is generated with one at either side of the cyclone  110  and the cyclone airflows flow toward the center, the cyclone airflow at the center increases. Therefore, a stronger cyclone airflow is generated at the center of the cyclone  110  than at the sides of the air inlets  120 . As a result, when the pair of cyclone airflows converges at the center of the cyclone  110 , the strength of the airflow is greater than in the case where a single cyclone airflow is generated in a single space, thereby increasing dust separating performance. 
         [0041]    Dust that moves to the center of the cyclone  110  can be discharged through the dust outlet  130  to the dust container  20  by means of the strong cyclone airflow, so that dust discharging performance can be increased. In addition, hair and other impurities that normally would adhere to the entrance or the inside of the dust outlet  130  because of static electricity do not adhere to the dust outlet  130  and are easily discharged to the dust container  20  because of the strong cyclone airflow generated at the dust outlet  130 . 
         [0042]    In this first exemplary embodiment, the cyclone  110  is formed so that its diameter increases from either side toward the center. Accordingly, the greatest diameter of the cyclone  110  is at its center  113 . Thus, because the cyclone  110  is formed to have a diameter that increases toward its center, a pair of cyclone airflows that is generated at either end of the cyclone  110 , respectively, can easily flow toward the center and converge. The cyclone airflows generated within the cyclone  110  move toward the center and converge, and the cyclone airflows that converge at the center of the cyclone move laterally at the center. Accordingly, in this first exemplary embodiment, the region of the cyclone  110  with the greatest diameter is at the center  113  in order to allow easy convergence of the respective cyclone airflows at the center  113  and prevent lateral movement. In particular, because the diameter at the center of the cyclone  110  is greater than at either side, the velocity of cyclone airflow at the center of the cyclone  110  decreases, thereby reducing the formation of eddies at the center of the cyclone  110 . 
         [0043]    The upper and lower perimeters  132  and  134  of the dust outlet  130  may form angles corresponding to the tilted angles of the cyclone  110 . 
         [0044]    When the diameter at the center of the cyclone  110  is greater than at either side, the center of the cyclone  110  may be configured to be mounted above the dust container  20 . Therefore, the dust container  230  may include a mounting recess  230  to mount the central portion of the cyclone  110  on. 
         [0045]    An outlet  116  is formed to pass through each side  115  to discharge air from which dust is separated in the cyclone  110 . Also, a filter member  150  is coupled to each outlet  116  to filter the discharged air. In particular, the filter member  150  is configured with a cylindrical fastener  152  fastened to the inside of the cyclone  110 , and a conical filter  154  extending from the fastener  152  to filter air. Also, a plurality of holes  156  is formed in the filter  154  for air to pass through. Accordingly, air separated from dust in the cyclone  110  passes through the plurality of holes  156  and is discharged from the cyclone  110  through the outlets  116 . 
         [0046]    In this first exemplary embodiment, the fastener  152  does not have through-holes formed therein so that air suctioned through the air inlet  120  is not immediately discharged, but is able to smoothly circulate within the cyclone  110 . That is, because of the fasteners  152 , the circulation of suctioned air can be guided to generate a smooth cyclone airflow within the cyclone  110 , thereby increasing dust separating performance. 
         [0047]    As seen in  FIG. 4 , a length (L 1 ) between the pair of filter members  150  provided within the cyclone may be made greater than a width (L 2 ) of the dust outlet  130 . In this first exemplary embodiment, when the length (L 1 ) between the pair of filter members  150  is made smaller than the width (L 2 ) of the dust outlet  130 , impurities such as hair and tissue paper are not discharged through the dust outlet  130 , and can adhere to the filter member  150  or lodge inside the holes  156 . As a result, the air cannot easily pass through the filter member  150 , causing a reduction in suctioning force. Accordingly, the length (L 1 ) between the pair of filter members  150  is made greater than the width (L 2 ) of the dust outlet  130  so that impurities such as hair and tissue paper can be completely discharged through the dust outlet  130 . 
         [0048]    As described above in this first exemplary embodiment, air is suctioned through the plurality of air inlets  120  into the cyclone  110 , and air separated from dust in the cyclone  110  is discharged from the cyclone  110  through the plurality of outlets  116 . Thus, air that is suctioned into the cyclone  110  through the respective air inlets  120  is discharged through the respective outlets  116  to allow easy discharging of air. When air is thus easily discharged from the cyclone  110 , suctioning force is actually increased, and cyclone airflow within the cyclone  110  is smoothly performed. Also, even when dust collects on one of the filter members  150  so that air cannot flow easily therethrough, air can be discharged through the other filter member  150 , thereby preventing a sudden loss of air suctioning force. 
         [0049]    An opening  112  is formed on the body  111  of the cyclone  110  to allow replacing and cleaning of the filter member  150 . The opening  112  is opened and closed by means of a cover member  160 . A sealing member  114  is provided at the coupling region of the opening  112  and the cover member  160 . In this first exemplary embodiment, the inner surface of the cover member  160  may be formed to have the same curvature as the inner periphery of the body  111  when the cover member  160  is coupled to the body  111 . Accordingly, changes to the cyclone airflow due to the cover member  160  within the cyclone  110  can be prevented, and the cyclone airflow can be uniformly maintained. Also, because the cover member  160  is detachably coupled to the cyclone  110 , a user can detach the cover member  160  to easily replace the filter members  150  and easily clean the inside of the cyclone  110  and the filter members  150 . 
         [0050]    A dust compartment  202  for storing dust is defined within the dust container  20 , and a dust inlet  210  is defined in the top of the dust container  20 . Also, a sealing member  212 , for sealing the contacting region between the dust inlet  210  and the dust outlet  130 , is provided on the dust inlet  210 . Here, the sealing member  212  may also be provided on the dust outlet  130 . 
         [0051]    The operation of the dust separator  1  will be described with reference to  FIGS. 6 and 7 . When suctioning force is generated by the vacuum cleaner, air including dust flows along the suctioning guide  30 . The air flowing through the suctioning guide  30  flows to the distribution unit  40  and is distributed to each air inlet  120  by the distribution unit  40 . Then, the air, including dust, passes through each air inlet  120  and is suctioned in tangential directions at either side of the cyclone  110 . 
         [0052]    The suctioned air rotates along the inner surface of the cyclone  110  to move toward and converge at the center of the cyclone  110 . During this process, air and dust are subjected to different centrifugal forces due to their differences in weight, so that dust is separated from the air. The separated dust (represented by the broken lines) is discharged from the center of the cyclone  110  through the dust outlet  130 , and the discharged dust flows through the dust outlets  130  and into the dust container  20 . Conversely, air (represented by the solid lines) separated from dust is filtered by the filter members  150 , and then passes through the outlets  116  and is discharged from the cyclone  110 . The discharged air flows through the respective air outlets  140 , converges at the converging passage  142 , and enters the main body of the vacuum cleaner. 
         [0053]    Having described a dust separator for a vacuum cleaner according to a first exemplary embodiment above, a dust separator for a vacuum cleaner according to a second exemplary embodiment will be described with reference to  FIGS. 8 and 9 . The second exemplary embodiment is the same as the first exemplary embodiment in all other aspects except that it is characterized by a difference in the shape of the cyclone. Therefore, description will be provided of only the different portions of the second exemplary embodiment. 
         [0054]    As shown in  FIGS. 8 and 9 , a dust separator  55  a cyclone  550  having a diameter greater at the center than at either end thereof. In particular, the cyclone  550  includes a cylindrical portion  552  with substantially constant diameter for a predetermined distance toward a center  555  from either end, and an oblique portion  553  extending from the cylindrical portion  552  and increasing in diameter toward the center  555 . The cyclone  550  is formed symmetrically to the left and right of the center  555 . A dust outlet  570  through which dust is discharged is formed in the oblique portion  553 . Accordingly, cyclone airflows generated in the cylindrical portions  552  move toward the oblique portions  553  and converge at the center  555  of the cyclone, and are prevented from moving laterally further by the center  555 . 
         [0055]    A dust separator for a vacuum cleaner according to a third exemplary embodiment of the present invention is shown in  FIGS. 10 and 11 . The third exemplary embodiment is the same as the first exemplary embodiment in all other aspects except that it is characterized by a difference in the shape of the cyclone. Therefore, description will be provided of only the different portions of the third exemplary embodiment. 
         [0056]    Referring to  FIGS. 10 and 11 , a dust separating unit  60  according to the third exemplary embodiment includes a cyclone  600  with a diameter greater at the center than at either end thereof. The cyclone  600  includes a pair of cylindrical portions  610 , and an expanded portion  611  formed between the cylindrical portions  610  and having a diameter (D 2 ) greater than a diameter (D 1 ) of the cylindrical portions  610 . The expanded portion  611  is also cylindrical. The cyclone  600  is symmetrical to the left and right of the expanded portion  611 . A dust outlet  630 , for discharging dust separated in the cyclone, is formed in the expanded portion  611 . In this exemplary embodiment, the width of the expanded portion  611  and the width of the dust outlet  630  may be equal, or the width of the dust outlet  630  may be less than the width of the expanded portion. 
         [0057]    The pair of cyclone airflows generated in the cyclone  600  moves in mutually convergent directions, for example, toward the expanded portion  611 , and combine together. In addition, the expanded portion  611  confines the lateral movement of the cyclone airflows therein to maintain stable cyclone airflow. Also, because the diameter (D 1 ) of the expanded portion  611  is greater than the diameter (D 2 ) of the cylindrical portions  610 , dust that moves to the expanded portion  611  is prevented from moving toward the filter members  640 . 
         [0058]    An opening  612  is defined in the expanded portion  611 . The opening  612  is opened and closed by means of a cover member  620  coupled to the expanded portion  611 . Therefore, when a user separates the cover member  620 , the inside of the cyclone  600  and the filter members  640  can be cleaned. 
         [0059]    Having described several exemplary embodiments of the present invention, one or more of these embodiments may provide various advantages over the related art dust separators. For example, because a plurality of air inlets is formed in a dust separator, and a plurality of cyclone airflows is formed within the dust separator, the airflow volume is increased and airflow loss is reduced, thereby improving dust separating performance. 
         [0060]    Also, because air inlets are formed at either side of the dust separator, and a dust outlet is formed in the center of the dust separator, a forceful cyclone airflow is generated at the central portion of the dust separator to allow dust to be easily discharged. 
         [0061]    Because the diameter at the center of the dust separator is greater than those at either end thereof, the center of the dust separator becomes the center of airflow, thereby ensuring reliable airflow. That is, the formation of eddies at the central portion of the dust separator can be reduced. In addition, cyclone airflows can easily converge at the center of the dust separator. 
         [0062]    Furthermore, because a dust outlet is formed tangentially to the dust separator, the dust can be discharged in the same direction in which it has been rotating. Thus, not only can dust of higher density be easily discharged, dust of lower density can also be discharged easily from the dust separator. 
         [0063]    Because a cover member is detachably coupled to the dust separator, a user can easily clean the inside of the dust separator and the filter member. 
         [0064]    The invention thus being described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

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