This started happening with both my DC41 and DC65 from day one. I know the high efficiency cyclones will never be 100% efficient. As airflow amounts change due to the tools used, and whether or not something (like a sofa cushion) is cutting off the airflow into the machine - the cyclone's efficiency changes. I knew fine dust would escape the cyclones and collect on the pre-motor filter.
What bothered me was the amount of fine dust on the outside of the filter, in the tube. I too, thought it was coming "around" the filter - but I now know that wasn't the case. The trap door on the bin has a large gasket. When the bin is emptied, the fine dust (from the fine dust collector) on the gasket is being pushed "up" into the tube. Static electricity, as well as a puff of air as the bin bottom is closed, puffs a bit of fine dust into the tube.
The problem is: as soon as the motor is started, this admittedly small amount of fine dust is inhaled into the motor. My DC65 and DC41's HEPA filters have dust on them when there normally would only be carbon residue.
I believe the fault lies in the fact that the airflow is coming from the bottom, not the top. This same thing happened with the Bissell Heavy Duty - the dust on the bin trap door seal got into the 'clean' air going into the motor.
The pictures are of my 2 year old DC41. The tremendous amount of fine dust that has escaped the cyclones is first. Second picture is of the seal on the bin trap door, showing how dangerously close the fine dust is to the motor's "clean" air intake. Third is of the fine dust collector - and how easy it is for this fine dust to find its way into the tube, as well as the motor's "clean" air intake.
