U.S. patent application number 09/746814 was filed with the patent office on 2001-08-23 for vacuum cleaner.
This patent application is currently assigned to REXAIR, INC.. Invention is credited to Daws, William R., Rohn, Dean, Selewski, Steven Ray.
Application Number | 20010015132 09/746814 |
Document ID | / |
Family ID | 23166782 |
Filed Date | 2001-08-23 |
United States Patent
Application |
20010015132 |
Kind Code |
A1 |
Rohn, Dean ; et al. |
August 23, 2001 |
Vacuum cleaner
Abstract
A vacuum cleaner assembly (10) comprising a main housing (12)
having an inlet (14) and an outlet (16). A motor (17a) is disposed
within the main housing (12) between the inlet (14) and the outlet
(16) for providing motive force to a cooling fan (17b), a blower
(17c), and a separator (22). The cooling fan (17b) is mounted
within the main housing (12) above the motor (17a) to circulate
cooling air around the motor (17a). The blower (17c) is mounted
within the main housing (12) below the motor (17a) for drawing air
into the inlet (14) and exhausting air outwardly through the outlet
(16). The separator (22) is mounted below the blower (17c) for
circulating the air and water bath (20) within a water bath pan
(36) and provides, in combination with the water bath (20), a
primary filter for filtering the air prior to exhausting the air
outwardly toward the outlet (16) of the vacuum cleaner to
atmosphere. A second filter assembly (24) is also provided
preferably including a high efficiency filter (100 or 100a), or
HEPA rated filter, for filtering microscopic dust and dirt
particles that escape the separator (22) and water bath (20) and is
disposed after both the water bath (20) and the separator (22) and
before the outlet (16) for additional filtering of the air prior to
being exhausted to atmosphere. Alternatively, it may be a non-HEPA
rated filter (101) in some combinations as follows. The second
filter assembly (24) may also include a third filter element, which
may be a carbon impregnated filter (110) for absorbing or trapping
odors and is disposed in the air flow path after the second filter
(100, 101, or 100a) and before the outlet (16) to atmosphere. The
second filter (100, 100a or 101) and third filter (110) element are
secured in a frame (112) as part of the second filter assembly
(24). The second filter (100, 101 or 100a) and the carbon
impregnated filter (110) within the frame (112) are disposed in a
recess (26) which is integral with the main housing (12) allowing
for direct and efficient flow of the air through the water bath
(20), separator (22), and second filter assembly (24).
Inventors: |
Rohn, Dean; (Cadillac,
MI) ; Selewski, Steven Ray; (Cadillac, MI) ;
Daws, William R.; (Honolulu, HI) |
Correspondence
Address: |
HOWARD & HOWARD ATTORNEYS, P.C.
THE PINEHURST OFFICE CENTER, SUITE #101
39400 WOODWARD AVENUE
BLOOMFIELD HILLS
MI
48304-5151
US
|
Assignee: |
REXAIR, INC.
|
Family ID: |
23166782 |
Appl. No.: |
09/746814 |
Filed: |
December 22, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09746814 |
Dec 22, 2000 |
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09302212 |
Apr 29, 1999 |
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6174350 |
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09302212 |
Apr 29, 1999 |
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09293137 |
Apr 16, 1999 |
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Current U.S.
Class: |
95/226 ; 15/353;
96/333; 96/337 |
Current CPC
Class: |
B01D 50/60 20220101;
B01D 46/10 20130101; Y10S 55/03 20130101; B01D 46/521 20130101;
A47L 9/182 20130101; A47L 9/22 20130101; A47L 9/122 20130101; B01D
47/027 20130101; B01D 2253/102 20130101; B01D 2279/55 20130101;
B01D 46/62 20220101; A47L 5/365 20130101 |
Class at
Publication: |
95/226 ; 96/333;
96/337; 15/353 |
International
Class: |
B01D 047/02 |
Claims
What is claimed is:
1. A vacuum cleaner assembly comprising: a main housing having an
inlet and an outlet, a motor disposed within said housing between
said inlet and said outlet for providing motive force to said
vacuum cleaner assembly components, a fan mounted within said main
housing driven by said motor for circulating air around said motor,
a primary filter system for filtering of the air prior to being
exhausted outwardly through said outlet, a secondary filter system
placed in downstream airflow from said primary filter system for
additional filtering of the air prior to being exhausted outwardly
through said outlet, said assembly characterized by said housing
defining a recess and said secondary filter system being seated in
said recess.
2. An assembly as set forth in claim 1, wherein said primary filter
system comprises: a water bath pan within said main housing below
said motor for holding a liquid bath and a separator mounted within
said main housing, driven by said motor, extending downward into
said water bath pan, for circulating the air and said liquid bath
within said water bath pan and filtering particles of dust and dirt
from the air prior to exhausting the air outwardly through said
secondary filter system.
3. An assembly as set forth in claim 1, wherein said secondary
filter system comprises a first filter and a carbon filter.
4. An assembly as set forth in claim 3, further comprising a one
piece frame molded from styrene, wherein said first filter and said
carbon filter are both glued into said frame with a glue and said
frame is seated within said recess in said main housing.
5. An assembly as set forth in claim 4, wherein said glue is
polyurethane based.
6. An assembly as set forth in claim 5, further comprising a gasket
that is applied to said frame to seal between said frame and said
main housing to prevent the escape of air around said frame.
7. An assembly as set forth in claim 6, wherein said gasket is made
of polyurethane.
8. An assembly as set forth in claim 4, wherein said frame surface
area adjacent said main housing is more than five times larger than
said main housing outlet surface area.
9. An assembly as set forth in claim 8, wherein said frame surface
area adjacent said main housing is nine times larger than said main
housing outlet surface area.
10. An assembly as set forth in claim 3, wherein said first filter
is not a HEPA rated filter.
11. An assembly as set forth in claim 3, wherein said first filter
is a HEPA rated filter.
12. An assembly as set forth in claim 3, wherein said first filter
is a pleated material where said pleats are separated into five
stages across.
13. An assembly as set forth in claim 12, wherein said pleated
material is polypropylene.
14. An assembly as set forth in claim 11, wherein said first filter
is pleated material where said pleats are separated into nine
stages across.
15. An assembly as set forth in claim 14, wherein said pleated
material is glass fiber.
16. An assembly as set forth in claim 11, wherein said HEPA rated
filter is made from a material that can be washed and reused.
17. An assembly as set forth in claim 3, wherein said carbon filter
is made from reticulated urethane foam impregnated with activated
charcoal.
18. A method of filtering air through a vacuum cleaner, comprising
the steps of: (A) drawing air into a vacuum cleaner housing; (B)
drawing air into a water bath to filter dirt and dust particles;
(C) filtering particles of dust and dirt from the air through a
separator; (D) filtering smaller particles of dust and dirt from
the air through a first filter; and (E) filtering odors from the
air through a carbon filter.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of presently
pending U.S. application entitled IMPROVED FILTER FOR VACUUM
CLEANER filed Apr. 23, 1999.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a vacuum cleaner of the type for
household use.
[0004] 2. Description of the Prior Art
[0005] Water bath vacuum cleaners typically include a main housing
with a removably attached water bath pan. An intake opening in the
water bath pan matingly engages an inlet in the main housing of the
vacuum cleaner to allow dust and dirt entrained air to be ingested
by a vacuum force through the inlet into the area defined by the
water bath pan. The primary advantage of the water bath filter is
that vacuum efficiency is not compromised as more dirt and dust is
accumulated in the water bath, and no further filtering is viewed
as necessary. The dust and dirt are trapped in the water bath as
the incoming air is directed into the water bath pan and circulated
within. Traditional filtering media allow the flow of air through
the filtering media to be impeded by the accumulation of the dirt
and dust that has collected thereon. However, just as traditional
filter media will allow very tiny microscopic particles to escape
capture, the water bath and separator may also fail to capture all
of the very small or microscopic particles that are light enough to
remain suspended in the air as the air is circulated in the water
bath pan.
[0006] High efficiency filters, or HEPA rated filters, are used on
vacuum cleaners in industrial and residential applications. These
filters are made up of filter media with very tiny openings that
are designed to capture the smallest microscopic particles that
most traditional filter media or methods are incapable of
capturing. The major drawback to the use of these types of filters
is that due to the small size of the openings in the filter media,
they capture all of the dirt and debris that hits them thereby
clogging up very quickly, and requiring cleaning or replacement
very often. For this reason, some vacuum cleaning products try to
combine the HEPA rated filter with a more conventional dry filter
media. The conventional dry filter media will capture the larger
particles of dirt and debris, and the HEPA rated filter will only
capture the smaller particles that escape the conventional dry
filter media. The overall efficiency of the vacuum cleaner (and the
conventional dry filter media) is affected as the air is redirected
and routed through the additional filter. Also, the full area of
the high efficiency filter is not utilized because the air is
typically directed through a small opening in the main housing of
the vacuum cleaner, which concentrates the flow of air on the
portion of the high efficiency filter that is directly in front of
the opening.
SUMMARY OF THE INVENTION AND ADVANTAGES
[0007] The present invention relates to a vacuum cleaner assembly
comprising a main housing having an inlet and an outlet. A motor is
disposed within the main housing between the inlet and the outlet
for providing motive force to a cooling fan, a blower, and a
separator. The cooling fan is mounted within the main housing above
the motor to circulate cooling air around the motor. A baffle is
mounted within the main housing for directing the cooling air
around the motor, and to filter the air that is circulated around
the motor before that air is exhausted. The blower is mounted
within the main housing below the motor for drawing air into the
inlet and exhausting air outwardly through the outlet. The
separator is mounted below the blower for circulating the air and
water within a water bath and providing, in combination with the
water bath, a primary filter for filtering the air prior to
exhausting the air outwardly through the outlet. A second filter
assembly including a high efficiency filter, known as a HEPA rated
filter, for filtering microscopic dust and dirt particles that
escape the separator and water bath and may be disposed after both
the water bath and the separator and before the outlet to
atmosphere for additional filtering of the air prior to being
exhausted. The second filter assembly may also include a third
filter comprising a carbon impregnated filter of a reticulated foam
or similar material for absorbing or trapping odors drawn from the
air, including smoke and fish odors. The second filter and the
carbon impregnated filter are disposed in a recess which is
integral with the main housing allowing for direct and efficient
flow of the air through the water bath, separator, second filter,
and carbon impregnated filter. In an alternative embodiment, the
second filter can be a non-HEPA filter used in combination with the
carbon impregnated filter.
[0008] Accordingly, the present invention will utilize the
separator and water bath filter to capture the larger particles of
dirt and debris prior to routing the air through the second, HEPA
rated or non-HEPA rated filter to capture microscopic particles
that escape the water bath, and finally through the carbon
impregnated filter to absorb or trap odors. The recess for the high
efficiency filter is located integrally to the main housing
allowing the air to flow directly from the water bath canister
through the second filter and the carbon impregnated filter with
minimal redirection of the air and no noticeable impact on the
primary filter. This will allow the air to flow smoothly through
the series of filters. The second filter assembly will not be
overly clogged because the separator and water bath will capture
the majority of the larger dust and dirt particles before the air
goes through the second filter assembly. The recess is designed to
allow the majority of the surface area of the high efficiency
filter to be in the direct line of airflow thereby the overall
efficiency of the vacuum cleaner is maximized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other advantages of the present invention will be readily
appreciated as the same becomes better understood by reference to
the following detailed description when considered in connection
with the accompanying drawings wherein:
[0010] FIG. 1 is a perspective view of the vacuum cleaner assembly,
partially broken away and in cross section;
[0011] FIG. 2 is an exploded perspective view of the vacuum cleaner
assembly;
[0012] FIG. 3 is an elevational view of the vacuum cleaner main
housing shown with the second filter seated in the recess defined
by the housing;
[0013] FIG. 4 is an exploded perspective view of the second filter
assembly including a five sectioned HEPA rated filter and a carbon
impregnated reticulated foam filter;
[0014] FIG. 5 is an exploded perspective view of the second filter
assembly including a nine sectioned HEPA rated filter and a carbon
impregnated reticulated foam filter;
[0015] FIG. 6 is an exploded perspective view of the second filter
assembly including a filter that is not HEPA rated and a carbon
impregnated reticulated foam filter; and
[0016] FIG. 7 is a cross-section along lines 7-7 of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Referring to the Figures, wherein like numerals indicate
like or corresponding parts throughout the several views a vacuum
cleaner assembly is generally shown at 10. The vacuum cleaner
assembly 10 includes a main housing 12 having an inlet 14 and an
outlet 16. A motor 17a is supported by support rings 18 within the
main housing 12 between the inlet 14 and the outlet 16 for
providing motive force to a cooling fan 17b, a blower 17c, and a
separator 22. The cooling fan 17b is mounted within the main
housing 12 above the motor 17a to circulate cooling air around the
motor 17a. A baffle 19 surrounds the motor 17a to direct the
cooling air around the motor 17a and to filter the cooling air
prior to being exhausted. The blower 17c is mounted within the main
housing 12 below the motor 17a for drawing air into the inlet 14
and exhausting air outwardly through the outlet 16. The separator
22 is mounted below the blower 17c for circulating the air and a
water bath 20 within a water bath pan 36 and providing, in
combination with the water bath 20, a primary filter for filtering
the air prior to exhausting the air outwardly through the outlet
16.
[0018] Vacuum cleaners using a water bath 20 filter are known to
those skilled in the art as described in U.S. Pat. No. 5,096,475,
which is hereby incorporated by reference to this
specification.
[0019] A second filter assembly 24 is secured to the main housing
12 and preferably includes a high efficiency filter 100 or 100a,
known as a HEPA rated filter, for filtering microscopic dust and
dirt particles that escape the separator 22 and water bath and is
disposed after both the water bath 20 and the separator 22 and
before the outlet 16 for additional filtering of the air prior to
being exhausted. The differences between filter 100 and filter 100a
are shown in FIGS. 4 and 5. The filter 100 has compartments
sectioned along five sets of ribs 102, and made preferably of sheet
polypropylene. The filter 100a has compartments sectioned along
nine sets of ribs 103. The ribs maintain the integrity of the
filter against air pressure and other environmental effects and are
preferably made from hot melt glue, although stamped aluminum and
plastic ribs are alternatives.
[0020] In another alternative embodiment, the second filter
assembly 24 can include a filter that is not HEPA rated 101, as
shown in FIG. 6 and combined in the description as discussed below
and shown in FIG. 6.
[0021] As a further alternative, a third filter 110 can be included
as shown in FIGS. 4, 5 and 6 which comprises a carbon impregnated
reticulated foam filter 110 for absorbing or trapping odors and is
disposed in the air flow after the second filter 100, 100a or 101
and before the outlet 16 to atmosphere. The second filter 100, 101,
or 100a and the carbon impregnated filter 110 are secured together
by glue or some equivalent means into a molded styrene frame 112
with a sealing gasket 114 associated with one edge of the frame
112. This is shown in section in FIG. 7 where the filter of FIG. 2
is shown with the non-HEPA rated filter configuration of filter
101, but which could just as readily be shown with the HEPA rated
filter configurations of 100 or 100a inserted for the filter 101.
The surface area of the frame 112 adjacent the main housing 12 is
at least five times larger than the surface area of the main
housing 12 outlet. Preferably, the surface area of the frame 112
adjacent the main housing is nine times larger than the surface
area of the main housing 12 outlet. The main housing 12 defines a
recess 26 and the second filter assembly 24 is seated in that
recess 26 with the sealing gasket 114 sealing against the main
housing 12 at surface 115 to force the air to the outlet 16 through
the second filter assembly 24.
[0022] FIG. 2 shows an exploded view of the vacuum cleaner assembly
10. The second filter assembly 24 is secured in position by a rear
cover 28 which is removably attached to the main housing 12 via
screws to cover the opening of the recess 26 and secure the second
filter assembly 24 in position. The rear cover 28 includes a
stowage device 30 for stowing an electrical cord. A foam seal 34 is
disposed between the assembly 24 and the rear cover 28 to cushion
and sound deaden that area of the vacuum as well as further prevent
air from escaping anywhere other than via the outlet 16. The second
filter assembly 24 has smaller openings to capture particles
passing through the separator 22 and water bath 20. In the
preferred embodiment, the second filter assembly 24 includes a HEPA
rated filter 100 or 100a for capturing tiny microscopic dust and
dirt particles.
[0023] Reuseable washable HEPA rated filter media, such as a
pleated GORE-TEX.TM. material, can also be used as the second
filter 100 or 100a. Preferably, the reuseable washable filter media
would be used as a HEPA rated filter, although if the particulate
penetration size of the media selected were greater, the filter
media would not be a HEPA rated filter, such as is the case with
filter 101. Reuseable washable filter media would be advantageous
in this device because it can be washed and reused along with or
intermittently with the disposal of the water bath 20 from the
water bath pan 36 after use.
[0024] The vacuum cleaner assembly 10 includes a water bath pan 36
for containing the water bath 20. The water bath pan 36 presents a
first opening 38 which is disposed directly below the main housing
12 which has a bottom opening 39 that corresponds to the first
opening 38 in the water bath pan 36. A foam seal 40 forms a sealed
engagement between the water bath pan 36 and the bottom opening 39
of the main housing 12. The water bath pan 36 also includes a
second opening 42 which corresponds to a tubular member extending
from an inlet face plate 44. The foam seal 40 forms a sealed
engagement between the second opening 42 in the water bath pan 36
and the inlet face plate 44. The inlet face plate 44 is mounted to
the main housing 12 at the inlet 14 and allows attachments to be
connected in direct communication with the inlet 14.
[0025] The motor 17a is centrally supported by support rings 18 in
the main housing 12 above the bottom opening 39. The separator 22
is attached to the motor 17a below the blower 17c and extends
downwardly through the bottom opening 41 in the main housing 12 and
the first opening 38 in the water bath pan 36. The separator 22 is
rotated by the motor 17a for circulating the air within the water
bath pan 36 and for drawing the dust and dirt entrained air, along
with water from the water bath 20, within the separator 22 for
further capture of debris in the water bath 20 and to direct, by
centrifugal force, the water and any remaining dirt or dust back
outward into the water bath pan 36 for additional separation as it
is drawn within the separator 22 again. As the dust, dirt, and
water are forced outward from the separator by centrifugal force,
the filtered air is drawn upward out of the separator 22 outwardly
through the second filter assembly 24.
[0026] A dolly 46 is positioned below the water bath pan 36. The
water bath pan 36 attaches to the main housing 12 with at pair of
latches 47 to secure the water bath pan 36 to the main housing 12.
The main housing 12 attaches to the dolly 46 and is held securely
in place by a latch which is released upon activation of a release
button 49. An interlock switch 48 is mounted to the main housing 12
and detects the presence of the water bath pan 36 when the dolly 46
is assembled to the main housing 12. The dolly 46 includes a seat
51 for the main housing and casters 50 are mounted to the dolly 46
to provide movable support for the vacuum cleaner assembly 10. The
vacuum cleaner assembly 10 also includes a top cover 52 with a
handle attached to the top of the main housing 12 to close off the
top and cover the motor 17a, cooling fan 17b, support rings 18, and
blower 19. The top cover 52, main housing 12, and dolly 46 when
assembled enclose all inner components of the vacuum cleaner
assembly 10.
[0027] The invention has been described in an illustrative manner,
and it is to be understood that the terminology which has been used
is intended to be in the nature of words of description rather than
of limitation.
[0028] Modifications and variations of the present invention are
possible in light of the above teachings. It is, therefore, to be
understood that within the scope of the appended claims, wherein
reference numerals are merely for convenience and are not to be in
any way limiting, the invention may be practiced otherwise than as
specifically described.
* * * * *