U.S. patent application number 10/700579 was filed with the patent office on 2004-11-04 for construction of a vacuum cleaner.
Invention is credited to Conrad, Wayne.
Application Number | 20040216266 10/700579 |
Document ID | / |
Family ID | 29736771 |
Filed Date | 2004-11-04 |
United States Patent
Application |
20040216266 |
Kind Code |
A1 |
Conrad, Wayne |
November 4, 2004 |
Construction of a vacuum cleaner
Abstract
A vacuum cleaner has a suction motor and fan assembly in a main
airflow conduit extending between the dirty air inlet, typically in
a surface cleaning head, and a filtration member.
Inventors: |
Conrad, Wayne; (Hampton,
CA) |
Correspondence
Address: |
BERESKIN AND PARR
SCOTIA PLAZA
40 KING STREET WEST-SUITE 4000 BOX 401
TORONTO
ON
M5H 3Y2
CA
|
Family ID: |
29736771 |
Appl. No.: |
10/700579 |
Filed: |
November 5, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60424018 |
Nov 6, 2002 |
|
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Current U.S.
Class: |
15/412 ;
15/351 |
Current CPC
Class: |
H01M 10/613 20150401;
H01M 10/6566 20150401; H01M 50/213 20210101; Y02E 60/10 20130101;
A47L 5/32 20130101; A47L 9/22 20130101; H01M 10/6562 20150401; A47L
9/2884 20130101; H01M 10/6551 20150401; A47L 9/2857 20130101; A47L
9/08 20130101; A47L 5/28 20130101; H01M 10/623 20150401 |
Class at
Publication: |
015/412 ;
015/351 |
International
Class: |
A47L 009/22 |
Claims
1. An upright surface cleaning apparatus comprising a surface
cleaning head and an upper casing pivotally mounted thereto, the
upper casing moveable between a storage position in which the upper
casing extends generally vertically upwardly from the surface
cleaning head and an in use position, the surface cleaning head
having a dirty air inlet, the surface cleaning apparatus having a
clean air outlet, an air flow passage extending between the dirty
air inlet and the clean air outlet, the air flow passage including
a conduit extending generally vertically upwardly when the upper
casing is in the storage position and a motor and fan assembly
positioned in the conduit.
2. The upright surface cleaning apparatus as claimed in claim 1
further comprising a filtration member positioned in the upper
casing and the conduit extends between the surface cleaning head
and the filtration member.
3. The upright surface cleaning apparatus as claimed in claim 1
wherein the motor and fan assembly is positioned adjacent the
surface cleaning head.
4. The upright surface cleaning apparatus as claimed in claim 1
wherein the conduit has a longitudinal axis and the motor and fan
assembly has an axial flow direction and is positioned in the
conduit portion such that the axial flow direction is parallel and
coplanar with the longitudinal axis of the conduit.
5. The upright surface cleaning apparatus as claimed in claim 1
wherein the conduit extends away from the surface cleaning
head.
6. The upright surface cleaning apparatus as claimed in claim 1
wherein the motor and fan assembly is positioned exterior to the
surface cleaning head.
7. A surface cleaning apparatus comprising a dirty air inlet, a
clean air outlet, an air flow passage extending between the dirty
air inlet and the dirty air outlet, the air flow passage in fluid
flow communication with a motor and fan assembly, the motor and fan
assembly having an axial flow direction and the air flow passage
having a portion having a longitudinal axis and a substantial
linear longitudinal extent and the motor and fan assembly is
positioned in the portion such that the axial flow direction is
parallel and coplanar with the longitudinal axis of the
portion.
8. The surface cleaning apparatus as claimed in claim 7 further
comprising a surface cleaning head and a filtration member and the
portion extends from the surface cleaning head to the filtration
member.
9. The surface cleaning apparatus as claimed in claim 7 wherein the
surface cleaning apparatus is an upright or stick vacuum
cleaner.
10. The surface cleaning apparatus as claimed in claim 9 wherein
the portion comprises a generally vertically extending airflow duct
when the surface cleaning apparatus is in a storage position and
the motor and fan assembly is provided in the generally vertically
extending airflow duct.
11. The surface cleaning apparatus as claimed in claim 9 wherein
the portion comprises two generally vertically extending air flow
ducts and a motor and fan assembly is provided in one of the
generally vertically extending airflow ducts.
12. The surface cleaning apparatus as claimed in claim 7 wherein
the motor and fan assembly and the portion each have a linear
extent and the linear extent of the portion is at least about three
times the linear extent of the motor and fan assembly.
13. The surface cleaning apparatus as claimed in claim 7 wherein
the motor and fan assembly and the portion each have a linear
extent and the linear extent of the portion is at least about five
times the linear extent of the motor and fan assembly.
Description
FIELD OF THE INVENTION
[0001] This application relates to a vacuum cleaner. In one
particular embodiment, this invention relates to an upright or
stick vacuum cleaner or sweeper.
BACKGROUND OF THE INVENTION
[0002] Various designs for vacuum cleaners are known in the art.
Vacuum cleaners require power to drive a suction fan to cause an
airflow, which entrains dirt and transports the dirt to a
filtration member. Traditionally, vacuum cleaners have been
developed which require a substantial amount of power input to the
suction fan to provide the desired airflow (e.g. 10 to 13 Amp). In
order to provide such amounts of power to a vacuum cleaner, the
vacuum cleaner is provided with an electric cord that is plugged
into an AC outlet in a building.
[0003] Battery operated vacuum cleaners have been developed. These
vacuum cleaners also require a substantial amount of battery power,
which limits the run time due to the amount of power required to
operate the suction motor. The amount of batteries required to
power the vacuum cleaner, have several disadvantages. These include
the increased weight of the vacuum cleaner due to the batteries,
the additional size of the vacuum cleaner to accommodate the
batteries on board, and the limited operational time of the vacuum
cleaner on a single battery charge if the vacuum cleaner is to have
a high level of cleaning efficiency.
SUMMARY OF THE INVENTION
[0004] In accordance with the instant invention, a vacuum cleaner
is provided with a suction motor and fan assembly in a main airflow
conduit extending between the dirty air inlet, typically in a
surface cleaning head, and a filtration member. For example, in an
upright or stick vacuum cleaner, an airflow conduit extends from
the surface cleaning head to the filtration member in a support
(e.g. an upper casing) pivotally mounted to the surface cleaning
head. By positioning the motor and fan assembly in the conduit and
linearly aligning the motor and fan assembly and the conduit, the
number of bends in the airflow passage is reduced. Each bend in the
airflow passage of a vacuum cleaner creates backpressure and
reduces the airflow rate therethrough, unless the power delivered
to the motor and fan assembly is increased. Accordingly, in a
battery-powered vacuum cleaner, a reduction in the backpressure can
result in an increase in the cleaning efficiency of the vacuum
cleaner and/or an increase in the run time of the vacuum cleaner on
a single battery charge and/or a reduction in the number of
batteries.
[0005] In accordance with the instant invention, it is preferred to
position the suction motor and fan assembly exterior to the surface
cleaning head. Typically, in upright vacuum cleaners, the suction
motor and fan assembly is positioned in the surface cleaning head.
This increases the height of the surface cleaning head and limits
the extent to which the vacuum cleaner may use the surface cleaning
head to clean under furniture. By positioning the suction motor and
fan assembly exterior to the surface cleaning head, and aligning
the suction motor and fan assembly with the upper casing, then the
depth of the upper casing may be minimized while reducing the
height of the surface cleaning head, thereby enhancing the ability
of the vacuum cleaner to clean under furniture.
[0006] In accordance with the instant invention, there is provided
an upright surface cleaning apparatus comprising a surface cleaning
head and an upper casing pivotally mounted thereto, the upper
casing moveable between a storage position in which the upper
casing extends generally vertically upwardly from the surface
cleaning head and an in use position, the surface cleaning head
having a dirty air inlet, the surface cleaning apparatus having a
clean air outlet, an air flow passage extending between the dirty
air inlet and the clean air outlet, the air flow passage including
a conduit extending generally vertically upwardly when the upper
casing is in the storage position and a motor and fan assembly
positioned in the conduit.
[0007] In one embodiment, the upright surface cleaning apparatus
further comprises a filtration member positioned in the upper
casing and the conduit extends between the surface cleaning head
and the filtration member.
[0008] In another embodiment, the motor and fan assembly is
positioned adjacent the surface cleaning head.
[0009] In another embodiment, the conduit has a longitudinal axis
and the motor and fan assembly has an axial flow direction and is
positioned in the conduit portion such that the axial flow
direction is parallel and coplanar with the longitudinal axis of
the conduit.
[0010] In another embodiment, the conduit extends away from the
surface cleaning head.
[0011] In another embodiment, the motor and fan assembly is
positioned exterior to the surface cleaning head.
[0012] In accordance with the instant invention, there is also
provided a surface cleaning apparatus comprising a dirty air inlet,
a clean air outlet, an air flow passage extending between the dirty
air inlet and the dirty air outlet, the air flow passage in fluid
flow communication with a motor and fan assembly, the motor and fan
assembly having an axial flow direction and the air flow passage
having a portion having a longitudinal axis and a substantial
linear longitudinal extent and the motor and fan assembly is
positioned in the portion such that the axial flow direction is
parallel and coplanar with the longitudinal axis of the
portion.
[0013] In one embodiment, the surface cleaning apparatus further
comprises a surface cleaning head and a filtration member and the
portion extends from the surface cleaning head to the filtration
member.
[0014] In another embodiment, the surface cleaning apparatus is an
upright or stick vacuum cleaner.
[0015] In another embodiment, the portion comprises a generally
vertically extending airflow duct when the surface cleaning
apparatus is in a storage position and the motor and fan assembly
is provided in the generally vertically extending airflow duct.
[0016] In another embodiment, the portion comprises two generally
vertically extending airflow ducts and a motor and fan assembly is
provided in one of the generally vertically extending airflow
ducts.
[0017] In another embodiment, the motor and fan assembly and the
portion each have a linear extent and the linear extent of the
portion is at least about three times the linear extent of the
motor and fan assembly.
[0018] In another embodiment, the motor and fan assembly and the
portion each have a linear extent and the linear extent of the
portion is at least about five times the linear extent of the motor
and fan assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other advantages of the instant application may be
more clearly and fully understood in accordance with the following
description of the preferred embodiments of this invention as
illustrated in the following drawings in which:
[0020] FIG. 1 is a schematic drawing of a vacuum cleaner according
to a first embodiment of this invention;
[0021] FIG. 1A is a perspective view of the vacuum cleaner in FIG.
1 in the storage position;
[0022] FIG. 2 is an alternate view of the vacuum cleaner of FIG. 1
with the dirt collection bin removed;
[0023] FIG. 3 is a schematic drawing of a vacuum cleaner of FIG. 1
wherein the auxiliary above floor cleaning hose has been removed
for use in an above the floor cleaning mode;
[0024] FIG. 4 is a schematic drawing of a rear view of the vacuum
cleaner of FIG. 1;
[0025] FIG. 5 is a schematic top plan view of the cleaner head of
the vacuum cleaner of FIG. 1;
[0026] FIG. 6 is a cross-section along the line 6-6 in FIG. 5
showing a configuration for the air flow pass in the vacuum cleaner
head;
[0027] FIG. 7 is a cross-section along the line 6-6 of FIG. 5
showing an alternate configuration for the air flow pass in the
vacuum cleaner head; and,
[0028] FIG. 8 is a top plan view of an alternate construction of a
vacuum cleaner head shown in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0029] As shown in the Figures attached hereto, an upright vacuum
cleaner 60 has a floor cleaning head 3 and an upper assembly 62
pivotally mounted thereto. It is to be appreciated that the instant
invention may be used with any vacuum cleaner including an upright
vacuum cleaner, a stick vacuum cleaner, a canister vacuum cleaner
(with the suction motor and fan assembly positioned in the wand
extending from the surface cleaning head to the canister unit), a
backpack vacuum cleaner (with the suction motor and fan assembly
positioned in the wand extending from the surface cleaning head to
the backpack unit) or the like. Preferably, the vacuum cleaner is
battery-operated.
[0030] As shown in FIG. 1, an upright vacuum cleaner 60 may
comprise a vacuum cleaner head 3 and an upper assembly 62. The
vacuum cleaner has a filtration member 11 that is provided in upper
assembly 62. In addition, the vacuum cleaner preferably has a
rotary brush 1 that is provided in cleaning head 3. In order to
provide a low profile for vacuum cleaner head 3, motor and fan
assembly 15 is preferably provided as part of upper assembly
62.
[0031] The vacuum cleaner may be provided with an on/off switch,
which may be provided at any location of the vacuum cleaner. For
example, as shown in FIG. 1, on/off toggle switch 43 may be
provided on upper assembly 62.
[0032] As shown in the Figures, the vacuum cleaner may be
constructed as a closed loop circulation vacuum cleaner. In
particular, air containing entrained dirt is passed through
filtration member 11 to produce a cleaned air stream. Typically,
the cleaned air stream in a vacuum cleaner is released to the room.
In accordance with the design of FIG. 1, the cleaned air stream is
recycled through the vacuum cleaner to produce air jets adjacent
rotary brush 1 to aid in entraining dirt. If the vacuum cleaner is
battery operated, then in order to assist in battery cooling, some
or all of the filtered air may be directed at the batteries to
provide forced cooling in addition to or in place of separate
cooling fans 26, 27. It will be appreciated that even if the
filtered air is not used to create air jets, that some or all of
the filtered air may be used to cool the batteries.
[0033] Referring to FIGS. 1, 6 and 7, air enters the cleaning head
via inlet 64 provided in bottom surface 66 of vacuum cleaner head
3. Dirt from the surface being cleaned is entrained with the
assistance of optional rotary brush 1. Suction fan and motor
assembly 15 produces an air stream denoted by reference number 4 in
FIG. 1, which enters duct 2. The dirty air stream passes through
inlet duct 2, through up-flow duct 8, through inlet port 10 and
into filtration member 11. The filtered air exists filtration
member 11 via outlet port 12 through down flow duct 14, through
motor and fan assembly 15 and into duct 17 to produce an air stream
for recycling (see FIG. 1). These members define the air
recirculation loop. It will be appreciated that other
configurations of the airflow passage through a vacuum cleaner may
be provided to produce an air stream for recycle. Some or all of
the filtered air may be used to cool optional batteries 5, 6 by
being directed to flow over the batteries.
[0034] Referring to FIGS. 6 and 7, duct 17 may consist of a
passageway extending through vacuum cleaner head 3 to a position in
front of inlet 64. Brush air ejection duct 18 is positioned at the
downstream end of duct 17 (see in particular FIGS. 1 and 8).
Preferably, duct 18 distributes the air laterally across the width
of vacuum cleaner head 3, preferably along the entire length of
rotary brush 1, and produces a stream 19 of cleaned air for recycle
that is directed generally parallel to the floor. The jets are
angled to direct the air downwardly towards the floor and
rearwardly towards brush 1. Preferably, the air is injected
downwardly at an angle A to the horizontal of between about 0 and
15.degree. (see FIG. 7). It will be appreciated by those skilled in
the art that duct 17 may be provided at any desired location in
cleaner head 3. For example, as shown in FIG. 6, duct 17 is
provided adjacent upper surface 68 of cleaner head 3. In the
embodiment of FIG. 7, duct 17 is provided approximate bottom
surface 66 of cleaner head 3.
[0035] The optional air jets produce an air stream, which travels
generally parallel to the floor. An advantage to this approach is
that the air is generally directed rearwardly towards the inlet of
duct 2 so that a substantial portion, and preferably essentially
all, of the air exiting ejection duct 18 enters air duct 2 and is
therefore recycled. Accordingly, a substantial portion of air
stream 4 entering duct 2 may comprise recycled air. By reducing the
amount of air that is exhausted from vacuum cleaner 60, the amount
of particulate matter, which is released into the room in which the
vacuum cleaner is operated, is also reduced. A further advantage is
that the kinetic energy in the exhaust air is used to entrain dirt
into air stream 4. As vacuum cleaner 60 may be battery powered,
then by using the kinetic energy of air stream 19, the number of
batteries required to provide a desired operating time for vacuum
cleaner 60 on a single cycle of the batteries may be reduced or, if
the same number of batteries are used, then air flow rate may be
increased without reducing the operating time of a single cycle of
the batteries.
[0036] It will be appreciated that if the vacuum cleaner is an
upright or a stick vacuum cleaner, that cleaning head 3 and upper
assembly 62 may be of any design and need not recycle air.
[0037] As shown in the preferred embodiment of the figures, the
vacuum cleaner is provided with up flow duct 8 and down flow duct
14 that may be connected to vacuum cleaner head 3 by any means
known in the art. Preferably, hollow tubular members, which are in
airflow communication with ducts 2 and 17, may be pivotally mounted
to vacuum cleaner head 3. Accordingly, ducts 8 and 14 may seat on
these hollow tubular members so as to complete the airflow path.
For example, up flow duct 8 and down flow duct 14 may be rigid
structural members that are themselves pivotally mounted to vacuum
cleaner head 3. Alternately, up flow duct 8 and down flow duct 14
may be mounted on a pivotal airflow tube similar to pivotal airflow
valves known in the vacuum cleaner art. Alternately, as shown in
FIG. 1A, up flow duct 8 and down flow duct 14 may be connected in
airflow communication with cleaner head 3 via flexible tubes 9 and
16 respectively. In this latter case, upper assembly 62 is
mechanically secured to pivotally mounted cross member 170, which
does not form part of the airflow path. Pivotally mounted cross
member 170 has axle portions 172 at the opposed ends thereof which
are pivotally mounted to sidewalls 174 of cleaner head 3. A similar
construction may be used if only a single generally vertically
extending duct 8 is provided.
[0038] It will be appreciated that ducts 8, 14 are preferably rigid
members, which provide a stable support for filtration member 11.
Alternately, ducts 8, 14 may be flexible and rigid reinforcing
members may be provided to provide a support or platform for
filtration member 11 may be supported.
[0039] It will be appreciated that if the vacuum cleaner is an
upright or stick vacuum cleaner, it may have only one airflow duct
8, 14 It will also be appreciated that ducts 8, 14 need not be
spaced apart. For example, they may be positioned side by side. In
addition, the same mounting means may be used if there is a single
duct 8, 14. For example, if none of the filtered air is recycled,
then there is no need to provide a duct 14. In such a case,
filtration member 11 may be mounted only on duct 8. Alternately, a
support member similar to duct 14, but through which there is no
air flow, may be provided so as to provide two supports for
filtration member 11. Alternately, if suction motor and fan
assembly 15 is cooled by the filtered air as is known in the art,
then duct 14 may be provided to deliver filtered air to a motor and
fan assembly 15 mounted in cleaning head 3.
[0040] It will be appreciated by those skilled in the art that
filtration member 11 may be any filtration member known in the art.
Preferably filtration member 11 comprises at least one cyclone
separator. For example, filtration member 11 may be a cyclone bin
or canister whereby inlet port 10 functions to direct the air
tangentially into a cyclone bin. It will also be appreciated that
filtration member 11 may comprise a plurality of cyclones which may
be provided in one or more cyclonic cleaning stages. However, it
will also be appreciate that a physical filter element may also be
utilized if desired. In such a latter case, the filtration member
may be replaceable or washable. If filtration member comprises a
cyclone bin, then the cyclone bin is preferably transparent.
[0041] Filtration member 11 is optionally secured to upper assembly
62 by upper cover assembly 25 (see FIG. 2). Pursuant to such an
optional embodiment, upper cover assembly 25 of filtration member
11 may incorporate inlet port 10 and outlet port 12. Upper cover
assembly 25 may accordingly provide the lid for filtration member
11 (e.g. if filtration member 11 is a cyclone bin, then upper cover
assembly 25 may comprise the lid of the cyclone bin). Inlet port 10
and outlet port 12 are optionally removably mounted on ducts 8, 14
thereby permitting filtration member 11 to be removed from vacuum
cleaner 60 for empting by lifting filtration member 11 and cover 25
upwardly off of ducts 8, 14. In this way, filtration member 11 may
be transported while still essentially sealed to a garbage can or
refuse container for emptying. It will be appreciated that if the
filtered air is not recycled, then the filtered air may be directed
to the ambient via outlet port 12. Further, if the vacuum cleaner
only has one duct 8, 14, then an outlet port 14 in cover 25 is not
required. The air may exit the vacuum cleaner via an outlet port
provided in filtration member 11 itself.
[0042] Preferably, filtration member 11, once removed from the
vacuum cleaner, is emptied by removing cover 25 and inverting
filtration member 11 so the contents empty into a garbage can or
refuse container by means of gravity. An advantage of this design
is that a user need not bend over to remove filtration member 11 or
to empty a cyclone bin. It will be appreciated that, in an
alternate embodiment, filtration member 11 may be a porous member
that is disposable or washable. Such a filtration member may be
designed to be washed while in a rigid housing that defines
filtration member 11 or, alternately, filtration member 11 may be
disposable. In any such case, a consumer may lift upwardly to
remove the filtration member 11 and to then place a new, cleaned or
emptied filtration member 11 on ducts 8, 14. If will be appreciated
that, if filtration member 11 is not disposable, cover 25 may be
permanently affixed to filtration member 11 if a door or other
openable cover member is provided to allow the filtration member to
be removed for cleaning or emptying. If will also be appreciated
that, if filtration member 11 is disposable, cover 25 may be
permanently affixed to filtration member 11 and no other openable
cover member need be provided.
[0043] Upper cover 25 may be secured to upper assembly 62 by any
means known in the art. In one preferred embodiment, cover assembly
25 is secured in position by at least one magnet and, preferably, a
plurality of magnets. For example, referring to FIG. 2, duct 8 is
provided with a magnet 33. The upper face of magnet 33 may have any
desired polarity (i.e. north or south). A magnet 32 is provided in
housing of inlet tube 10 so as to be aligned with magnet 33 when
upper cover 25 is mounted on upper assembly 62. The lower or bottom
face of magnet 32 has the opposite polarity of the upper or top
face of magnet 33. Accordingly, when duct 8 is in airflow
communication with inlet port 10, magnets 32 and 33 assist in
securing, or secure, cover 25 on duct 8. A similar pair of mating
magnets may be provided on duct 14 and the housing of outlet port
12. It will be appreciated that any other means to removably affix
cover 25 to filtration member 11, which is known in the art, may be
used. For example, the physical engagement of male and female
members may be utilized (e.g. cover 25 may be screwed onto
filtration member 11, a release button or catch may be used, a
bayonet mount may be used).
[0044] In conventional vacuum cleaners, the cleaned air is fed past
the motor prior to the air exiting the vacuum cleaner. In this way,
the cleaned air is used to cool the motor such that the air that
exits the vacuum cleaner is heated. If the filtered air is
recycled, as optionally exemplified herein, and also used to cool
motor 15, then the air in the recirculation air stream exiting duct
17 in cleaner head 3 is heated. The air is therefore preferably
cooled as it passes through the vacuum cleaner prior to again
encountering motor 15. Accordingly, at least a portion of the
airflow passage through the vacuum cleaner is preferably
constructed from metal. For example, one or more of duct 2,
flexible hose 9, up flow tube 8, down flow tube 14, flexible tube
19, duct 17 and duct 18, as well the housing for motor 15, may be
made from metal. Some or all of these surfaces may be provided with
pin fins or other heat dissipation members. In addition, one or
more fans may be provided to pass cooling air over the ducts to
assist in dissipating the heat. Preferably, a substantial number of
the components of the air flow path and, most preferably, all or
essentially all of the components of the airflow path are made from
metal. The metal provides a heat sink for adsorbing heat produced
by motor 15. By constructing a substantial portion of the vacuum
cleaner from metal, a large heat sink is provided. Further, the
surface area available for dissipating the heat to the ambient is
also increased.
[0045] Optional rotary brush 1 may be driven by any means known in
the art. For example, as shown in FIG. 1, rotary brush 1 is
provided with a brush motor 48, which is drivingly connected to
gear 49. Similarly, gear 51 is drivingly connected to rotary brush
1. A fan belt 50 extends around gears 49 and 51 so as to drivingly
connect brush motor 48 to rotary brush 1. In such an embodiment,
rotary brush 1 may be selectively engaged and disengaged by means
of an on/off toggle switch 44. Thus, brush 1 may be shut off when
it is not required, such as when an extension hose 21 is in use for
above floor cleaning.
[0046] In an alternate embodiment (not shown), gear 49 may be
driven by an air turbine. Preferably the air turbine is provided in
air duct 17. An advantage of this design is that the air turbine
would be driven by clean air. Generally, an air turbine comprises a
turbine provided within a housing. As clean air would be used to
power the turbine, the air gap between the outer end of the blades
of the air turbine and the inner wall of the housing may be
reduced, thus increasing the amount of power, which may be obtained
from an air turbine. In addition, the turbine would be powered by
pressurized air (i.e. it is downstream from suction fan and motor
assembly 15) as opposed to a negative pressure (e.g. if the air
turbine was provided upstream of suction fan and motor assembly
15).
[0047] Optionally, duct 2 may include a portion, such as a trough
shaped member, for accumulating material prior to the material
being fed with the air stream to filtration member 11. For example,
if an area of heavy dirt concentration is encountered, the airflow
may not be sufficient to entrain all of the dirt. By providing a
storage area, the excess material which is not entrained may be
stored for entrainment in the air stream once the concentration of
material being entrained in air stream 4 decreases.
[0048] In accordance with the instant invention, motor and fan
assembly 15 is provided in one of ducts 8, 14. In the embodiment
shown in FIG. 1, motor and fan assembly 15 is provided in the clean
air stream, e.g. in down flow duct 14. Accordingly, the vacuum
cleaner is a clean air system (i.e. the air has already been
filtered prior to the air encountering the suction fan). It will be
appreciated that, in accordance with an alternate embodiment,
suction fan and motor assembly 15 may be provided in up flow duct
8. In such a case, motor and fan assembly 15 is provided in the
dirty air stream, e.g. in up flow duct 8. Accordingly, the vacuum
cleaner is a dirty air system (i.e. the air has already been
filtered prior to the air encountering the suction fan). In either
case, an advantage of such a preferred design is that the motor and
fan assembly is provided exterior to cleaning head 3. Typically,
the suction motor and fan assembly is the largest element provided
in a vacuum cleaner head thus setting the necessary vertical height
of a vacuum cleaner head (i.e. the distance from bottom surface 66
to upper surface 68). By removing suction fan and motor assembly 15
from cleaner head 3, the vertical height of cleaner head 3 may be
reduced. This reduces the profile of cleaner head 3 enabling it to
pass underneath furniture having a lower clearance from the
floor.
[0049] Preferably, suction motor and fan assembly 15 are axial
aligned (i.e. the fan is mounted on an axle that extends outwardly
from the suction motor and rotates about that axle such that the
air passes sequentially through the suction motor and the fan). By
positioning suction fan and motor assembly 15 so that its
longitudinal direction (i.e. the direction defined by the axle upon
which the suction fan is mounted for rotation) is parallel to and
in the same plane as the axis of ducts 8 and 14, the profile of
upper assembly 62 (i.e. the width of upper assembly 62 from the
front surface thereof to the rear surface thereof) may be reduced
thus creating a low profile for upper assembly 62. When it is
desired to vacuum underneath furniture, upper assembly 62 may be
lowered so as to extend rearwardly behind cleaner head 3. In this
configuration, the extent to which cleaner head 3 may extend
underneath furniture is limited by the extent that upper assembly
62 extends vertically above the surface being cleaned. By
positioning suction fan and motor assembly 15 in one of ducts 8 and
14 and aligning the axle of the motor and fan assembly with the
longitudinal axis of the duct, the vertical extent of upper
assembly 62 when in this configuration is minimized thus increasing
the ability of the vacuum cleaner to clean underneath furniture.
Also, such an arrangement also reduces the backpressure through the
vacuum cleaner, by reducing the number of bends in the airflow
passage, and therefore reduces the power required to obtain the
same airflow rate through the vacuum cleaner.
[0050] If the vacuum cleaner is battery-powered, then the batteries
to operate the vacuum cleaner 60 may be provided at any location.
Batteries 5, 6 are preferably mounted in cleaner head 3 so as to
reduce hand weight of the handle of the vacuum cleaner. For
example, referring to FIG. 1, two battery sticks 5, 6 are provided
in cleaner head 3. The batteries may be individually mounted in
vacuum cleaner 60 or they may be provided in one or more battery
sticks as is known in the battery art. The number of batteries will
depend upon a number of factors including the operational time of
vacuum cleaner 60 on a single charge and the airflow rate produced
by motor 15.
[0051] The batteries may be provided with an airflow stream to cool
the batteries during charging and/or discharging. The cooling air
is preferably provided by one or more cooling fans 26, 27 that are
positioned to blow cooling air over the batteries 5 and 6.
Preferably a fan is provided for each battery stick. As shown in
FIG. 1, the cooling fans 5, 6 are preferably positioned to blow air
longitudinally along the length of a plurality of batteries or a
battery stick.
[0052] The batteries may be charged in situ. In such a case, the
vacuum cleaner is provided with a power cord 45 and a battery
charging control circuit. Any charging circuit known in the battery
art may be used. In one embodiment, the vacuum cleaner may be
configured to also operate on AC power, e.g., when the batteries
are discharged. Accordingly, power cord 45 may be any cord known in
the vacuum cleaner art. However, if vacuum cleaner 60 is not
designed to operate on AC power (i.e. it only operates on batteries
5, 6), then power cord may be relatively short (e.g. from 1 to 10
feet long, preferably from about 1 to 6 feet long and most
preferably about 3 feet long). If the vacuum cleaner includes the
power control system for charging the batteries (e.g. if may be a
part of electronic control board 7), and if the vacuum cleaner
operates only on batteries, then power cord 45 may be of a thinner
gauge. In such a case, the power cord may be 16-18 gauge. Thus, a
relatively lightweight cord may be used. Advantageously, this
requires a smaller volume to store the cable and a lighter spring
may be used on an automatic cord rewind mechanism.
[0053] The power cord may be secured in position when it is not in
use to charge the batteries by, e.g., a holder 46 provided on one
of ducts 8, 14. A battery life indicator 47 may be provided, such
as on electronics board 7. Battery life indicator is preferably a
read out, and more preferably a digital readout, showing the
operating time remaining in the battery cycle.
[0054] Batteries 5, 6 are preferably removed prior to the disposal
of the vacuum cleaner. Thus, an optional openable panel 34 is
preferably provided in cleaner head 3 so as to permit access to the
compartment in which batteries 5, 6 are placed. For example, panel
34 may be pivotally mounted to permit it to be opened or it may be
removable mounted the vacuum cleaner. Preferably, as shown in FIGS.
1 and 8, cover 34 is provided in upper surface of cleaner head 3
with the batteries positioned immediately under cover 34. Cover 34
is preferably transparent so as to permit the batteries to be
visible to the user. This facilitates the user locating the
batteries when they are to be replaced (e.g., the batteries have
been subjected to the recommended number of charging cycles) or
removed for disposal. Cover 34 may be secured to cleaner head 3 by
any means known in the art. For example, cover 34 may be secured by
male and female engagement members. Alternately, a plurality of
screws 35, 36, 37 and 38 may be provided around the perimeter of
cover 34 to secure cover 34 to cleaner head 3.
[0055] The vacuum cleaner may include an electronic control board
7, which regulates the power to suction fan and motor assembly 15.
Alternately, or in addition, board 7 may also perform other
functions. If vacuum cleaner 60 contains optional board 7, then
board 7 is preferably provided in cleaner head 3 so that it is
visible to the user. To this end, board 7 may be provided under
transparent openable cover 34 or under a separate transparent cover
(not shown).
[0056] It will be appreciated that board 7 and batteries 5, 6 may
be provided in a variety of configurations. For example, as shown
in FIG. 1, board 7 may be provided to the rear of batteries 5, 6.
Alternately, as shown in FIG. 8, board 7 may be provided in front
of batteries 5, 6. In an alternate embodiment, which is not shown,
board 7 may be provided between batteries 5, 6.
[0057] In order to cool board 7, a fan 28 may be provided to direct
cooling air over board 7. Alternately, or in addition, one or both
of battery cooling fans 26 and 27 could be utilized to provide
cooling air to board 7, depending upon the position of board 7 and
the direction of the air flow which is produced by fans 26, 27. It
will be appreciated that if vacuum cleaner 60 is not
battery-powered, a board 7 is not required.
[0058] Vacuum cleaner 60 may be provided with at least one LED and
preferably a plurality of LED's, which are directed so as to
function as headlights for the vacuum cleaner. Preferably, each
headlight comprises at least 2 LEDs and more preferably from 2 to 8
LEDs and most preferably from 2 to 4 LEDs. Thus a vacuum cleaner
may have 2 headlights each of which has, for example, 2 to 4
LEDs.
[0059] The LEDs may have a light intensity of at least 500
minicandella (mcd). Preferably, the LED's are super bright LED's.
Generally, super bright LEDs are considered in industry to be any
LED having a light intensity of at least about 1,000 mcd and may
have a light intensity of up to 13,000 mcd or more. Preferably
super bright LEDs which are used in a vacuum cleaner as disclosed
herein have a light intensity from 1,000 to 10,000 mcd, more
preferably from 2,000 to 8,000 mcd and most preferably from 2,000
to 4,000 mcd. Accordingly a headlight having 2 LEDs may have a
light intensity of from 4,000 to 16,000 mcd.
[0060] Preferably, the LED's are provided directly on board 7 to
minimize wiring of the lights. For example, as shown in FIG. 1,
LED's 41 and 42 are provided as headlights. The LED's may be
provided with or without a reflector to concentrate and direct the
light produced by the LED's.
[0061] Optionally, filtration member 11 may comprise a transparent
or at least translucent portion and, preferably, all of filtration
member 11 is transparent or at least translucent. The use of a
transparent or translucent filtration member, in combination with
the use of optional LEDs, permits a user to view the interior of
the filtration member. Preferably, filtration member 11 is a
cyclone bin, such as is known in the art. In this preferred
embodiment, vacuum cleaner 60 includes at least one, and preferably
a plurality of LED's (for example LED's 39 and 40), which are
angled so as to illuminate the transparent filtration member 11.
The LED's may be angled so as to illuminate the filtration member
11 only when the vacuum cleaner is being used to clean a carpet
(the normal carpet cleaning position wherein upper assembly 62 is
angled rearwardly behind cleaner head 3), when the vacuum cleaner
is in the upright or storage position (e.g. upper assembly 62
extends generally vertically upwardly from cleaner head 3) or when
in both positions. The LED's may provide constant illumination or
they may be strobed to illuminate the motion of dirt within a
transparent or translucent cyclone bin. Preferably the LED's are
super bright LED's. In this embodiment, board 7 is preferably
positioned so that the LED's may shine upwardly onto the cyclone
bin. Accordingly, it is preferred to position board 7 towards the
rear of cleaner head 3, (e.g. as shown in FIG. 5). To aid in
construction, a transparent cover is preferably provided over the
portion of board 7 on which LEDs 39, 40 are positioned so that the
light from the LEDs is directed at filtration member 11. This is
preferably cover 34. If a transparent cover is not provided, then
an opening may be provided in upper surface 68 of cleaner head 3.
Alternately, the LEDs may be mounted on an exterior surface of the
vacuum cleaner.
[0062] The vacuum cleaner may have an optional extendible stretch
hose 21 for use in above the floor cleaning. In such an embodiment,
a valve 20 is provided to connect flexible hose 21 in airflow
communication with suction fan and motor assembly 15. As shown in
FIG. 1, valve 20 may be provided in up flow duct 8. Valve 20 may be
any valve known in the art. An advantage of providing valve 20 in
duct 8 is that the construction of vacuum cleaner head 3 is
simplified. In particular, a valve structure need not be
incorporated into the pivotal connection of the upper assembly 62
to cleaner head 3 but may be provided in cleaner head 3 as is
common in the industry.
[0063] In another embodiment, the optional extension wand for the
above floor cleaning hose 21 preferably also functions as the
handle for the vacuum cleaner. As shown in FIG. 2, according to
this alternate embodiment, hose 21 is provided with a rigid tube
22. When mounted on the vacuum cleaner, tube 22 functions as the
handle for the vacuum cleaner. When removed from the vacuum
cleaner, tube 22 functions as an extension wand so that the dirty
air travels through wand 22 into hose 21 and then into up flow duct
8 via valve 20. An advantage of this construction is that tube 22
may be used both as the handle for the vacuum cleaner as well as an
extension for hose 21.
[0064] Tube 22 may be removably mounted to upper assembly 62 by any
means known in the art. In accordance with an alternate embodiment
of this invention, the mount for releasable receiving tube 22
preferably also functions as a carry handle for the vacuum cleaner
such as, for example, mount 24 (see FIG. 4). In this embodiment,
mount 24 comprises a first portion for releasable receiving tube 22
and a second portion for securing the first portion to upper
assembly 62. The first portion may comprise a dovetail receiver 29
which is configured for receiving dovetail 23 which is provided on
tube 22. The second portion may comprise one or more rigid rods 52
which extend outwardly from filtration member 11 to provide a
securing point for dove tail receiver 29 and to permit a user to
pick up vacuum cleaner 60 using mount 24. It will be appreciate
that other releasable engagement means may be utilized. An
advantage of this construction is that when tube 22 is detached
from the vacuum cleaner as shown in FIGS. 3 and 4, mount 24
provides a user with a handle which may be used to move vacuum
cleaner 60. Accordingly, a rigid handle is always accessible to the
user to facilitate moving the vacuum cleaner regardless of whether
tube 22 is in the above floor cleaning position.
[0065] Referring to FIG. 2, upper assembly 62 may comprise up flow
duct 8, down flow duct 14 and one or more cross members to
dynamically stabilize ducts 8 and 14 and define a space frame. For
example, referring to FIG. 2, cross-members 30 and 31 are provided
to limit and, preferably, prevent any relative motion of duct 8
with respect to duct 14. Preferably, support member 30, 31
dimensionally stabilize ducts 8 and 14 in two dimensions (i.e. to
prevent ducts 8 and 14 bending forward or backwards relative to
each other or to prevent side to side motion of ducts 8, 14). For
example, support members 30, 31 may be ovals thus cross-stabilizing
ducts 8, 14. Preferably, ducts 8, 14 and supports 30, 31 are made
from metal (e.g. aluminum). This provides a rigid, lightweight
construction, which may weigh less than conventional plastic cover
casings, which are manufactured for vacuum cleaners. It will be
appreciated that if ducts 8, 14 are sufficiently stiff, then no
cross-members may be required.
[0066] A supplemental filtration media 13 may be provided in down
flow duct 14 (see FIGS. 1 and 2). In accordance with this
embodiment, as the cleaned air exits filtration member 11, the air
travels through outlet port 12 and then through filtration member
13 as the air travels downwardly through duct 14. Filtration member
13 may be removed for cleaning or replacement whenever cover 25 is
removed from upper assembly 62. When cover 25 has been removed from
upper assembly 62, filtration member 13 may merely be lifted
upwardly out of duct 14 thereby permitting filter media 13 to be
cleaned or replaced. An advantage of this design is that the
interior volume of an airflow duct is utilized to house a
supplemental filtration member thereby reducing the overall profile
of vacuum cleaner 60.
[0067] It will be appreciated by a person skilled in the art that a
battery-operated vacuum cleaner may use one or more of the
different embodiments disclosed herein and the different embodiment
may be combined in any combination of features to provide a unique
vacuum cleaner.
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