U.S. patent application number 11/140844 was filed with the patent office on 2005-12-15 for ac/dc portable wet/dry vacuum having improved portability and convenience.
Invention is credited to DiPasquale, Kathy E., DiTommaso, Maria, Harrison, Edward A., Lopano, Daniel N., Watson, James B..
Application Number | 20050273969 11/140844 |
Document ID | / |
Family ID | 36952848 |
Filed Date | 2005-12-15 |
United States Patent
Application |
20050273969 |
Kind Code |
A1 |
Watson, James B. ; et
al. |
December 15, 2005 |
AC/DC portable wet/dry vacuum having improved portability and
convenience
Abstract
A wet/dry utility vacuum with a canister, a powerhead assembly
with a fan, a shut-off device that prevents the fan from drawing
liquids into the fan inlet when a volume of the liquid in the
canister exceeds a predetermined volume. The powerhead assembly
includes a controller that permits the utility vacuum to be
operated in a desired power mode so that the user may employ either
an AC power source or a DC power source, such as a battery pack,
for example. In some applications, the battery pack may be
interchangeable with the battery packs of various cordless tools,
including drill/drivers and saws. A tool set and a method for
operating a battery-powered tool set are also provided.
Inventors: |
Watson, James B.; (Fallston,
MD) ; DiPasquale, Kathy E.; (Baltimore, MD) ;
Lopano, Daniel N.; (Towson, MD) ; Harrison, Edward
A.; (Bel Air, MD) ; DiTommaso, Maria;
(Baltimore, MD) |
Correspondence
Address: |
Mehul R. Jani
Black & Decker Corporation
Mail Stop TW199
701 E. Joppa Rd
Towson
MD
21286
US
|
Family ID: |
36952848 |
Appl. No.: |
11/140844 |
Filed: |
May 31, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11140844 |
May 31, 2005 |
|
|
|
10640267 |
Aug 13, 2003 |
|
|
|
60425371 |
Nov 12, 2002 |
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Current U.S.
Class: |
15/344 |
Current CPC
Class: |
A47L 9/26 20130101; A47L
9/0036 20130101; A47L 7/0042 20130101; A47L 7/0038 20130101; A47L
9/22 20130101; A47L 7/0028 20130101; A47L 9/0009 20130101; A47L
5/24 20130101; A47L 9/0027 20130101; A47L 9/0063 20130101; A47L
9/242 20130101; A47L 11/4019 20130101; A47L 9/2857 20130101; A47L
9/2889 20130101; H02J 2207/40 20200101; A47L 9/2878 20130101; A47L
5/14 20130101; A47L 9/0045 20130101; A47L 5/36 20130101; A47L 9/106
20130101; A47L 9/2842 20130101 |
Class at
Publication: |
015/344 |
International
Class: |
A47L 005/24 |
Claims
What is claimed is:
1. A utility vacuum comprising: a housing having an intake portion;
a canister removeably attached to the housing; a powerhead assembly
located within the housing and having a fan, a motor for providing
rotary power to the fan, and a power supply for distributing
electrical power to the motor; and a battery associated with the
power supply, the battery providing a source of direct current
electrical power for powering the power supply, wherein the
powerhead assembly is oriented in a substantially vertical
fashion.
2. The utility vacuum of claim 1, wherein the powerhead assembly is
located above the canister.
3. The utility vacuum of claim 1, wherein the housing includes an
inlet and an outlet, wherein operation of the utility vacuum draws
an intake flow of air into the canister through the inlet and
discharges a discharge flow of air through the outlet.
4. The utility vacuum of claim 3, further comprising a filter,
wherein the flow of air into the canister also passes through the
filter.
5. The utility vacuum of claim 4, wherein the filter includes a
washable material.
6. The utility vacuum of claim 3, further comprising a flexible
hose that is configured to be coupled with the inlet.
7. The utility vacuum of claim 6, wherein the flexible hose has a
first end, a second end opposite the first end and a body
interconnecting the first end and second end, the flexible hose
being positionable in a storage position wherein the first end is
coupled to the inlet and the body is coupled to a portion of a
handle portion of the housing.
8. The utility vacuum of claim 7, wherein the second end of the
hose is coupled to the intake portion of the housing.
9. The utility vacuum of claim 1, wherein the battery is removeable
from the utility vacuum.
10. The utility vacuum of claim 1, wherein the battery is located
adjacent the intake portion of the housing between the canister and
the intake portion of the housing.
11. A utility vacuum comprising: a housing having an inlet; a
canister removeably attached to the housing; a powerhead assembly
located within the housing and having a fan, a motor for providing
rotary power to the fan, and a power supply for distributing
electrical power to the motor; a battery associated with the power
supply, the battery providing a source of direct current electrical
power for powering the power supply, and a flexible hose, wherein
the flexible hose has a first end, a second end opposite the first
end and a body interconnecting the first end and second end, the
flexible hose being positionable in a storage position wherein the
first end is coupled to the inlet and the body is coupled to a
portion of a handle portion of the housing.
12. The utility vacuum of claim 11, wherein the second end of the
hose is coupled to an intake portion of the housing.
13. The utility vacuum of claim 11, wherein the battery is located
adjacent an intake portion of the housing between the canister and
the intake portion of the housing.
14. The utility vacuum of claim 11, wherein the battery is
removeable from the utility vacuum.
15. The utility vacuum of claim 11, wherein the housing includes an
outlet, wherein operation of the utility vacuum draws an intake
flow of air into the canister through the inlet and discharges a
discharge flow of air through the outlet.
16. The utility vacuum of claim 15, further comprising a filter,
wherein the flow of air into the canister also passes through the
filter.
17. The utility vacuum of claim 16, wherein the filter includes a
washable material.
18. The utility vacuum of claim 11, wherein the powerhead assembly
is oriented in a substantially vertical fashion.
19. The utility vacuum of claim 18, wherein the powerhead assembly
is located above the canister.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of
application Ser. No. 10/640,267, filed Aug. 13, 2003, now pending,
which claims the benefit of U.S. Provisional Application No.
60/425,371, filed Nov. 12, 2002.
FIELD OF THE INVENTION
[0002] The present invention generally relates to vacuum appliances
and more particularly to an AC/DC powered hand-portable wet/dry
vacuum having improved convenience and performance.
BACKGROUND OF THE INVENTION
[0003] Vacuum appliances that are capable of picking up both wet
and dry materials are commonly known as wet/dry vacuums. Such
wet/dry vacuums are well known in the art and are commercially
available in a variety of sizes and configurations. Recent consumer
trends have placed significant cost pressures the commercially
available wet/dry vacuums and as such, many manufacturers are
presently producing low-end, relatively small capacity low-cost
units and/or high-end, relatively high capacity high-cost
professional grade units.
[0004] The low-end, low-cost units are frequently employed by
professional users, such as installers, service technicians and
tradespeople in residential construction. These professionals are
commonly required to clean their job site prior to leaving for
their next job and as such, they frequently prefer the smaller size
and portability that are typical of these units. These units,
however, are known to have several drawbacks.
[0005] One such drawback relates to convenience of the known
wet/dry vacuums and in particular the relatively long amount of
time that is necessary for their set-up, the frequency with which
the hose becomes disconnected during transport or use and the
frequency with which the attachments are lost. Due to the relative
bulk of the known wet/dry vacuums and their attachments, the
professional user frequently makes a dedicated trip to transport
the wet/dry vacuum to or from a jobsite.
[0006] Another drawback relates to the availability of electrical
power on a given jobsite. In new residential construction, it is
relatively common to encounter a jobsite where electrical power
from an electrical utility is unavailable. In some situations, it
may be possible to acquire electrical power from a nearby location
(e.g., a neighbor) through long, heavy extension cords.
Alternatively, a portable generator is required. The inconvenience
of heavy extension cords and the expense and inconvenience of a
portable generator is highly undesirable to a professional user,
particularly considering that the professional user frequently uses
the wet/dry vacuum for less than 10 minutes on a given jobsite.
[0007] Yet another drawback concerns the filter system of the known
wet/dry vacuums. These filter systems typically employ a disposable
filter that is fixedly attached to the lid of the vacuum or some
other supporting structure that fits around and covers the fan.
When clogged, the disposable filter can severely limit the flow of
air through the fan, which significantly impairs the ability of the
wet/dry vacuum to pick up debris. Often times, however, a
replacement filter is not available to the professional user so
that the wet/dry vacuum is simply used at reduced efficiency. Other
drawbacks of the known filtering systems include the inconvenience
of servicing a filter, which usually entails disassembly of the
wet/dry vacuum so as to expose the jobsite to the contents of the
canister, and insufficient filtering that results in the discharge
of dust from the wet/dry vacuum when the wet/dry vacuum is turned
on.
[0008] Accordingly, there remains a need in the art for a wet/dry
vacuum having improved convenience and performance.
SUMMARY OF THE INVENTION
[0009] In one form, the present invention provides a utility vacuum
that includes a canister, a powerhead assembly, a shut-off device,
an electrical cord, and a battery pack. The powerhead assembly is
coupled to the canister and includes a fan, a motor for providing
rotary power to the fan, and a power supply for distributing
electrical power to the motor. The shut-off device is associated
with the powerhead assembly and configured to prevent the fan from
drawing a liquid into an inlet of the fan when a volume of the
liquid in the canister exceeds a predetermined volume. The
electrical cord is associated with the power supply and configured
to selectively couple the power supply to a source of alternating
current power. The battery is associated with the power supply and
provides a source of direct current electrical power for powering
the power supply when the power supply is not receiving alternating
current power from the source of alternating current power.
[0010] In another form, the present invention provides a tool set
with a battery pack, a power tool and a utility vacuum. The power
tool includes a receptacle assembly for detachably coupling the
battery pack to the power tool. The utility vacuum having a
canister, a powerhead assembly and a shut-off device. The powerhead
assembly is coupled to the canister and has a fan, a motor for
providing rotary power to the fan, and a power supply for
distributing electrical power to the motor. The shut-off device is
associated with the powerhead assembly and configured to prevent
the fan from drawing a liquid into the fan inlet when a volume of
the liquid in the canister exceeds a predetermined volume. The
power supply includes a receptacle assembly for detachably
receiving the battery pack. The battery pack may be selectively
coupled to either of the power tool and the utility vacuum to
provide a source of electrical power thereto.
[0011] In another form, the present invention provides a utility
vacuum with a canister, a powerhead assembly, a shut-off device and
a battery. The powerhead assembly is coupled to the canister and
has a fan, a motor for providing rotary power to the fan, and a
power supply for distributing electrical power to the motor. The
shut-off device is associated with the powerhead assembly and
configured to prevent the fan from drawing a liquid into an inlet
of the fan when a volume of the liquid in the canister exceeds a
predetermined volume. The battery is associated with the power
supply and is a source of direct current electrical power for
powering the power supply.
[0012] In another form, a utility vacuum is provided with a
canister, a powerhead assembly, a battery, and a hose aseembly. The
powerhead assembly is coupled to the canister and has a fan, a
motor for providing rotary power to the fan, and a power supply for
distributing electrical power to the motor. The battery is
associated with the power supply and is a source of direct current
electrical power for powering the power supply. The hose is in
fluid connection with the canister and can be coupled to a handle
portion on the housing of the utility vacuum.
[0013] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter.
It should be understood that the detailed description and specific
examples, while indicating the preferred embodiment of the
invention, are intended for purposes of illustration only and are
not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Additional advantages and features of the present invention
will become apparent from the subsequent description and the
appended claims, taken in conjunction with the accompanying
drawings, wherein:
[0015] FIG. 1 is a perspective view of a wet/dry utility vacuum
constructed in accordance with the teachings of the present
invention;
[0016] FIG. 2 is an exploded view of the wet/dry vacuum of FIG.
2;
[0017] FIG. 3 is a schematic illustration of a portion of the
wet/dry vacuum of FIG. 1 illustrating the controller and charging
circuit in detail;
[0018] FIG. 4 is a sectional view of a portion of the wet/dry
vacuum of FIG. 1 illustrating the receptacle assembly in greater
detail;
[0019] FIG. 5 is a schematic view of the wet/dry vacuum of FIG. 1
illustrating the flow path when the wet/dry vacuum is used in the
vacuuming mode;
[0020] FIG. 6 is a schematic view of the wet/dry vacuum of FIG. 1
illustrating the flow path when the wet/dry vacuum is used in the
blowing mode;
[0021] FIG. 7 is a sectional view of a second wet/dry vacuum
constructed in accordance with the teachings of the present
invention;
[0022] FIG. 8 is a sectional view of a third wet/dry vacuum
constructed in accordance with the teachings of the present
invention;
[0023] FIG. 9 is a sectional view similar to FIG. 8 but
illustrating the powerhead assembly in a raised condition and the
canister assembly removed from the housing;
[0024] FIG. 10 is a sectional view of a fourth wet/dry vacuum
constructed in accordance with the teachings of the present
invention;
[0025] FIG. 11 is a sectional view similar to FIG. 10 but
illustrating the canister assembly removed from the housing;
[0026] FIG. 12 is a sectional view of a fifth wet/dry vacuum
constructed in accordance with the teachings of the present
invention;
[0027] FIG. 13 is a sectional view similar to FIG. 12 but
illustrating the secondary filter in a removed condition;
[0028] FIG. 14 is a perspective view of a sixth wet/dry vacuum
constructed in accordance with the teachings of the present
invention;
[0029] FIG. 14A is a front elevation view of the wet/dry vacuum of
FIG. 14;
[0030] FIG. 15 is a longitudinal section view of the wet/dry vacuum
of FIG. 14;
[0031] FIG. 16 is an enlarged portion of FIG. 15 illustrating the
cooling inlet aperture in greater detail;
[0032] FIG. 17 is an enlarged portion of FIG. 15 illustrating the
cooling outlet aperture in greater detail;
[0033] FIG. 18 is a schematic view of a portion of the wet/dry
vacuum of FIG. 14 illustrating the controller in greater
detail;
[0034] FIG. 19 is a perspective view of the wet/dry vacuum of FIG.
14 illustrating the lid in a lowered condition and the battery pack
exploded from the battery pack enclosure;
[0035] FIG. 20 is a schematic view of a portion of the wet/dry
vacuum of 14 illustrating the power supply in greater detail;
[0036] FIG. 21 is a schematic view of a portion of the wet/dry
vacuum of FIG. 14 illustrating the switching device in greater
detail;
[0037] FIG. 21A is a schematic view similar to that of FIG. 21 but
illustrating an alternately constructed controller;
[0038] FIG. 22 is an enlarged portion of FIG. 15 illustrating the
primary filter in greater detail;
[0039] FIG. 23 is a top plan view of the primary filter;
[0040] FIG. 24 is a side elevation view of a portion of the primary
filter illustrating the configuration of the retaining tab in
greater detail;
[0041] FIG. 25 is a bottom view of a portion of the wet/dry vacuum
of FIG. 14 illustrating the housing of the powerhead assembly in
greater detail;
[0042] FIG. 26 is a side elevation view of a portion of the housing
of the powerhead assembly illustrating one of the retaining slots
in greater detail;
[0043] FIG. 27 is a top plan view of a portion of the wet/dry
vacuum of FIG. 14 illustrating the coupling end of the hose
assembly in greater detail;
[0044] FIG. 28 is a rear elevation view of the wet/dry vacuum of
FIG. 14 illustrating the hose assembly in a first stored
condition;
[0045] FIG. 29 is a view similar to that of FIG. 28 but
illustrating the hose assembly in a second stored condition;
[0046] FIG. 30 is a top view of a portion of the wet/dry vacuum
illustrating the electrical cord in a stored condition;
[0047] FIG. 31 is a perspective view of a tool set constructed in
accordance with the teachings of the present invention;
[0048] FIG. 32 is a schematic side view of a seventh wet/dry vacuum
constructed in accordance with the teachings of the present
invention; and
[0049] FIG. 33 is a partial cross-sectional schematic side view of
the wet/dry vacuum of FIG. 32.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] With reference to FIG. 1 of the drawings, a hand-portable
wet/dry vacuum constructed in accordance with the teachings of the
present invention is generally indicated by reference numeral 10.
In the particular example illustrated, the vacuum 10 is shown to
include a powerhead assembly 12, a canister assembly 14, a filter
system 16, a hose assembly 18, a plurality of conventional hose-end
attachments 20, a shoulder strap 22, a first electrical cord 24, a
second electrical cord 26 and a battery pack 28.
[0051] With additional reference to FIG. 2, the powerhead assembly
12 may be removably attached to the canister assembly 14 and
includes a housing 40, a motor 42, a fan 44 and a controller 46.
The housing 40 defines an inlet port 50, an outlet port 52, a
handle 54 and a central cavity 56 into which the motor 42, fan 44
and controller 46 are housed. The inlet port 50 may be routed to
the canister assembly 14 on a first side of the filter system 16
while the outlet port 52 may be routed to the canister assembly 14
on a second side of the filter system 16. Air flowing into the
inlet port 50 flows into the canister assembly 14 and through the
filter system 16 prior to being directed out of the outlet port 52.
The motor 42 and the fan 44, which is coupled for rotation with the
output shaft (not shown) of the motor 42, cooperate to blow air out
of the outlet port 52 to thereby draw air into the powerhead
assembly 12 via the inlet port 50.
[0052] In FIG. 3, the controller 46 is illustrated to preferably
include a first electrical socket 60, a second electrical socket
62, a receptacle assembly 64, a power supply 66, a power switch 68
and a charger circuit 70. Each of the first and second electrical
sockets 60 and 62 and the receptacle assembly 64 are electrically
coupled to the power supply 66 and configured to conduct electrical
power thereto as will be described in detail, below. The power
supply 66 is electrically coupled to the motor 42 and the power
switch 68 in a conventional manner to permit the user to
selectively enable or disable the flow of electrical power to the
motor 42.
[0053] The first electrical cord 24 preferrably includes a
conventional pronged plug end 74, which is configured to be
electrically coupled to a conventional electrical outlet 76, and a
conventional first connector-end 78 that is configured to be
electrically coupled to the first electrical socket 60.
Accordingly, the first electrical cord 24 permits the user of the
wet/dry vacuum 10 to couple the power supply 66 to a source of
alternating current (AC) power.
[0054] The second electrical cord 26 preferably includes a
conventional cylindrical plug-end 84, which is configured to be
electrically coupled to a conventional cigarette lighter socket 86
of an automotive vehicle, and a conventional second connector-end
88, which is configured to be electrically coupled to the second
electrical socket 62. Accordingly, the second electrical cord 26
permits the user to couple the power supply 66 to a source of
direct current (DC) power, such as to the electrical system and
battery of an automotive vehicle.
[0055] In the example of FIGS. 3 and 4, the receptacle assembly 64
is illustrated as being flexibly connected to the housing 40 via a
flexible gasket 90. Preferably, the gasket 90 is made of a flexible
resilient material, such as rubber or another elastomer. The
receptacle assembly 64 includes a receptacle housing 94, which is
configured to receive the battery pack 28, and a connector 96 that
is floatingly disposed in the receptacle housing 94 to minimize the
shock received by a battery pack 28 if the wet/dry vacuum 10 is
dropped. The connector 96 has a plurality of terminals (not shown)
with a configuration that contacts the associated terminals (not
shown) of the battery pack 28. Preferably, the battery pack 28,
terminals, receptacle housing 94 and connector 96 are configured in
the manner disclosed in U.S. Pat. No. 5,144,217, the disclosure of
which is hereby incorporated by reference as if fully set forth
herein. Accordingly, the receptacle assembly 64 permits the user to
couple the power supply 66 to the battery pack 28 so that the
wet/dry vacuum 10 may be operated without either of the first and
second electrical cords 24 and 26 being coupled thereto, as when,
for example, a source of AC or DC electrical power is unavailable
or inconvenient to access. Also preferably, the power supply 66 is
compatible with battery packs having various different voltages
(e.g., 18 v, 14 v, 12 v, and/or 9.6 v) in a manner that is well
known in the art. Those skilled in the art will appreciate that any
manual or automatic means may be employed to select the source of
power for the wet/dry vacuum 10. For example, a conventional rotary
switch may be provided to permit the user to manually select
between AC power, DC power (from the second power cord 26) and a
battery pack 28. Alternatively, an automatic switch (comprising
transistors or any other suitable electrical device) may be
employed such that the power supply 66 will "look" for one power
type, such as AC power, first, and should it not be available, look
for "DC" power from the second power cord 26 next and thereafter
from the battery pack 28.
[0056] In FIG. 3, the charger circuit 70 is coupled to the power
supply 66 and the receptacle assembly 64 in a manner that is well
known in the art. The charger circuit 70 allows for the charging of
battery packs having different voltages, as is well known in the
art. An example of a suitable charger circuit is disclosed in U.S.
Pat. No. 6,427,070, the disclosure of which is incorporated by
reference as if fully set forth herein.
[0057] Accordingly, a user can charge a battery pack 28, when the
motor 42 is not running, by placing the battery pack 28 in the
receptacle assembly 64 such that the terminals of the connector 96
electrically engage the associated terminals of the battery pack 28
and providing the wet/dry vacuum 10 with another source of
electrical power via one of the first and second electrical cords
24 and 26. Once charged, the battery pack 28 may then be removed
from the receptacle assembly 64 and employed to power another
device, such as the heavy-duty audio equipment of U.S. Pat. No.
6,427,070 or the cordless drill/driver of U.S. Pat. No.
6,431,289.
[0058] Returning to FIG. 2, the canister assembly 14 preferably
includes a canister 100 and a latching system 102 that releasably
secures the canister 100 to the powerhead assembly 12. The
particular canister illustrated has a capacity of about two
gallons, but those skilled in the art will appreciate that the
canister 100 may in the alternative have a capacity that is larger
or smaller.
[0059] The filter system 16 may be completely attached to the
powerhead assemly 12 but in the particular example provided, is
carried canister 100 and includes a plenum 110 that is releasably
attachable to the powerhead assembly 12, a float ball 112, a
primary filter 114 and a secondary filter 116. The plenum 110 may
have a hollow, cage-like construction that permits air to flow
therethrough. The plenum 110 serves to retain and support the
primary filter 114 as well as retain and guide the float ball 112
in a generally vertical orientation. The float ball 112 rises
automatically within the plenum 110 to close off the filter system
16 from the fan 44 (which cuts off the flow of air through the
powerhead assembly 12) when liquid in the canister 100 reaches a
predetermined level.
[0060] The primary filter 114 may include a filter structure (not
specifically shown), which is formed from a rigid plastic material,
and a fabric filter material (not specifically shown) that
completely surrounds at least side of the filter structure. The
fabric filter material is preferably formed of a washable filter
material so as to permit the primary filter 114 to be washed when
loaded with dust or dirt, rather than disposed of and replaced. As
those skilled in the art will appreciate, however, the primary
filter 114 may be made of any suitable filtering material,
including an open-cell foam or a conventional filter paper (in
which case the primary filter 114 would be disposable). Optionally,
a pre-filter structure (not shown) may also be employed. Suitable
pre-filter structures include wire mesh or plastic screens, or
open-cell foam which serve to collect dust and dirt (e.g., drywall
dust) before the dust-carrying airflow contacts the primary filter
114.
[0061] The secondary filter 116, which is optional and in the
particular example provided carried by the powerhead assembly 12,
is disposed upstream of the primary filter 114 and is of a
generally finer mesh or porosity so as to collect relatively small
dust particles before they are expelled through the outlet port 52.
The secondary filter 116 is preferably removable from the filter
system 16 without disassembling the canister assembly from the
powerhead assembly 12. In the example provided, an access port 130
is formed in the housing 40 between the primary filter 114 and the
fan 44. When the secondary filter 116 is received into the access
port 130, a gasketed door 132 that may be hingedly coupled to the
housing 40 is closed to seal the access port 130 and ensure that
air flowing to the fan 44 encounters the primary filter 114 and
then the secondary filter 116. The purpose of the secondary filter
116 is to provide very fine filtering of the air passing through
the wet/dry vacuum 10 so that dirt and dust are not expelled from
the outlet port 52 when the wet/dry vacuum 10 is operated.
Preferably, the wet/dry vacuum 10 may also be used without the
secondary filter 116 when the expelling of relatively fine dust
from the outlet port 52 is not an issue.
[0062] With reference to FIGS. 1 and 2, the hose assembly 18 is
preferably a flexible vacuum hose which is fixedly coupled to the
inlet port 50. Also preferably, the hose assembly 18 is at least
partially retractable into the inlet port 50 so as to provide a
convenient means for storage of the hose assembly 18.
Alternatively, the hose assembly 18 may be removably friction
fitted on a selective basis to the inlet port 50 (for vacuuming) or
the outlet port 52 (for blowing).
[0063] The distal end of the hose assembly 18 may be
friction-fittable to any of the hose-end attachments 20. Such
hose-end attachments 20 are well known in the art and as such, a
detailed discussion of their construction and use need not be
provided herein. To prevent the hose-end attachments 20 from being
lost, a plurality of receiving slots 140 may be formed into the
housing 40 and/or canister 100. The receiving slots 140 may be
constructed to frictionally engage an associated one of the
hose-end attachments 20. When not in use, each hose-end attachment
20 may be coupled to the housing 40 and/or canister 100 via its
associated receiving slot 140.
[0064] The shoulder strap 22, which is optional, is coupled to the
powerhead assembly 12 and permits the user of the wet/dry vacuum 10
to wear the unit over their shoulder so that their hands may be
used for other tasks, including transporting other equipment or
manipulating the hose assembly 18 when the wet/dry vacuum 10 is in
use. In the particular embodiment illustrated, the shoulder strap
22 is coupled to the handle 54, which is integrally formed with the
housing 40.
[0065] As noted above, the hose assembly 18 is preferably fixedly
coupled to the inlet port 50 and as such, is not connectable to the
outlet port 52 so that the wet/dry vacuum 10 can be used as a
blower in a conventional manner (i.e., by connecting the hose
assembly 18 to the outlet port 52). As best shown in FIGS. 1, 5 and
6, the wet/dry vacuum 10 may include a valve assembly 150 that
selectively controls the flow of air to the fan 44. More
specifically, the valve assembly 150 may be a two-position four-way
valve that includes an actuator 154 and a valve element 156. In the
particular embodiment illustrated, the actuator 154 is a rotary
style actuator that is movable between a first setting 160 and a
second setting 162. The valve element 156 is coupled for rotation
with the actuator 154 such that when the actuator 154 is positioned
in the first setting 160, air is drawn from the inlet port 50
through the filter system 16 and into the fan 44 in the manner
described above. When the actuator 154 is positioned in the second
setting 162, the valve element 156 moves (e.g., rotates in the
example provided) to cause the outlet port 52 to be in fluid
communication with the inlet side of the filter system 16 and the
inlet port 50 to be in fluid communication with the discharge side
of the fan 44.
[0066] As those skilled in the art will appreciate, various
components of the wet/dry vacuum 10, such as the motor 42, the fan
44 and the primary filter 114, may be constructed and/or arranged
in a manner that is well known in the art. Such components,
constructions and arrangements are illustrated and discussed, for
example, in U.S. Pat. No. 6,363,574, which is hereby incorporated
by reference as if fully set forth herein.
[0067] With reference to FIG. 7, a second wet/dry vacuum
constructed in accordance with the teachings of the present
invention is generally indicated by reference numeral 10a. Although
schematically illustrated, the wet/dry vacuum 10a is generally
similar to the wet/dry vacuum 10 of FIG. 1 except that the filter
system 16a is integrated with the canister assembly 14a. More
specifically, the plenum 110a is coupled to the canister 100a and
the primary filter 114a completely shrouds the plenum 110a. When
the powerhead assembly 12a is coupled to the canister assembly 14a,
a gasket 170 is compressed between the primary filter 114a and the
powerhead assembly 12a to thereby sealingly engage the primary
filter 114a to the powerhead assembly 12a.
[0068] When the canister 100a is to be emptied, the powerhead
assembly 12a is unlatched from the canister 100a, the primary
filter 114a is removed from the canister 100a and the canister 100a
may be overturned to empty its contents. Like the primary filter
114, the primary filter 114a is preferably at least partially
constructed from a washable and re-usable filtering material to
thereby eliminate the need for replacement filters. This
configuration is advantageous in that all of the dirty components
are located together and remain in an upright condition when they
are being removed. In contrast to the known wet/dry vacuums wherein
the filter system is coupled to the powerhead, dust and other
debris remain contained within the canister 100a when the powerhead
assembly 12a is removed. Furthermore, removal and/or replacement of
the primary filter 114a is quick and efficient, as no fasteners are
employed to fix the position of the primary filter 114a relative to
the powerhead assembly 12a.
[0069] With reference to FIGS. 8 and 9, another wet/dry vacuum
constructed in accordance with the teachings of the present
invention is generally indicated by reference numeral 10b. Although
schematically illustrated, the wet/dry vacuum 10b is generally
similar to the wet/dry vacuum 10a of FIG. 7 except that the
powerhead assembly 12b is pivotally (via a hinge 179, for example)
attached to a housing 180 that houses the canister assembly
14b.
[0070] When the canister assembly 14b is to removed from or
inserted into the housing 180, the powerhead assembly 12b is
pivoted upwardly as shown in FIG. 9. Once the canister assembly 14b
is seated within the housing 180, the powerhead assembly 12b is
pivoted downwardly so that a gasket 182 that is carried by the
powerhead assembly 12b sealingly engages the canister 100b. Those
skilled in the art will appreciate that the gasket 182 may
alternatively be carried by the canister 100b. A conventional latch
mechanism 183 may be employed to secure the powerhead assembly 12b
to the canister assembly 14b.
[0071] With reference to FIGS. 10 and 11, a fourth wet/dry vacuum
constructed in accordance with the teachings of the present
invention is generally indicated by reference numeral 10c. Although
schematically illustrated, the wet/dry vacuum 10c is generally
similar to the wet/dry vacuum 10b of FIGS. 8 and 9 except that the
powerhead assembly 12c is fixedly attached attached to the housing
180c that houses the canister assembly 14c. The canister assembly
14c is therefore inserted to and removed from the housing 180c by
sliding the canister assembly 14c into or out of the housing
180c.
[0072] With reference to FIGS. 12 and 13, yet another wet/dry
vacuum constructed in accordance with the teachings of the present
invention is generally indicated by reference numeral 10d. The
wet/dry vacuum 10d is generally similar to the wet/dry vacuum 10c
of FIGS. 10 and 11, except that a secondary filter 116d is
incorporated into the filter system 16d. Like the secondary filter
116 shown in FIG. 5, the secondary filter 116d may be located
between the fan 44 and the primary filter 114d and is relatively
finer in porosity/mesh so that dirt and dust are not expelled from
the outlet port 52 when the wet/dry vacuum 10d is operated.
Advantageously, the secondary filter 116d may be removed and
cleaned or replaced without removal of the canister assembly
14d.
[0073] With reference to FIG. 14, a sixth vacuum constructed in
accordance with the teachings of the present invention is generally
indicated by reference numeral 10e. The vacuum 10e is shown to
preferably include a powerhead assembly 12e, a canister assembly
14e, a filter system 16e, a hose assembly 18e, a plurality of
conventional hose-end attachments 20e, a shoulder strap 22e, an
electrical cord 24e and a battery pack 28e.
[0074] With additional reference to FIG. 15, the powerhead assembly
12e may be removably attached to the canister assembly 14e and may
include a housing 40e, a motor 42e, a fan 44e and a controller 46e.
The housing 40e may define one or more of an inlet port 50e, an
outlet port 52e, a handle 54e and a central cavity 56e into which
the motor 42e, fan 44e and controller 46e may be housed. The inlet
port 50e is routed into the canister assembly 14e on a first side
of the filter system 16e while the outlet port 52e routes air out
of the powerhead assembly 12e on a second side of the filter system
16e. Air flowing into the inlet port 50e may flow into the canister
assembly 14e and through the filter system 16e prior to being
directed out of the outlet port 52e. The motor 42e and the fan 44e,
which is coupled for rotation with the output shaft (not shown) of
the motor 42e, cooperate to preferably blow air out of the outlet
port 52e which thereby draws air into the canister assembly 14e via
the inlet port 50e.
[0075] In the example provided, the housing 40e may be configured
to aid in the cooling of the motor 42e during its operation. More
specifically, the housing 40e may be configured with one or more
cooling inlet apertures 500 and one or more cooling outlet
apertures 502, with both of the cooling inlet and outlet apertures
500 and 502 being in fluid communication with the central cavity
56e as will be described in greater detail, below. In the
embodiment provided, a single cooling inlet aperture 500 and a
single cooling outlet aperture 502 are employed. With additional
reference to FIGS. 16 and 17, the cooling inlet aperture 500 is
illustrated as being concentrically disposed about the inlet port
50e to thereby disguise its location on the housing 40e, but those
skilled in the art will appreciate that the cooling inlet
aperture(s) 500 may be located at various other locations on the
housing 40e. The cooling outlet aperture 502 may be located in the
portion of the housing 40e that defines the outlet port 52e. In the
example provided, the cooling outlet aperture 502 extends through a
trailing portion 510 of a protrusion 512 that is formed on the wall
514 of the outlet port 52e and oriented in a direction such that a
longitudinal axis of the protrusion 512 is generally parallel to
the flow of air through the outlet port 52e.
[0076] The particular vacuum 10e provided is configured such that
during its operation, air flows through the outlet port 52e to
create a zone 520 of relatively low static pressure proximate the
cooling outlet aperture 502, causing air to flow from the central
cavity 56e through the cooling outlet aperture 502 where it merges
with the air flowing through the outlet port 52e. The air departing
from the central cavity 56e likewise draws fresh air into the
central cavity 56e through the cooling inlet aperture 500. The
exchange of air in the central cavity 56e permits the motor 42e to
reject relatively higher levels of heat. More specifically, the air
flowing through the central cavity 56e provides an air stream
permits that flows against the motor 42e to thereby permit the
motor 42e to reject heat therefrom with a convective heat transfer
mechanism.
[0077] In FIG. 18, the controller 46e is illustrated to preferably
include a receptacle assembly 64e, a power supply 66e, a power
switch 68e and an optional charger circuit 70e. The receptacle
assembly 64e is electrically coupled to the power supply 66e and
configured to conduct electrical power thereto as will be described
in detail, below. The power supply 66e is electrically coupled to
the motor 42e and the power switch 68e to permit the user to
selectively enable or disable the flow of electrical power to the
motor 42e.
[0078] The electrical cord 24e may include a conventional pronged
plug end 74e, which is configured to be electrically coupled to a
conventional electrical outlet 76e, and an opposite end (not shown)
which is electrically coupled in a conventional manner to the power
supply 66e. Accordingly, the electrical cord 24e may permit the
user of the wet/dry vacuum 10e to couple the power supply 66e to a
source of alternating current (AC) power.
[0079] The receptacle assembly 64e may be generally similar to the
receptacle assembly 64 of FIGS. 3 and 4 and as such, need not be
discussed in significant detail. In the example provided, the
receptacle assembly 64e is illustrated in FIG. 19 to be disposed in
a battery enclosure 550 that is coupled to or integrally formed
with the housing 40e. A lid 552 may be hingedly coupled to the
battery enclosure 550 and is movable between a closed position
(FIG. 14), which substantially closes the battery enclosure 550,
and an open position, which substantially clears the battery
enclosure 550. An over-center camming latch mechanism 556 may be
employed to selectively maintain the lid 552 in the closed
position. An optional battery pack gasket 560 and leaf spring 562
may also be employed. The battery pack gasket 560 may be disposed
between the battery pack 28e and one or both of the receptacle
assembly 64e and the battery enclosure 550 (i.e., battery pack
gaskets 560 in the latter example), while the leaf spring 562 may
be attached to the lid 552 and positioned so as to push the battery
pack 28e into electrical contact with the receptacle assembly 64e
and sealing contact with the battery pack gasket 560 when the lid
552 is positioned in the closed position. The battery pack gasket
560 inhibits liquids from entering the receptacle assembly 64e and
the interior of the housing 40e despite the presence of vent
apertures 564 (FIG. 25) that extend through the battery enclosure
550 and/or lid 552.
[0080] The receptacle assembly 64e permits the user to couple the
power supply 66e to the battery pack 28e so that the wet/dry vacuum
10e may be operated when, for example, a source of AC electrical
power is unavailable or inconvenient to access. Also preferably,
the power supply 66e is compatible with battery packs having
various different voltages (e.g., 18 v, 14 v, 12 v, and/or 9.6 v).
Stated another way, the power supply 66e is preferably configured
such that a first battery pack having a first output voltage and a
second battery pack having a second output voltage that is
different than the first output voltage may be used interchangeably
to power the power supply 66e. In the particular example provided,
the power supply 66e includes an AC/DC converter 600 and a DC/DC
converter 602 as shown in FIG. 20. The AC/DC converter 600
preferably has an electromagnetic interference suppression module
610, a rectifier 612 for rectifying alternating current power input
thereto from the electrical cord 24e, and a switching power supply
614 for pulse-modulating the rectified (i.e., direct current) power
provided by the rectifier 612. The switching power supply 614
switches (i.e., turns on and off) to control its output to the
motor 42e. By controlling the duration of each of the "on" and
"off" events, the switching power supply 614 is able to apply power
of a desired voltage to the motor 42e. A feedback loop 620 may
optionally be included in the power supply 66e for more accurate
control of the voltage. Similarly, the DC/DC converter 602 may
include a switching power supply 624 that is similar to the
switching power supply 614 of the AC/DC converter 600 in that it
switches (i.e., turns on and off) to control its output to the
motor 42e to thereby apply power of a desired voltage to the motor
42e. Consequently, electrical power of a relatively identical
voltage may be provided to the motor 42e regardless of the voltage
of the battery pack 28e.
[0081] The power supply 66e preferably includes a switch device 630
for automatically selecting the source of power for the wet/dry
vacuum 10e. With reference to FIG. 21, the switch device 630 is
illustrated to be optionally integrated with the DC/DC converter
602 and may include, for example, an integrated circuit 640, first
and second resistors 642 and 644, respectively, and a transistor
646. The integrated circuit 640 may be configured such that if it
receives power from the AC/DC converter 600, the integrated circuit
640 will turn the transistor 646 "off" so that the power from the
battery pack 28e will not be transmitted to the motor 42e.
Accordingly, the switch device 630 may be configured so that the
battery pack 28e will power the vacuum 10e unless the vacuum 10e is
coupled to a source of alternating current power in the manner
described above.
[0082] With brief reference to FIG. 21A, an alternately constructed
power supply 66e' is illustrated. The power supply 66e' differs
from the power supply 66e of FIG. 21 in that the switch device 630
is associated with the AC/DC converter 600. More specifically, the
switch device 630 is illustrated as being a relay 630-1 with first
and second contacts 630-2, 630-3, respectively, that are employed
to control the flow of electricity. The relay 630-1 is illustrated
in its normal condition wherein a lead 630-4 from the motor 42e is
electrically coupled to the first contact 630-2, which is in turn
electrically coupled to the DC/DC converter 602 (via the power
switch 68e). The relay 630-1 remains in its normal condition unless
the AC/DC converter 600 provides power (through the power switch
68e in the example provided) to the relay 630-1. When the vacuum
10e is coupled to a source of alternating current power and the
power switch 68e is switched on, the relay 630-1 causes the lead
630-4 from the motor 42e to be electrically coupled to the second
contact 630-3, which is in turn electrically coupled to the AC/DC
converter 600 (via the power switch 68e). Those skilled in the art
will appreciate from this disclosure that the power supply, in its
broader aspects, may be constructed somewhat differently and as
such, the particular examples described and illustrated in this
application are exemplary only and not intended to be limiting in
any manner.
[0083] Returning to FIG. 18, the charger circuit 70e may be coupled
to the power supply 66e and the receptacle assembly 64e. The
charger circuit 70e allows for the charging of battery packs having
different voltages, as is well known in the art. An example of a
suitable charger circuit is disclosed in U.S. Pat. Nos. 6,427,070
and 6,496,688, the disclosures of which are hereby incorporated by
reference as if fully set forth herein.
[0084] Accordingly, a user can charge a battery pack 28e, when the
power supply 66e is coupled to a source of alternating current
power by placing the battery pack 28e in the receptacle assembly
64e such that the terminals (not shown) of the connector (not
shown) of the receptacle assembly 64e electrically engage the
associated terminals (not shown) of the battery pack 28e. Once
charged, the battery pack 28e may then be employed to power the
vacuum 10e or removed from the receptacle assembly 64e and employed
to power another device, such as the heavy-duty audio equipment of
U.S. Pat. No. 6,427,070 or the cordless drill/driver of U.S. Pat.
No. 6,431,289.
[0085] With brief reference to FIG. 14A, the housing 40e may be
configured so as to define a recess 41e into which the power switch
68e is disposed. In the particular example provided, the power
switch 68e is a toggle switch.
[0086] Returning to FIG. 14, the canister assembly 14e preferably
includes a canister 100e and an over-center cam latching system
102e that employs a pair of over-center cam latches 700 to
releasably secure the canister 100e to the powerhead assembly 12e.
The particular canister 100e illustrated has a capacity of about
two gallons, but those skilled in the art will appreciate that the
canister 100e may in the alternative have a capacity that is larger
or smaller. Preferably, the canister assembly 14e also includes a
reservoir emptying means 101e that permits a liquid to be emptied
from the interior of the canister 100e without removing the
powerhead assembly 12e from the canister assembly 12e. The
reservoir emptying means 101e may be a valve (not shown), such as a
ball valve or gate valve. In the particular example provided, the
reservoir empting means 101e includes a threaded boss 101-1, a
gasket 101-2 and a threaded cap 101-3. The threaded boss 101-1
extends outwardly from the canister 100e and is threaded about at
least a portion of its exterior surface. The threaded cap 101-3
includes an internal thread that is configured to threadably engage
the threaded boss 101-1. The gasket 101-2, which is formed from a
resilient, elastomeric material in the example provided, is
disposed between the end of the threaded boss 101-1 and an interior
surface of the threaded cap 101-3; the gasket 101-2 sealingly
engages the end of the threaded boss 101-1 and the threaded cap
101-3 when the threaded cap 101-3 is tightened against the threaded
boss 101-1.
[0087] In contrast to the filter system 16 of FIG. 1, the filter
system 16e may be configured to be carried entirely by the
powerhead assembly 12e as is shown in FIG. 15. The filter system
16e includes a shut-off device 740, a primary filter 114e and an
optional secondary filter 116e. In the example provided, the
secondary filter 116e may be a pad of fiberous material that is
coupled to the fan inlet 742, but it could also be made of a mesh
or screen material or omitted altogether depending upon the
filtering capabilities of the primary filter 114e. Also, the
secondary filter 116e may be coupled to the power head assembly 12e
at a point after (downstream) of the fan 44e.
[0088] The shut-off device 740 is associated with the powerhead
assembly 12e and configured to prevent the fan 44e from drawing a
liquid into the fan inlet 742 when a volume of liquid in the
canister assembly 14e exceeds a predetermined volume. The shut-off
device 740 may be configured in various ways and may, for example,
prevent electrical power from being transmitted to the motor 42e or
close-off the fan inlet 742 in response to a volume of liquid in
the canister assembly 14e increasing above the predetermined
volume. In the particular example provided, the shut-off device 740
includes a plenum 110e and a float 112e. The plenum 110e may be a
hollow, cage-like construction that permits air to flow
therethrough and which serves to retain and guide the float 112e
along a generally vertical axis. The float 112e, which is
illustrated in the example provided as being a hollow sphere, is
configured to rise automatically within the plenum 110e to close
off the fan inlet 742e (to thereby halt the flow of air into the
fan 44e and through the powerhead assembly 12e) when liquid in the
canister 100e reaches a predetermined level. Those skilled in the
art will appreciate from this disclosure that the float 112e may be
configured with a shape that may not be spherical or even closed.
For example, the float 112e may have a generally cylindrical shape
that is closed on a single end.
[0089] The primary filter 114e may include a filter body 760, an
internal support structure 762, a lower end cap 764 and an upper
end cap 766. The filter body 760 may be formed from any appropriate
filter material, including paper or fabric. In the particular
example provided, however, the filter body is formed from a pleated
material that is air and vapor permeable, but resistant to the
infiltration or penetration of liquids therethrough so that the
filter body 760 may be readily cleaned as through washing.
Optionally, the material from which the filter body 760 is made is
also hydrophobic and/or oleophobic so that the filter body 760 will
not be wetted by water and/or oils that are drawn into the canister
assembly 14e. Our testing has shown that one particularly suitable
material for the filter body 760 is comprised of a filter media
support bonded to a porous expanded PTFE membrane, with one such
suitable material being marketed as Gore Wet/Dry Filter Products
manufactured by W.L. Gore & Associates, a Delaware Corporation
having a place of business in Elkton, Md. Also optionally, the
filter body 760 may be configured to provide HEPA (high efficiency
particulate air) filtration or ULPA (ultra low penetration air)
filtration.
[0090] The internal support structure 762 may be a cage-like
structure that is disposed about the interior of the filter body
760 and fixedly coupled to one or both of the lower and upper end
caps 764 and 766. The internal support structure 762 is configured
to axially and radially support the filter body 760 during the
operation of the vacuum 10e to thereby prevent the filter body 760
from crushing or distorting in response to a pressure differential
between the interior and exterior surfaces of the filter body
760.
[0091] The lower end cap 764 may be a plate-like structure that is
formed from a rigid material and is sealingly bonded to a lower end
of the filter body 760. Alternatively, the lower end cap 764 may be
wholly or partially formed from the material from which the filter
body 760 is manufactured.
[0092] The upper end cap 766 may be an annular flange that is
sealingly bonded to an upper end of the filter body 760. With
reference to FIGS. 15 and 22 through 24, the upper end cap 766
preferably includes a body 770 that defines a receiving aperture
772, which receives the plenum 110e therethrough when the primary
filter 114e is coupled to the powerhead assembly 12e, a seal
engagement structure 774, which is illustrated as extending axially
from the body 770 and oriented generally concentric with the
receiving aperture 772, and a plurality of retaining tabs 776 that
are circumferentially spaced about the perimeter of the body 770
and which extend radially outward therefrom.
[0093] The seal engagement structure 774 is sized to engage a
corresponding filter gasket 780 that is formed from an elastomeric
material and disposed about the fan inlet 742 adjacent a lower
surface of the housing 40e. In the particular embodiment
illustrated, the filter gasket 780 is fixedly coupled to the
housing 40e, but could alternatively be fixedly coupled to the
upper end cap 766 or removably coupled to either the housing 40e or
the upper end cap 766.
[0094] With additional reference to FIGS. 25 and 26, the retaining
tabs 776 may be configured to matingly engage corresponding
retaining slots 790 that are formed in the housing 40e in an area
proximate the fan inlet 742. In the particular example provided,
the retaining tabs 776 are illustrated as having a generally flat
upper surface 792, a tapered lower surface 794 and an engagement
feature 796.
[0095] The retaining slots 790 may be formed in the inner surface
800 of a collar 802 that extends generally perpendicularly from the
bottom surface of the housing 40e concentric to the fan inlet 742.
Each retaining slot 790 may be generally L-shaped, with a first
portion 810, which is configured to axially receive a corresponding
one of the retaining tabs 776, and a second portion 812 that
extends around a portion of the circumference of the collar 802.
The second portion 812 includes an engagement surface 814 that is
configured to engage the lower surface 794 of a corresponding one
of the retaining tabs 776. In the example provided, the engagement
surface 814 is tapered and includes a notch-like retaining feature
816 that is configured to receive therein the engagement feature
796 of a corresponding one of the retaining tabs 776.
[0096] With reference to FIGS. 22, 23 and 26, when the primary
filter 114e is to be coupled to the housing 40e, the primary filter
114e is installed over the plenum 110e and the retaining tabs 776
are each inserted to the first portion 810 of an associated
retaining slot 790. The primary filter 114e may then be rotated to
move the retaining tabs 776 into the second portion 812 of the
retaining slots 790. With sufficient rotation of the primary filter
114e, the engagement features 796 of each of the retaining tabs 776
are coupled with an associated retaining feature 816 (i.e.,
received into an associated retaining feature 816 in the particular
example provided) to thereby hinder opposite rotation of the
primary filter 114e so that the primary filter 114e will not
disengage the housing 40e during the operation of the vacuum
10e.
[0097] The tapered lower surface 794 on the retaining tabs 776 and
the tapered engagement surface 814 cooperate when the primary
filter 114e is being rotated so as to translate the primary filter
114e axially toward the housing 40e. In this way, the seal
engagement structure 774 is forced into sealing engagement with the
filter gasket 780 to thereby inhibit the introduction of liquids
into the fan 44e from a point between the upper end cap 766 and the
housing 40e. The ability to seal the primary filter 114e against
the housing 40e is of particular importance in those instances
where a HEPA or ULPA filter material is employed for the filter
body 760, since the filter gasket 780 also inhibits debris from
infiltrating between the housing 40e and the upper end cap 766.
[0098] In the particular example provided, both the second portion
812 of the retaining slots 790 and the tapered lower surfaces 794
of the retaining tabs 776 are tapered in a way that not only
facilitates axial movement of the primary filter 114e as the
primary filter 114e is rotated relative to the housing 40e but also
distributes the load that is exerted by the resilient filter gasket
780 over the entire width of the retaining tabs 776. Those skilled
in the art will appreciate, however, that the lower surface 794 of
the retaining tabs 776 need not be tapered, and that the retaining
tabs 776 and retaining slots 790 could, in the alternative, be
formed on the housing 40e and the upper end cap 766,
respectively.
[0099] With renewed reference to FIG. 15 and additional reference
to FIG. 27, the hose assembly 18e is preferably a flexible vacuum
hose which may be removably coupled to either the inlet port 50e or
the outlet port 52e. In the example provided, the hose assembly 18e
preferably includes a coupling end 850 with a tapered cylindrical
body 852 and a pair of attachment lugs 854. The tapered cylindrical
body 852 is constructed to be inserted into and frictionally engage
a desired one of the inlet and outlet ports 50e and 52e. The
attachment lugs 854 extend outwardly from the tapered cylindrical
body 852 and are configured to be received into corresponding lug
slots 860 formed in the walls of the inlet and outlet ports 50e and
52e. As best shown in FIGS. 15 and 16, each of the lug slots 860
may be L- or J-shaped having an insertion portion 864, which
receives an associated one of the attachment lugs 854 when the
coupling end 850 is axially inserted into the associated inlet or
outlet port 50e or 52e, and a retaining portion 866, which extends
around a portion of the inner circumference of the associated inlet
or outlet port 50e or 52e. The terminal end 868 of the retaining
portion 866 is somewhat elongated in a direction that is generally
parallel to the insertion portion 864 so that when an attachment
lug 854 is disposed therein and a force is applied to the hose
assembly 18e that tends to withdraw it from the powerhead assembly
12e, the attachment lug 854 is able to move forwardly somewhat. As
such, the exemplary coupling end 850 illustrated must be further
inserted to the port and rotated to effect the uncoupling of the
hose assembly 18e from the powerhead assembly 12e. The need to both
further insert and rotate the coupling end 850 aids in resisting
the uncoupling of the hose assembly 18e from the port at an
undesired time.
[0100] With reference to FIG. 14, the opposite end 880 of the hose
assembly 18e may be friction-fittable to any of the hose-end
attachments 20e. Such hose-end attachments 20e are well known in
the art and as such, a detailed discussion of their construction
and use need not be provided herein. To ensure that the hose-end
attachments 20e are secure and handy, the vacuum 10e preferably
includes a tool retainer 890 that may be integrally formed with the
housing 40e or discretely formed and coupled to the housing 40e, as
with screws (not shown).
[0101] In the example provided, the tool retainer 890 includes a
pair of cylindrical recesses 900, which are configured to receive
therein a crevice tool 20e' and a nozzle 20e", and a C-shaped
collar 802 that is configured to frictionally engage (i.e., clamp
about the perimeter of) the hose assembly 18e. Accordingly, the
user may store the hose assembly 18e in a storage position as shown
in FIG. 28 by inserting the coupling end 850 of the hose assembly
18e to the inlet port 50e, wrapping the hose assembly 18e about a
lateral side of the vacuum 10e such that the hose assembly 18e is
captured below the battery enclosure 550 and lid 552 and clipping a
portion of the hose assembly 18e into the C-shaped collar 802. With
the hose assembly 18e thus stowed, the opposite end 880 of the hose
assembly 18e is maintained in a stationary position, which may have
additional utility in situations where the vacuum 10e is being
operated to remove debris from an object and the user of the vacuum
10e is using one hand to hold an object and the other hand to aid
in clearing debris from the object. Stated another way, the
C-shaped collar 802 may be used as a "third hand" to hold the
opposite end 880 of the hose assembly 18e as necessary. Preferably,
the portion of the hose assembly 18e between the C-Shaped collar
802 and the coupling end 850 (i.e., the body of the hose assembly
18e) is in a state of tension (owing to the stretchy nature of the
body of the hose assembly 18e) so that the body of the hose
assembly 18e is secured to the housing 40 and canister 100e when
the hose assembly 18e is placed in the storage position.
[0102] Alternatively, the coupling end 850 of the hose assembly 18e
may be inserted to one of the inlet and outlet ports 50e and 52e,
the hose assembly 18e wrapped about a lateral side of the vacuum
10e such that the hose assembly 18e is captured below the battery
enclosure 550 and lid 552 and the opposite end 880 coupled to the
other one of the inlet and outlet ports 50e and 52e as is
illustrated in FIG. 29. Preferably, the portion of the hose
assembly 18e between the opposite end 880 and the coupling end 850
(i.e., the body of the hose assembly 18e) is in a state of tension
(owing to the stretchy nature of the body of the hose assembly 18e)
so that the body of the hose assembly 18e is secured to the housing
40 and canister 100e when the hose assembly 18e is placed in this
storage position.
[0103] Returning to FIG. 14, the shoulder strap 22e may be coupled
to the powerhead assembly 12e to permit the user of the wet/dry
vacuum 10e to selectively wear the unit over their shoulder so that
their hands may be used for other tasks, including transporting
other equipment or manipulating the hose assembly 18e when the
wet/dry vacuum 10e is in use. In the particular embodiment
illustrated, the shoulder strap 22e is coupled to the two clips 920
that extend from the housing 40e in areas proximate the inlet and
outlet ports 50e and 52e.
[0104] With additional reference to FIG. 30, an optional cord wrap
930 is also included with the vacuum 10e. In the example provided,
the cord wrap 930 comprises two L-shaped brackets 960 that are
coupled to the housing 40e. The brackets 960 include a large flange
962 that is spaced apart from the housing 40e to define
therebetween a cord-wrap cavity 964 about which the electrical cord
24e may be wrapped for storage.
[0105] In FIG. 31, a tool set constructed in accordance with the
teachings of the present invention is generally indicated by
reference numeral 1000. The tool set 1000 includes various power
tools 1002 and the above-described utility vacuum 10e, which
includes the battery pack 28e. Each of the power tools 1002 are of
a construction that includes a receptacle assembly 64e with a
configuration that is compatible and preferably similar or
identical to the receptacle assembly 64e of the utility vacuum 10e
to thereby permit the battery pack 28e to be selectively coupled to
a given one of the power tools 1002 to transmit electrical power
thereto for the operation of the given power tool 1002.
Advantageously, the battery pack 28e may be selectively coupled to
any of the components of the tool set 1000 to thereby power the
selected power tool 1002 or the utility vacuum 10e. While the
particular power tools 1002 are illustrated to include a drill
driver 1002a, a circular saw 1002b, a reciprocating saw 1002c and a
flashlight 1002d, those skilled in the art will appreciate in light
of this disclosure that the particular power tool may be of any
desired type and may include, for example, hammer drills, jig saws,
screw drivers, impact wrenches, rotary hammers, routers, spiral
saws, plate joiners, metal working shears, grinders, sanders,
buffers, self-leveling rotary lasers, manually-leveled rotary
lasers and heavy-duty audio equipment.
[0106] With reference to FIGS. 32 and 33, yet another wet/dry
vacuum constructed in accordance with the teachings of the present
invention is generally indicated by reference numeral 10f. In the
particular example illustrated, the vacuum 10f is shown to include
a powerhead assembly 1112, a canister assembly 1114, a filter 1116,
a hose assembly 1118, and a battery pack 1120.
[0107] The powerhead assembly 1112 is located within a housing 1121
and includes a motor 1122, and a fan 1124. The housing 1121 defines
an inlet port 1126, an outlet port 1128, a handle portion 1130 and
a central cavity 1132 into which the motor 1122, and the fan 1124
are housed. The inlet port 1126 may be routed to the canister
assembly 1114 on a first side of the filter 1116 while the outlet
port 1128 may be routed to the canister assembly 1114 on a second
side of the filter 1116. Air flowing into the inlet port 1126 flows
into the canister assembly 1114 and through the filter 1116 prior
to being directed out of the outlet port 1128. The motor 1122 and
the fan 1124, which is coupled for rotation with the output shaft
(not shown) of the motor 1124, cooperate to blow air out of the
outlet port 1128 to thereby draw air toward the powerhead assembly
1112 via the inlet port 1126.
[0108] The powerhead assembly 1112 is preferably located within the
cavity 1132 of the housing 1121 adjacent to the battery 1120 and
above the canister assembly 1114. In a preferred embodiment, the
powerhead assembly 1112 is disposed in a substantially vertical
fashion wherein the motor 1122 is located above the fan 1124 which
is located above the canister assembly 1114.
[0109] As shown in FIG. 33, the battery 1120 is preferably located
between the canister assembly 1114 and the intake 1136 of the
vacuum 10f near the front end of the vacuum 10f. In a preferred
embodiment, the battery 1120 is electrically coupled to the motor
1122 and a power trigger switch 1134 via a power supply to permit
the user to selectively enable or disable the flow of electrical
power to the motor 1122 thereby allowing the user to operate the
vacuum 10f. Preferably, the battery 1120 is inserted into the
vacuum 10f in a direction that is substantially parallel to the
motor axis and is removeably attached to the housing 1121 via at
least one latch member.
[0110] Turning back to FIGS. 32 and 33, the canister assembly 1114
preferably includes a canister 1138 and a latching system 1140 that
releasably secures the canister 1138 to the housing 1121. The
latching system 1140 preferably includes at least hinge assembly
that allows the tank to pivot with respect to the housing 1121 when
unlatched, but also allows the canister 1138 to be removed from the
housing 1121 when unlatched. The canister 1138 is in fluid
connection with the intake 1136 via the hose assembly 1118 and the
inlet port 1126. Those skilled in the art will appreciate that the
canister 1138 may have a capacity that is large, medium, or
small.
[0111] Located within the canister 1138 is the filter 1116. The
filter 1116 may be attached to the powerhead assembly 1112 or may
be carried within canister 1138. The filter 1116 may include a
filter structure (not specifically shown), which is formed from a
rigid plastic material, and a fabric filter material (not
specifically shown) that completely surrounds at least side of the
filter structure. The fabric filter material is preferably formed
of a washable filter material so as to permit the filter 1116 to be
washed when loaded with dust or dirt, rather than disposed of and
replaced. As those skilled in the art will appreciate, however, the
filter 1116 may be made of any suitable filtering material,
including an open-cell foam or a Gore-Tex type material or a
conventional filter paper (in which case the filter 1116 would be
disposable).
[0112] With continued reference to FIGS. 32 and 33, the hose
assembly 1118 is preferably a flexible vacuum hose which is fixedly
coupled to the inlet port 1126. Also preferably, the body of the
hose assembly 1118 is at least partially friction fit into a
portion of the handle portion 1130 so as to provide a convenient
means for storage of the hose assembly 1118.
[0113] The front end of the hose assembly 1118 may be friction-fit
into the front portion 1142 of the housing 1121 during use or may
be friction fitted with hose-end attachments 20. Such hose-end
attachments 20 are well known in the art and as such, a detailed
discussion of their construction and use need not be provided
herein. The hose assembly 1118, when used with hose-end attachments
20, can be removed from the handle portion 1130 of the housing 1121
for greater flexibility during use of the vacuum 10f.
[0114] While the invention has been described in the specification
and illustrated in the drawings with reference to a preferred
embodiment, it will be understood by those skilled in the art that
various changes may be made and equivalents may be substituted for
elements thereof without departing from the scope of the invention
as defined in the claims. In addition, many modifications may be
made to adapt a particular situation or material to the teachings
of the invention without departing from the essential scope
thereof. Therefore, it is intended that the invention not be
limited to the particular embodiment illustrated by the drawings
and described in the specification as the best mode presently
contemplated for carrying out this invention, but that the
invention will include any embodiments falling within the foregoing
description and the appended claims.
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