U.S. patent application number 11/334467 was filed with the patent office on 2007-07-19 for vacuum cleaner dustcup and conduit construction.
Invention is credited to William Reimer, Arnold Sepke.
Application Number | 20070163073 11/334467 |
Document ID | / |
Family ID | 38261734 |
Filed Date | 2007-07-19 |
United States Patent
Application |
20070163073 |
Kind Code |
A1 |
Sepke; Arnold ; et
al. |
July 19, 2007 |
Vacuum cleaner dustcup and conduit construction
Abstract
An upright vacuum cleaner having a housing with a handle at an
upper end and a base at the bottom end. The base is pivotally
attached to the housing and has a floor inlet nozzle facing
generally downwardly from it. A dustcup assembly is associated with
at least one of the housing and the base, and includes a sidewall
defining an interior space having an open top end and a bottom end,
a bottom wall extending across the bottom end and having a dustcup
outlet therethrough, a dustcup inlet, a dustcup lid adapted to
selectively cover the open top, and a fluid conduit formed
separately from the bottom wall and attached to the bottom wall at
the dustcup outlet. The fluid conduit extends into the interior
space defined by the sidewall. The vacuum cleaner also has a vacuum
source associated with at least one of the housing and the base.
The vacuum source is adapted to create a working air flow that
enters the floor inlet nozzle, passes into the dustcup assembly
through the dustcup inlet, and exits the dustcup assembly through
the dustcup outlet.
Inventors: |
Sepke; Arnold; (Hudson,
IL) ; Reimer; William; (Normal, IL) |
Correspondence
Address: |
HUNTON & WILLIAMS LLP;INTELLECTUAL PROPERTY DEPARTMENT
1900 K STREET, N.W.
SUITE 1200
WASHINGTON
DC
20006-1109
US
|
Family ID: |
38261734 |
Appl. No.: |
11/334467 |
Filed: |
January 19, 2006 |
Current U.S.
Class: |
15/353 ;
15/352 |
Current CPC
Class: |
A47L 9/1683 20130101;
A47L 9/1608 20130101; A47L 9/1691 20130101; A47L 9/1666 20130101;
A47L 9/1658 20130101 |
Class at
Publication: |
015/353 ;
015/352 |
International
Class: |
A47L 9/10 20060101
A47L009/10; A47L 9/16 20060101 A47L009/16 |
Claims
1. An upright vacuum cleaner comprising: a housing having an upper
housing end and a lower housing end; a handle associated with the
upper housing end; a base pivotally attached to the lower housing
end, the base comprising a floor inlet nozzle facing generally
downwardly therefrom; a dustcup assembly associated with at least
one of the housing and the base, the dustcup assembly comprising: a
sidewall defining an interior space having an open top end and a
bottom end, a bottom wall extending across the bottom end and
having a dustcup outlet therethrough, a dustcup inlet, a dustcup
lid adapted to selectively cover the open top, and a fluid conduit
formed separately from the bottom wall and attached to the bottom
wall at the dustcup outlet, the fluid conduit extending into the
interior space defined by the sidewall; and a vacuum source
associated with at least one of the housing and the base, the
vacuum source being adapted to create a working air flow that
enters the floor inlet nozzle, passes into the dustcup assembly
through the dustcup inlet, and exits the dustcup assembly through
the dustcup outlet.
2. The vacuum cleaner of claim 1, wherein the fluid conduit is
attached to the bottom wall by one or more screws.
3. The vacuum cleaner of claim 1, wherein the fluid conduit is
attached to the bottom wall by a rotating cam lock arrangement.
4. The vacuum cleaner of claim 1, wherein the fluid conduit is
attached to the bottom wall by one or more flexible latching
tabs.
5. The vacuum cleaner of claim 1, wherein the fluid conduit is
attached to the bottom wall by snap-fit engagement.
6. The vacuum cleaner of claim 1, wherein the fluid conduit is
attached to the bottom wall by an interference fit.
7. The vacuum cleaner of claim 1, wherein the fluid conduit is
attached to the bottom wall by bayonet fittings.
8. The vacuum cleaner of claim 1, wherein the fluid conduit is
attached to the bottom wall by a fastening ring.
9. The vacuum cleaner of claim 1, further comprising a gasket
interposed between the fluid conduit and the bottom wall.
10. The vacuum cleaner of claim 1, wherein the fluid conduit
comprises an airfoil cross-section.
11. The vacuum cleaner of claim 1, wherein the fluid conduit
comprises one or more integrally formed contours to assist with
dust separation.
12. The vacuum cleaner of claim 1, wherein the fluid conduit
comprises one or more integrally formed airflow deflectors.
13. The vacuum cleaner of claim 1, wherein the bottom wall
comprises at least one additional dustcup outlet, and the dustcup
assembly comprises at least one additional fluid conduit attached
to the bottom wall at the at additional dustcup outlet and
extending into the interior space defined by the sidewall.
14. The vacuum cleaner of claim 1, wherein the fluid conduit
comprises a first section having a first geometric profile, and a
second section having a second geometric profile, the second
geometric profile being different from the first geometric
profile.
15. The vacuum cleaner of claim 1, wherein the dustcup assembly is
adapted to be releasably attached to the housing, and the dustcup
lid is formed by the housing.
16. The vacuum cleaner of claim 1, wherein the dustcup assembly is
adapted to be releasably attached to the housing, and the dustcup
lid is a separate part that is removable with the dustcup assembly
from the housing.
17. The vacuum cleaner of claim 1, wherein the dustcup inlet enters
the interior space defined by the sidewall through the lid.
18. The vacuum cleaner of claim 1, wherein the dustcup inlet enters
the interior space defined by the sidewall through the
sidewall.
19. The vacuum cleaner of claim 1, wherein the fluid conduit is
releasably attached to the bottom wall.
20. The vacuum cleaner of claim 1, wherein the fluid conduit is not
releasably attached to the bottom wall.
21. A vacuum cleaner comprising: a housing; one or more air inlet
nozzles associated with the housing; a dustcup assembly associated
with the housing, the dustcup assembly comprising: a sidewall
defining an interior space having an open top end and a bottom end,
a bottom wall extending across the bottom end and having a dustcup
outlet therethrough, a dustcup inlet, a dustcup lid adapted to
selectively cover the open top, and a fluid conduit formed
separately from the bottom wall and releasably attached to the
bottom wall at the dustcup outlet, the fluid conduit extending into
the interior space defined by the sidewall; and a vacuum source
associated with the housing, the vacuum source being adapted to
create a working air flow that enters the one or more inlet
nozzles, passes into the dustcup assembly through the dustcup
inlet, and exits the dustcup assembly through the dustcup
outlet.
22. The vacuum cleaner of claim 21, wherein the fluid conduit is
attached to the bottom wall by one or more of the following
devices: one or more screws, a rotating cam lock arrangement, one
or more flexible latching tabs, snap-fitting members, interference
fitting members, bayonet fittings, a fastening ring.
23. The vacuum cleaner of claim 21, further comprising a gasket
interposed between the fluid conduit and the bottom wall.
24. The vacuum cleaner of claim 21, wherein the fluid conduit
comprises an airfoil cross-section.
25. The vacuum cleaner of claim 21, wherein the fluid conduit
comprises one or more integrally formed contours to assist with
dust separation.
26. The vacuum cleaner of claim 21, wherein the fluid conduit
comprises one or more integrally formed airflow deflectors.
27. The vacuum cleaner of claim 21, wherein the bottom wall
comprises at least one additional dustcup outlet, and the dustcup
assembly comprises at least one additional fluid conduit attached
to the bottom wall at the at additional dustcup outlet and
extending into the interior space defined by the sidewall.
28. The vacuum cleaner of claim 21, wherein the fluid conduit
comprises a first section having a first geometric profile, and a
second section having a second geometric profile, the second
geometric profile being different from the first geometric
profile.
29. The vacuum cleaner of claim 21, wherein the dustcup assembly is
adapted to be releasably attached to the housing, and the dustcup
lid is formed by the housing.
30. The vacuum cleaner of claim 21, wherein the dustcup assembly is
adapted to be releasably attached to the housing, and the dustcup
lid is a separate part that is removable with the dustcup assembly
from the housing.
31. The vacuum cleaner of claim 21, wherein the dustcup inlet
enters the interior space defined by the sidewall through the
lid.
32. The vacuum cleaner of claim 21, wherein the dustcup inlet
enters the interior space defined by the sidewall through the
sidewall.
33. A vacuum cleaner comprising: a housing; one or more air inlet
nozzles associated with the housing; a dustcup assembly associated
with the housing, the dustcup assembly comprising: a sidewall
defining an interior space having an open top end and a bottom end,
a bottom wall extending across the bottom end and having a dustcup
outlet therethrough, a dustcup inlet, a dustcup lid adapted to
selectively cover the open top, and a fluid conduit attached to the
bottom wall at the dustcup outlet, the fluid conduit extending into
the interior space defined by the sidewall, wherein the fluid
conduit and at least a portion of the bottom wall form a combined
conduit/bottom wall part that is formed separately from the
sidewall and attached thereto; and a vacuum source associated with
the housing, the vacuum source being adapted to create a working
air flow that enters the one or more inlet nozzles, passes into the
dustcup assembly through the dustcup inlet, and exits the dustcup
assembly through the dustcup outlet.
34. The vacuum cleaner of claim 33, wherein the combined
conduit/bottom wall part is removably attached to the sidewall by a
fastener that does not comprise threads formed on the combined
conduit/bottom wall part itself.
35. The vacuum cleaner of claim 33, wherein the combined
conduit/bottom wall part is attached to the sidewall by one or more
screws.
36. The vacuum cleaner of claim 33, wherein the combined
conduit/bottom wall part is attached to the sidewall by a rotating
cam lock arrangement.
37. The vacuum cleaner of claim 33, wherein the combined
conduit/bottom wall part is attached to the sidewall by one or more
flexible latching tabs.
38. The vacuum cleaner of claim 33, wherein the combined
conduit/bottom wall part is attached to the sidewall by snap-fit
engagement.
39. The vacuum cleaner of claim 33, wherein the combined
conduit/bottom wall part is attached to the sidewall by an
interference fit.
40. The vacuum cleaner of claim 33, wherein the combined
conduit/bottom wall part is attached to the sidewall by bayonet
fittings.
41. The vacuum cleaner of claim 33, wherein the combined
conduit/bottom wall part is attached to the sidewall by a fastening
ring.
42. The vacuum cleaner of claim 33, further comprising a gasket
interposed between the combined conduit/bottom wall part and the
sidewall.
43. The vacuum cleaner of claim 33, wherein the combined
conduit/bottom wall part is releasably attached to the
sidewall.
44. The vacuum cleaner of claim 33, wherein the combined
conduit/bottom wall part is not releasably attached to the
sidewall.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to vacuum cleaners, and more
particularly, to a bagless dust cup assembly to be used with a
vacuum cleaner apparatus in lieu of a disposable dirt collection
bag.
BACKGROUND OF THE INVENTION
[0002] Floor cleaning devices, such as vacuums, have been produced
in the prior art. These prior art devices are typically provided in
canister, upright, hand-held and other portable configurations, and
may be powered by an electrical cord or by batteries. In many
cases, the device is provided with a bagless dustcup assembly that
utilizes a cyclonic separation action and/or one or more filters to
facilitate separation of the vacuumed debris and air. These bagless
dustcup assemblies generally include, for example, a separation
chamber having a dirty air inlet, a dirt separation system
including a cyclone and/or a filter, and at least one outlet for
removing cleaned air. In some cases the outlet may comprise a
conduit passing through the chamber itself. Various systems for
emptying dirt from the separation chamber are known in the art,
such as an openable lower door, a dustbin located at the bottom of
the separation chamber, or a removable lid that covers and may form
part of the separation chamber.
[0003] Known bagless dustcup assemblies are often formed of a
single integrated piece of plastic comprising a cup-like
arrangement of walls. In some cases, a fluid conduit may be formed
as part of this cup. An example of such a device is shown in U.S.
Pat. No. 6,141,826, in which an outlet conduit is shown as being
integrally molded with a cyclone chamber dustcup. While the outlet
is often through the bottom of the cup, it may alternatively exit
through the lid. For example, one such device is shown in European
Patent Application EP 0 728 435, in which a clean air outlet is
shown molded with the cyclone chamber lid. Other conduits may be
integrally formed to the outside of dirt-receiving portion of the
bagless dustcup, such as in U.S. Pat. No. 5,779,745, which shows an
integrally-molded outlet conduit, and U.S. Pat. No. 6,168,641,
which shows an integrally-molded inlet conduit. All of the
foregoing patents are incorporated herein by reference.
[0004] The prior art also discloses devices in which an outlet
conduit is formed separately from the cyclone chamber, and attached
thereto. For example, U.S. Pat. No. 2,684,125 shows an outlet
conduit that appears to be welded or otherwise bonded to a cyclone
chamber. U.S. Pat. No. 6,902,596 also discloses that an outlet
conduit may be welded or removably attached to a cyclone chamber by
mechanical locking means, but does not illustrate or describe how
these locking means would operate. U.S. Pat. No. 6,578,230,
discloses a outlet and bottom wall that are integrally formed with
one another, and attached to the side wall of the cup by threaded
engagement. While such threaded engagement may be useful to
initially attach the two parts, it is likely that manufacturing
tolerances and friction between the parts will make repeated
disassembly and reassembly of the parts difficult. Furthermore, the
presence of fine particles may rapidly deteriorate the integrity of
the threads, as well as add to the difficulty in separating and
joining the parts. The foregoing patents are incorporated herein by
reference.
[0005] While the known cyclone chamber designs can be useful for
providing dirt separation for vacuum cleaners and the like, the
present inventors have discovered new and useful alternative
cyclone chamber construction techniques to supplement and advance
the prior art.
SUMMARY OF THE INVENTION
[0006] The present invention provides, in a first aspect, an
upright vacuum cleaner having a housing with a handle at an upper
end and a base at the bottom end. The base is pivotally attached to
the housing and has a floor inlet nozzle facing generally
downwardly from it. A dustcup assembly is associated with at least
one of the housing and the base, and includes a sidewall defining
an interior space having an open top end and a bottom end, a bottom
wall extending across the bottom end and having a dustcup outlet
therethrough, a dustcup inlet, a dustcup lid adapted to selectively
cover the open top, and a fluid conduit formed separately from the
bottom wall and attached to the bottom wall at the dustcup outlet.
The fluid conduit extends into the interior space defined by the
sidewall. The vacuum cleaner also has a vacuum source associated
with at least one of the housing and the base. The vacuum source is
adapted to create a working air flow that enters the floor inlet
nozzle, passes into the dustcup assembly through the dustcup inlet,
and exits the dustcup assembly through the dustcup outlet.
[0007] In a second aspect, the present invention provides a vacuum
cleaner with a housing, one or more air inlet nozzles associated
with the housing, and a dustcup assembly associated with the
housing. The dustcup assembly has a sidewall defining an interior
space having an open top end and a bottom end, a bottom wall
extending across the bottom end and having a dustcup outlet
therethrough, a dustcup inlet, a dustcup lid adapted to selectively
cover the open top, and a fluid conduit formed separately from the
bottom wall and releasably attached to the bottom wall at the
dustcup outlet, the fluid conduit extending into the interior space
defined by the sidewall. The vacuum cleaner also has a vacuum
source associated with the housing, which is adapted to create a
working air flow that enters the one or more inlet nozzles, passes
into the dustcup assembly through the dustcup inlet, and exits the
dustcup assembly through the dustcup outlet.
[0008] In a third aspect, the present invention provides a vacuum
cleaner having a housing, one or more air inlet nozzles associated
with the housing, and a dustcup assembly associated with the
housing. The dustcup assembly includes a sidewall defining an
interior space having an open top end and a bottom end, a bottom
wall extending across the bottom end and having a dustcup outlet
therethrough, a dustcup inlet, a dustcup lid adapted to selectively
cover the open top, and a fluid conduit attached to the bottom wall
at the dustcup outlet, the fluid conduit extending into the
interior space defined by the sidewall. The fluid conduit and at
least a portion of the bottom wall form a combined conduit/bottom
wall part that is formed separately from the sidewall and attached
thereto. The vacuum cleaner also includes a vacuum source
associated with the housing. The vacuum source being adapted to
create a working air flow that enters the one or more inlet
nozzles, passes into the dustcup assembly through the dustcup
inlet, and exits the dustcup assembly through the dustcup
outlet.
[0009] In various embodiments of the foregoing aspects of the
invention, the fluid conduit or combined conduit/bottom wall part
may be attached by screws, a rotating cam lock arrangement, one or
more flexible latching tabs, snap-fit engagement, an interference
fit, bayonet fittings, or a fastening ring. The conduit/bottom wall
part may also be attached by a fastener that does not include
threads formed on the conduit/bottom wall part itself. A gasket may
be interposed between the fluid conduit and the bottom wall or
between the conduit/bottom wall part and the sidewall. The fluid
conduit may have an airfoil cross-section, one or more integrally
formed contours to assist with dust separation, or one or more
integrally formed airflow deflectors. The fluid conduit may also
comprise a first section having a first geometric profile, and a
second section having a second geometric profile that is different
from the first geometric profile. The bottom wall may have an
additional dustcup outlet with an additional fluid conduit attached
to this outlet and extending into the interior space defined by the
sidewall. The dustcup assembly may be releasably attached to the
housing, with the dustcup lid formed by the housing or as a
separate part that is removable with the dustcup assembly from the
housing. Also, the dustcup inlet may pass through the lid or the
sidewall. Finally, the fluid conduit or combined conduit/bottom
wall part may or may not be releasably attached.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a prior art upright vacuum cleaner suitable for
use with an embodiment of the present invention.
[0011] FIG. 2 is an exemplary prior art dustcup assembly.
[0012] FIG. 3A is a partially exploded view of a first embodiment
of a dustcup assembly of the present invention.
[0013] FIG. 3B is an assembled view the embodiment of FIG. 3A.
[0014] FIG. 4A is a partially exploded view of a second embodiment
of a dustcup assembly of the present invention.
[0015] FIG. 4B is an assembled view the embodiment of FIG. 4A.
[0016] FIG. 5A is an exploded view of a third embodiment of a
dustcup assembly of the present invention.
[0017] FIG. 5B is a fragmented and exploded view of the attachment
arrangement of the embodiment of FIG. 5A.
[0018] FIG. 6A is a fragmented, partially cut away, exploded view
of a fourth embodiment of a dustcup assembly of the present
invention.
[0019] FIG. 6B is an assembled view of the embodiment of FIG.
6A.
[0020] FIG. 7A is an exploded view of a fifth embodiment of a
dustcup assembly of the present invention.
[0021] FIG. 7B is a fragmented, cross-sectional detail view of the
embodiment of FIG. 7A, showing the portion encompassed by circle A
thereof.
[0022] FIG. 8A is a partially exploded view of a sixth embodiment
of a dustcup assembly of the present invention.
[0023] FIG. 8B is another partially exploded view of the embodiment
of FIG. 8A.
[0024] FIG. 8C is a top view of the embodiment of FIG. 8A.
[0025] FIG. 9A is a schematic representation of a variation of the
locking mechanism of the embodiment of FIG. 8A.
[0026] FIG. 9B is a schematic representation of another variation
of the locking mechanism of the embodiment of FIG. 8A.
[0027] FIG. 10A is an exploded view of a seventh embodiment of a
dustcup assembly of the present invention.
[0028] FIG. 10B is a fragmented, cross-sectional detail view of the
embodiment of FIG. 10A, showing the portion encompassed by circle A
thereof.
[0029] FIG. 11 is an exploded view of an eighth embodiment of a
dustcup assembly of the present invention.
[0030] FIG. 12 is an alternative embodiment of an outlet tube that
may be used with the present invention.
[0031] FIG. 13A is a ninth embodiment of a dustcup assembly of the
present invention.
[0032] FIG. 13B illustrates the installation of the embodiment of
FIG. 13A in an exemplary vacuum cleaner housing.
[0033] FIG. 14A depicts an embodiment of an outlet conduit with a
rectangular cross-section.
[0034] FIG. 14B depicts an embodiment of an outlet conduit with a
square cross-section.
[0035] FIG. 14C depicts an embodiment of an outlet conduit with a
triangular cross-section.
[0036] FIG. 14D depicts an embodiment of a multi-part outlet
conduit with rectangular cross-sections.
[0037] FIG. 14E depicts an embodiment of a multi-part outlet
conduit with square cross-sections.
[0038] FIG. 14F depicts an embodiment of a multi-part outlet
conduit with circular and triangular cross-sections.
[0039] FIG. 14G depicts an embodiment of an outlet conduit with an
airfoil cross-sections.
[0040] FIG. 15A is side view of another embodiment of a dustcup
assembly of the present invention.
[0041] FIG. 15B is a top view of the embodiment of FIG. 15A, shown
along line I-I thereof.
[0042] FIG. 15C is an exploded view of the embodiment of FIG. 15A,
shown with the lid and filter removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] The present invention provides an improved cyclonic
separation chamber for cleaning devices. Embodiments of the present
invention may be used with any type of vacuum cleaning device,
including, but not limited to, upright vacuum cleaners, canister
vacuum cleaners, wet extractors, hand-held vacuum cleaners,
so-called "stick" vacuum cleaners, and so on. The implementation of
the present inventions with such devices will be within the
understanding and skill of persons of ordinary skill in the art
after review of the present disclosure and with routine
experimentation with the present invention.
[0044] An example of a conventional upright vacuum cleaner to which
the present invention may be applied is shown in FIG. 1. The
upright vacuum cleaner 100 generally includes a floor engaging base
102, an upright rear housing 104, and a handle 106. The base 102
typically includes a laterally extending, downwardly-facing inlet
nozzle 108 that is positioned to lift dirt and debris from the
floor. A known rotating brush element (not shown) may be located in
the nozzle 108 to agitate the surface being cleaned and help with
the cleaning operation. The rear housing 104 is pivotally attached
to the base 102, and the handle 106 is attached to the rear housing
104. A conventional vacuum source (not shown) is located in the
base 102 or rear housing 104, and is operated to generate a working
air flow that is used to clean surfaces. The working air flow
applies suction to the inlet nozzle 108, causing dirt and debris to
be entrained in the working air flow. The working air flow then
passes through a dirt cup assembly 110, which is typically mounted
on the rear housing 104, but may instead be on the base 102, to
remove all or part of the entrained dirt and debris. The dirt cup
assembly 110 is typically located upstream of the vacuum source so
that it operates under negative pressure, but may alternatively be
downstream of the vacuum source so that it operates under positive
pressure. A hose 110 may also be provided to access and clean
surfaces that are above the floor or difficult to reach with the
nozzle. Various pre- and post-motor filters may also be added to
the device to further filter the incoming and exiting working air.
Additional features of upright vacuum cleaners are known in the
art, and shown, for example, in U.S. Pat. Nos. 6,829,804, which is
incorporated herein by reference. Any such features, or other
features known in the art or generally understood to be useful for
cleaning floors and other surfaces, may be included in embodiments
of the present invention.
[0045] Referring now to FIG. 2, a typical prior art cyclone
assembly 200 is shown. The assembly 200 comprises a sidewall 202, a
bottom wall 204, and a lid 206 that form a generally air-tight
chamber with the exception of an air inlet 208 and an air outlet
210. All or part of the assembly 200 may be transparent so that a
user can view its operation and determine when it needs to be
emptied, but the lid 206 is typically opaque. In use, dirt laden
air enters the assembly 200 through the inlet 208, and travels in a
cyclonic path to thereby separate dirt from the air in a known
manner. Various means may be used to generate cyclonic airflow. In
the shown device, the cyclonic airflow is generated by introducing
the air in a tangential direction, as shown by arrow A. In other
devices, such as the device shown in U.S. Pat. No. 6,829,804, the
air may be introduced along a helical ramp in the lid to impart the
desired cyclonic motion. In still other devices the air may be
introduced perpendicular to the chamber, but diverted by a surface
to travel in a tangential direction, as shown in U.S. Pat. Nos.
6,341,404 and 6,436,160, which are incorporated herein by
reference. The present invention is applicable to these and any
other cyclone generation configurations.
[0046] In the cyclone assembly of FIG. 2, the outlet 210 comprises
a tube that extends through a portion of the assembly 200 and along
its central axis, and exits through the bottom wall 204. In
alternative embodiments, the outlet may extend through an upper
wall or the lid 206, such as shown in U.S. Pat. No. 6,558,453,
which is incorporated herein by reference. A filter (not shown),
such as the one shown in U.S. Pat. No. 6,829,804, may be placed
over or in the outlet 120 to further filter the air, as is known in
the art. Various filters and filtration devices are known in the
art, such as paper or sheet filters, mesh screens, perforated
shrouds, HEPA (High Efficiency Particulate Air) filters, ULPA
(ultra low penetration air) filters, and so on, which may be
reusable and may have any shape, such as a porous foam block or a
pleated air permeable filter. Any such filters may be used with the
present invention, or the filter may be omitted as will be
appreciated by those of ordinary skill in the art.
[0047] Prior art cyclone assemblies are operatively associated with
vacuum cleaners in a variety of ways. For example, all or part of
the cyclone assembly 200 may be formed as part of the vacuum
cleaner's base 102 or rear housing 104 (or canister, in the case of
canister-style vacuum cleaners), and intended to remain attached
thereto during operation and emptying. However, in many instances
the cyclone assembly 200, or portions thereof, is selectively
removable from the rest of the vacuum cleaner. For example,
referring to FIG. 1, the cyclone assembly 110 of the device shown
in U.S. Pat. No. 6,829,804, includes a sidewall 112 and bottom wall
114 that form a dirt cup upon which a removable lid 116 is
positioned. The outlet 120 is in the form of a tube that is molded
directly into the bottom wall 114, and a filter 122 removably
secured to the top of the outlet 120. In addition to forming a
cyclonic separation chamber, the sidewall 112, bottom wall 114, and
outlet tube 120 form a cup-like structure that holds dirt captured
by the device. When it is desired to empty the cup, the cup and lid
are removed from the rear housing 104 as a unit, then the lid 116
is removed and the dirt cup inverted to empty its contents. One or
more handles (not shown) may be provided to assist with handling
the cyclone chamber, dirt cup, or lid.
[0048] In other devices, such as in U.S. Pat. Nos. 6,579,334 and
6,910,245, which are incorporated herein by reference, the cyclone
assembly lid is formed as part of the rear housing, and only the
cup portion of the cyclone assembly--that is, the portion formed by
the sidewall and the bottom wall--is removable to empty it. In
addition, while the foregoing embodiments describe the cup being
removed from the lid to be emptied, the cyclone chamber may
alternatively be emptied by opening or removing the lower wall,
such as shown in U.S. Pat. No. 6,546,593, which is incorporated
herein by reference. In still other embodiments, the cyclone
assembly may deposit dirt and debris into a separate chamber by
inertia, as in U.S. Pat. No. 6,168,641, or by the operation of a
manual or automatic trapdoor, as in U.S. Pat. No. 6,344,064. These
patents are incorporated herein by reference. The present invention
may be used with any suitable configuration for attaching the
cyclone assembly to the vacuum cleaner.
[0049] As noted before, the prior art contemplates forming the
outlet 210 integrally with the bottom wall 204 and sidewall 202.
The present inventors have found that using this one-piece
construction can limit the manufacturer's ability to economically
produce desirable inlet and outlet conduit configurations. The
prior art also contemplates welding an outlet conduit to a dirt
cup, such as shown in U.S. Pat. No. 2,684,125. However this
prevents removal of the outlet conduit, and may also require
expensive manufacturing equipment and increased manufacturing time.
The prior art also contemplates forming these parts separately, and
joining them, but does so using threads formed on the parts being
joined. For example, U.S. Pat. No. 6,578,230, which is incorporated
herein by reference, discloses a outlet and bottom wall that appear
to be integrally formed with one another, and attached to the
sidewall by threaded engagement. The threads are located at the
outer perimeter of the bottom wall, where it meets the lower edge
of the cylindrical sidewall. This construction is believed to
suffer from various disadvantages, such as thread degradation
caused by the intrusion of dirt particles into the threads, and
assembly difficulties caused by dirt accumulation, friction,
misalignment and thread stripping. This configuration also appears
to require relatively high manufacturing tolerances to ensure that
the parts are close enough in shape to properly thread together,
and requires both parts to include threaded portions, which
increases the thickness at those locations, thus also increasing
the weight and cost of the materials and their manufacture. In view
of these expected shortcomings, it is preferred, in at least some
embodiments of the invention, to avoid the use of such threads
formed on the parts that form the dustcup assembly itself.
[0050] The present invention provides alternative dustcup
assemblies that provide various advantages over the prior art, and
may ameliorate or lessen the known and expected shortcomings of the
prior art. It will be understood that it is not required for each
embodiment of the claimed invention to address all, or even any, of
the listed shortcomings of the prior art.
[0051] A first exemplary embodiment of a dustcup assembly 300 of
the present invention is shown in FIGS. 3A and 3B. In this
embodiment, the dustcup assembly 300 comprises a generally
cylindrical sidewall 302 (although other shapes may be used), a
bottom wall 304, and an open top 303 to which a lid (not shown) may
be fastened in any conventional manner. For example in this
embodiment, the lid is fastened using bayonet fasteners, and one
receiving slot 305 for the lid's bayonet fastener tabs is visible
at the upper end of the sidewall 302. It will also be appreciated
that the lid may be omitted, and the dustcup assembly 300 fastened
directly to the vacuum cleaner housing to close and seal the
dustcup assembly 300, such as in the device of U.S. Pat. No.
6,910,245. The dustcup assembly 300 also includes an inlet (not
shown) to generate the desired cyclonic air movement. The inlet may
enter the dustcup assembly 300 through the sidewall 302 (as, for
example, in the embodiment of FIGS. 4A and 4B), through the lid, or
in any other manner. The foregoing variations regarding the dustcup
shape, lid attachment and inlet style, and any other typical
variations to these or other features, may be made to this or any
other embodiment of the inventions described herein, as will be
appreciated by those of ordinary skill in the art, and further
reference to such variations is omitted in the following discussion
for the sake of brevity.
[0052] The embodiment of FIGS. 3A and 3B includes a fluid conduit
310, which in this case is an outlet tube, that is removably
installed in a hole through the center of the bottom wall 304. When
installed, the outlet tube 310 extends generally along the
cylindrical axis 301 of the dustcup assembly 300. It is preferred
that the outlet tube 310 extend a substantial distance, preferably
along at least about 50% of the length of the sidewall 302, however
this length are not strictly required for the invention. One or
more screws 312 or other fasteners, such as quarter-turn fasteners,
snaps, and the like, may be used to attach the two parts. To this
end, the bottom wall 304 is provided with a recess 314 into which a
corresponding flange 316 on the outer perimeter of the bottom end
of the outlet tube 310 fits. An o-ring seal 326, or other type of
sealing member (such a foam gasket) is preferably provided to fit
between the recess 314 and the flange 316 to prevent air from
passing through this location. A supplemental adhesive and or
sealant may also be provided between the parts, if desired. In some
instances, however, it might be desirable to omit this seal 326,
and even provide a small bleed air passage to ensure that air can
pass to the vacuum source if the dustcup assembly 300 becomes
blocked, and thereby prevent overheating. A second seal (not shown)
may also be provided on the bottom side of the flange 316 to mate
with a lip or other surface surrounding the inlet to the vacuum
source. The flange may also serve as a mounting location for a
filter installed in or at the bottom of the outlet tube 310. As
noted before, a filter may also be located at the top of the outlet
tube 310, if desired.
[0053] The recess 314 and flange 316 are preferably, but not
necessarily, shaped so that the flange 316 can not rotate relative
to the recess 314 when it is installed therein. While any
non-circular shape will suffice, relative rotation is prevented in
the embodiment of FIGS. 3A and 3B by providing several protrusions
318 on the flange 316 that fit into corresponding openings 320 in
the recess 314. These protrusions 318 and openings 320 also serve
as screw mounting locations, and each protrusion 318 has a screw
passage 322, and each opening 320 has a screw mounting boss 324.
The mounting bosses 324 have internal threads to receive the screws
312 and hold the outlet tube 310 in place. The mounting bosses 324
may be provided with inserts (not shown), such as metal nuts that
are captured or molded in place, to assist with engaging and
retaining the screws 312. Conveniently, when the flange 316 is
fully seated in the recess 314, the screw openings 322 and mounting
bosses 324 are aligned relative to one another by the engagement of
the protrusions 318 in the openings 320, and no further
manipulation of the parts is necessary to prepare them for the
installation of the screws 312, which potentially saves
manufacturing time and allows relatively simple automated assembly.
As shown in FIG. 3B, the flange 316 is preferably flush with the
bottom wall 304 when it is fully installed to minimize the overall
height of the dustcup assembly 300. To remove the outlet tube 310,
the screws 130 are simply backed out of the mounting bosses.
[0054] Various modifications to this design are possible. For
example, the screws could pass through the lower wall 304 and be
installed into the flange 316. The screws may also be omitted, and
the flange 316 and recess 314 may be adapted to have snap-fitting
tabs and detents to allow the outlet tube 310 to simply be pressed
into place. The flange 316 and recess 314 may also be slightly
tapered or provided with interfering dimensions to allow them to be
press-fit together. Furthermore, while releasable attachment is
preferred, the outlet tube 310 may be permanently attached, such as
by ultrasonic welding, spin welding, adhesives, and so on.
[0055] In addition, while the embodiment of FIGS. 3A and 3B
illustrates the bottom wall 304 being integrally formed with the
sidewall 302, and the recess 314 being formed in the bottom wall
304, it will be appreciated that all or a portion of the bottom
wall 304 may instead be formed as part of the flange 316 and outlet
tube 310 (or the flange may simply form the bottom wall), and this
combined outlet tube /bottom wall part could then be attached to
the lower periphery of the sidewalls 302 or to the remaining
portion of the bottom wall 304. Other variations will be apparent
to those of ordinary skill in the art in view of the present
specification and with routine practice of the inventions described
herein.
[0056] A second exemplary embodiment of the present invention is
shown in FIGS. 4A and 4B as dustcup assembly 400. In this
embodiment, the dustcup assembly once again comprises a sidewall
402, bottom wall 404, and open top 403 that is covered by a
removable lid (not shown), which may be a separate part, or simply
part of the housing to which the dustcup assembly 400 is ultimately
attached. The dustcup assembly 400 includes an air inlet 408 (FIG.
4B) through the sidewall 402, and an air outlet tube 410 through
the bottom wall 404. The outlet tube 410 and bottom wall 404 are
preferably formed together as a single part, such as by plastic
molding, and attached to the lower peripheral edge of the sidewall
402.
[0057] The bottom wall 404 is preferably attached by an arrangement
including a latch 412 on one side of the sidewall 402, and a tab
414 on the opposite side of the sidewall 402. The tab 414 fits into
a corresponding slot or opening 416 on a raised portion 418 of the
bottom wall 404. This raised portion 418 preferably surrounds or
abuts the lower edge of the sidewall 402 and includes a seal to
form an airtight seal between the two parts when they are
assembled. In the shown embodiment, the tab 414 is located in a
recess 420 to help minimize the radial dimension of the
assembly.
[0058] The latch 412 comprises a pivoting member including a hook
422 at its lower end, a button 424 at its upper end, and a pivot
426 or other fulcrum between the hook 422 and the button 424. The
latch 412 is oriented on the sidewall 402 with the hook 422 located
to engage a corresponding portion of the bottom wall 404. The
combined engagement of the latch 412 on one side and the tab 414
and opening 416 on the other side of the bottom wall 404 prevent it
(and the attached outlet tube 410) from being separated from the
dustcup assembly 400. The pivot 426 is attached to the sidewall 402
so that the button 424 can be pressed radially inwardly, which
moves the hook 422 radially outward, and out of engagement with the
bottom wall 404, thereby allowing disassembly. A spring (not
shown), is preferably captured between the button 424 and the
sidewall 402 to resiliently bias the button 424 outward, and
therefore the hook 422 inward, and in the locked position.
[0059] Like the tab 414, the latch 412 is preferably located in a
recess 428 to help minimize the radial dimension of the dustcup
assembly 400. Furthermore, the latch 412 preferably is positioned
so that it is inaccessible when the dustcup assembly 400 is
installed to the vacuum cleaner for use, such as by being located
on the back side of the assembly along with the air inlet 408. As
such, the latch is inaccessible in order to prevent accidental
openings, and can only be activated when the dustcup assembly 400
is removed from the vacuum cleaner. In addition, while the latch
412 and tab 414 are illustrated as being on the sidewall 402, with
the corresponding mating structures on the bottom wall 404, these
positions can be reversed for the latch 412, tab 414, or both.
[0060] While it would be possible in the embodiment of FIGS. 4A and
4B to empty the dustcup assembly 400 by removing the lid and
inverting the assembly, it may also be emptied by simply removing
the bottom wall 404 and outlet tube 410. As such, in variations of
this embodiment, the open top 403 may be covered by a lid (not
shown) that is permanently affixed to the sidewall 402 (such as by
being integrally formed therewith), or a lid that is not intended
to be removed during normal use (such as by being screwed in
place). In such an embodiment, the dustcup assembly 400 may be
emptied by removing it from the vacuum cleaner, inverting it,
removing the bottom wall 402 and outlet tube 410 (which, by virtue
of the inversion of the assembly are now above the lid end), and
then inverting the assembly once again to empty its contents.
Reassembly would follow the opposite procedure. This procedure may
prove to be advantageous, as the movement of the outlet conduit 410
relative to the sidewall 402 may help to dislodge dirt that becomes
packed down in the dustcup assembly 400, and the outlet conduit 410
or a filter (not shown) located at the top end of the outlet
conduit 410 may act as a piston to pull the dirt and debris out of
the dustcup assembly 400 without requiring the user to otherwise
mechanically agitate the assembly to dislodge the dirt.
[0061] Referring now to FIGS. 5A and 5B, a third embodiment of the
present invention provides a dustcup assembly 500 comprising a
combined lower wall 504 and fluid conduit 510 that is connected to
the sidewall 502 by flexible latching tabs 512. The flexible tabs
512 extend, in a cantilevered fashion, from an annular wall 514
that protrudes upwardly from the bottom wall 504. Each tab 512
comprises a vertical wall 516 having an opening 518 therein, and a
finger tab 520 that protrudes away from the dustcup assembly 500 to
allow a user easily manipulate the tab 512. Each opening 518 is
positioned to overlie and engage a corresponding catch 522 formed
on the outer surface of the sidewall 502. The catches 522
preferably include a ramped lower surface, and a flat upper
surface. The ramped lower surfaces help press the flexible tabs 512
outward to allow the bottom wall/outlet tube assembly to be
installed without manipulating the flexible tabs 512. Once in
place, the openings 518 surround the catches 522, and the flat
upper surfaces prevent disassembly until the user presses on one or
both of the finger tabs 520 to release the openings 518 from the
catches 522. While the latching tabs 512 are shown as having
openings 518 that fit over catches 522 on the sidewall 502, the
catches may instead be positioned on the tabs and adapted to fit
into corresponding openings (or detents) on the sidewall. For
simplicity, the term flexible latching tab will be understood to
encompass any variation of a flexible tab that hold parts together
by engagement between a catch and a detent or opening (or two
catches), regardless of which part has the catch, and which has the
opening or detent.
[0062] In use, it is likely that the operator will only have to
operate a single one of the flexible latching tabs 512, and
therefore the other flexible tab 512 may optionally be replaced by
an inflexible tab, such as the one shown in the embodiment of FIGS.
4A and 4B. Of course, many variations are possible, and additional
tabs may be used, or the 512 may be located on the sidewall 502 and
the catches 522 located on the bottom wall 504.
[0063] The upper end of the dustcup assembly 500 comprises an open
end 503 that is covered with a removable lid (not shown). The
dustcup assembly 500 is emptied by removing it from the vacuum
cleaner, and inverting it to drop out the contents. This is done
without disassembling the bottom wall 504 and outlet tube 510 from
the sidewall 502. However, as with the embodiment of FIGS. 4A and
4B, the latching arrangement for the bottom wall 514 and outlet
tube 510 allows relatively quick and simple disassembly, and
therefore this may alternatively be used as the primary emptying
means. In such a case, the upper end may be closed or a provided
with a permanent or semi-permanent lid, and the emptying procedure
described above with respect to FIGS. 4A and 4B could be used to
empty it.
[0064] In the embodiments described thus far herein, the outlet
tube is attached to the dustcup assembly by inserting it from below
the sidewalls. However, the opposite assembly is also possible with
the present invention. An embodiment of such a construction is
illustrated in FIGS. 6A and 6B. In this embodiment, the dustcup
assembly 600 comprises a sidewall 602, a bottom wall 604, and
outlet tube 610. The bottom wall 604 and outlet tube 610 are formed
as a single part that is assembled with the sidewall 602 by
advancing it downward through the sidewall until it snaps into
place or is otherwise attached.
[0065] The embodiment of FIGS. 6A and 6B is held together in a
similar manner as the embodiment of FIGS. 5A and 5B--namely, by the
use of flexible tabs 612. The flexible latching tabs 612 extend
downwardly from the bottom wall 604, and each tab 612 includes a
catch 614 that protrudes radially outward. When the bottom wall
604/outlet tube 610 part is fully seated, the catches 614 engage a
corresponding structure on the sidewall 602 to hold the parts
together. While four tabs 612 are preferred (the fourth being
omitted from the figures by virtue of them being cutaway views
taken along the centerline of the device), more or fewer tabs 612
may be used.
[0066] While the structure with which the catches 614 engage may
simply comprise the lower edge of the sidewall 602 or an
inwardly-extending lip on the sidewall 602, it is preferred to
provide the sidewall 602 with a radially inwardly-extending flange
616 with a downwardly-extending annular wall 618. The catches 614
engage the annular wall as shown in FIG. 6B. The use of this
inwardly-extending flange 616 allows the radially outermost portion
of the bottom wall 604' to overlie the flange 616 and create a
serpentine passage to prevent dirt from escaping through the bottom
of the dustcup assembly 600, and prevent air from entering the
dustcup assembly 600 through this juncture during operation. A
gasket or other seal (not shown) may be provided between the parts
to assist with sealing any air gap. Similarly, the bottom wall is
provided with an annular recess 622 into which a gasket 624 is
fitted to seal against a corresponding annular wall on the vacuum
cleaner housing (not shown) to which the dustcup assembly is
attached. Alternatively (or in addition), a seal (not shown) may be
provided in the annular space 626 between the annular wall 618 and
the sidewall 602, which, when engaged by a corresponding portion of
the vacuum cleaner housing, could effectively seal the entire
bottom of the dustcup assembly 600 against air leaking into the
assembly during operation of the vacuum source.
[0067] The manufacture of the bottom wall 604, the flexible tabs
612 and the catches 614 may be facilitated by creating the bottom
wall 604 with small openings 620 over each catch 614, which allows
injection molding the part with only two mold portions. The bottom
wall 604 may also include an annular wall that lies adjacent to
annular wall 618, although this is not shown in the Figures. As
with the embodiment of FIGS. 5A and 5B, the flexible tabs 612 are
shaped and sized to allow them to be flexed inwardly, as shown by
the arrows A, far enough to allow the catches 614 to bypass the
annular wall 618 as the part is installed, but firmly snap back
approximately into their unflexed position to hold the parts
together. The precise considerations of length, with and material
thickness will depend on the material selected for the part, as
will be appreciated by those of ordinary skill in the art. The
annular wall 618 may also include ramps or slightly tapered
surfaces (not shown) along which the catches 614 may ride as they
are being installed to gradually flex them inwardly, which should
decrease the amount of effort required to attach the parts. Such
ramps may be particularly useful if it is desired to make the
flexible tabs 612 resilient enough to attach the parts together,
but difficult to flex them back by hand to disassemble the parts,
thereby providing a somewhat more permanent assembly. If it is
desired to orient the outlet tube 610 and bottom wall 604 in a
particular angular orientation relative to sidewall 602, the parts
may be provided with one or more keys and slots that engage with
one another to prevent assembly in any but the desired position, as
will be appreciated by those of ordinary skill in the art in view
of the present disclosure.
[0068] A fifth embodiment of the invention is shown in FIGS. 7A and
7B. In this embodiment, the dustcup assembly 700 comprises a
sidewall 702 having a plurality of openings 712 arranged in an
annular pattern around the bottom end of the sidewall 702. The
bottom wall 704 and outlet tube 610 are again constructed as a
single part, although, as with other embodiments, they may be
separately formed and connected together. The bottom wall 704
includes an annular sidewall 714 that is constructed such that its
exterior surface fits within the interior surface of the dustcup
sidewall 702. A plurality of tabs 716 extend radially outward from
the sidewall 714. Each opening 712 is adapted to receive a
corresponding tab 716, as illustrated in FIG. 7B in order to secure
the bottom wall 704 and outlet tube 710 the sidewall 702 to form
the dustcup assembly 700. Of course, the openings 712 may be
replaced by indentations on the inner surface of the sidewall 702
that do not pass all the way through the sidewall 702.
[0069] In this embodiment, one or both of the dustcup sidewall 702
and the bottom wall sidewall 714 must flex in a manner to allow the
parts to be pushed together for assembly. To this end, one or both
parts may be made of a somewhat flexible material, or may be
provided with slots between the openings 712 and/or tabs 716 (not
shown) that increase the local flexibility of the material in the
region proximate to the openings 712 and/or tabs 716. The tabs 716
may also be beveled to ease their entry into the sidewall 702, and
the sidewall 702 may be provided with a chamfered interior edge or
ramps for the same purpose. A seal (not shown) may also be provided
between the parts to assist with forming an air- and dirt-tight
connection. As with the foregoing embodiment, it will be
appreciated that the number and size of the tabs 716 and openings
712 can be varied according to the manufacturer's desires.
Generally, the use of more tabs 716 and openings 712 provides a
more positive lock between the parts, but may require greater
manufacturing tolerances or steps to produce the parts. A greater
number of tabs 716 and openings 712 also increases the difficulty
of disassembling the parts, making it a one-shot snap-fit, which
may be preferred if it not desired for the end-user to be able to
perform such disassembly. For example, one instance in which
disassembly may not be desired is when the parts are provided with
an airtight seal by an adhesive tape or epoxy that could be damaged
or destroyed by disassembly.
[0070] FIGS. 8A to 8C show a sixth embodiment of a dustcup assembly
800 of the present invention, in which rotating cam locks are used
to hold the parts together. This embodiment comprises a sidewall
802 and bottom wall 804 that are integrally molded as a single
part, and an outlet conduit 810 that is attached to the bottom wall
804 by a cam lock mechanism. Like the embodiment of FIGS. 4A and
4B, the dustcup assembly 800 includes an inlet 808 through the
sidewall 802, and an open top 803 that is covered by a lid (not
shown), but variations of these features are within the scope of
the invention, as explained previously herein. One or more ribs 811
are provided on the sidewall 802 to fit into corresponding slots
(not shown) on the vacuum cleaner housing to help orient the
dustcup assembly 800 for proper installation.
[0071] The bottom of the outlet tube 810 includes three cam
followers 812 (two of which are visible in FIG. 8A) that extend
radially from the outlet tube wall. The outlet tube 810 also has an
outwardly-extending flange 814 at its end. There is a small gap
between each cam follower 812 and the flange 814. Each cam follower
812 includes a small tab 820 that extends downward into this gap. A
seal (not shown) may be positioned between the cam followers 812
and the flange 814 to seal the dustcup assembly 800 when the outlet
tube 810 is installed.
[0072] As shown in FIGS. 8B and 8C, the bottom wall 804 has a
central opening 816 into which the outlet tube 810 fits. The
central opening 816 has three notches 818 that are arranged in the
same pattern as the cam followers 812 so that the cam followers 812
can be received therein. As shown most clearly in FIG. 8C, each
notch is located circumferentially adjacent a portion of the upper
surface of the bottom wall 804 that includes an upwardly-extending
catch 822, and a cam stop 824. (The outlet tube 810 is shown
inserted into the central opening in FIG. 8C, but not yet rotated
into place.) To secure the outlet tube 810 to the dustcup assembly
800, the tube 810 is inserted into central opening 816 along the
longitudinal axis 801 of the dustcup assembly until the cam
followers 812 pass through the notches 818, and the flange 814 is
seated against the bottom wall 804. If a seal is provided, some
compression of the seal may be necessary to reach this point, but
this is not required. The outlet tube 810 is then rotated relative
to the sidewall 802 and bottom wall 804, preferably by about
1/8.sup.th of one turn (45 degrees). As this happens, the cam
followers 812 and the downwardly-extending tabs 820 are pushed
against and over the upwardly-extending catches 822, after which,
the sides of the cam followers 812 abut the cam stops 824. The
contact between the tabs 820 and the catches 822 creates a physical
obstruction to hold the outlet tube 810 in place. The cam stops 824
prevent over-rotation of the outlet tube 810, and thereby ensures
proper installation. Removal is done by simply reversing the
rotation of the outlet tube 810 and overcoming the retaining force
generated by contact between the tabs 820 and the catches 822.
Providing relatively gentile ramps on the tabs 820 and catches 822
will reduce the force necessary to assemble and disassemble the
parts. If it is desired to provide a more permanent installation,
the tabs 820 and catches 822 may be made with square back sides
that lock together once the parts are rotated into place. A
schematic of this variation is shown in FIG. 9A.
[0073] In a variation of this embodiment, shown in FIG. 9B, the
portion of the bottom wall 804 between the notches 818 and the
catches 822 is made with a gradually thickening profile 902 that is
ultimately nearly equal or greater in thickness than the size of
the gap between the cam followers 812 and the flange 820 (or the
seal, if one is provided) on the outlet tube 810. In this
variation, the catches 822 are replaced with detents 904 into which
the tabs 820 fit when the outlet tube 810 is rotated to the desired
installation position. It will be understood, of course, that all
of these variations essentially use a rotating cam lock arrangement
having a tab on one part, and a catch, ramp or notch (or a
combination thereof) on the other part.
[0074] Other variations of rotating cam locking devices may be used
with the present invention. In addition, as with other embodiments
described herein, the outlet tube may actually be formed integrally
with the bottom wall, and these parts may be cam locked to the
sidewall. The bottom wall may also be formed in two parts, one of
which is attached to the sidewall, and the other of which is
attached to the outlet tube, and which are attached together by cam
locks to form the dustcup assembly. Other variations of the cam
locking devices and their location and use to form a dustcup
assembly will be appreciated by those of ordinary skill in the art
in view of the present disclosure, and with routing experimentation
with the present invention.
[0075] Referring now to FIGS. 10A and 10B, a seventh embodiment of
a dustcup assembly 1000 of the present invention comprises a
combined outlet tube 1010 and bottom wall 1004 that is attached to
a sidewall 1002 by a fastening ring 1012. The fastening ring 1012
includes a lower radial wall 1014, an upper radial wall 1016, and
an annular wall 1018 that connects the upper and lower radial
walls. The upper radial wall 1016 includes a number of notches 1020
extending therethrough. The sidewall 1002 includes a number of
radially-extending catches 1022, which are spaced and sized to fit
into the notches 1020.
[0076] The dustcup assembly 1000 is assembled by positioning the
bottom wall 1004 to abut the lower edge of the sidewall 1002, and
installing the fastening ring 1012 over the bottom wall 1004. The
catches 1022 pass through the notches 1020 in the upper radial wall
1016, and the fastening ring 1012 is rotated until he catches are
located under the upper radial wall 1016. In this position, the
bottom wall 1004 is captured in place between the fastening ring
1012 and the sidewall 1002, and secured by the catches 1022. One or
both of the catches 1022 and the lower surface of the upper radial
wall 1016 may include detents, cam surfaces, or other devices to
provide a compression force or a locking engagement to hold the
parts together, as described above with reference to FIGS. 8A to
9B, or as otherwise known in the art. For example, in one
embodiment, the foregoing arrangement may comprise bayonet
fittings. The foregoing arrangement may alternatively comprise
threads, rather than catches 1022, which is made more practical in
this embodiment than in the known art by locating the threads where
they do not risk substantial contact with dirt and debris from the
dustcup assembly 1000. One or more seals (not shown) may be
provided between one or more of the sidewall 1002, bottom wall 1004
and fastening ring 1012.
[0077] The foregoing embodiments and variations thereof provide
several performance advantages in dustcup assemblies. For example,
the use of such heterogeneous parts can provide weight savings,
improved cleanability, additional options for emptying the dustcup
assembly, improved aesthetics, and so on. This construction also
allows the dustcup assembly to include specialty materials without
unduly raising the cost of the device. For example the outlet
conduit may be produced with an anti-microbial additive, such as
MICROBAN (available from Microban International, Ltd. of New York,
N.Y.), to assist with keeping the dustcup assembly microbe free,
but the sidewall may not be treated to reduce expense.
[0078] In addition, the present invention can provide a number of
manufacturing and engineering benefits. For example, in many
instances, the parts can be manufactured as two simple assemblies
using two-part injection molds. This two-part construction allows
the parts to be made from different materials, with different
thicknesses, or with different colors or graphics. Other
manufacturing advantages may include quicker molding time, reduced
tooling cost, reduced molding scrap, eliminating the need for
providing a mold-griping surface on the parts, and so on. The
two-part construction of the present invention also allows, if
desired, the parts to be disassembled for more economical shipping,
as removal of the outlet tube from the center of the dustcup
assembly can allow additional parts of the device to be shipped
within the dustcup assembly itself. Still another benefit of using
a separate part for the outlet tube is that the outlet tube can be
replaced with different shaped tubes (e.g., longer, shorter, wider,
or narrower) to facilitate the use of different filter sizes and to
make different end products, without requiring an entirely new
dustcup assembly mold to be produced. This has one particular
advantage of improving product development lead times.
[0079] In addition, while the embodiments described herein describe
the outlet tube as being an air passage for air to exit the dustcup
assembly, the present teachings are also applicable to air inlet
passages that are attached to or pass through the dustcup assembly,
and are also applicable to dustcup assembly inserts that do not
actually carry an airflow therethrough.
[0080] Still other benefits of the two-piece construction of
present invention are described below with respect of various
additional embodiments, which may be used with any of the foregoing
embodiments.
[0081] Referring now to FIG. 11, the use of a separate outlet tube
according to the present invention allows practical formation of
airflow-enhancing shapes on the dustcup assembly sidewall and
outlet tube. In this embodiment, the dustcup assembly 1100 comprise
a sidewall 1102 and a combined bottom wall 1104 and outlet tube
1104. The bottom wall 1104 attaches to the sidewall, as in any of
the foregoing embodiments or variations thereof, at or near the
outer edge of the sidewall 1102. This allows airflow-enhancing
contours 1112 to be molded into the inner surface of the sidewall
1102 using a conventional injection molding techniques, and may
even be performed using simple two-part molds. This construction
similarly allows airflow-enhancing contours 1114 to be molded on
the outlet tube 1110. As with the contours 1112 on the sidewall
1102, these contours 1114 can be molded much more readily than if
the outlet tube 1110 were molded with the remainder of the dustcup
assembly 1100. Either set of contours 1112, 1114 may also be
provided on a separate sleeve that is assembled with the dustcup
assembly 1100.
[0082] An alternative embodiment of an outlet tube that may be used
with the present invention is shown in FIG. 12. In this embodiment,
the outlet tube 1210 comprises an airflow deflector 1212 that is
integrally molded with the outlet tube 1210. In embodiments in
which the outlet tube 1210 is installed through a hole through the
bottom of the dustcup assembly (not shown), the airflow deflector
1212 is limited in size and shape to being insertable through the
installation hole, but in embodiments in which it is installed
through the open top end of the dustcup assembly, the airflow
deflector 1212 may be larger. The airflow preferably has a flat,
disk-like shape, which allows the outlet tube 1210 to be made by
clamshell molds that form either lateral side of the outlet tube
1210 with an third mold insert to form the hollow interior of the
outlet tube 1210. However, the deflector 1212 may be made with a
compound, curved or angled surfaces, or any other deflector shapes
known in the art. the proper molding techniques for such shapes
will be understood to those of ordinary skill in the art based on
the present disclosure.
[0083] Another embodiment of a dustcup assembly of the present
invention that is facilitated by the use of a two-part assembly is
shown in FIGS. 13A and 13B. In this embodiment, the dustcup
assembly 1300 comprises a sidewall 1302, a bottom wall 1304, and an
outlet tube 1310 that exits through the sidewall 1302. The outlet
tube 1310 is installed using screws, cam-lock fasteners, or the
like, as described previously herein. This construction would be
relatively difficult or expensive with conventional injection
molding techniques, but is greatly simplified by forming the outlet
tube 1310 separately. Since the outlet tube 1310 is manufactured
separately from the sidewall 1302, it can also be economically
manufactured with a plurality of perforations 1312 around its end
to act as a fine or coarse filter, or to act as an emergency screen
to prevent the filter (not shown), if used, from entering the
outlet tube 1310 and then the vacuum motor if it is torn or
otherwise disintegrates. Of course, this feature may be provided
with any of the other embodiments of the invention as well.
[0084] A particular advantage of two-part construction of the
present invention is that this embodiment may be manufactured from
any of the foregoing embodiments by molding the sidewall 1302 with
an opening to receive the outlet tube 1310, and covering the
original opening through the bottom wall 1304 with an airtight
cover (or vice versa for making any of the foregoing embodiments
from the present embodiment). This facilitates the manufacture of a
variety of products using a single sidewall as a platform.
[0085] The installation of the embodiment of FIG. 13 into an
exemplary vacuum cleaner is shown in FIG. 13B. Here, the vacuum
cleaner comprises an upright vacuum having a nozzle base 1314 to
which a rear housing 1316 is pivotally attached. the rear housing
includes a dustcup assembly receiving portion 1318 having an air
inlet connection 1320 and an air outlet connection 1322. The inlet
connection 1320 mates with the dustcup assembly inlet 1308, and the
outlet connection mates with the outlet tube 1310 when the dustcup
assembly 1310 is installed. A suitable latch, as are known in the
art, holds the dustcup assembly 1300 in place.
[0086] While the foregoing embodiments have depicted the sidewall
being cylindrical, this shape is not required, and conical,
frusto-conical, and other shapes may be used. In addition the
outlet tube may have any number of non-circular profiles. The use
of the two-part assembly of the present invention also facilitates
the manufacture of outlet tubes having relatively complex shapes.
Referring to FIGS. 14A to 14G, a number of exemplary variations are
shown. These shapes may be used with any embodiment of the present
invention.
[0087] FIG. 14A illustrates an alternative outlet tube 1410a having
a rectangular profile. FIG. 14B illustrates an alternative outlet
tube 1410b having a square profile. FIG. 14C illustrates and
alternative outlet tube 1410c having a triangular profile. Such
rectilinear profiles may, by virtue of not being circular, initiate
the creation of sub-cyclones within the dustcup assembly that help
separate particles from the air.
[0088] The embodiments of FIGS. 14D to 14F illustrate multi-part
conduits, which have upper and lower portions having different
shapes and/or sizes. In the embodiment of FIG. 14D, both outlet
tube sections 1410d' and 1410d'' are rectangular, but the lower
section 1410d' is larger than the upper section 1410d''. Of course,
the opposite arrangement, that is, having the lower section 1410d'
smaller than the upper section 1410d'', may also be used. In the
embodiment of FIG. 14E, both outlet tube sections 1410e' and
1410e'' are square, but the lower section 1410e' is rotated
relative to the upper section 1410e''. In the embodiment of FIG.
14F, the lower outlet tube section 1410f' is triangular, and the
upper outlet tube section 1410f'' is cylindrical. These embodiments
are provided only by way of example, and many other embodiments
will be apparent to those of ordinary skill in the art in view of
the present disclosure and with routine experimentation with the
present invention. Additional examples of outlet tube geometries
and airflow enhancing contours that may be produced on the outlet
tube are provided in U.S. Pat. No. 6,419,719, which is incorporated
herein by reference.
[0089] FIG. 14G illustrates still another embodiment of an
alternative outlet tube geometry of the present invention. In this
embodiment, the outlet tube 1410g comprises an airfoil-like shape.
While this airfoil shape may be located in the center of the
dustcup assembly 1400, it may alternatively be located closer to
the sidewall 1402. As the air in the dustcup assembly 1400 circles
around the sidewall 1402 and past the airflow shaped outlet tube
1410, a lower pressure develops between the outlet tube 1410 and
the sidewall 1402, which is expected to increase the efficiency of
the cyclonic separating action. In this embodiment, an
airfoil-shaped filter 1412 may be used to further assist with
cyclone separation and enhance the aesthetic quality of the
device.
[0090] The present invention also allows the use of multiple outlet
tubes having relatively complex geometry. Referring now to FIGS.
15A to 15C, in another embodiment of the invention the dustcup
assembly 1500 comprises a sidewall 1502, bottom wall 1504, and lid
1506. The single outlet tube of the previous embodiments is
replaced by a pair of curved outlet tubes 1510 that extend
downwardly in a spiral pattern that may enhance the cyclonic
airflow within the dustcup assembly 1500. The outlet tubes 1510 may
be formed separately from one another, and separately assembled to
the bottom wall 1504, as described previously herein, or both
outlet tubes 1510 may be formed as a single piece with the bottom
wall 1504 attaching them, and this assembly installed to the
sidewall 1502. Other variations will be understood by those of
ordinary skill in the art with consideration of the present
disclosure.
[0091] In one embodiment, the a filter 1512 is located at the top
of the tubes 1510, but this is not required. If such a filter 1512
is provided, the outlet tubes 1510 may be attached to the bottom of
the filter 1512 to draw air from the filter 1512 in a tangential
manner, which may enhance the post-filter airflow through the
device.
[0092] While the embodiments of the invention described above are
preferred, it will be recognized and understood that these
embodiments are not intended to limit the invention, which is
limited only by the appended claims. Various modifications may be
made to these embodiments without departing from the spirit of the
invention and the scope of the claims.
* * * * *