U.S. patent application number 16/487502 was filed with the patent office on 2019-12-26 for handheld vacuum cleaner.
The applicant listed for this patent is TTI (Macao Commercial Offshore) Limited. Invention is credited to Shadi Sumrain, Patrick Truitt.
Application Number | 20190387940 16/487502 |
Document ID | / |
Family ID | 63254186 |
Filed Date | 2019-12-26 |
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United States Patent
Application |
20190387940 |
Kind Code |
A1 |
Truitt; Patrick ; et
al. |
December 26, 2019 |
HANDHELD VACUUM CLEANER
Abstract
A method of controlling a handheld vacuum cleaner (10) having a
fluid flow path extending from a dirty air inlet (14) to a clean
air outlet (18) is provided. The method includes measuring a
pressure value of an airflow through the fluid flow path, and
determining whether the pressure value exceeds a predetermined
threshold, which is indicative of a clog within the fluid flow
path. The method further includes alerting a user of the handheld
vacuum cleaner (10) when the pressure value exceeds the
predetermined threshold. Alerting the user includes transmitting an
alert to a personal device (418) of the user and identifying to the
user a plurality of possible clog locations along the fluid flow
path.
Inventors: |
Truitt; Patrick; (Concord,
NC) ; Sumrain; Shadi; (Hudson, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TTI (Macao Commercial Offshore) Limited |
Macau |
|
CN |
|
|
Family ID: |
63254186 |
Appl. No.: |
16/487502 |
Filed: |
February 27, 2017 |
PCT Filed: |
February 27, 2017 |
PCT NO: |
PCT/CN2017/075034 |
371 Date: |
August 21, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47L 9/2894 20130101;
A47L 9/22 20130101; A47L 9/2884 20130101; A47L 9/2821 20130101;
A47L 9/19 20130101; A47L 9/322 20130101; A47L 9/122 20130101; A47L
9/16 20130101; A47L 5/24 20130101; A47L 9/246 20130101; A47L 9/2857
20130101 |
International
Class: |
A47L 9/19 20060101
A47L009/19; A47L 5/24 20060101 A47L005/24 |
Claims
1. A method of controlling a handheld vacuum cleaner having a fluid
flow path extending from a dirty air inlet to a clean air outlet,
the method comprising: measuring a pressure value of an airflow
through the fluid flow path; determining whether the pressure value
exceeds a predetermined threshold, which is indicative of a clog
within the fluid flow path; alerting a user of the handheld vacuum
cleaner when the pressure value exceeds the predetermined
threshold; wherein alerting the user includes transmitting an alert
to a personal device of the user and identifying to the user a
plurality of possible clog locations along the fluid flow path.
2. The method of claim 1, wherein transmitting an alert to the
personal device is transmitted with direct vacuum-to-device
wireless data communication.
3. The method of claim 1, wherein transmitting an alert to the
personal device is transmitted with wireless internet or network
communication.
4. The method of claim 1, wherein the personal device is a cell
phone.
5. The method of claim 1, wherein the personal device is a personal
computer.
6. The method of claim 1, wherein the alert includes instructions
for the user to clean the possible clog locations along the fluid
flow path to remove the clog.
7. The method of claim 1, wherein alerting the user further
includes activating a visual indicator positioned on the handheld
vacuum cleaner.
8. The method of claim 1, wherein measuring the pressure value of
the airflow is measured downstream of a pre-motor filter.
9. The method of claim 1, further comprising disabling the airflow
through the fluid flow path when the pressure value exceeds the
predetermined threshold.
Description
BACKGROUND
[0001] The present invention relates to handheld vacuum cleaners,
and more particularly, to cyclonic handheld vacuum cleaners.
SUMMARY
[0002] In one embodiment, the invention provides a method of
controlling a handheld vacuum cleaner having a fluid flow path
extending from a dirty air inlet to a clean air outlet. The method
includes measuring a pressure value of an airflow through the fluid
flow path, and determining whether the pressure value exceeds a
predetermined threshold, which is indicative of a clog within the
fluid flow path. The method further includes alerting a user of the
handheld vacuum cleaner when the pressure value exceeds the
predetermined threshold. Alerting the user includes transmitting an
alert to a personal device of the user and identifying to the user
a plurality of possible clog locations along the fluid flow
path.
[0003] Other aspects of the invention will become apparent by
consideration of the detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a perspective view of a handheld vacuum cleaner
according to an embodiment of the invention.
[0005] FIG. 2 is another perspective view of the handheld vacuum
cleaner of FIG. 1.
[0006] FIG. 3 is a cross-sectional view of the handheld vacuum
cleaner of FIG. 1, taken along lines 3-3 shown in FIG. 1.
[0007] FIG. 4 is a cross-sectional view of the handheld vacuum
cleaner of FIG. 1, shown in an in-use position with a separator
axis oriented vertically.
[0008] FIG. 5A is a partial cross-sectional view of the handheld
vacuum cleaner of FIG. 1, illustrating a battery latch in a locked
position.
[0009] FIG. 5B is a partial cross-sectional view of the handheld
vacuum cleaner of FIG. 1, illustrating the battery latch in a
released position.
[0010] FIG. 6 perspective view of the handheld vacuum cleaner of
FIG. 1, showing an inlet nozzle in phantom.
[0011] FIG. 7 is a partial cross-sectional view of the handheld
vacuum cleaner of FIG. 1.
[0012] FIG. 8 is a cross-sectional view of the handheld vacuum
cleaner of FIG. 1, with a cyclonic separator assembly partially
removed from a main body.
[0013] FIG. 9 is a schematic view of an alert transmission system
for the handheld vacuum cleaner of FIG. 1.
[0014] FIG. 10 is a flow chart illustrating a method of controlling
the handheld vacuum cleaner of FIG. 1.
[0015] FIG. 11 is a perspective view of the handheld vacuum cleaner
of FIG. 1 coupled to a surface cleaning attachment according to an
embodiment of the invention.
[0016] FIG. 12 is a cross-sectional view of the handheld vacuum
cleaner and the surface cleaning attachment of FIG. 11, in a stored
position.
[0017] FIG. 13 is a cross-sectional view of the handheld vacuum
cleaner and the surface cleaning attachment of FIG. 11 in an in-use
position.
[0018] FIG. 14 is a bottom perspective view of a handheld vacuum
cleaner according to another embodiment of the invention.
[0019] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways.
DETAILED DESCRIPTION
[0020] FIGS. 1-8 illustrate a handheld vacuum cleaner 10. The
handheld vacuum cleaner 10 includes a fluid flow path extending
from a dirty air inlet 14 to a clean air outlet 18. The handheld
vacuum cleaner 10 also includes a main body 22 (i.e., a main
housing) and a cyclonic separator assembly 26 removably coupled to
the main body 22. The cyclonic separator assembly 26 includes a
cyclonic chamber 30 that defines a separator axis 34, a dirt
collection region 38, and an inlet nozzle 42 that defines an inlet
axis 46. The handheld vacuum cleaner 10 includes a front 50, a rear
54, a first lateral side 58, a second lateral side 62, a top 66,
and a bottom 70. Similarly, the main body 22 includes a front 74, a
rear 78, a first lateral side 82, a second lateral side 86, a top
90, and a bottom 94. In the illustrated embodiment, the dirty air
inlet 14 is positioned at the front 50 of the handheld vacuum
cleaner 10 and the clean air outlet 18 is positioned on the first
and second lateral sides 58, 62 toward the rear 54 of the handheld
vacuum 10. As described in greater detail below, the dirty air
inlet 14 extends along the inlet axis 46.
[0021] With reference to FIGS. 1-3, the main body 22 includes a
handle 98 and a bottom surface 102 on the bottom 94, upon which the
handheld vacuum cleaner 10 is configured to be positioned on (i.e.,
supported on, rested on) a horizontal surface 106 (FIG. 3). The
handle 98 of the main body 22 extends along a handle axis 110 (FIG.
3) and includes a trigger 100. The handheld vacuum cleaner 10
further includes a motor assembly 114 positioned within the main
body 22 and operable to generate an airflow through the fluid flow
path. In particular, the motor assembly 114 includes a motor 118
with a motor shaft 122 defining a motor rotational axis 126 and a
fan 130 coupled to the motor shaft 122 for co-rotation. In the
illustrated embodiment, the handle axis 110 interests the motor
assembly 114. In addition, the motor rotational axis 126 intersects
the inlet axis 46. In other words, the inlet axis 46 intersects the
motor assembly 114. In particular, the motor rotational axis 126
intersects the inlet axis 46 forming an acute angle 134 (FIG. 3)
extending between the dirty air inlet 14 and the motor 118 (i.e.,
counter-clockwise from the inlet axis 46 as viewed from FIG. 3). In
the illustrated embodiment, the inlet axis 46 intersects the handle
axis 110 but does not intersect the handle 98.
[0022] For the purpose of the description herein, two axes
intersecting to form an angle includes two axes that are
non-parallel and intersect as viewed in at least one plane. In some
embodiments, two axes intersecting to form an angle may include two
axes that are co-planar and that intersect at a single point. In
other embodiments, the two axes intersecting to form an angle may
include two axes that are skewed with respect to each other (i.e.,
not co-planar), but the axes intersect as viewed from a certain
perspective (e.g., a side view, a top view, etc.).
[0023] With continued reference to FIGS. 1-3, the handheld vacuum
cleaner 10 includes a battery 138 (i.e., a removable, rechargeable
battery pack) to supply power to the motor assembly 114 and other
electrical components. The battery 138 includes a first side
surface 142 and a second side surface 146 opposite the first side
surface 142. The main body 22 includes a receptacle 150 having an
inlet 154 to receive the battery 138. In other words, the battery
138 is configured to be selectively received within the receptacle
150. As described in greater detail below, the battery 138 is
inserted into the receptacle 150, through the inlet 154, along a
battery insertion axis 158. In other words, the main body 22 is
configured such that the battery 138 is insertable into the
receptacle 150 through the bottom surface 102. In addition, at
least a portion of the battery 138 is positioned between the
cyclone chamber 30 and the bottom surface 102.
[0024] With reference to FIG. 3, the battery insertion axis 158
intersects the separator axis 34. In addition, the battery
insertion axis 158 is offset from and in some embodiments parallel
to the handle axis 110. In alternative embodiments, the battery
insertion axis is along the separator axis and intersects the
handle axis (e.g., FIG. 14). Also, the motor rotational axis 126
intersects the battery insertion axis 158. Furthermore, the battery
insertion axis 158 intersects the inlet axis 46. In particular, the
battery insertion axis 158 intersects the inlet axis 46 to form an
obtuse angle 162 extending between the dirty air inlet 14 and the
battery 138 (i.e., counter-clockwise from the inlet axis 46 as
viewed from FIG. 3).
[0025] In the illustrated embodiment, the receptacle 150 is defined
by a first wall 166, a second wall 170 opposite the first wall 166,
and a curved third wall 174 extending between the first wall 166
and the second wall 170. In the illustrated embodiment, the first
wall 166 and the second wall 170 are only connected by the third
wall 174. In other words, in the illustrated embodiment, the
receptacle 150 includes a first aperture 178 at the first lateral
side 82 of the main body 22 and a second aperture 182 at the second
lateral side 86 of the main body 22. Moreover, the first aperture
178 and the second aperture 182 extend toward the receptacle inlet
154 such that the battery 138 is graspable by a user between the
installed position (i.e., with the battery 138 fully inserted into
the receptacle 150, e.g., FIG. 5A) and the removed position (i.e.,
with the battery 138 at least partially removed from the receptacle
150, e.g., FIG. 5B). In the illustrated embodiment, the first
aperture 178 and the second aperture 182 are continuous with the
receptacle inlet 154. In other words, the apertures 178, 182 and
the inlet 154 form a slot that is open to the first lateral side 82
of the main body 22, open to the second lateral side 86 of the main
body 22, and open to the bottom 94 of the main body 22. The first
side surface 142 and the second side surface 146 of the battery 138
extend parallel to the insertion axis 158 when the battery 138 is
positioned within the receptacle 150. In alternative embodiments,
the apertures 178, 182 are not continuous with the receptacle inlet
154 or are only partially continuous with the receptacle inlet 154
yet still configured for the battery to be graspable, or engaged
by, a user through the apertures, for example to aid in insertion
and removal of the battery.
[0026] When the battery 138 is positioned within the receptacle
150, each of the first side surface 142 and the second side surface
146 of the battery 138 are substantially exposed through the
apertures 178, 182 at the respective first and second lateral sides
82, 86 of the main body 22 such that the first and second side
surfaces 142, 146 are graspable by a user. In some embodiments, the
first side surface 142 and the second side surface 146 are
substantially exposed with at least 25 percent of the surfaces 142,
146 exposed through the apertures 178, 182 at the respective first
and second lateral sides 82, 86 of the main body 22. In other
embodiments, the first side surface 142 and the second side surface
146 are substantially exposed with at least 50 percent of the
surfaces 142, 146 exposed through the apertures 178, 182 at the
respective first and second lateral sides 82, 86 of the main body
22. In other embodiments, the first side surface 142 and the second
side surface 146 are substantially exposed with at least 75 percent
of the surfaces 142, 146 exposed through the apertures 178, 182 at
the respective first and second lateral sides 82, 86 of the main
body 22. In other embodiments, the first side surface 142 and the
second side surface 146 are substantially exposed with 100 percent
of the surfaces 142, 146 exposed through the apertures 178, 182 at
the respective first and second lateral sides 82, 86 of the main
body 22 (i.e., entirely exposed). As such, the battery 138 is
readily graspable by a user (i.e., at the first and second side
surfaces 142, 146) when the battery 138 is positioned within the
receptacle 150.
[0027] With reference to FIGS. 1-3, the battery 138 further
includes a first surface 186, a second surface 190, a third surface
194, and a fourth surface 198 each extending between the first side
surface 142 and the second side surface 146. In the illustrated
embodiment, the first surface 186 is opposite the third surface 194
and the second surface 190 is opposite the fourth surface 198. At
least one of the first surface 186, second surface 190, and fourth
surface 198 includes an electrical contact 202 that is selectively
electrically connected to a corresponding electrical contact 206
formed in the receptacle 150. In the illustrated embodiment, the
electrical contact 206 in the receptacle 150 is formed on the third
wall 174 of the receptacle 150 corresponding to the electrical
contact 202 on the first surface 186.
[0028] When the battery 138 is positioned within the receptacle
150, the third surface 194 of the battery 138 is substantially
exposed such that the third surface 194 is in the direction of the
receptacle inlet 154 (i.e., exposed at the bottom surface 102 of
the main body 22). In some embodiments, the third surface 194 of
the battery 138 is entirely exposed. Alternatively, the receptacle
inlet 154 may be selectively closed by a cover or door that at
least partially covers the third surface 194 of the battery. Also
when the battery 138 is positioned within the receptacle 150, the
first surface 186, the second surface 190, and the fourth surface
198 are in facing relationship with the main body 22. More
specifically, the first surface 186 is in facing relationship with
the third wall 174 of the main body 22, the second surface 190 is
in facing relationship with the first wall 166 of the main body 22,
and the fourth surface 198 is in facing relationship with the
second wall 170 of the main body 22. Moreover, when the battery 138
is positioned within the receptacle 150, at least a portion of the
battery 138 is positioned between the cyclonic chamber 30 and the
handle 98. In other words, the receptacle 150 is formed in the main
body 22 between at least a portion of the cyclonic separator
assembly 26 (e.g., the cyclonic chamber 30) and the handle 98.
[0029] With reference to FIG. 14, a handheld vacuum cleaner 1010
according to an alternative embodiment is illustrated. The handheld
vacuum cleaner 1010 is similar to the handheld vacuum cleaner 10,
with only the differences described herein. In particular, the
handheld vacuum cleaner 1010 includes a main body 1022 including a
front 1074, a first lateral side 1082, a second lateral side 1086,
a handle 1098, and a receptacle 1150 having an inlet 1154. The
handheld vacuum cleaner 1010 also includes a motor assembly 1114
positioned within the main body 1022, a dirty air inlet 1014
positioned at a front 1050 of the handheld vacuum cleaner 1010, and
a cyclonic chamber 1030 in fluid communication with the dirty air
inlet 1014 and the motor assembly 1114. The handheld vacuum cleaner
1010 also includes a battery 1138 having a first side surface 1142
and a second side surface 1146 opposite the first side surface
1142. Similar to the battery 138, the battery 1138 is configured to
be selectively received through the receptacle inlet 1154 and
movable by a user between an installed position in the receptacle
1150 and a removed position separate from the main body 1022.
[0030] With continued reference to FIG. 14, the main body 1022
includes a first aperture 1178 through the first lateral side 1082
aligned with at least a portion of the battery first side surface
1142 when the battery 1138 is positioned within the receptacle
1150. At least a portion of the battery first side surface 1142 is
viewable by a user through the first aperture 1178 when the battery
1138 is positioned within the receptacle 1150. The main body 1022,
in some embodiments, may include a second aperture (not shown)
through the second lateral side 1086. The second aperture may be a
minor image of the first aperture 1178 aligned with at least a
portion of the battery second side surface 1146 when the battery
1138 is positioned within the receptacle 1150. At least a portion
of the battery second side surface 1146 is viewable by a user
through the second aperture when the battery 1138 is positioned
within the receptacle 1150. Each of the first side surface 1142 and
the second side surface 1146 are at least 25 percent exposed at the
lateral sides 1082, 1086 of the main body 1022 when the battery
1138 is positioned within the receptacle 1150, such that the first
and second side surfaces 1142, 1146 are graspable by a user.
Similar to the apertures 178, 182, the first aperture 1178 and the
second aperture extend toward the receptacle inlet 1154 such that
the battery 1138 is graspable by a user between the installed
position and the removed position. As such, the apertures provide a
visual indication to the user that the battery 1138 is installed
within the receptacle 1150. The battery insertion axis 1158 is
along and may be parallel to the separator axis 1034 in the
alternative handheld vacuum cleaner 1010 of FIG. 14.
[0031] With reference to FIG. 3 and the handheld vacuum cleaner 10,
when the bottom surface 102 is placed on the horizontal surface
106, the separator axis 34 is inclined relative to a vertical axis
210. In addition, the inlet axis 46 is within 10 degrees of
horizontal when the bottom surface 102 is placed on the horizontal
surface 106. In alternative embodiments, the inlet axis 46 is
parallel with the horizontal surface 106 when the bottom surface
102 is placed on the horizontal surface 106.
[0032] With reference to FIG. 4 and FIG. 13, the inlet axis 46 and
the separator axis 34 intersect to form an acute angle 214
extending between the dirty air inlet 14 and the cyclonic chamber
30 (i.e., counter-clockwise from the inlet axis 46 as viewed from
FIG. 3). The acute angle 214 is within the range of approximately
30 degrees to approximately 70 degrees such that when the handheld
vacuum cleaner 10 is operated in a normal operating condition
(e.g., FIG. 4, FIG. 13) with the dirty air inlet 14 pointed
downwardly, the separator axis 34 is oriented vertically. In
alternative embodiments, the acute angle 214 is within a range of
approximately 40 degrees to approximately 60 degrees. In further
embodiments, the acute angle 214 is within a range of approximately
45 degrees to approximately 55 degrees. In some embodiments, the
acute angle 214 is approximately 50 degrees.
[0033] With reference to FIG. 2, the main body 22 includes a
rear-facing surface 218 opposite the dirty air inlet 14. In other
words, the rear-facing surface 218 is formed on the rear 78 of the
main body 22 and faces a user during operation. A user interface
222 is positioned on the rear-facing surface 218 adjacent the
handle 98. The user interface 222 may include a button, switch,
touch screen, dial or other user-manipulative interface. In the
illustrated embodiment, the user interface 222 includes a visual
indicator or display 422 operable to display information on the
user-facing surface 218. The visual indicator 422 may be a screen,
LEDs, graphical interface, or other visual indicator. The user
interface 222 is electrically connected to the battery 138 and a
vacuum controller 410 and is connected to and operable to control
and display information about features of the vacuum cleaner, for
example battery life, power setting, system performance or other
information. The user interface 222 may be connected to and
operable to control and display information about features on
attached accessory tools, such as brush motors or sensors. In the
illustrated embodiment, the user-interface 222 may be configured to
vary operation of a brushroll (e.g., brushroll 578 of FIG. 12). In
particular, activation of the user-interface 222 varies operation
of the brushroll between a carpet mode and a hard floor mode, or
between a high brushroll speed and low or off brushroll speed.
[0034] The inlet nozzle 42 is positioned at the front 50 of the
handheld vacuum cleaner 10 when the cyclonic separator assembly 26
is coupled to the main body 22. In the illustrated embodiment, the
dirty air inlet 14 includes an inlet aperture 226 formed in the
inlet nozzle 42. As part of the dirty air inlet 14, the inlet
nozzle 42 houses a first air passage 230 (e.g., a first air tube)
and a second air passage 234 (e.g., a second air tube) downstream
of the first air passage 230. The first air passage 230 extends
along the inlet axis 46 (i.e., a first axis), and the second air
passage 234 defines a second axis 238 extending toward a cyclone
inlet 302. The first axis 46 and the second axis 238 intersect to
form an angle 242 as viewed from a vertical cross-section taken
from a lateral side (e.g., 58, 62) of the handheld vacuum cleaner
10 (e.g., FIG. 3). In the illustrated embodiment, the second air
passage 234 includes a tangential inlet 246 to the cyclonic chamber
30. In other words, the first air passage 230 extends from the
front 50, while the second air passage 234 extends toward the
bottom 70 and extends toward the first lateral side 58 toward the
cyclone inlet 302 of the handheld vacuum cleaner 10.
[0035] With reference to FIG. 3, the inlet axis 46 and the handle
axis 110 intersect to form an obtuse angle 250 extending between
the dirty air inlet 14 and the handle 106. In other words, the
angle 250 formed by the intersection of the inlet axis 46 and the
handle axis 110 is greater than 90 degrees and less than 180
degrees, taken in a direction from the inlet axis 46 toward the
handle 98 (i.e., counter-clockwise from the inlet axis 46 as viewed
from FIG. 3)).
[0036] With reference to FIG. 6, the inlet nozzle 42 includes an
upstream portion 254 having a first cross-sectional area 258 and a
downstream portion 262 having a second cross-sectional area 266.
The inlet nozzle 42 also includes an upstream height 270 measured
perpendicular to the inlet axis 46 and a downstream height 274
measured parallel to the separator axis 34. The downstream height
274 is larger than the upstream height 270. In some embodiments,
the downstream height 274 is at least 1.3 times larger than the
upstream height 270. Alternatively, the downstream height 274 is at
least 1.5 times larger than the upstream height 270. In some
embodiments, the downstream height 274 is in the range from 1.5 to
3 times larger than the upstream height 270. In yet another
embodiment, the downstream height 274 is at least 3 times larger
than the upstream height 270. In other words, height of the inlet
nozzle 42 increases in the downstream direction.
[0037] Generally, the upstream height 270 is measured at a location
where the inlet nozzle 42 begins increasing in height in the
downstream direction. In some embodiments, the upstream height 270
is measured at a height 290 at the inlet 14 (i.e., at the inlet
aperture 226). In other embodiments, the upstream height 270 is
measured between the inlet 14 and the downstream height 274. In the
illustrated embodiment, the upstream end of the inlet nozzle 42
includes a space 278 for an accessory latch (e.g., the attachment
554 of FIG. 11) and a space 282 for an electrical connection 286.
In other words, in some embodiments, the inlet nozzle 42 increases
in height in the downstream direction, throughout the entire length
of the inlet nozzle 42. In other embodiments, the inlet nozzle 42
increases in height in the downstream direction for at least a
portion of the inlet nozzle 42 length. Said another way, the inlet
nozzle height may increase in the upstream direction and in the
downstream direction, with a minimum height therebetween. In the
illustrated embodiment, the height 270 is approximately 53
millimeters. In some embodiments, the downstream height 274 is
measured where the inlet nozzle 42 and the cyclonic chamber 30 meet
(FIG. 3). In the illustrated embodiments, the downstream height 274
is approximately 90 millimeters.
[0038] With continued reference to FIG. 6, the second
cross-sectional area 266 is at least 1.5 times larger than the
first cross-sectional area 258. In alternative embodiments, the
second cross-sectional area 266 is at least 3 times larger than the
first cross-sectional area 258. With reference to FIGS. 3 and 4,
the cyclonic separator assembly 26 defines a separator height 298
(FIG. 4) that extends along the separator axis 34, and the
downstream height 274 (FIG. 3) parallel to the separator axis 34 is
greater than one half of the separator height 298. In other words,
the inlet nozzle 42 expands in both the horizontal direction (i.e.,
transverse the separator axis 34) and the vertical direction (i.e.,
parallel to the separator axis 34). The increased second
cross-sectional area 266 (i.e., the increased downstream height
274) provides for improved structural integrity of the inlet nozzle
42 connection to the remaining portions of the cyclonic separator
assembly 26. In other words, the size and shape of the inlet nozzle
42 provides improved strength and reliability of the inlet nozzle
42 connecting to the remaining portions of the cyclonic separator
assembly 26.
[0039] The cyclonic chamber 30 is in fluid communication with the
dirty air inlet 14 and the motor assembly 114. In addition, the
cyclonic chamber 30 (i.e., the cyclonic separator) includes the
cyclone dirty fluid inlet 302, a dirt outlet 306, and a clean fluid
outlet 310. In the illustrated embodiment, the cyclonic chamber 30
includes a primary cyclonic stage 314 and a secondary cyclonic
stage 318 positioned between the dirty fluid inlet 302 and the
clean fluid outlet 310 (FIG. 4). In alternative embodiments, the
cyclonic chamber 30 may include more or less than two cyclonic
stages. In particular, the cyclonic chamber 30 includes a
perforated shroud 322 through which air cleaned by the primary
cyclonic stage 314 flows through. The secondary cyclonic stage 318
is positioned downstream of the perforated shroud 322 and the
secondary cyclonic stage 318 includes a secondary dirty air
tangential inlet 326 (FIG. 4), a secondary funnel 330, and a
secondary dirt outlet 334. The air cleaned by the secondary
cyclonic stage 318 flows to the clean fluid outlet 310. In
alternative embodiments, the illustrated cyclonic chamber 30 can be
replaced with alternative dirt separators (e.g., over-the-wall
cyclonic separators, bagged separators, etc.)
[0040] As described above, the inlet axis 46 and the separator axis
34 intersect to form the acute angle 214 extending between the
dirty air inlet 14 and the cyclonic chamber 30. In other words, the
angle 214 formed by the intersection of the inlet axis 46 and the
separator axis 34 is less than 90 degrees, taken in a direction
from the inlet axis 46 toward the cyclonic chamber 30 (i.e.,
counterclockwise as viewed from FIG. 3). In addition, the separator
axis 34 and the motor rotational axis 126 interest to form an
obtuse angle 342 extending between the cyclonic chamber 30 and the
motor assembly 114. In other words, the angle 342 formed by the
intersection of the separator axis 34 and the motor rotational axis
126 is in a range from about 90 degrees to180 degrees, taken in a
direction from the cyclonic chamber 30 toward the motor assembly
114 (i.e., counterclockwise as viewed from FIG. 3). In some
embodiments, the obtuse angle 342 extending between the cyclonic
chamber 30 and the motor assembly 114 is within a range of
approximately 90 degrees to approximately 165 degrees. In
alternative embodiments, the obtuse angle 342 extending between the
cyclonic chamber 30 and the motor assembly 114 is within a range of
approximately 135 degrees to approximately 150 degrees. In further
alternative embodiments, the obtuse angle 342 extending between the
cyclonic chamber 30 and the motor assembly 114 is approximately 140
to 145 degrees.
[0041] With reference to FIG. 1, the dirt collection region 38 is
configured to receive debris from the dirt outlets 306, 334 that
has been separated in the cyclonic chamber 30. Specifically, the
dirt collection region 38 receives debris separated by the primary
cyclonic stage 314 at the dirt outlet 306 and receives debris
separated by the secondary cyclonic stage 318 at the dirt outlet
334. In the illustrated embodiment, the dirt collection region 38
includes an expanded portion 346. The dirt collection region 38
includes a bottom door 350 that is openable to empty out the dirt
collection region 38. In particular, a latch 354 secures the door
350 in a closed position and the latch 354 is actuated to pivot the
door 350 about a pivot 358 to an open position.
[0042] With reference to FIG. 7, the cyclonic separator assembly 26
further includes a pre-motor filter 362 in the fluid flow path
downstream from the cyclonic chamber 30 and upstream from the motor
assembly 114. Specifically, the pre-motor filter 362 includes an
upstream surface 366 facing the cyclonic clean fluid outlet 310 and
a downstream surface 370 opposite the upstream surface 366. The
pre-motor filter 362 is positioned within a filter chamber 374
downstream of the cyclonic clean fluid outlet 310. In the
illustrated embodiment, the motor rotational axis 126 and the
separator axis 34 intersect at or below the pre-motor filter 362.
The filter chamber 374 further includes a screen 378 and a
plurality of ribs 382 positioned between the screen 378 and the
pre-motor filter 362.
[0043] With continued reference to FIG. 7, a plenum 386 is in the
fluid flow path immediately upstream from the motor assembly 114.
In the illustrated embodiment, the plenum 386 is positioned within
the main body 22 and is immediately downstream of the pre-motor
filter 362 and the screen 378. In other words, the screen 378 is
positioned between the pre-motor filter 362 and the plenum 386. The
plenum 386 is funnel-shaped and may be referred to as a bell-mouth
plenum. The plenum 386 directs the airflow from the pre-motor
filter 362 to an inlet 390 to the motor assembly 114. The inlet 390
to the motor assembly 114 is open and the screen 378 is positioned
upstream and spaced from the open motor inlet 390. In some
embodiments, the fluid flow path through the plenum 386 includes a
volumetric flow rate of at least 20 cubic feet per minute (CFM)
measured at the suction inlet (i.e., the inlet aperture 226). The
plenum 386 includes a wall portion 394 facing the downstream
surface 370 of the pre-motor filter 362. A cavity 398 is formed
between the plenum 386 and the main body 22.
[0044] With continued reference to FIG. 7, the handheld vacuum
cleaner 10 further includes a sensor 402 operable to measure a
characteristic of the fluid flow path (e.g., air pressure,
volumetric air flow rate, etc.). In the illustrated embodiment, the
sensor 402 is positioned on the plenum 386. Specifically, the
sensor 402 is positioned on the wall portion 394 of the plenum 386
facing the downstream surface 370 of the pre-motor filter 362. In
other words, the sensor 402 is positioned within the cavity 398,
with at least a portion of the sensor 402 in fluid communication
with the airflow within the plenum 386 via an aperture 406 formed
in the plenum 386. In alternative embodiments, the sensor 402 may
be positioned in a different location along the air flow path.
Additionally, more than one sensor 402 may be utilized to measure
one or more air flow characteristics. As described in greater
detail below, the measurements from the sensor 402 are utilized to
control the handheld vacuum cleaner 10.
[0045] With reference to FIG. 9, a schematic of an information
transmission system 408 is illustrated. The information
transmission system 408 includes the vacuum controller 410 (e.g.,
microprocessor, etc.), the sensor 402, and a transmitter 414. As
explained in greater detail below, the handheld vacuum cleaner 10
includes the transmitter 414, which is electrically coupled to the
controller 410, and the transmitter 414 is operable to transmit a
wireless communication signal (e.g., via radio signal, Wi-fi.RTM.,
Bluetooth.RTM., or any other wireless internet or network
communication) providing information to a personal device 418 of a
user. Specifically, the personal device 418 includes a device
controller 426, a receiver 430 electrically coupled to the device
controller 426, and a display 434 electrically coupled to the
controller 426. In particular, the receiver 430 is configured to
receive the information transmitted by the transmitter 414, and the
display 434 is configured to provide a display to the user in
response to the information. For example, the vacuum controller 410
monitoring the sensor 402 may provide an alert to the visual
indicator 422 and to the personal device 418 through the
transmitter 414 if the sensor indicates that the filter needs
maintenance or if the system has a clog. In some embodiments, the
personal device 418 is a cell phone. In other embodiments, the
personal device 418 is a personal computer.
[0046] With reference to FIG. 8, the cyclonic separator assembly 26
is removable from the main body 22. In particular, the inlet nozzle
42, the cyclonic chamber 30, and the dirt collection region 38 are
removed as a single unit when the cyclonic separator assembly 26 is
removed from the main body 22. In other words, the dirty air inlet
14 and the cyclonic chamber 30 are part of the cyclonic separator
assembly 26. A release actuator 438 is configured to release the
cyclonic separator assembly 26 from the main body 22 when actuated
by a user. In the illustrated embodiment, the release actuator 438
is positioned on and accessible from the bottom 94 of the main body
22. In addition, the actuator 438 is positioned between the
cyclonic separator assembly 26 and the battery 138. Specifically,
the actuator 438 is positioned between the expanded portion 346 of
the dirt collection region 38 and the battery 138.
[0047] With reference to FIGS. 4 and 8, the release actuator 438 is
movable between a locking position (FIG. 4) that prevents removal
of the cyclonic separator assembly 26 from the main body 22, and a
released position (FIG. 8) that allows removal of the cyclonic
separator assembly 26 from the main body 22. Movement of the
actuator 438 between the locking position and the released position
is along an actuation axis 442. In the illustrated embodiment, the
actuation axis 442 is parallel to the battery insertion axis 158.
Specifically, the actuator 438 includes a user-actuated portion 446
and a locking portion 450 that engages the cyclonic separator
assembly 26 when the actuator 438 is in the locking position (FIG.
4). In particular, the locking portion 450 engages a corresponding
hook portion 454 formed on the cyclonic separator assembly 26 when
the actuator 438 is in the locking position. In addition, the
locking portion 450 includes an inclined surface 458 such that when
the cyclonic separator assembly 26 is being coupled to the main
body 22, the hook portion 454 on the cyclonic separator assembly 26
engages the inclined surface 458 to move the actuator 438 to the
released position. A spring 562 is positioned between the actuator
438 and the main body 22 to bias the actuator 438 toward the
locking position.
[0048] With continued reference to FIG. 8, a lip 466 is formed on
the main body 22 and the inlet nozzle 42 includes a corresponding
notch 470. In alternative embodiments, the lip is formed on the
inlet nozzle 42 and the corresponding notch is formed on the main
body 22. In the illustrated embodiment, the lip 466 is received
within the notch 470 when the cyclonic separator assembly 26 is
coupled to the main body 22. In particular, the cyclonic chamber 30
is positioned between the lip 466 and the actuator 438 when the
cyclonic separator assembly 26 is coupled to the main body 22. The
lip 466 and the notch 470 define a pivot axis 474 about which the
cyclonic separator assembly 26 is configured to pivot with respect
to the main body 22. To secure the cyclonic separator assembly 26
to the main body 22, the lip 466 is inserted into the notch 470 to
provide support of the cyclonic separator assembly 26 at the top 90
of the main body 22. Then, the cyclonic separator assembly 26 is
pivoted about the axis 474 toward the main body 22 until the
actuator 438 securely engages with the hook portion 454 formed on
the cyclonic separator assembly 26. Likewise, to remove the
cyclonic separator assembly 26, a user depresses the user-actuated
portion 446 of the actuator 438 to release the hook portion 454.
Once released, the cyclonic separator assembly 26 pivots about the
axis 474 away from the main body 22 and then the notch 470 is
separated from the lip 466 on the main body 22. When the cyclonic
separator assembly 26 is removed from the main body 22, the
downstream surface 370 of the pre-motor filter 362 is exposed on
the cyclonic separator assembly 26 and the screen 378 is exposed on
the main body 22.
[0049] With continued reference to FIGS. a seal 478 is made between
the main body 22 and the cyclonic separator assembly 26 when the
cyclonic separator assembly 26 is coupled to the main body 22. In
the illustrated embodiment, the seal 478 is the only seal made
between the cyclonic separator assembly 26 and the main body 22,
thereby minimizing the potential for leaks. Compression of the
pre-motor filter 362 forms the seal 478 between the main body 22
and the cyclonic separator assembly 26. In particular, the
pre-motor filter 362 includes a circumferential face or flange 482
around an outer periphery of the pre-motor filter 362 that is
compressed to form the seal 478. The main body 22 may include a
corresponding protrusion 486 (e.g., an annular rib) that engages
the flange portion 482 of the pre-motor filter 362 when the
cyclonic separator assembly 26 is coupled to the main body 22. In
other words, the annular rib 486 compresses the face or flange 482
on the pre-motor filter 362 to create an air-tight seal between the
cyclonic separator assembly 26 and the main body 22. The face or
flange 482 may include an elastomeric surface integral with the
filter 362 forming the contacting surface to the main body.
[0050] With reference to FIGS. 5A-5B, the battery receptacle 150
includes a latch 490 moveable between a blocking position (FIG. 5A)
that prevents removal of the battery 138 from the receptacle 150,
and a released position (FIG. 5B) that allows removal of the
battery 138 from the receptacle 150. The latch 490 is a single
integrally molded part. In other words, the latch 490 elastically
deforms to move between the blocking position (FIG. 5A) and the
released position (FIG. 5B). In the illustrated embodiment, the
latch 490 flexes between the blocking position and the released
position as a cantilever. The latch 490 includes a user-actuated
portion 494 and a locking portion 498 that engages the battery 138
when the latch 490 is in the blocking position. Specifically, the
locking portion 498 abuts a surface 502 of the battery 138 when the
latch 490 is in the blocking position.
[0051] In addition, the latch 490 includes a fixed connection 506
secured to the main body 22. The locking portion 498 of the latch
490 is positioned between the fixed connection 506 and the
user-actuated portion 494. More specifically, the locking portion
498 includes a connecting portion 510 extending to the fixed
connection 506. In the illustrated embodiment, the connecting
portion 510 is wave-shaped. The connecting portion 510 deforms when
the latch 490 moves between the blocking and released portions.
Optionally, the latch 490 also includes a spring 514 formed
integrally with the latch 490 (e.g., an integrally molded spring)
that pushes the latch 490 toward the blocking position. The spring
514 contacts the main body 22 pressing the latch 490 toward the
blocking position. Additional springs, such as a spring 518
(separate from the latch 490) may be positioned between the latch
490 and the main body 22 to further position the latch 490 toward
the blocking position. As such, the connecting portion 510, the
spring 514, and the spring 518 each urge the latch 490 toward the
blocking position.
[0052] With continued reference to FIG. 5A, the battery receptacle
150 further includes an eject assist assembly 522 that presses the
battery 138 away from the electrical contacts 202 and out of a
position engagable by the locking portion 498. In other words, the
eject assist assembly 150 aids in the removal of the battery 138
from the receptacle 150 when the battery 138 is released from the
main body 22. In particular, the eject assist assembly 522 includes
an ejector 526 (e.g., an elastomeric cover) and a spring 530 that
pushes the ejector 526 toward the receptacle 150. The ejector 526
is configured to extend into the receptacle 150 when the battery
138 is removed from (i.e., not positioned completely within) the
receptacle 150. As such, when the user actuates the latch 490 to
release the battery 138, the ejector 526 pushes the battery 138 out
of a position engagable by the locking portion 498 so that the user
can remove the unlatched battery.
[0053] With continued reference to FIG. 5B, the battery receptacle
150 and the battery 138 are coupled together upon insertion of the
battery 138 in the receptacle 150 by a tongue and groove connection
534. One of the fourth surface 198 and the second surface 190 is
coupled to the main body 22 with the tongue and groove connection
534 when the battery 138 is positioned within the receptacle 150.
In the illustrated embodiment, the second surface 190 of the
battery 138 includes a tongue 538 of the tongue and groove
connection 534, and the first wall 166 of the receptacle 150
includes a corresponding groove 542 of the tongue and groove
connection 534. In alternative embodiments, the tongue is
positioned on the receptacle 150 and the groove is positioned on
the battery 138.
[0054] In addition, the battery 138 includes a ramp 546 that moves
the latch 490 from the blocking position to the released position
when the battery 138 is inserted into the receptacle 150. In other
words, when the battery 138 is inserted into the receptacle 150,
engagement of the locking portion 498 with the ramp 546 causes the
latch 490 to deflect to the released position (FIG. 5B) until the
battery 138 is fully inserted. Once the battery 138 is fully
inserted into the receptacle 150, the latch 490 is biased back into
the locking state (FIG. 5A) by at least the spring 514, the spring
518, or the connecting portion 510.
[0055] Actuation of the user-actuated portion 494 deflects the
locking portion 498 to the released position (FIG. 5B). In
particular, the user-actuated portion 494 of the latch 490 is
constrained by the main body 22 to translate along a single axis
550 only. When the user-actuated portion 494 is translated along
the axis 550, in one example sliding in a direction away from the
battery, the remaining portions of the latch 490 elastically deform
or deflect such that the locking portion 498 is moved to the
released position. In the released position (FIG. 5B), the locking
portion 498 is spaced from the surface 502 on the battery 138
disengaged from the battery. In some embodiments, the single axis
550 is transverse to the direction of the battery insertion axis
158. In other embodiments, the single axis 550 is generally along
the battery insertion axis 158, in which case the user-actuated
portion of the latch is pulled toward the user. Once released, the
eject assist assembly 522 at least partially ejects the battery 138
from the receptacle 150 and the user is able to remove the battery
138 completely from the receptacle 150. Various latch shapes may be
configured to provide elastic deformation causing the locking
portion to move to the released position when the user-actuated
portion is moved in a direction desired for the application.
[0056] With reference to FIGS. 11-13, the handheld vacuum cleaner
10 is operable with a cleaning attachment. Specifically, the inlet
nozzle 42 is selectively coupled to the cleaning attachment. In the
illustrated embodiment, the cleaning attachment is a surface
cleaning attachment 554 with a rigid wand 558 having an end 562
mounted to the dirty air inlet 14 and an opposed end 566 mounted on
a surface cleaning head 570. The wand 558 is linear and defines a
wand axis 574. The wand axis 574 is collinear with the inlet axis
46. As described above, the bottom door 350 of the cyclonic
separator assembly 26 is openable, even when the wand 558 is
mounted to the dirty air inlet 14. In alternative embodiments, the
handheld vacuum cleaner 10 is coupled to alternative cleaning
attachments (e.g., extension wands, mini surface cleaning heads,
crevice tools, etc.).
[0057] With reference to FIG. 12, the handheld vacuum cleaner 10
may be stored with the surface cleaning attachment 554 in an
upright, stored position. With reference to FIG. 13, the separator
axis 34 is vertical when the handheld vacuum cleaner 10 is attached
to the surface cleaning attachment 554 and oriented in an inclined,
in-use position. Since the separator axis 34 is vertical when the
handheld vacuum cleaner 10 is in the in-use position (FIGS. 4 and
13), the effectiveness of the cyclonic chamber 30 during use (i.e.,
operation) is improved. In other words, operation of the cyclonic
chamber 30 is improved when the separator axis 34 remains vertical
during use (i.e., when the handheld vacuum cleaner 10 is being used
as a handheld (FIG. 4), or with a surface cleaning attachment 554
(FIG. 13)).
[0058] With continued reference to FIGS. 1 and 12, the inlet nozzle
42 includes the electrical connection 286 proximate the dirty air
inlet 14. The electrical connection 286 provides electrical power
to the cleaning attachment. In the illustrated embodiment, the
electrical connection 286 provides electrical power to rotate a
brushroll 578 positioned within the surface cleaning head 570. In
alternative embodiments, the electrical connection 286 may provide
electrical power to a light, sensor, or other electrical components
in the cleaning attachment.
[0059] In the embodiment illustrated in FIG. 3, the trigger 100
actuates a micro-switch in electrical communication with the vacuum
controller 410. Upon user activation of the trigger 100, the
micro-switch provides an electrical output to the controller 410
signaling for the controller to activate the vacuum. The vacuum
controller may be configured to provide power while the user holds
the trigger against the micro-switch. In one embodiment, the
controller 410 is programmed to identify two actuations of the
trigger within a short period, for example, two actuations of the
trigger within 1 second, or 1.5 second, or 2 second, indicating a
double tap of the trigger. When the vacuum controller receives a
double tap of the trigger, the vacuum controller provides power
without the user holding the trigger, remaining on until the user
actuates the trigger again.
[0060] As such, the controller 410 includes instructions for a
method of controlling the handheld vacuum cleaner 10 that includes
monitoring a user activated switch (i.e., the trigger 100 and/or
the micro-switch), and activating the motor 118 providing airflow
along the fluid flow path while the user activated switch is
activated. The method further includes determining when the user
activated switch is activated by a user twice within a
predetermined period of time (i.e., 1 second, 1.5 seconds, 2
seconds, etc.), and continuously activating the motor without
further activation of the user activated switch upon determining
the user activated switch has been activated twice within the
predetermined period of time. The method further includes
deactivating the motor 118 upon the next activation of the user
activated switch. In other words, when the user activated switch is
activated twice in the predetermined period of time, the motor 118
will operate continuously until the user activates the user
activated switch a third time.
[0061] In operation, upon user activation of the trigger 100, the
battery 138 provides power to the motor 118 to rotate the fan 130,
generating a suction airflow drawn through the inlet nozzle 42
along with debris. The airflow, entrained with debris, travels into
the cyclonic chamber 30 where the airflow and debris rotate about
the separator axis 34. Rotation of the airflow and debris in the
primary cyclonic stage 314 causes the debris to separate from the
airflow and the debris is discharged through the dirt outlet 306.
The separated debris then falls from the dirt outlet 306 into the
dirt collection region 38. The clean air travels through the
perforated shroud 322 into the secondary cyclonic stage 318 where
debris is separated from the airflow and the debris is discharged
through the dirt outlet 334 into the dirt collection region 38. The
clean airflow then travels through the cyclonic clean air outlet
310 to the filter chamber 374, where the airflow then travels
through the pre-motor filter 362. Downstream of the pre-motor
filter 362 the airflow is routed by the plenum 386 to the input 390
to the motor assembly 114. After traveling through the motor
assembly 114, the airflow is exhausted from the handheld vacuum
cleaner 10 through the clean air outlet 18 formed in the main body
22.
[0062] After using the handheld vacuum cleaner 10, the user can
open the door 350 to empty the dirt collection region 98. After
several uses, debris may have collected on, for example, the shroud
322 or generally within the cyclonic chamber 30. If so, the user
can remove the cyclonic separator assembly 26 from the main body 22
by depressing the actuator 438. Removing the cyclonic separator
assembly 26 from the main body 22 provides improved access to the
cyclonic chamber through either the filter chamber 374 or the
bottom door 350.
[0063] As described above, the sensor 402 measures a characteristic
of the airflow and is used in a method 582 of controlling the
handheld vacuum cleaner 10 (FIG. 10). The method 582 includes
measuring a pressure value of the airflow through the fluid flow
path (step 586). Specifically, measuring the pressure value of the
airflow is measured downstream of the pre-motor filter 362, within
the plenum 386. The method 582 also includes determining whether
the pressure value exceeds a predetermined threshold, which is
indicative of a clog within the fluid flow path (step 590). When
the pressure value exceeds the predetermined threshold, the method
582 includes alerting a user of the vacuum cleaner (step 594).
Alerting the user at step 594 includes transmitting an alert to the
personal device 418 (e.g., cell phone, personal computer, etc.) of
the user and, optionally, providing to the personal device
information identifying to the user a plurality of possible clog
locations along the fluid flow path on the display 434. In some
embodiments, transmitting an alert to the personal device 418 is
transmitted with direct vacuum-to-device wireless data
communication (e.g., Wi-Fi.RTM., Bluetooth.RTM., or other radio
signal). In other embodiments, transmitting an alert to the
personal device 418 is transmitted via wired or wireless internet
or network communication. The alert also includes instructions for
the user to clean the possible clog locations along the fluid flow
path to remove the clog, which are illustrated on the device
display 434. Alerting the user further includes activating the
visual indicator 422 positioned on the handheld vacuum cleaner 10.
In some embodiments, the method 582 may further include the step of
disabling the airflow through the fluid flow path when the pressure
value exceeds the predetermined threshold. In some embodiments, the
controller 426 is executing instructions in the form of an
application program (a.k.a. an app), which enables the user to
interface with the handheld vacuum cleaner 10 through the display
434.
[0064] Various features and advantages of the invention are set
forth in the following claims.
* * * * *