U.S. patent application number 17/216137 was filed with the patent office on 2021-07-15 for replacement head for a vacuum.
The applicant listed for this patent is SharkNinja Operating LLC. Invention is credited to Michael DOUGLAS, Richard MATHIAS, Brandon J. SULESKI.
Application Number | 20210212536 17/216137 |
Document ID | / |
Family ID | 1000005482185 |
Filed Date | 2021-07-15 |
United States Patent
Application |
20210212536 |
Kind Code |
A1 |
MATHIAS; Richard ; et
al. |
July 15, 2021 |
Replacement Head for a Vacuum
Abstract
A replacement head for a vacuum device includes a plastic tray,
a filter and a pad. The plastic tray includes a dust chamber and a
front guard portion. An opening is provided that allows air, dust
and debris to be drawn into the dust chamber during use. The front
guard portion preferably has at least a portion that has a
triangular cross-sectional shape and defines an interior space. The
pad is attached to the lower side of the plastic tray and is in
contact with the floor during cleaning. The filter is connected to
the plastic tray such that the filter substantially covers a top
opening in the dust chamber.
Inventors: |
MATHIAS; Richard; (Needham,
MA) ; SULESKI; Brandon J.; (Cambridge, MA) ;
DOUGLAS; Michael; (London, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SharkNinja Operating LLC |
Needham |
MA |
US |
|
|
Family ID: |
1000005482185 |
Appl. No.: |
17/216137 |
Filed: |
March 29, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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16670319 |
Oct 31, 2019 |
10959584 |
|
|
17216137 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47L 9/066 20130101;
A47L 9/0626 20130101; A47L 9/0666 20130101; A47L 9/0673 20130101;
A47L 9/122 20130101 |
International
Class: |
A47L 9/06 20060101
A47L009/06; A47L 9/12 20060101 A47L009/12 |
Claims
1. A replacement head, comprising: a plastic tray that includes a
dust chamber defining a top opening bounded by a sealing surface,
the dust chamber also having a bottom wall, a front wall, a rear
wall, a left wall and a right wall, the bottom wall of the dust
chamber defining an exterior bottom surface; an opening that
extends through at least one of the walls into the dust chamber; a
pad having at least one layer of material, the pad defining a first
surface and a second surface, the first surface being connected to
bottom wall of the plastic tray and the second surface generally
facing away from the first surface; and a filter connected to the
plastic tray such that the filter substantially covers the top
opening; wherein the plastic tray includes a front guard portion
that integrally formed with the plastic tray and has a bottom
surface that has a lowest point that is closer to the second
surface of the pad than the sealing surface.
2. The replacement head of claim 1, wherein at least one portion of
the front guard portion has a cross-sectional shape that is
generally triangular.
3. The replacement head of claim 2, wherein substantially all of
the front guard portion has a cross-sectional shape that is
generally triangular.
4. The replacement head of claim 1, wherein the front guard portion
defines at least one interior space located below the sealing
surface and adjacent the dust chamber.
5. The replacement head of claim 4, wherein at least a portion of
the sealing surface extends between the front guard portion and the
top opening.
6. The replacement head of claim 1, wherein the front guard portion
extends in front of at least a portion of the opening.
7. The replacement head of claim 6, wherein the front guard portion
extends to a position outside one side of the opening.
8. The replacement head of claim 7, wherein the front guard portion
extends to a position outside of both sides of the opening.
9. The replacement head of claim 1, wherein the front guard portion
includes at least one castellation.
10. The replacement head of claim 9, wherein the front guard
portion includes at one castellation located directly in front of
the opening.
11. The replacement head of claim 9, wherein the front guard
portion includes at least two castellations.
12. The replacement head of claim 10, wherein the front guard
portion includes at least three castellations.
13. The replacement head of claim 1, wherein the front guard
portion is integrally formed with the dust chamber.
14. The replacement head of claim 1, wherein the front guard
portion includes at least one hole that extends through the front
guard portion.
15. The replacement head of claim 1, wherein the front guard
portion is located forward of the entire pad.
16. The replacement head of claim 1, wherein the front guard
portion is located forward of the entire filter.
17. The replacement head of claim 1, wherein the front guard
portion is located forward of the dust chamber.
18. The replacement head of claim 1, wherein a front suction
chamber is located between the front guard portion and the dust
chamber.
19. The replacement head of claim 1, wherein the pad includes at
least a first and a second layer, the first and second layers of
the pad being ultrasonically welded together.
20. The replacement head of claim 19, wherein the ultrasonic weld
is generally continuous along at least one edge of the pad.
21. The replacement head of claim 19, wherein at least one edge of
the pad has at least two localized weld locations that are spaced
apart from one another.
22. The replacement head of claim 1, wherein the front guard
portion defines an interior space that includes a wall that is
least partially substantially vertical.
23. The replacement head of claim 22, wherein the vertical wall is
located on the side of the interior space that is closest to the
dust chamber.
24. The replacement head of claim 22, wherein the ultrasonic weld
is positioned away from the edge of the pad.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/670,319 filed on Oct. 31, 2019, entitled
"Replacement Head for a Vacuum," which is hereby incorporated
herein by reference in its entirety.
FIELD
[0002] The present disclosure relates generally to replacement
heads for cleaning devices, and more specifically to replacement
heads for certain vacuum devices.
BACKGROUND
[0003] Hardfloor cleaning can be challenging when there are a
variety of mixed media debris present. In some instances, there is
a desire to both vacuum dry, loose debris, scrub stuck debris and
absorb any wet debris that may be present. Prior art tools, such as
vacuums, dry mops and wet mops are capable of handling some of
these types of media, but not all at once. As a result, many often
sweep dry debris before mopping wet or stuck-on debris.
[0004] Known tools that can handle both dry and wet media have
higher set-up times than a broom/mop combination and the after-use
maintenance can be especially high when liquids are involved. If
the combination tool is not properly cleaned after each use, they
can become smelly and unpleasant. Lastly, clean up can be quite
messy and the user may be required to either dirty his or her hands
and/or wear gloves.
[0005] Therefore, an improved hardfloor cleaner that can be easily
attached and detached to a vacuum device with minimal effort and
mess is desired.
SUMMARY
[0006] According to one aspect of the invention, the replacement
head includes a filter, a plastic tray and a pad. The plastic tray
includes a dust chamber, and a front guard portion. The dust
chamber defines a top opening bounded by a sealing surface. The
dust chamber also has a bottom wall, a front wall, a rear wall, a
left wall and a right wall. The bottom wall of the dust chamber
defines an exterior bottom surface. An opening extends through at
least one of the walls (preferably, the front wall) into the dust
chamber just behind the front guard portion. The pad includes at
least one layer of material and defines a first surface and a
second surface. The first surface is connected to bottom wall of
the plastic tray and the second surface generally faces away from
the first surface. The filter is connected to the plastic tray such
that the filter substantially covers the top opening. The front
guard portion is integrally formed with the plastic tray and has a
bottom surface that has a lowest point that is closer to the second
surface of the pad than the sealing surface
[0007] According to another aspect of the invention, at least one
portion of the front guard portion has a cross-sectional shape that
is generally triangular.
[0008] According to a further aspect of the invention, the front
guard portion defines at least one interior space located below the
sealing surface and adjacent the dust chamber.
[0009] According to an even further aspect of the invention, the
front guard portion extends in front of at least a portion of the
opening and, in some embodiments, extends to the outside of one or
both sides of the opening.
[0010] According to an even further aspect of the invention, the
front guard portion includes at least one castellation.
[0011] One advantage of the present invention is that the user can
easily remove and replace a soiled replacement head with a fresh
replacement head in a short amount of time with very little
mess.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows an isometric view of a vacuum device and
replacement head of the present invention;
[0013] FIG. 2 shows an isometric view of the vacuum device and
replacement head of FIG. 1 separated from one another;
[0014] FIG. 3 shows a cross-sectional view of FIG. 1 along line 3-3
showing the vacuum head and replacement head attached and with
connector arms in the locked position;
[0015] FIG. 3A shows a cross-sectional view of FIG. 1 along line
3A-3A showing the vacuum head and replacement head attached and
with a connector arm in the open position;
[0016] FIG. 4 shows an isometric view of the replacement head of
the present invention;
[0017] FIG. 5 shows an isometric view of the replacement head of
FIG. 4 from a different angle;
[0018] FIG. 6 shows an isometric view of the plastic tray of the
present invention;
[0019] FIG. 7 shows a front view of the plastic tray of the present
invention;
[0020] FIG. 8 shows a rear view of the plastic tray of the present
invention;
[0021] FIG. 9 shows a side view of the plastic tray of the present
invention;
[0022] FIG. 10 shows a bottom view of the plastic tray of the
present invention;
[0023] FIG. 11 shows a top view of the plastic tray of the present
invention;
[0024] FIG. 12 shows a cross-sectional view of FIG. 4 along line
12-12 depicting the opening cover in a closed position;
[0025] FIG. 12A shows a cross-sectional view of FIG. 4 along line
12A-12A depicting the opening cover in an open position;
[0026] FIG. 13 shows an enlarged front view of one side of the
replacement head;
[0027] FIG. 14 shows a cross-sectional view of FIG. 4 along line
14-14 depicting the shape of the first connector lip;
[0028] FIG. 15 shows a cross-sectional view of FIG. 1 along line
15-15 depicting the interaction between the vacuum head and the
front guard of the plastic tray;
[0029] FIG. 16 shows an exploded view of one embodiment of the pad
of the present invention;
[0030] FIG. 17 shows a perspective view of the underside of the
plastic tray in an embodiment where the front guard portion does
not have castellations;
[0031] FIG. 18 shows a top view of one embodiment of the present
invention where the front guard portion includes openings; and
[0032] FIG. 18A is a cross-sectional view of FIG. 18 along line
18A-18A.
DETAILED DESCRIPTION OF THE INVENTION
[0033] FIGS. 1 and 2 illustrate a perspective view of a vacuum
device 2 and a replacement head 4 that can be selectively attached
and detached. The vacuum device 2 includes a handle 6, a vacuum
body 8 that includes a suction source (not visible), a vacuum head
10, and a trigger 11 for selectively activating the suction source.
The vacuum device 2 may also include a container for holding a
fluid (e.g., a cleaning fluid), a jet nozzle 12 and a
user-activated button 14 to selectively spray the fluid from the
jet nozzle 12. The jet nozzle 12 is preferably aimed to spray fluid
from the jet nozzle 12 to a position in front of the replacement
head 4 when the button 14 is activated by the user during normal
use. Referring now to FIGS. 3 and 3A, the vacuum head 10 includes a
vacuum sealing surface 16 and at least two connector arms 18, 20.
In the embodiment shown, at least one the connector arms 18 are
movable between a closed position (FIG. 3) and an open position
(FIG. 3A).
[0034] Referring now to FIGS. 4-6, the replacement head 4 includes
a plastic tray 22, a pad 24, and a filter 26. The plastic tray 22
includes a dust chamber 28, a sealing surface 30 (see e.g., FIG. 6)
and a front guard portion 40.
[0035] The plastic tray 22 can be made of any suitable material
(including non-plastics); however, materials that are inexpensive
and readily disposable are preferred. For example, polyethylene
terephthalate (or "PET") is considered a preferred material, in
part, because PET is inexpensive and is readily thermoformed to the
desired shape. Injection molding, blow molding or any other common
manufacturing processes would also be acceptable and appropriate
alternatives. As shown, the plastic tray 22 can be formed of a
single, unitary piece, or can be comprised of two or more parts
that are connected or joined during the assembly of the replacement
head 4.
[0036] The plastic tray 22 as shown in FIGS. 6-12 includes a dust
chamber 28 that is sized and shaped to collect and retain dust and
debris that is suctioned into the plastic tray 22 during use. In
the embodiment shown, the dust chamber 28 has a bottom wall 34, a
front wall 36, a rear wall 38, a left wall 40, and a right wall 42.
At the top of the dust chamber 28 is a top opening 46. Together,
the walls and the top opening 46 generally define a volume of space
capable of collecting and retaining common household dust and
debris. One of skill in the art would understand that varying the
size and shape of the walls and top opening 46 would increase or
decrease the overall volume of the dust chamber without departing
from the spirit of the invention. Although the rear wall 38, and
left and right walls 40, 42 are shown as generally straight in
FIGS. 9 and 10, the walls can include at least one curve or bend,
or include other features that make them not straight. For example,
the front wall 36, as shown in FIG. 10, includes a series of curves
and features. The curves and bends, among other benefits, increase
the structural stability without increasing the thickness of the
material. The bottom wall 34 defines a bottom surface 48 and may
include ridges 50 (see FIGS. 8 and 10) to assist with retaining
dust in place that has collected at the bottom of the dust chamber
28 during use. Alternatively, the bottom wall 34 can be generally
flat.
[0037] Referencing now to FIGS. 3, 3A, 6 and 11, a sealing surface
30 extends circumferentially around the top opening 46 of the
plastic tray 28. The sealing surface 30 is complementary to a
vacuum sealing surface 16 on the vacuum head 10. The sealing
surface 30 and the vacuum sealing surface 16 are either directly or
(preferably) indirectly in contact with one another during use. In
a preferred embodiment, where the sealing surface 30 and the vacuum
surface 16 are indirectly in contact, the filter 26 may be
sandwiched therebetween during use (see e.g., FIG. 3). To
facilitate an effective seal that prevents a loss of suction during
use, the sealing surface must be held in place with sufficient
enough force against the vacuum sealing surface. In the embodiment
shown, the sealing surface is a generally rectangular ring with a
generally flat surface. The term generally rectangular is intended
to describe a shape with a width greater than a length. However,
the shape is not intended to be limited to a precise rectangle. For
example, as shown in e.g., FIG. 10, the generally rectangular shape
includes corners that are rounded. Other embodiments could have
chamfered corners, or non-straight sidewalls.
[0038] Referring to FIGS. 5, 10 and 11, at least one opening 52
exists that enables air, dust and debris to be drawn in from a
position outside the replacement head 4 into the dust chamber 28
during use. In a preferred embodiment, a single rectangular-shaped
opening 52 is located on the front wall 36 of the dust chamber 28.
One of skill in the art would understand that alternative
embodiments, although not shown, could include: multiple openings
on a single wall; an opening that extends over two or more adjacent
walls; at least opening on one wall, and another opening on another
wall; or any combination of the above alternatives.
[0039] The opening 52 is preferably covered by an opening cover 54.
The opening cover 54 can be made of any suitable material; however,
in a preferred embodiment the material is either spunbond
polypropylene, 1.25 oz and extruded PET, 0.7 Mil, or 80 gsm
spunbond PP. Preferably, the opening cover 54 is a cantilevered
flap that, when open (FIG. 12A), permits air, dust and debris to
enter into the dust chamber and, when closed (FIG. 12), generally
covers the opening 52 to retain collected dust and debris within
the dust chamber 28. While the cantilevered flap described above is
a cost-effective solution, alternatives can include, for example,
an opening cover 54 that is made of plastic or metal. The opening
cover 54 is, preferably, attached to the underside of the filter
26. However, although not shown, the opening cover 54 can, for
example, be attached to the plastic tray. In addition, while the
preferred embodiment generally relies on the flexibility and
resiliency of the opening cover 54 material employed, the opening
cover 54 can also employ a hinge that defines a pivot axis, or a
living hinge.
[0040] In some embodiment, and now referring FIG. 5, the opening
may further include an opening rib 55. The opening rib 55 is
preferably integral with the dust chamber 28 and provides a stop
surface to prevent the opening cover 54 from becoming either stuck
in the opening 52 or from exiting the opening 52 during either
shipment or normal use.
[0041] Referring to FIGS. 7-11 and 13, the first connector lip 56
extends outwards from the left wall 40 of the dust chamber 28,
outside of the sealing surface 30. Also, at least a portion of the
first connector lip 56 is located between the front wall 36 and the
rear wall 38 of the dust chamber, as shown, e.g., in FIG. 11. The
first connector lip 56 includes a lower surface 58 that is located
below the sealing surface 30. More particularly, and as shown in
FIGS. 13 and 14, the lower surface 58 of the first connector lip 56
is located between the level of the sealing surface 30 and the
second surface 60 of the pad 24 (described in greater detail
below). Even more particularly, the lower surface 58 of the first
connector lip 56, in some embodiments, is closer to the sealing
surface 30 than the second surface 60 of the pad 24. The
cross-sectional shape of the first connector lip 56 may be of any
chosen by the designer. However, it is preferred, in order to
increase rigidity and reduce material, that the first connector lip
56 has a cross-sectional shape that includes at least one curve.
The actual relative positioning of the lower surface 58 of the
first connector lip 56 should be complementary to the design of the
of the vacuum head 10 and connector arms 18, 20. In the locked
position, as shown in FIG. 3, the connector arms 18, 20 of the
vacuum head engage with the lower surface 58 of the first connector
lip 56. When held in position by the connector arms 18, 20 of the
vacuum head 10, the sealing surface 30 of the replacement head 4 is
engaged with, either directly or indirectly, vacuum sealing surface
16.
[0042] In some embodiments, and now referring to FIGS. 10 and 11,
the first connector lip 56 may extend rearward of the rear wall 38
and/or further forward of the front wall 36. In even further
embodiments, the first connector lip 56 may extend forward of the
front guard 32 (described below). The first connector lip 56 may be
formed integrally with the other features of the plastic tray 22
(e.g., the dust chamber), or may be a separate element that is
combined with the remaining features of the plastic tray 22 prior
to end use.
[0043] Referring to FIGS. 7-11 and 13, the second connector lip 62
extends outwards from the right wall 42 of the dust chamber 28,
outside of the sealing surface 30. Also, at least a portion of the
second connector lip 62 is located between the front wall 36 and
the rear wall 38 of the dust chamber 28, as shown, e.g., in FIGS.
10 and 11. Similar to the first connector lip 56 shown in FIGS. 13
and 14, the second connector lip 62 includes a lower surface 64
that is located below the level of the sealing surface 30 (see
e.g., FIGS. 7 and 8). More particularly, the lower surface 64 of
the second connector lip 62 is located between the level of the
sealing surface 30 and the second surface 60 of the pad 24
(described in greater detail below). Even more particularly, the
lower surface 64 of the second connector lip 62, in some
embodiments, is closer to the sealing surface 30 than the second
surface 60 of the pad 24. The cross-sectional shape of the second
connector lip 62 may be of any chosen by the designer and may be
the same as, or different than, the first connector lip 56. It is
preferred that the second connector lip 62, for the same reasons
stated above, has a cross-sectional shape that includes at least
one curve. The relative positioning of the lower surface 64 of the
second connector lip 62 should be set such that it is complementary
to the design of the of the vacuum head 4 and connector arms 18,
20. In the locked position, as shown in FIG. 3, the connector arms
18, 20 of the vacuum head 4 engage with the lower surface 64 of the
first connector lip 56. When held in position by the connector arms
18, 20 of the vacuum head, the sealing surface 30 of the
replacement head 4 is engaged with, either directly or indirectly,
vacuum sealing surface 16.
[0044] In some embodiments, and now referring to FIGS. 10 and 11,
the second connector lip 62 may extend rearward of the rear wall 38
and/or further forward of the front wall 36. In even further
embodiments, the second connector lip 62 may extend forward of the
front guard 32 (described below). The second connector lip 62 may
be formed integrally with the other features of the plastic tray 22
(e.g., the dust chamber 28), or may be a separate element that is
combined with the remaining features of the plastic tray 28 prior
to end use. In some embodiments, the first and second connector
lips 56, 62 may be separate elements while, in other embodiments,
such as the embodiment shown in, e.g., FIG. 6, the first and second
connector lips 56, 62 may be interconnected across the front and/or
rear of the plastic tray 22.
[0045] Referring now to FIGS. 5, 7, 9 and 10, the plastic tray 22
can include a front guard portion 32 that is located at least
partially forward of the dust chamber 28. Preferably, the front
guard portion 32 is located directly in front of the opening 52 and
extends to a position outside of one or both sides of the opening
52. In the embodiment shown, the front guard portion 32 is located
forward of the dust chamber 28 and defines a shaped bottom surface
66, an interior space 68 and extends generally from the right side
of the plastic tray 22 to left side. The cross-sectional shape of
the front guard 32 can be any suitable shape; however, a generally
triangular cross-section (as shown in FIG. 9) has been shown to
have particular utility. The lowest portion of the bottom surface
66 is preferably in close proximity to the floor being cleaned to
assist in controlling the airflow into the dust chamber 28. In
other words, the bottom surface 48 is closer to the second surface
60 of the pad than the sealing surface 30.
[0046] In some embodiments, as shown in, e.g., FIGS. 5 and 7, it is
preferable that the front guard 32 includes one or more
castellations 70. While it is desirable for sections of the front
guard 32 to be in close proximity to the ground during the cleaning
process, the castellations 70 provide sections that permit larger
pieces of debris (e.g., pieces of cereal) to come into close
proximity to the opening 52 of the dust chamber 28 in order to be
drawn into the dust chamber 28. Castellations can be located in any
desired location on the front guard portion 32. Referring to, e.g.,
FIGS. 10-11, at least one castellation 70 is located directly in
front of the opening 52. In addition, castellations 70, as also
shown in FIGS. 10-11, can be located outside the outer edges of the
opening 52.
[0047] In other embodiments, such as the one shown in FIG. 17, the
front guard portion 32 may not have any castellations 70. In this
embodiment, the front guard portion 32 has a generally uniform
shape along substantially the entire length.
[0048] The interior space 68 of the front guard 32, as shown in
FIGS. 4 and 14, provides space to receive corresponding,
complementary features 72 on the vacuum head 10. Preferably, the
interior space 68 is located at an asymmetrical location on the
plastic tray 22 such that, if the replacement head 4 were to be
unintentionally reversed by the end user, the features on the front
of the vacuum head 10 would contact plastic tray material (e.g.,
the sealing ring 30), thus cueing the end user that the replacement
head 4 is being attached incorrectly. The vacuum head 10 may
include a single feature that enters the interior space 68 of the
front guard 32 during attachment, or, as shown in FIG. 3, may
include multiple features.
[0049] The interior space 68 is generally located below the sealing
surface 30 and adjacent the dust chamber 28. As shown in FIGS.
10-11, at least a portion of the sealing surface 30 extends between
the interior space 68 and the top opening 46 of the dust chamber
28. As noted above, the interior space 68 may be generally
triangular in shape. In these embodiments, the generally converging
walls of the interior space 68 function to assist the user to
position the vacuum head 10 into the proper attachment position by
urging the vacuum head either slightly forwards or backwards during
attachment.
[0050] Referring now to FIG. 9, the interior space 68 may have a
partial vertical wall 86 on the side closer to the dust chamber 28.
The partial vertical wall 86 can interact with features on the
vacuum head 10 to prevent motion relative to the vacuum head 10
during a pull-back stroke.
[0051] Located between the front guard portion 32 and the dust
chamber 28 is the front suction chamber 88. The front suction
chamber 88 extends across the plastic tray 22 from side to side.
The front suction chamber 88, as shown in FIG. 9, is bounded on the
front by the rear side of the front guard portion 32 and at the
rear by the front wall 36 of the dust chamber and the opening 52.
The size and shape can be determined by the designer; however, it
is preferable to shape the front suction chamber 88 in such a
manner to encourage airflow to direct dust, dirt towards the
opening(s) 52.
[0052] The filter 26 is made of a suitable material that will
permit air to pass therethrough during use, yet block at least a
substantial portion of the dust that is drawn into the dust chamber
28 during cleaning. In addition, it is desirable for the filter 26
to have the ability to absorb and/or block moisture prior to
entering the vacuum device 2. It is desirable to choose a material
that is inexpensive to manufacture, readily cut to size and easily
attachable to the plastic tray 22. In the embodiment shown, the
filter 26 is a non-woven, hydrophobic material made of SMS
Polypropylene, 40 gsm. In embodiments where the filter material is
printable, an additional printed pattern may appear on the filter
26 that includes, e.g., a logo or directions for use.
[0053] The filter 26 is attached to the plastic tray 22 such that
substantially the entire top opening 46 is covered, as shown in
FIG. 4. It is desirable that most, if not all, of the air that is
drawn into the dust chamber 28 during vacuuming passes through the
filter 26 prior to entering the vacuum device 2 so that the amount
of dust, debris and moisture that enters into, and therefore can
potentially damage, the suction source is minimized. The embodiment
shown in FIG. 3, the filter 26 is attached to the sealing surface
30 such that, when the replacement head 4 is attached to the vacuum
head 10, the filter 26 is sandwiched between the sealing surface 30
of the plastic tray 22 and the vacuum sealing surface 16. While it
is desirable for the filter 26 to cover substantially all of the
top opening 46 of the dust chamber 28, it is preferable that the
filter 26 does not cover interior space 68 of the front guard 32 so
that features 72 on the vacuum head 10 can enter into the interior
space 68 of the front guard 32 unimpeded during attachment. The
filter 26 may be attached to the plastic tray 22 in any acceptable
manner. Suitable methods include using heat to bond the materials
together, as well as the use of glues and adhesives. While it is
preferable that the filter 26 is attached in a permanent manner to
the plastic tray 22, other embodiments can have a removable
connection. Even further embodiments can include an end user
placing the filter 26 over the top opening 46 during use.
[0054] The pad 24 includes a first surface 74 and a second surface
60 and is made from any suitable material that, preferably, can be
used to scrub the surface being cleaned and/or absorb moisture.
Pads 24 are well-known in the art and can include one or more
layers. For example, a pad with a single layer made of 100% PET
material or Carded Spunlace PET, 58 gsm; Spunbond PP, 10 gsm may be
used. Or, as shown in FIG. 16, the pad 24 can include, e.g., four
layers that each provide utility (e.g., absorption, retention,
scrubbing). Exemplary layers include:
[0055] Layer 1: Air Laid Retention Layer; 180 gsm, 47% Pulp, 53%
Bico
[0056] Layer 2: Air Laid Acquisition Layer; 100 gsm, 47% Pulp, 53%
Bico
[0057] Layer 3: Face Layer; Carded Spunlace PET, 58 gsm; Spunbond
PP, 10 gsm
[0058] Layer 4: Multi-function Strip; Melt Blown PP, 35 gsm
[0059] Referring to FIGS. 4 and 5, a multi-layer pad 24 is shown.
In order to bond the various layers together, multiple methods are
shown. In FIG. 5, the layers are ultrasonically welded together in
a continuous manner along the entire edge. In certain embodiments,
additional welds can be made in the body of the filter, as shown in
a generally hexagonal pattern in FIG. 5. The continuous weld along
the front and rear edges tends to provide a suitable bond between
the layers to prevent delaminating. In FIG. 4, tack welding at
localized positions along the front and rear edges is shown. In
some embodiments, a total of about eight (8) weld locations are
provided. In other embodiments, approximately about fifty (50) weld
locations has been found to work suitably well. In addition, and
still referring to FIG. 4, the spaced apart weld locations may be
positioned along the edge of the pad 24. In other embodiments, as
shown along the front edge of the pad in FIG. 4, the weld locations
may be set back. By welding the layers together in localized
positions, it has been shown that the welds maintain acceptable
attachment between the layers, but allow for some expansion
therebetween. The expansion between the welds has been found to
permit additional absorption of liquids during use. For example, in
some instances, where a continuously welded multi-layer pad might
tend to push an amount of water that is on the floor either in
front of or behind the vacuum device 2, an intermittently welded
pad may absorb the liquid due to slight delamination that can occur
between the welds. In embodiments where the welds are set back from
the edge of the pad 24, localized delamination can be increased
and, in certain circumstances, result in increased performance. The
number of welds and location of the welds between the front and
rear of the pad 24 can be the same, or different depending on the
discretion of the designer.
[0060] The outer shape of the pad 24 can be any suitable known to
one of skill in the art. As shown in FIG. 5, the pad 24 can be
generally rectangular. The first surface 74 of the pad 24 is
attached to the bottom surface 48 of the dust chamber 28 such that
the second surface 60 of the pad 24 material is in contact with the
floor during cleaning. Preferably, the first surface 74 of the pad
24 covers at least most of the bottom surface 48 of the dust
chamber 28 and, even more preferably, covers the entirety. The pad
24 may extend outward from the bottom surface 48 of the dust
chamber 28. As shown in FIGS. 4 and 5, the pad 24 extends rearward
and to the sides of the bottom surface 48 of the plastic tray 28.
Although it is acceptable for the pad 24 to extend forward of the
front wall 36 of the dust chamber 28, such an arrangement has the
potential to hinder usability by, e.g., blocking the opening 52 to
the dust chamber 28 and/or the potentially causing the pad 24 to
fold or buckle when the vacuum device 2 is pushed forward by the
user during cleaning.
[0061] The pad 24 can be attached in any suitable manner.
Preferably, the first surface 74 of the pad 24 is attached to the
bottom surface 66 of the dust chamber 28 in a permanent manner.
Suitable methods include using heat bonding or adhesives.
Alternatively, the pad 24 can be replaceable and attached in a
removable manner by, e.g., hook and loop fasteners.
[0062] In use, and now referring to FIGS. 1-3A, the end user moves
at least one of the connector arms 18, 20 of the vacuum head 10 to
the open position and places a replacement head 4 such that the
filter 26 material is sandwiched between the sealing surface 30 of
the plastic tray 22 and the vacuum sealing surface 16. The at least
one connector arm 18, 20 is then released such that the connector
arms engage the first and second connector lips 56, 62 on the
plastic tray, holding the replacement head 4 in place for use. The
user then activates the vacuum device 2, creating suction. The air
drawn into the dust chamber 28 causes the opening cover 54 to move
to an open position (as shown in FIG. 12A). As the user moves the
vacuum device 2 and replacement head 4 over the floor to be
cleaned, the suction source draws air, dirt and debris from the
area in front of the replacement head 4 under the front guard 32,
and through the opening 52 into the dust chamber 28. The air, dust
and debris, once inside the dust chamber 28, are then drawn towards
the filter 26 where the air passes through. The dust and debris are
not able to pass through the filter 26 and are retained in the dust
chamber 28. As desired, the user may activate the button 14 on the
vacuum device 2 to spray fluid onto the floor in front of the
replacement head 4. The user can then thoroughly clean the floor
using the second surface 60 of the pad 24 to scrub the floor with
cleaning fluid.
[0063] During the cleaning process, one or more of the following
will occur: the dust chamber 28 will fill with dust and debris, the
filter 26 will become clogged, and the pad 24 will become soiled.
The user, at any time, may selectively replace the replacement head
4 by moving at least one of the connector arms 18, 20 to the open
position, thereby releasing the first and second connector lips 56,
62 from engagement with the vacuum head 10. Advantageously, in the
embodiment described, the user can replace the entire replacement
head 4 all at once and replace with a refreshed replacement head 4
for future use with minimal mess.
[0064] Referring now to FIGS. 18 and 18A, an alternative embodiment
is shown where the front guard portion includes at least one
opening 90. In this embodiment, rather than having a substantially
enclosed interior space, the front guard has a front and bottom
surface that is cantilevered from the plastic tray. In such an
embodiment, the features from the vacuum head extend into the
opening 90 to ensure proper orientation during use.
[0065] One of skill in the art would know that additional
embodiments, or variations to the above description can be made
without departing from the spirit or scope of the invention. In
addition, the term about is used herein to describe a range of
additional values known to one of skill in the art to be equivalent
to the stated range. When the term about is used with regard to a
range, the term is intended to apply to both ends of the range.
* * * * *