U.S. patent application number 17/693138 was filed with the patent office on 2022-09-15 for vacuum cleaner docking station.
The applicant listed for this patent is Techtronic Cordless GP. Invention is credited to Bradley Hooley, Damian Jenks, James Materdo, Kirti Kant Paulla.
Application Number | 20220287528 17/693138 |
Document ID | / |
Family ID | 1000006251719 |
Filed Date | 2022-09-15 |
United States Patent
Application |
20220287528 |
Kind Code |
A1 |
Paulla; Kirti Kant ; et
al. |
September 15, 2022 |
VACUUM CLEANER DOCKING STATION
Abstract
A vacuum cleaner docking station is disclosed, the vacuum
cleaner docking station includes a vacuum cleaner separator and a
dock. The vacuum cleaner separator is operable to separate debris
from a suction airflow. The vacuum cleaner separator includes a
dirty air inlet, a clean air outlet, and a debris collector having
a debris outlet. The vacuum cleaner separator is removably coupled
to the dock. The dock includes an airflow source operable to
generate an airflow. The dock further includes a dock debris
collector and an airflow outlet in fluid communication with the
airflow source such that the airflow generated by the airflow
source is discharged from the airflow source through the airflow
outlet. Airflow generated by the airflow source of the dock travels
through the vacuum cleaner separator and through the debris outlet
of vacuum cleaner to blow debris out of the debris outlet and into
the dock debris collector.
Inventors: |
Paulla; Kirti Kant; (Indian
Land, SC) ; Materdo; James; (Charlotte, NC) ;
Jenks; Damian; (Sherrills Ford, NC) ; Hooley;
Bradley; (Charlotte, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Techtronic Cordless GP |
Anderson |
SC |
US |
|
|
Family ID: |
1000006251719 |
Appl. No.: |
17/693138 |
Filed: |
March 11, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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63159715 |
Mar 11, 2021 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47L 9/2842 20130101;
A47L 9/106 20130101; A47L 9/2873 20130101; A47L 9/2894
20130101 |
International
Class: |
A47L 9/28 20060101
A47L009/28; A47L 9/10 20060101 A47L009/10 |
Claims
1. A vacuum cleaner docking station comprising: a vacuum cleaner
separator, the vacuum cleaner separator operable to separate debris
from a suction airflow, the vacuum cleaner separator including a
dirty air inlet, a clean air outlet, and a debris collector having
a debris outlet; a dock, the vacuum cleaner separator removably
coupled to the dock, the dock including, an airflow source operable
to generate an airflow, an airflow outlet in fluid communication
with the airflow source such that the airflow generated by the
airflow source is discharged from the airflow source through the
airflow outlet, a dock debris collector, wherein the vacuum cleaner
separator is configured to be coupled to the dock with the vacuum
cleaner separator in fluid communication with the airflow outlet of
the dock and the debris outlet of the vacuum cleaner separator in
fluid communication with the dock debris collector such that the
airflow generated by the airflow source of the dock travels through
the vacuum cleaner separator and through the debris outlet of the
vacuum cleaner separator to blow debris out of the debris outlet
and into the dock debris collector.
2. The vacuum cleaner docking station of claim 1, further
comprising a vacuum cleaner, the vacuum cleaner including, a body,
the vacuum cleaner separator coupled to the body the body or the
vacuum cleaner separator including a vacuum suction inlet, and a
suction source in fluid communication with the suction inlet and
the vacuum cleaner separator, the suction source operable to
generate the suction airflow through the suction inlet to draw
debris from a surface being cleaned into the vacuum cleaner
separator through the dirty air inlet of the vacuum cleaner
separator.
3. The vacuum cleaner of claim 2, wherein the suction inlet is
removably coupled to the airflow outlet of the dock such that
airflow generated by the airflow source of the dock travels through
the suction inlet of the vacuum cleaner when the vacuum cleaner
separator is coupled to the dock.
4. The vacuum cleaner docking station of claim 2, wherein the
vacuum cleaner further comprises a wand and a foot, the wand
pivotally coupled to the foot, the foot including a foot suction
inlet, and the wand provides fluid communication between the foot
suction inlet and the vacuum suction inlet, wherein the foot
suction inlet is removably coupled to the airflow outlet of the
dock such that airflow generated by the airflow source of the dock
travels through the foot suction inlet, the wand, and the suction
inlet of the vacuum cleaner when the vacuum cleaner separator is
coupled to the dock.
5. The vacuum cleaner docking station of claim 2, wherein the
vacuum cleaner further comprises a wand and a foot, the wand
pivotally coupled to the foot, the foot including a foot suction
inlet, and the wand provides fluid communication between the foot
suction inlet and the vacuum suction inlet, wherein the wand
includes an aperture, wherein the wand aperture is removably
coupled to the airflow outlet of the dock such that airflow
generated by the airflow source of the dock travels through the
aperture, the wand, and the separator when the vacuum cleaner is
coupled to the dock.
6. The vacuum cleaner of claim 5, wherein the wand includes a valve
movable between an open position to open the aperture and a closed
position to close the aperture, and wherein the valve of the wand
is biased toward the closed position.
7. The vacuum cleaner docking station according to claim 2, wherein
the vacuum includes a foot having a suction inlet nozzle and a
passageway between the suction inlet nozzle and the separator,
wherein the passageway has a valve connectable to the airflow
outlet of the dock such that airflow generated by the airflow
source of the dock travels through the valve, the passageway, and
the separator when the vacuum cleaner is coupled to the dock.
8. The vacuum cleaner docking station of claim 2, wherein the
vacuum cleaner separator is uncoupled from the body of the vacuum
cleaner in order to couple the vacuum cleaner separator to the dock
such that the dirty air inlet of the vacuum cleaner separator is
coupled to the airflow outlet of the dock so that the airflow
generated by the airflow source travels from the airflow outlet of
the dock and through the dirty air inlet of the vacuum cleaner
separator.
9. The vacuum cleaner docking station of claim 2, wherein the
vacuum cleaner separator is uncoupled from the body of the vacuum
cleaner in order to couple the vacuum cleaner separator to the dock
such that the clean air outlet of the vacuum cleaner separator is
coupled to the airflow outlet of the dock so that the airflow
generated by the airflow source travels from the airflow outlet of
the dock and through the clean air outlet of the vacuum cleaner
separator.
10. The vacuum cleaner docking station of claim 9, wherein the
vacuum cleaner separator includes a filter having a downstream side
and a dirty side, wherein the airflow generated by the airflow
source travels through the filter in the direction from the
downstream side to the dirty side pushing dust and debris from the
filter before passing through the debris outlet of the vacuum
cleaner separator.
11. The vacuum cleaner docking station according to claim 1,
wherein the vacuum cleaner separator includes a door that moves
between an open position to open the debris outlet and a closed
position to close the debris outlet, and wherein the door is
automatically opened when the vacuum cleaner separator is coupled
to the dock.
12. The vacuum cleaner docking station of claim 11, wherein the
vacuum cleaner separator includes a latch that retains the door in
the closed position, wherein either the dock or the vacuum cleaner
separator includes an actuator that operates the latch to allow the
door to move to the open position when the vacuum cleaner separator
is coupled to the dock.
13. The vacuum cleaner docking station according to claim 1,
wherein the dock debris collector includes a filter bag.
14. The vacuum cleaner docking station according to claim 1,
wherein the dock includes a return duct in fluid communication with
the dock debris collector, wherein the vacuum cleaner separator is
received in the return duct when the vacuum cleaner separator is
coupled to the dock such that debris travels out of the debris
outlet, through the return duct, and into the dock debris
collector.
15. The vacuum cleaner of the docking station of claim 14, wherein
the return duct includes a seal that seals against the vacuum
cleaner separator.
16. The vacuum cleaner of the docking station according to claim 1,
wherein the airflow source includes a motor and a fan.
17. The vacuum cleaner docking station according to claim 1,
wherein the dock includes a sensor operable to determine a
characteristic regarding the vacuum cleaner docking station and to
send a signal to a dock controller, the dock controller being
operable to operate the airflow source in accordance with the
signal.
18. The vacuum cleaner docking station of claim 17, wherein the
sensor is operable to determine whether the vacuum cleaner
separator is attached to the dock, and the dock controller operates
the airflow source based on the attachment of the vacuum cleaner
separator to the dock.
19. The vacuum cleaner docking station according to claim 17,
wherein the sensor is a pressure sensor in fluid communication with
the airflow source, the pressure sensor operable to sense a
pressure of fluid from the airflow source, and the dock controller
operates the airflow source in accordance with the pressure.
20. The vacuum cleaner docking station according to claim 17,
wherein the vacuum cleaner separator further includes an identifier
indicative of a characteristic of the vacuum cleaner separator, the
sensor is operable to sense the identifier, and the dock controller
operates the airflow source in accordance with the identifier.
21. The vacuum cleaner docking station according to claim 1,
wherein the vacuum cleaner separator includes a vacuum contact and
the dock includes a dock contact, wherein when the vacuum cleaner
separator is connected to the dock, the vacuum contact and the dock
contact are electrically connected and operable to transfer
electricity between the vacuum cleaner separator and the dock.
22. The vacuum cleaner docking station of claim 21, wherein the
vacuum cleaner separator includes a vacuum controller and the dock
includes a dock controller, wherein when the vacuum cleaner
separator is connected to the dock and the vacuum contact is
electrically connected to the dock contact, the vacuum controller
sends a signal to the dock controller through the vacuum contact
and the dock contact indicative of a characteristic of the vacuum
cleaner separator.
23. The vacuum cleaner docking station according to claim 21,
wherein the dock is configured to receive and charge a battery
separate from the vacuum cleaner.
24. A vacuum cleaner docking station operated by a user, the vacuum
cleaner docking station comprising: a vacuum cleaner operable to
separate debris from a suction airflow, the vacuum cleaner
including, a first sidewall that faces in a direction away from the
user in a normal in-use vacuuming position of the vacuum cleaner, a
second sidewall that faces in a direction toward the user in the
normal in-use vacuuming position of the vacuum cleaner, and a
debris collector having a debris outlet; and a dock configured to
receive and store the vacuum cleaner in a docked position, the dock
including a dock debris collector, and in the docked position the
dock is configured to selectively couple the dock debris collector
and the debris collector of the vacuum cleaner such that the dock
debris collector receives debris separated by the vacuum cleaner
from the debris outlet of the debris collector of the vacuum
cleaner when the vacuum cleaner is coupled to the dock; wherein the
vacuum cleaner is coupled to the dock by the user with the second
sidewall facing in a direction toward the user and the first side
wall faces in a direction away from the user.
25. The vacuum cleaner docking station of claim 24, wherein in the
normal in-use vacuuming position, the second sidewall faces away
from a reference plane and in the docked position, the second
sidewall also faces away from the reference plane.
26. The vacuum cleaner docking station of claim 24, wherein the
vacuum cleaner is moved to the docked position by the user without
rotating the second sidewall away from the user.
27. The vacuum cleaner docking station of claim 24, wherein the
vacuum cleaner includes a handle that is configured to be used by
the user to move the vacuum cleaner into the docked position and
also to move the vacuum cleaner when the vacuum cleaner is being
used in the normal in-use vacuuming position.
28. The vacuum cleaner docking station of claim 27, wherein the
handle is used to move the vacuum cleaner to the docked position by
the user without rotating the second sidewall away from the
user.
29. The vacuum cleaner of claim 24, wherein the vacuum cleaner
includes a battery, wherein the battery is adjacent the second
sidewall.
30. The vacuum cleaner docking station of claim 29, wherein the
vacuum cleaner includes a vacuum contact, the dock includes a dock
contact, and when the vacuum cleaner is coupled to the dock in the
docked position, the vacuum contact is electrically coupled to the
dock contact to charge the battery.
31. A vacuum cleaner docking station comprising: a vacuum cleaner
separator, the vacuum cleaner separator operable to separate debris
from a suction airflow, the vacuum cleaner separator having a first
sidewall and a second sidewall opposite the first sidewall; a dock,
the vacuum cleaner separator removably coupled to the dock, the
dock including, a first sidewall configured to face a reference
plane, a second sidewall opposite the first sidewall, wherein in
regular use of the vacuum cleaner separator, the vacuum cleaner
separator is advanced in an advancing direction extending away from
the first sidewall of the vacuum cleaner separator; and wherein the
vacuum cleaner separator is configured to be coupled to the dock
with the vacuum cleaner separator in fluid communication with the
dock and with the second sidewall of the vacuum cleaner separator
facing the second sidewall of the dock and with the second sidewall
of the vacuum cleaner separator facing away from the reference
plane.
32. The vacuum cleaner docking station of claim 31, wherein the
vacuum cleaner separator further includes a dirty air inlet, a
clean air outlet, a debris collector having a debris outlet, the
dock further includes an airflow source operable to generate an
airflow, an airflow outlet in fluid communication with the airflow
source such that the airflow generated by the airflow source is
discharged from the airflow source through the airflow outlet, a
dock debris collector, and wherein the vacuum cleaner separator is
configured to be coupled to the dock with the vacuum cleaner
separator in fluid communication with the airflow outlet of the
dock and the debris outlet of the vacuum cleaner separator in fluid
communication with the dock debris collector such that the airflow
generated by the airflow source of the dock travels through the
vacuum cleaner separator and through the debris outlet of the
vacuum cleaner separator to blow debris out of the debris out of
the debris outlet and into the dock debris collector.
33. The vacuum cleaner docking station of claim 31, further
comprising a vacuum cleaner, the vacuum cleaner including, a body,
the vacuum cleaner separator coupled to the body a suction inlet,
and a suction source in fluid communication with the suction inlet
and the vacuum cleaner separator, the suction source operable to
generate suction airflow through the suction inlet to draw debris
from a surface being cleaned into the vacuum cleaner separator.
34. The vacuum cleaner docking station of claim 33, wherein the
suction source is powered by a battery and the battery is coupled
to the body, when the vacuum cleaner separator is coupled to the
dock the battery of the vacuum cleaner is adjacent the second
sidewall of the dock.
35. The vacuum cleaner docking station according of claim 34,
wherein the vacuum cleaner includes a vacuum contact and the dock
includes a dock contact, and wherein when the vacuum cleaner is
connected to the dock, the vacuum contact and the dock contact are
electrically connected and operable to transfer electricity between
the vacuum cleaner separator and the dock.
36. The vacuum cleaner docking station of claim 33, wherein the
body further includes a handle configured for a user to grasp the
handle during regular use of the vacuum cleaner separator and the
handle configured for a user to couple the vacuum cleaner separator
to the dock.
37. The vacuum cleaner docking station of claim 33, wherein the
vacuum cleaner further comprises a wand and a foot, the wand
pivotally coupled to the foot, the foot including a foot suction
inlet, and the wand provides fluid communication between the foot
suction inlet and the suction inlet of the body, wherein the foot
suction inlet is removably coupled to the airflow outlet of the
dock such that airflow generated by the airflow source of the dock
travels through the foot suction inlet, the wand, and the suction
inlet of the vacuum cleaner when the vacuum cleaner separator is
coupled to the dock.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 63/159,715, filed Mar. 11, 2021, the entire
contents of which are hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to docking stations, and more
particularly to docking stations for vacuum cleaners.
BACKGROUND
[0003] Vacuum docking systems include docks that are typically used
to store and charge floor cleaners. Hand vacuums are used either by
themselves or with a connected wand and foot such that the hand
vacuum functions as a stick vacuum. The hand vacuum may be
removable from the wand, and thus the foot, to function as a hand
vacuum separated from the wand and thus the foot. Finally, hand
vacuums or vacuums other than hand vacuums may include dust cups
that are removable from the rest of the vacuum, for example, for
cleaning or emptying debris from the dust cup.
SUMMARY
[0004] In one embodiment, a vacuum cleaner docking station includes
a vacuum cleaner separator and a dock. The vacuum cleaner separator
is operable to separate debris from a suction airflow. The vacuum
cleaner separator includes a dirty air inlet, a clean air outlet,
and a debris collector having a debris outlet. The vacuum cleaner
separator is removably coupled to the dock. The dock includes an
airflow source operable to generate an airflow, an airflow outlet
in fluid communication with the airflow source such that the
airflow generated by the airflow source is discharged from the
airflow source through the airflow outlet, and a dock debris
collector. The vacuum cleaner separator is configured to be coupled
to the dock with the vacuum cleaner separator in fluid
communication with the airflow outlet of the dock and the debris
outlet of the vacuum cleaner in fluid communication with the dock
debris collector such that the airflow generated by the airflow
source of the dock travels through the vacuum cleaner separator and
through the debris outlet of the vacuum cleaner separator to blow
debris out of the debris outlet and into the dock debris
collector
[0005] In another embodiment, a vacuum cleaner docking station is
operated by a user, the vacuum cleaner docking station includes a
vacuum cleaner operable to separate debris from a suction airflow.
The vacuum cleaner includes a first sidewall that faces in a
direction away from the user and away from a floor in a normal
in-use vacuuming position of the vacuum cleaner. A second sidewall
faces in a direction toward the user and toward the floor in the
normal in-use vacuuming position of the vacuum cleaner. The vacuum
cleaner further includes a debris collector having a debris outlet.
A dock is configured to receive and store the vacuum cleaner in a
docked position, the dock including a dock debris collector, and in
the docked position the dock is configured to selectively couple
the dock debris collector and the debris collector of the vacuum
cleaner such that the dock debris collector receives debris
separated by the vacuum cleaner from the debris outlet of the
debris collector of the vacuum cleaner when the vacuum cleaner is
coupled to the dock. The vacuum cleaner is coupled to the dock by
the user with the second sidewall facing in a direction toward the
user and the first side wall faces in a direction away from the
user.
[0006] In another embodiment a vacuum cleaner docking station
includes a vacuum cleaner separator, the vacuum cleaner separator
operable to separate debris from a suction airflow, the vacuum
cleaner separator having a first sidewall and a second sidewall
opposite the first sidewall. The vacuum cleaner docking station
further includes a dock, the vacuum cleaner separator removably
coupled to the dock, the dock including, a first sidewall
configured to face a reference plane, a second sidewall opposite
the first sidewall and configured to face a user. In regular use of
the vacuum cleaner separator, the vacuum cleaner separator is
advanced in an advancing direction extending away from the first
sidewall of the vacuum cleaner separator. The vacuum cleaner
separator is configured to be coupled to the dock with the vacuum
cleaner separator in fluid communication with the dock and with the
first sidewall of the vacuum cleaner adjacent the first sidewall of
the dock and the second sidewall of the vacuum cleaner adjacent the
second sidewall of the dock.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a docking station system
having a vacuum assembly disposed from a dock in accordance with a
first embodiment of the disclosure.
[0008] FIG. 2 is a side view of the docking station system of FIG.
1.
[0009] FIG. 3 is a side view of the docking station system of FIG.
1 with the vacuum assembly connected to the dock.
[0010] FIG. 4 is an enlarged side view of an actuator of the vacuum
cleaner of FIG. 3 taken along section line 4-4 in FIG. 3.
[0011] FIG. 5 is a partial cross-sectional view of the docking
station system of FIG. 3 with the section taken through a separator
of the vacuum cleaner.
[0012] FIG. 6 is a front view of a docking station system in
accordance with a second embodiment of the disclosure.
[0013] FIG. 7 is a side view of the docking station system of FIG.
6.
[0014] FIG. 8 is a partial cross section view of the docking
station system of FIG. 7 with the section taken through a separator
of the vacuum cleaner.
[0015] FIG. 9 is a perspective view of a vacuum cleaner for use in
a docking station system in accordance with a third embodiment of
the disclosure.
[0016] FIG. 10 is a side view of the docking station system
including the vacuum cleaner of FIG. 9.
[0017] FIG. 11 is an enlarged cross-sectional view of the docking
station system taken along section line 11-11 in FIG. 10 and
showing a valve in a closed position.
[0018] FIG. 12 is an enlarged cross-sectional view of the docking
station system taken along section line 11-11 in FIG. 10 and
showing the valve in an aligned position.
[0019] FIG. 13 is a perspective view of a dock for use in a docking
station system in accordance with a fourth embodiment of the
disclosure.
[0020] FIG. 14 is a perspective view of the docking station system
including the dock of FIG. 13.
[0021] FIG. 15 is a side view of the docking station system of FIG.
14.
[0022] FIG. 16 is a perspective view of a dock for use in a docking
station system in accordance with a fifth embodiment of the
disclosure.
[0023] FIG. 17 is a perspective view of the docking station system
including the dock of FIG. 16 with a lid of the dock in an open
position.
[0024] FIG. 18 is a perspective view of the docking station system
including the dock of FIG. 16 with the lid of the dock in a closed
position.
[0025] FIG. 19 is partial cross sectional side view of the docking
station system of FIG. 16 with the section taken through a
separator of a dust bin.
DETAILED DESCRIPTION
[0026] Before any embodiments of the present 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.
[0027] FIGS. 1-5 illustrate a first embodiment of a vacuum cleaner
docking station 100. The docking station 100 includes a dock 108
configured to receive a vacuum cleaner 104 and discharge dirt and
debris contained inside the vacuum cleaner 104 into the dock 108.
In the first embodiment, the vacuum cleaner 104 is a hand vacuum
104A. The hand vacuum 104A may be replaced by a stick or other type
of vacuum. The vacuum cleaner 104 may also be other types of
vacuums 104B, 104C including a wand 112 and a foot 116, or a vacuum
cleaner separator 104D, 104E removed from a vacuum cleaner. As
illustrated in FIGS. 1 and 2, the vacuum cleaner 104 defines a
longitudinal axis LA extending therethrough. In each embodiment of
the docking station 100, the vacuum cleaner 104 is operable to be
connected with the dock 108 to be placed in fluid communication
with the dock 108. The dock 108 includes an airflow source 120
configured to impart fluid flow through both the dock 108 and the
vacuum cleaner 104, as will be discussed in detail with various
embodiments. In the illustrated embodiment, the airflow source 120
includes a blower such as a centrifugal fan, axial fan, or other
fan arrangement.
[0028] As illustrated in FIG. 3, the vacuum 104A includes a vacuum
separator 132 having a dirty air inlet 124 (FIG. 5) configured to
receive dirty air. The vacuum separator 132 is configured to
separate dirty air from debris during use of the vacuum cleaner. A
debris outlet 128 is operable to be opened to remove debris from
the vacuum separator 132 after use of the vacuum cleaner. The
debris outlet 128 is fluidly connected to the dirty air inlet 124.
The vacuum separator 132 can be, for example and without
limitation, a cyclonic separator or a filter. As illustrated in
FIG. 5, the vacuum separator 132 of the vacuum 104A is a cyclonic
separator with a shroud 133. With continued reference to FIG. 5,
the vacuum 104A further includes a body 106 housing a motor 136 and
an impeller 140 connected to the motor 136 for rotation therewith.
The impeller 140 generates an airflow in the vacuum 104A when the
motor 136 is rotated to draw air from the vacuum cleaner inlet 114
through the separator 132 coupled to the body to a vacuum exhaust
port 220. The motor 136 is powered by a battery 144. The vacuum
separator 132 further includes a clean air outlet 130 adjacent the
impeller 140.
[0029] During normal operation of the vacuum 104A, electric power
is transmitted from the battery 144 to the motor 136 for rotating
the impeller 140 and generating an airflow within the vacuum 104A.
During normal operation of the vacuum 104A, the vacuum 104A is not
connected to the dock 108. The dirty air inlet 124 functions as an
inlet to receive dirty air and debris. Further, the separator dirty
air inlet 124 passes the dirty air and debris from the vacuum
cleaner inlet 114 to the separator 132. The separator 132 separates
the debris from the clean air. The debris is retained in the
separator 132 and falls into a debris collector 148. The clean air
passes through the separator 132 through the shroud 133 and is
exhausted from the vacuum 104A through the clean air outlet 130 and
ultimately the vacuum exhaust port 220.
[0030] With reference to FIGS. 3 and 4, the debris collector 148
includes a dust bin door 152. The dust bin door 152 is pivotably
connected to the debris collector 148 by a hinge 154. An operator
can open the dust bin door 152 by pivoting the dust bin door 152
relative to the debris collector 148 to empty collected debris
within the debris collector 148. The dust bin door 152 includes a
latch 156 that connects the dust bin door 152 to the debris
collector 148 to retain debris in the debris collector 148 (FIG. 4)
when a user is not emptying the debris collector 148. The other
embodiments of the docking station 100 and the vacuum cleaner 104
may include a dust bin door 152 similar to that described with
respect to the first embodiment and the vacuum cleaner 104A.
[0031] With continued reference to FIG. 3, the vacuum 104A may
include an identifier 160 unique to a characteristic of the vacuum
104A. In the illustrated embodiment, the characteristic of the
vacuum 104A is an identifier 160 specific to the type or model of
the vacuum 104A. The identifier 160 may be, for example, and
without limitation, a physical identifier 160 such as a bar code or
geometric shape, or a software identifier 160 such as a unique
signal. The identifier 160 may be positioned on an exterior portion
of the vacuum 104A so to be readily accessible by either a user or
the dock 108. In the case of a software or signal identifier 160, a
vacuum contact 164 is provided on the vacuum 104A. The vacuum
contact 164 is configured to engage and electrically connect to
another contact. The contact 164 is operable to transfer
electricity to and from the vacuum 104A. The electricity
transferred through the vacuum contact 164 may be related to the
identifier 160, for powering the battery 144, both, or another
electrical function of the vacuum 104A. Optionally, the vacuum 104A
includes a controller 168. Among other functions, the controller
168 is operable to send a signal identifier 160 through the vacuum
contact 164.
[0032] With reference to FIG. 5, the dock 108 includes a dock
housing 172 that surrounds each of the components of the dock 108.
The dock 108 further includes the blower 120 and a blower duct 176
having an inlet 176A in fluid communication with the blower 120 and
an outlet 176B. The outlet 176B functions as an airflow outlet 176B
in fluid communication with the airflow source 120 such that the
airflow generated by the airflow source 120 is discharged from the
airflow source 120 through the airflow outlet 176B. The dock 108
includes a return duct 180. Considering the dock 108 by itself, in
the illustrated embodiment, the return duct 180 is not in fluid
communication with the blower duct 176 such that when the blower
120 is operated and the vacuum 104 is not connected to the dock,
airflow from the blower 120 is exhausted by the outlet 176B to the
surroundings. The return duct 180 includes an inlet 180A and an
outlet 180B (FIG. 3). The dock 108 further includes an exhaust
opening 184 in fluid communication with the return duct 180. The
exhaust opening 184 is located adjacent the outlet 180B of the
return duct 180. The dock 108 includes a dock debris collector 188
located between the return duct 180 and the exhaust outlet 180. The
illustrated dock debris collector 188 is a filter bag, such as a
vacuum cleaner filter bag, but may be, for example and without
limitation, a cyclonic or non-cyclonic separator or a filter.
[0033] As illustrated in FIGS. 2 and FIG. 4, the return duct 180
may include an actuator 192 that pivotably opens the dust bin door
152 upon connection of the vacuum 104A to the dock 108. Thus, upon
connection of the vacuum 104A to the dock 108, fluid may pass
through the vacuum 104A from the dirty air inlet 124, through the
separator 132, and through the debris outlet 128. In the
illustrated embodiment, the actuator 192 is in the form of a
protrusion on the interior periphery of the return duct 180
adjacent the inlet 180A of the return duct 180. In the illustrated
embodiment, the actuator 192 rotates the latch 156 to an open
position, and as illustrated in FIG. 5, the dust bin door 152
freely pivots away from the debris collector 148 or is pushed open
by the airflow from the blower 120. Other such actuators 192 on the
dock 108 or on the vacuum 104A may otherwise open the dust bin door
152 upon connection of the vacuum 104A to the dock 108. In one
embodiment, the dock 108 activates an actuator disposed on the
vacuum (not shown) that moves the latch 156. In one embodiment, the
actuator is electrically or pneumatically activated with blower
operation. With the dust bin door 152 open, the debris collector
148 of the vacuum 104A opens into the return duct 180.
[0034] As illustrated in FIG. 5, the dock 108 includes a seal 196
adjacent the inlet end 180A of the return duct 180. The seal 196
circumscribes the inlet end 180A of the return duct 180 for
engaging outer walls of the debris collector 148. As such, the seal
196 directs air and debris into the dock debris collector 188. In
the vacuum 104A, the opening formed by the open dust bin door 152
forms the debris outlet 128 of the vacuum 104A.
[0035] As illustrated in FIGS. 2, 3, and 5, the vacuum 104A is
configured to be connected to the dock 108. In the illustrated
embodiment, the vacuum 104A is translated into engagement with the
dock 108. The vacuum 104A is aligned with and connects the vacuum
cleaner inlet 114 with the blower duct outlet 176B. The debris
outlet 128 of the vacuum 104A is aligned with and connects with the
return duct inlet 180A. Upon connection of the vacuum 104A to the
dock 108, the actuator 192 opens the dust bin door 152. The seal
196 engages outer walls of the debris collector 148. As such, the
vacuum cleaner separator 132 is configured to be coupled to the
dock 108 with the vacuum cleaner separator 132 in fluid
communication with the airflow outlet 176B of the dock 108 and the
debris outlet 128 of the separator 132 in fluid communication with
the dock debris collector 188 such that the airflow generated by
the airflow source 120 of the dock 108 travels through the vacuum
cleaner separator 132 and through the debris outlet 128 of the
vacuum cleaner separator 132 to blow debris out of the debris
outlet 128 and into the dock debris collector 188.
[0036] The dock 108 may include a sensor 200 that determines that
the vacuum 104A is connected to the dock 108. The sensor 200 may be
in the form of a sensor or a mechanical switch. As will be
described in detail below, the sensor 200 may be a user-activatable
switch. Additionally or alternatively, the dock 108 may further
include a pressure sensor 204. The pressure sensor 204 is mounted
to be in operative communication with the blower duct 176. The
pressure sensor 204 monitors a pressure within the blower duct
176.
[0037] The dock 108 may further include a dock controller 208
operable to electrically communicate with the dock sensors 200, 204
and the blower 120. The dock 108 may further comprise a dock
contact 212 connected to the dock controller 208 operable to
electrically communicate with the vacuum 104A through the vacuum
contact 164 when the dock 108 is connected to the vacuum 104A. In
one embodiment, the dock contact 212 is operable to electrically
communicate with the dock sensors 200, 204. In the first embodiment
of the docking station 100 as illustrated in FIG. 3, the dock
contact 212 is located adjacent the outlet end 176B of the blower
duct 176. As such, the dock contact 212 is configured to
operatively engage the vacuum contact 164 when the vacuum 104A and
the dock 108 are connected.
[0038] In one embodiment, when the vacuum 104A is connected to the
dock 108, the dock controller 208 determines from sensor 200 that
the vacuum is connected and the dock controller 208 operates the
blower 120 for a predetermined period of time to empty the debris
collector 148 of the vacuum 104A, for example, for a period of 5 or
10 or 15 or 30 seconds or another desired duration. In one
embodiment, the duration of blower operation may be determined by
the type or model of vacuum attached to the dock 108. In one
example, when the vacuum 104A is connected to the dock 108, the
vacuum contact 164 and the dock contact 212 are mechanically and
electrically connected and operable to transfer electricity between
the vacuum 104A and the dock 108. When the vacuum 104A is connected
to the dock 108, the vacuum controller 168 sends a signal to the
dock controller 208 through the dock contact 212, the signal
indicative of the type of vacuum 104A or another characteristic.
The controller 208 receives the signal indicative of the
characteristic. And, based on the signal indicative of the
characteristic of the vacuum 104A, the controller 208 operates the
blower 120 for a predetermined period of time. In the illustrated
embodiment, the controller 208 may operate the blower 120, for
example, for a period of 5 or 10 or 15 or 30 seconds or another
desired duration. Alternatively, the controller 208 may operate the
blower 120 to operate in a pulse-like fashion by delivering airflow
that increases and decreases for a period of time. Alternatively,
the controller 208 may operate the blower 120 such that power sent
to the motor is received in a pulse-like fashion that increases and
decreases for a period of time.
[0039] In one embodiment, the sensor is a user-activatable switch
operable to turn the blower 120 on and off. In another embodiment,
the user-activatable switch activates the dock controller 208 to
operate the blower 120 for a predetermined period after which the
controller 208 turns off the blower.
[0040] The dock controller 208 monitors a signal from the pressure
sensor 204 indicative of the pressure within the blower duct 176
and determines if the pressure within the blower duct 176 is
outside of a predetermined range. Variations in the pressure are
indicative of the operation of the docking station 100, and
pressures outside of a predetermined range may indicate a fault,
for example, if the dust bin door 152 is closed, if the dock debris
collector 188 is clogged, or if airflow is otherwise blocked. In
one embodiment, the dock controller 208 operates the blower 120 to
empty the debris collector 148 for a duration that is a function of
the pressure measured by the pressure sensor 204.
[0041] The dock controller 208 may also monitor for signals from
the sensor 200 indicative of when the connection between the vacuum
104A and the dock 108 is made. The sensor 200, the pressure sensor
204, and the vacuum controller 168, are configured to send a signal
indicative of a characteristic to the dock controller 208.
[0042] In one embodiment, the vacuum controller 168 controls the
operation of the dock 108. In such an embodiment, the vacuum
controller 168 monitors for signals from the sensor 200 indicative
of when the connection between the vacuum 104A and the dock 108 is
made and sends a signal to operate the blower 120 through the
vacuum contact 164 to the dock contact 212 to the controller 208.
The vacuum controller 168 also monitors for a signal from the
pressure sensor 204 indicative of the pressure within the blower
duct 176, and/or the dock controller 208 monitors the pressure
sensor 204 and operatively signals to the vacuum controller
168.
[0043] As illustrated in FIGS. 2 and 3, the dock 108 is powered by
a power source 216. The power source 216 may be a battery or
household AC power. The power source 216 may directly or indirectly
power the blower 120, the dock controller 208 and the sensors 200,
204. When the vacuum 104A is connected to the dock 108, the
connection between the vacuum contact 164 and the dock contact 212
may electrically transfer power from the power source 216 of the
dock 108 to the battery 144 of the vacuum 104A. As such, a user may
charge the vacuum battery 144 by connection of the vacuum 104A to
the dock 108 between the vacuum contact 164 and the dock contact
212. In one embodiment, such as illustrated in FIG. 6, the dock 108
is configured to receive additional batteries 144 or other
accessories that are separate from the vacuum cleaner 104B. In this
embodiment, the dock 108 is configured to charge the additional
batteries 144 when the additional batteries 144 are connected to
the dock 108. The dock 108 thus functions as a charging and storage
station when the additional batteries 144 or other accessories are
connected.
[0044] As illustrated in FIG. 5, when the vacuum 104A, and thus,
the vacuum separator 132 is connected to the dock 108, the dirty
air inlet 124 is fluidly connected to the outlet 176B of the blower
duct 176. Similarly, when the vacuum 104A is connected to the dock
108, the debris outlet 128 is fluidly connected to the return duct
180. More specifically, the debris outlet 128 is fluidly connected
to the inlet end 180A of the return duct 180. When the vacuum 104A
is fluidly connected to the dock 108 and the blower 120 is
operated, fluid flow from the blower 120 passes debris from the
vacuum separator 132 to the dock debris collector 188 and fluid
passes through the exhaust opening 184. When the blower 120 is
operated, fluid flow from the blower 120 passes debris from the
vacuum separator 132 to the dock debris collector 188.
[0045] In the illustrated embodiment shown in FIG. 5 of the docking
station 100 with the vacuum 104A, the flow of fluid from the blower
120 passes from the blower 120 into the blower duct 176, from the
blower duct 176 into the dirty air inlet 124 of the vacuum
separator 132, and through the vacuum separator 132. From the
vacuum separator 132, fluid flow is passed through the debris
outlet 128 and into the inlet 180A of the return duct 180. The
fluid then passes through the dock debris collector 188 to the
outlet 180B of the return duct 180 and through the exhaust opening
184 to the surroundings. If the vacuum separator 132 is a cyclonic
separator, the airflow around the cyclonic separator 132 aids in
wiping dust and debris from the shroud 133 of the vacuum separator
132.
[0046] Additionally or alternatively, as shown in FIGS. 2 and 3,
the vacuum exhaust port 220 provides a flow path to exhaust air
from the docking station 100 when the blower 120 is operated and
the dock debris collector 188 is filled or clogged. Upon clogging
of the dock debris collector 188, increased pressure in the dock
debris collector 188 causes at least a portion of the fluid
entering through inlet 124 to flow through the shroud 133 and
outlet 130, and to be exhausted from the vacuum 104A through the
vacuum exhaust port 220.
[0047] FIGS. 6-8 illustrate a second embodiment of the docking
station 100 in which the vacuum cleaner 104 is a vacuum 104B
including a wand 112 and a foot 116 having a suction inlet nozzle
118 (FIG. 7), and airflow is passed through both the foot 116 and
the wand 112. Each of the second through fifth embodiments of the
docking station 100 may include any of the features of the first
embodiment of the docking station 100. In the second embodiment of
the docking station 100, the vacuum 104B includes the vacuum
separator 132 operable to separate debris from a suction airflow
during use of the vacuum cleaner 104B. The vacuum separator 132
includes a dirty air inlet 124 (FIG. 8), a clean air outlet 130,
and a debris collector 148 having a debris outlet 128. Some of the
features of the first embodiment may be rearranged or modified for
operation with the second embodiment and the vacuum 104B. For
example, the docking station 100 in accordance with the second
embodiment has a dock contact 212 which is located adjacent the
foot 116 as opposed to the dock contact 212 of the first embodiment
which is located adjacent the outlet end 176B of the blower duct
176.
[0048] The vacuum cleaner 104B includes the vacuum separator 132
having the dirty air inlet 124 and the debris outlet 128 as
described above with reference to the vacuum cleaner 104A and the
first embodiment of the docking station 100. The wand 112 has a
first end 112A connected to the dirty air inlet 124 of the vacuum
separator 132 and an opposite second end 112B. The foot 116 is
connected to the second end 112B of the wand 112.
[0049] In the second embodiment of the docking station 100, the
blower duct 176 is configured to deliver air to the vacuum cleaner
104B through the suction inlet nozzle 118 of the foot 116. When the
vacuum cleaner 104B is connected to the dock 108, the dirty air
inlet 124 of the vacuum separator 132 is connected to the outlet
176B of the blower duct 176 through the wand 112, and the debris
outlet 128 is connected to the return duct 180. More specifically,
the debris outlet 128 is fluidly connected to the inlet end 180A of
the return duct 180. When the vacuum cleaner 104B is fluidly
connected to the dock 108, fluid flow from the blower 120 passes
debris from the debris collector 148 to the dock debris collector
188 and fluid passes through at least the exhaust opening 184.
[0050] During normal operation of the vacuum 104B, electric power
is transmitted from the battery 144 to the motor 136 for rotating
the impeller 140 and generating an airflow within the vacuum 104B.
During normal operation of the vacuum 104B, the vacuum 104B is not
connected to the dock 108. The suction inlet nozzle 118 (FIG. 7) of
the foot 116 functions as an inlet to receive dirty air and debris
and is in fluid communication with the dirty air inlet 124 in the
vacuum 124B. In the vacuum 104B, the opening formed by the open
dust bin door 152 forms the debris outlet 128 of the vacuum 104B.
Further, the separator dirty air inlet 124 passes the dirty air and
debris from the foot 116 and the wand 112 to the separator 132. The
separator 132 separates the debris from the clean air. The debris
is retained in the separator 132 and falls into a debris collector
148 with the dust bin door 152 closed. The clean air passes through
the separator 132 and through the shroud 133 and is exhausted from
the vacuum assembly through the clean air outlet 130 and ultimately
the vacuum exhaust port 220. Alternatively, the wand 112 and thus
the foot 116 can be removed from the vacuum cleaner inlet 114 of
the vacuum 104B to operate the vacuum 104B as a hand vacuum,
similar to the hand vacuum 104A.
[0051] As illustrated in FIGS. 6-7, in the docking station 100 in
accordance with the second embodiment, the dock 108 includes a base
224 on which the foot is supported when the vacuum 104B is
connected to the dock 108 and the vacuum 104B is fluidly connected
to the dock 108. The base 224 of the dock 108 includes a plenum 228
in fluid communication with the outlet 176B of the blower duct and
configured to be fluidly connected with the inlet nozzle 118 of the
foot 116 such that when the blower 120 is operated, fluid flow from
the blower 120 passes through, successively, the plenum 228, the
foot 116, the wand 112, the separator dirty air inlet 124, the
debris outlet 128 with the dust bin door 152 open, the return duct
180, and the exhaust opening 184. In one embodiment, the base 224
includes a seal 230 (FIG. 7) disposed to surround the inlet nozzle
118 when the foot 116 is seated on the base 224. The seal 230
directs airflow from the plenum 228 into the inlet nozzle 118 when
the vacuum 104B is connected to the dock 108.
[0052] As illustrated in FIGS. 6, 7, and 8, the vacuum 104B is
configured to be connected to the dock 108. In the illustrated
embodiment, the vacuum 104B engages the dock 108 with the foot 116
on the base 224 aligning the plenum 228 with the inlet nozzle 118.
The debris outlet 128 of the vacuum 104B is aligned with and
connects with the return duct inlet 180A. Upon connection of the
vacuum 104B to the dock 108, the dust bin door 152 may be opened in
a manner described with respect to the first embodiment. The seal
196 engages outer walls of the debris collector 148. As such, the
vacuum cleaner separator 132 is configured to be coupled to the
dock 108 with the vacuum cleaner separator 132 in fluid
communication with the airflow outlet 176B of the dock 108 and the
debris outlet 128 of the separator 132 in fluid communication with
the dock debris collector 188 such that the airflow generated by
the airflow source 120 of the dock 108 travels through the vacuum
cleaner separator 132 and through the debris outlet 128 of the
vacuum cleaner separator 132 to blow debris out of the debris
outlet 128 and into the dock debris collector 188. The blower 120
may be controlled in a manner described with respect to the first
embodiment.
[0053] FIGS. 9-12 illustrate a third embodiment of the docking
station 100 in which the vacuum cleaner 104 is a vacuum 104C. The
vacuum 104C has many common elements as described with respect to
the vacuum 104B of the second embodiment described above and with
reference to FIGS. 6-8. The vacuum 104C includes the foot 116
having the suction inlet nozzle 118 and a passageway 112' between
the suction inlet nozzle 118 and the separator 132. The passageway
112' of the third embodiment is similar to the wand 112 of the
second embodiment. The passageway 112' is interchangeably named a
wand 112'. The passageway 112' has a valve 236 connectable to the
dock 108. In the third embodiment, the passageway 112' extends
between the suction inlet nozzle 118 and the separator 132. Many
features of the second embodiment of the docking station 100 apply
equally to the third embodiment of the docking station 100.
However, the third embodiment of the docking station 100 passes
airflow into a valve 236 on the wand 112'. In the illustrated
embodiment, the valve 236 is disposed on the wand 112'. In other
embodiments, the valve 236 may be provided in another airpath as
desired for other vacuum cleaners, such as a passageway between the
foot and the separator on an upright vacuum or any other desired
arrangement cooperative with the docking station.
[0054] The wand 112' of the vacuum cleaner 104C includes an
aperture 232. The aperture 232 is located at an intermediate
position between the first end 112'A and the second end 112'B of
the wand 112'. The vacuum cleaner 104C further includes a valve
236. FIG. 11 illustrates the valve 236 in a closed position. The
valve 236 in the closed position covers the aperture and airflow
during operation of the vacuum 104C passes from the foot 116,
through the wand 112', and into the vacuum cleaner 104C. FIG. 12
illustrates the valve 236 in an open position with the aperture 232
aligned with the blower duct outlet 176B such that the blower duct
176 is in fluid communication with the aperture 232, and thus, the
wand 112' at the intermediate position between the first end 112'A
and the second end 112'B of the wand 112'.
[0055] The valve 236 is movable between the open position (FIG. 12)
and the closed position (FIG. 11). The valve includes a tab 240
positioned to engage a corresponding protrusion 244 on the dock
housing 172 when the vacuum 104C is docked on the dock 108. The tab
240 engages the protrusion at a height corresponding to the valve
236 being in the open position when the vacuum 104C and the wand
112' are fully docked. After the tab 240 engages the protrusion
244, continued movement of the vacuum 104C and wand 112' into the
docked position causes the valve 236 to slide axially along the
wand 112' from the closed position (FIG. 11) to the open position
(FIG. 12). The valve 236 includes a valve aperture 246 configured
to align with the aperture 232 of the wand 112' in the open
position (FIG. 12). As such, when the valve 236 is moved to the
open position (FIG. 12), the blower outlet duct 176B is placed in
fluid communication with the aperture 232. As such, in the third
embodiment of the docking station 100, fluid passes to the vacuum
104C through only a portion of the wand 112' between the aperture
232 and the second end 112B.
[0056] As illustrated in FIG. 12, a seal 248 is provided on the
dock 108 disposed at the end of the blower duct outlet 176B. The
seal 248 is configured to engage the valve 236 around the valve
aperture 246 to direct airflow from the blower duct 176 into the
valve aperture 246 and wand aperture 232. Referring to FIG. 10, the
base 224 of this embodiment may include a blocking seal 254
disposed to engage the suction inlet nozzle 118 to inhibit airflow
from exiting through the second wand end 112'B and through the
nozzle 118. The blocking seal 254 thereby directs airflow entering
the wand aperture 232 to be directed to the first wand end 112'A
and the separator dirty air inlet 124. In one embodiment, the base
224 is shaped to cover the suction inlet nozzle 118.
[0057] The valve 236 may include a spring 252 connected between the
wand 112' and the valve 236 urging the valve 236 toward the closed
position (FIG. 11). When the vacuum 104C and wand 112' are
undocked, the spring pulls the valve 236 to the closed position
(FIG. 11). As illustrated in FIG. 10, the spring 252 may be covered
by a spring cover 250 to protect the spring 252 from the
environment.
[0058] FIGS. 13-15 illustrate a fourth embodiment of the docking
station 100 in which a vacuum cleaner separator 104D is removed
from the vacuum cleaner 104 before engaging the dock 108, and
airflow from the dock 108 is passed to the dirty air inlet 124
(FIG. 15) of the vacuum cleaner separator 132 to the debris outlet
128 of the vacuum cleaner separator 132.
[0059] In the fourth embodiment, the vacuum cleaner separator 104D
(FIGS. 13-15) is configured for use in a vacuum cleaner (not
shown), and is removable from the vacuum cleaner for emptying dirt
and debris from the vacuum cleaner separator 104D with the dock
108. When attached to the vacuum cleaner, the vacuum cleaner
separator 104D functions to separate dirty air from debris during
operation of the vacuum cleaner. The vacuum cleaner separator 104D
includes the vacuum cleaner separator 132, and the vacuum cleaner
separator 104D is attachable to the dock 108 to fluidly connect the
dirty air inlet 124 of the vacuum cleaner separator 104D with the
airflow outlet 176B and the debris end 128 of the vacuum cleaner
separator 132 with the dock debris collector 188.
[0060] As such, in the fourth embodiment, the blower duct 176 is
configured to deliver air to the vacuum cleaner separator 104D
through the dirty air inlet 124. When the vacuum cleaner separator
104D is removed from the vacuum and connected to the dock 108, the
vacuum cleaner separator 132 is in fluid communication with the
dock 108 such that the dirty air inlet 124 is connected with the
outlet 176B of the blower duct 176 and the debris outlet 128 of the
vacuum cleaner separator 132 is fluidly connected to the return
duct 180. More specifically, the debris outlet 128 of the vacuum
cleaner separator 132 is fluidly connected to the inlet end 180A of
the return duct 180. When the vacuum cleaner separator 104D is
fluidly connected to the dock 108 and the blower 120 is operated,
fluid flow from the airflow source 120 passes debris from the
debris collector 148 to the dock debris collector 188 and fluid
passes through the exhaust opening 184.
[0061] In normal operation of the vacuum cleaner separator 104D
when attached to a vacuum cleaner, the dirty air inlet 124 is an
inlet configured to receive dirty air and debris, the vacuum
separator 132 is configured to separate debris from the clean air,
where the debris is retained in the separator 132 and falls into a
debris collector 148 with the dust bin door 152 closed. The clean
air passes through the separator 132 and through the shroud 133 and
is exhausted from the vacuum assembly through the clean air outlet
130 and ultimately through a vacuum exhaust port of the vacuum
cleaner. When the vacuum cleaner separator 104D separated from the
vacuum cleaner and is attached to the dock 108, the dirty air inlet
124 of the vacuum cleaner separator 104D is directly fluidly
connected to the outlet of the blower duct 176B such that when the
blower 120 is operated, fluid flow from the blower 120 passes
through the dirty air inlet 124 of the vacuum cleaner separator
104D towards the debris outlet 128 of the vacuum cleaner separator
104D with the dust bin door 152 open through the vacuum separator
132.
[0062] As illustrated in FIG. 13, the fourth embodiment of the
docking station 100 includes a first seal 196 and a second seal
258. The first seal 196 corresponds with the seal 196 of the first
embodiment of the docking station 100. In other words, the first
seal 196 is adjacent the inlet end 180A of the return duct 180, and
is configured to circumscribe the inlet end 180A of the return duct
180 for engaging outer walls of the vacuum cleaner separator 104D.
The second seal 258 is provided on the blower duct outlet 176B to
engage the vacuum cleaner separator 104D around the dirty air inlet
124 to direct air from the blower duct 176 into the dirty air inlet
124.
[0063] Upon connection of the vacuum 104D to the dock 108, the dust
bin door 152 may be opened by actuator 192 in a manner described
with respect to the first embodiment. The seal 196 engages outer
walls of the debris collector 148 and the second seal 258 engages
around the dirty air inlet 124 such that the airflow generated by
the airflow source 120 of the dock 108 travels through the vacuum
cleaner separator 132 and through the debris outlet 128 of the
vacuum cleaner separator 132 to blow debris out of the debris
outlet 128 and into the dock debris collector 188. The blower 120
may be controlled in a manner described with respect to the first
embodiment.
[0064] In operation of the fourth embodiment of the docking station
100, airflow generated by the blower 120 passes through,
successively, the blower duct 176, dirty air inlet 124 of the
vacuum cleaner separator 132, the vacuum separator 132, the debris
outlet 128 of the vacuum cleaner separator 132, the return duct
180, and the exhaust opening 184.
[0065] FIGS. 16-19 illustrate a fifth embodiment of the docking
station 100 in which a vacuum cleaner separator 104E is removed
from the vacuum cleaner 104 before engaging the dock 108, and
airflow is passed from the blower duct 180 into the vacuum cleaner
separator 132 through what is the clean air outlet 130 during
normal operation of the vacuum cleaner separator 104E. In the fifth
embodiment, the dirty air inlet 124 that typically receives dirty
air in normal operation of the vacuum cleaner separator 104E is
sealed from the surroundings.
[0066] The vacuum cleaner separator 104E includes a pre-motor
filter 256 disposed within or adjacent the clean air outlet 130 of
the vacuum cleaner separator 132. In use in the vacuum cleaner of
the fifth embodiment, the pre-motor filter 256 is configured to
cleanse relatively clean environmental air of debris prior to
contacting the impeller 140 of the vacuum cleaner (not shown). The
pre-motor filter 256 has a dirty side (i.e., an upstream side) 256B
and an opposite downstream side 256A. Debris collects at the dirty
side 256B when the vacuum cleaner operates as air travels through
the pre-motor filter 256 to the downstream side of the filter
before contacting the impeller 140. The fifth embodiment of the
docking station 100 relates to delivering air into the pre-motor
filter 256 so that air enters the downstream side of the pre-motor
filter 256, pushing dust and debris from the pre-motor filter 256,
then into the separator 132 and ultimately into the dock debris
collector 188. In other words, when the separator 132 is positioned
in the dock 108, the pre-motor filter 256 is disposed between the
blower tube outlet 176B of the docking station 100 and the vacuum
separator 132 such that, when the vacuum cleaner separator 104E is
connected to the dock 108 and the blower 120 is operated, air
enters the downstream side 256A of the pre-motor filter 256,
pushing debris from the pre-motor filter 256 into the debris
collector 148 and into the dock debris collector 188.
[0067] In the fifth embodiment of the docking station system, as
illustrated in FIGS. 16-18, the dock 108 includes a manifold 260 in
fluid communication with the blower duct outlet 176B. The manifold
260 is formed within a lid 264 that is pivotably connected to the
dock 108. The lid 264 is pivotable between an open position (FIGS.
16-17) in which the vacuum cleaner separator 104E is connectable to
the dock 108, and a closed position (FIG. 18) in which the manifold
260 fluidly connects the blower duct outlet 176B with the clean air
outlet 130 of the vacuum cleaner separator 104E.
[0068] Similar to the vacuum cleaner separator 104D fourth
embodiment, the vacuum cleaner separator 104E is removable from a
vacuum cleaner. During normal operation of the vacuum cleaner
separator 104E when the separator is attached to the vacuum cleaner
104, the separator dirty air inlet 124 is an inlet configured to
pass dirty air and debris from the environment to the separator
132. The separator 132 separates the debris from the clean air. The
debris is retained in the separator 132 and falls into the debris
collector 148 with the dust bin door closed. During normal
operation of the vacuum cleaner separator 104E, the clean air
outlet 130 exhausts clean air from the separator 132 to a vacuum
exhaust port of the vacuum cleaner, and ultimately to the
surroundings. The pre-motor filter 256 is configured to separate
debris from the air prior to ejection to the surroundings. The
opening formed by the open dust bin door 152 (illustrated with
regards to the first embodiment in FIG. 3) forms the dust bin
debris outlet 128 configured to exhaust debris from the vacuum
cleaner. When the vacuum cleaner separator 104E is removed from the
vacuum cleaner and attached to the dock, the downstream side 256A
of the filter 256 and the clean air outlet 130 of the vacuum
cleaner separator 104E are fluidly connected to the outlet of the
blower duct 176B such that when the blower 120 is operated, fluid
flow from the blower 120 passes through the pre-motor filter 256 of
the vacuum cleaner separator 104E towards the debris outlet 128 of
the vacuum cleaner separator 104E through the vacuum separator
132.
[0069] As illustrated in FIG. 16, the fifth embodiment of the
docking station 100 includes a first seal 196, a second seal 266,
and a third seal 268. The first seal 196 is adjacent the inlet end
180A of the return duct 180 and is configured to circumscribe the
inlet end 180A of the return duct 180 for engaging outer walls of
the vacuum cleaner separator 104E. The second seal 266 is provided
on the dock 108 to fluidly seal the dirty air inlet 124 from the
surroundings (see FIG. 19) to inhibit airflow from exiting through
the dirty air inlet 124. The third seal 268 is provided on the lid
264 around the manifold 260 to fluidly connect blower duct outlet
176B with the vacuum cleaner separator 104E around perimeter of the
clean air outlet 130 and/or the perimeter of the pre-motor filter
256 to direct air from the blower duct 176 into the downstream side
of the pre-motor filter 256A.
[0070] Upon connection of the vacuum 104E to the dock 108, the dust
bin door 152 may be opened by actuator 192 in a manner described
with respect to the first embodiment. The seal 196 engages outer
walls of the debris collector 148 and the second seal 266 blocks
the dirty air inlet 124 inhibiting airflow generated by the airflow
source 120 of the dock 108 from passing out of the dirty air inlet
124. The user closes the lid 264 to engage the third seal 268
around the clean air outlet 130 and/or the filter 256 connecting
the blower exhaust duct 176B to the vacuum cleaner separator 132.
In operation of the fifth embodiment of the docking station system,
airflow generated by the blower 120 passes through, successively,
the blower duct 176, the downstream side 256A of the pre-motor
filter 256 of the vacuum cleaner separator 132, the vacuum
separator 132, the debris outlet 128 of the vacuum cleaner
separator 132, the return duct 180, and the exhaust opening 184.
The blower 120 may be controlled in a manner described with respect
to the first embodiment.
[0071] Each of the embodiments of the docking station 100 include
the dock 108 including the blower 120 which generates fluid flow
which passes debris from the vacuum cleaner 104 to the dock debris
collector 188. As previously mentioned, various other elements of
the first embodiment of the docking station 100 may be applied to
the other embodiments of the docking station 100. Other variations
of the described and illustrated embodiments are possible.
[0072] Each of the vacuum cleaners 104 is movable between an in-use
position (e.g., FIG. 2) decoupled from the dock 108 and a docked
position (e.g., FIG. 3) coupled to the dock 108. In transitioning
between the in-use position (FIG. 2) and the docked position (FIG.
3), a user grasping a handle 324 of the vacuum cleaner 104 (e.g.,
the vacuum cleaner 104A in FIGS. 2, 3) does not have to rotate the
vacuum cleaner 104 about the longitudinal axis LA to couple the
vacuum cleaner 104 to the dock 108. Accordingly, the user is
relieved from having to twist the handle 324 to couple or decouple
the vacuum cleaner 104 to or from the dock 108. Insertion and
removal of the vacuum cleaner 104 to and from the dock 108 is
simplified. Movement of the vacuum cleaner 104 to both insert and
remove the vacuum cleaner 104 from the docket 108 are in directions
similar to how the vacuum cleaner 104 is moved during normal
operation. This configuration along with the vacuum contact 164 and
the dock contact 212 can further simplify electrically coupling the
vacuum cleaner 104 to the dock 108.
[0073] Each of the vacuum cleaner separators 132, 104D, 104E each
defines a plurality of surfaces. Each of the vacuum cleaner
separators 132, 104D, 104E defines a first sidewall 300 (i.e., a
"surface") configured to generally face a reference plane W when
the vacuum 104 is moving in a forward direction. The reference
plane W in the description and claims herein is defined to be a
vertical plane of reference in front of a user as the user
approaches the reference plane W along a direction perpendicular to
the plane. The reference plane W may be, for example, a wall, an
imaginary plane, or the like. As illustrated in FIGS. 2 and 3, the
reference plane W may extend transverse to the surface S. More
specifically, the reference plane W may be perpendicular to the
surface S. As used here, the reference plane W may be behind the
dock 108 as a frame of reference as a user approaches the dock 108
with a separator to connect to the dock. The dock 108 is configured
to have a docking side, which is a side toward which a user is or
may be positioned while coupling the vacuum 104 to the dock 108.
The docking side, and as such the user, is positioned on the
opposite side of the dock 108 from the reference plane W during
docking. The first sidewall 300 of the vacuum 104 is a surface that
faces the docking side and the reference plane W when in the docked
position (FIG. 3). The first sidewall 300 would also be oriented
toward the reference plane W when the vacuum 104 is used during
normal vacuuming operation as the user approaches the reference
plane W. The first sidewall 300 also faces in a direction away from
the user and generally away from the floor S in a normal in-use
vacuuming position (not shown). The vacuum 104 connects to the dock
108 with the first sidewall 300 facing the docking side and facing
the reference plane W. That is, the user simply sets the vacuum 104
onto to dock 108 in much the same way as the user moves the vacuum
104 during in-use normal vacuuming operation.
[0074] Each of the vacuum cleaner separators 132, 104D, 104E
further defines a second sidewall 304 opposite the first sidewall
300. The second sidewall 304 faces toward a user of the docking
station 100 in the docked position (FIG. 3) when the user is
positioned on the docking side, or the opposite side of the dock
108 from the reference plane W. The second sidewall 304 also faces
in a direction toward the user and generally toward the floor S in
a normal in-use vacuuming position (not shown).
[0075] Each of the vacuum cleaner separators 132, 104D, 104E
further defines a top end 308 and an opposite bottom end 312
supported on the dock 108 when the separator 132, 104D, 104E is
coupled to the docking station 100. The separators 132, 104D, 104E
each further defines a first lateral sidewall 316 generally
corresponding with a left side of the separator 132, 104D, 104E and
an opposite second lateral sidewall 320 generally corresponding
with a right side of the separator 132, 104D, 104E.
[0076] Finally, the vacuum cleaners 104A, 104B each include the
handle 324. The handle 324 includes a first end 324a and an
opposite second end 324b oriented for a user to grasp the handle
324 in a normal grasping position to maneuver the vacuum cleaner
104A, 104B during use. The normal grasping position in the
description and claims herein is defined to be a user grasping the
handle with the user's index finger IF closer to the first end 324a
of the handle 324 and the user's little (i.e., pinky) finger LF
closer to the second end 324b of the handle 324. A user grasps the
handle 324 of the vacuum cleaner 104 (e.g., the vacuum cleaner 104A
in FIGS. 2, 3) in the normal grasping position to transition
between the docked position (FIG. 3 and the in-use position (FIG.
2), and does not have to rotate the vacuum cleaner 104 about the
longitudinal axis LA to couple the vacuum cleaner 104 to the dock
108. In the illustrated embodiments, the handle 324 is located
adjacent the top end 308 of the separator 132. In the illustrated
embodiments, the battery 144 is located adjacent the handle 324 and
the second sidewall 304. Accordingly, when in both the normal
in-use vacuuming position and the docked position (FIG. 3), the
battery 144 is positioned adjacent the user and between the user
and the reference plane W. Other location of the handle 324 and the
battery 144 are possible as desired for the application.
[0077] The dock 108 also defines a plurality of surfaces. The dock
108 defines a first sidewall 400 configured to face the reference
plane W. The dock further defines a second sidewall 404 opposite
the first sidewall 400. The second sidewall 404 is the docking side
configured to face a user during docking. The dock 108 further
defines a top end 408 and an opposite bottom end 412 supported on a
surface S. The surface S is a floor or floor surface cleaned by the
vacuum cleaner 104. The dock 108 further defines a first lateral
sidewall 416 generally corresponding with a left side of the dock
108 and an opposite second lateral sidewall 420 generally
corresponding with a right side of the dock 108.
[0078] In regular use of the separators 132, 104D, 104E, the
separator 132, 104D, 104E assembled as a vacuum cleaner is advanced
at least partially in an advancing direction extending away,
typically forwardly, from the first sidewall 300 thereof. In
regular use of the separators 132, 104D, 104E, the separator 132,
104D, 104E as a vacuum cleaner is retreated at least partially in a
retreating direction extending away, typically rearwardly, from the
second sidewall 304 thereof. In regular use of the vacuum 104A,
104B, the user grasps the handle 324 to maneuver the vacuum 104A,
104B in the advancing and retreating directions across a surface to
be cleaned, or to move the vacuum to desired locations.
[0079] While the separator 132, 104D, 104E is coupled to the dock
108, the separator 132, 104D, 104E approaches the dock 108 with a
first sidewall 300 of the separator 132, 104D, 104E facing the
first sidewall 400 of the dock 108. In one embodiment, the bottom
end 312 is coupled to the top end 408 of the dock 108. As
illustrated in the embodiment of FIG. 2, the vacuum 104A houses the
separator 132, and the vacuum 104A is translated along arrow A1 to
couple the debris outlet 128 of the vacuum 104A in fluid
communication with the return duct inlet 180A of the dock 108.
Accordingly, the fluid flow path from the blower 120 can pass
through the separator 132, 140D, 104E as described above. In the
embodiment illustrated in FIG. 2, the direction of insertion along
arrow A1 extends along the longitudinal axis LA through the vacuum
cleaner.
[0080] FIG. 3 illustrates the position in which the vacuum 104A is
coupled to the dock 108. In this position, the first sidewall 300
of the separator 132 is adjacent the first sidewall 400 of the dock
108 and the second sidewall 304 of the separator 132 is adjacent
the second sidewall 404 of the dock 108. As illustrated in FIG. 3,
the first sidewall 300 of the separator 132 (a component of the
vacuum 104A) faces the first sidewall 400 of the dock 108. The
second sidewall 304 of the separator 132 (a component of the vacuum
104A) faces the second sidewall 404 of the dock 108. Accordingly,
the second sidewall 304 of the separator 132 is configured to face
the user (e.g., where the user is positioned to the left of the
dock 108, the vacuum 104A, and the separator 132 as viewed in FIG.
3) when the vacuum cleaner separator 132 is coupled to the dock
108. In coupling the vacuum 104A including the separator 132 to the
dock 108, neither the vacuum 104A nor the separator 132 was rotated
about the arrow A1 and longitudinal axis LA. Rather, the separator
132 is aligned with the dock 108, and is translated along the arrow
A1. Accordingly, a user can grasp the handle 324 during both
regular operation of the vacuum 104A, 104B and during docking of
the vacuum 104A, 104B onto the dock 108. This eliminates the need
for a user to twist the vacuum 104A, 104B, or the separator 104D,
104E prior to coupling the vacuum 104A, 104B, or the separator
104D, 104E to the dock 108. Similarly, when the vacuum 104A, 104B
is uncoupled from the dock, the vacuum is oriented with the first
sidewall 300 facing away from the user as in the use orientation
eliminating the need for a user to twist and re-orient the vacuum
104A, 104B prior to using the vacuum.
[0081] Components of the vacuum 104A face certain surfaces of the
separator 132. For example, as illustrated in FIGS. 2, 3, and 5,
the battery 144 faces the second sidewall 304. Accordingly, the
battery 144 is spaced from the reference plane W and is readily
accessible to a user when the vacuum 104A is coupled to the dock.
The battery 144 may face a user in both the in-use position (FIG.
2) as well as the docked position (FIG. 3). With this location of
the battery 144, the battery 144 may be selectively coupled to the
vacuum 104A by a user positioned adjacent the second sidewall 304
without requiring the user to reach over or around the vacuum 104A.
Accordingly, the battery 144 is more accessible to a user in the
docked position (FIG. 3) of the vacuum 104A.
[0082] With continued reference to FIG. 5, the handle 324 of the
vacuum 104A extends in a direction between the first end of the
separator 132 and the second end of the separator 132. In the
illustrated embodiment, the handle 324 is angled and extends at
least partially in a direction between the top end 308 and the
bottom end 312. The handle 324 permits a user to connect or
disconnect the vacuum cleaner 104A from the dock 108 by moving the
vacuum cleaner 104A along the axis A1. The handle permits the user
to connect or disconnect the vacuum cleaner 104A from the dock 108
with the first sidewall 300 facing away from the user as in the use
orientation, without requiring rotation of the vacuum cleaner 104A
about the longitudinal axis LA or the arrow A1.
[0083] Components of the dock 108 face certain surfaces of the dock
108. For example, as illustrated in FIG. 3, the blower duct 176,
and the airflow outlet 176B thereof are positioned adjacent the
second sidewall 404 of the dock 108. The exhaust opening 184, which
is downstream of the dock debris collector 188, is positioned
adjacent the first sidewall 400 of the dock. The blower 120 is
positioned adjacent both the first sidewall 400 and the bottom end
412 of the dock 108. As illustrated in FIG. 6, the battery 144 may
be separable from the vacuum 104B and coupled to the dock 108
adjacent both the second lateral sidewall 420 and the top end 408
of the dock 108. Other positions of the airflow outlet 176B, the
exhaust opening 184, the blower 120, and the battery 144 are
possible.
[0084] With continued reference to FIG. 6, the vacuum 104B is
supported upon the dock 108 with the foot 116 resting upon the base
224. The base 224 is located adjacent the bottom end 412 of the
dock 108, and is supported upon the surface S. Turning to FIG. 7,
the wans 112 is adjacent the second sidewall 404 of the dock
108.
[0085] The various embodiments of vacuums 104A-104C and vacuum
separators 104D-104E have different locations of vacuum cleaner
inlets 114 and separator inlets 124. In the vacuums 104A-104C and
the vacuum separator 104D, the separator inlet 124 is adjacent the
second sidewall 304 of the separators 132, 104D. As illustrated in
FIG. 19, when the vacuum separator 104E is coupled to the base 108,
the airflow outlet 176B and the separator inlet 124 are each
adjacent the top end 308 of the separator 104E. The suction inlet
114 may be positioned on the body 106 of the vacuums 104A-104C. In
other embodiments, the vacuum cleaner separator 104D-104E may
include the suction inlet 114. Positioning of the suction inlet 114
varies as desired for the application.
[0086] The various embodiments of vacuums 104A-104C and vacuum
separators 104D, 104E have different locations of debris outlets
128. In the vacuums 104A-104C, the debris outlets 128 are adjacent
the first sidewall 300 of the separator 132. As best illustrated in
FIG. 5, in these embodiments, the airflow outlet 176B is positioned
adjacent the second sidewall 404 of the dock 108, and faces the top
end 408 of the dock 108.
[0087] As illustrated in FIGS. 15 and 19, in the vacuum separators
104D, 104E, the debris outlets 128 are adjacent the second sidewall
304 of the separators 104D, 104E. In these embodiments, the blower
duct 176 is adjacent the first sidewall 400 of the dock 108. In the
embodiment of FIG. 15, the air outflow outlet 176B is adjacent the
first sidewall 400 of the dock 108, and extends towards the second
sidewall 404 of the dock 108. In the embodiment of FIG. 19, the
airflow outlet 176B of the duct 176 is positioned adjacent the top
end 408 of the dock 108, and faces the bottom end 412 of the dock
108. Other locations of the debris outlets 128 and blower duct 176
are possible.
[0088] FIG. 15 illustrates the position in which the separator 132
is coupled to the dock 108. In this position, the first sidewall
300 of the separator 132 is adjacent the first sidewall 400 of the
dock 108 and the second sidewall 304 of the separator 132 is
adjacent the second sidewall 404 of the dock 108. As illustrated in
FIG. 15, the first sidewall 300 of the separator 132 faces the
first sidewall 400 of the dock 108. The second sidewall 304 of the
separator 132 faces the second sidewall 404 of the dock 108.
Accordingly, the second sidewall 304 of the separator 132 is
configured to face the user (e.g., where the user is positioned to
the right of the dock 108, the vacuum 104A, and the separator 132
as viewed in FIG. 15) when the vacuum cleaner separator 132 is
coupled to the dock 108.
[0089] One or more independent features and/or advantages of the
invention may be set forth in the following claims.
* * * * *