CA1273168A - Vacuum cleaner - Google Patents

Abstract

ABSTRACT
In a vacuum cleaner having an upper housing and a lower housing, said lower housing having a working air inlet, said upper housing having a by-pass type blower motor and a working air inlet, the improvement comprising:
a water filter system comprising a working air inlet deflector in association with said working air inlet, a bottom pan assembly included in said lower housing and including a preselected amount of water for water filtering of working air and, a static water separator element fixed relative to said working air inlet for separating water from the working air and communicating the working air from said lower housing to said upper housing and said working air outlet; said water separator element having a bottom wall generally positioned at the water level of the pan assembly, an air porous portion and a generally water non-porous portion for separating water from said working air.

Description

~273168 VACUUM CLEANER
Background of the Invention The present invention relates to the vacuum cleaner art and more particularly to vacuum cleaners employing a water filter.
The invention is particularly applicable to a 5 vacuum cleaner employing a bypass type blower motor in association with a water pan, separator and filter assembly. However, it will be appreciated to those skilled in the art that the invention could be readily adapted for use with other types of vacuum cleaners or other types of devices.
Conventional vacuum cleaners employing a water filter are known but have suffered the problems resulting from unreliable water filtration, excessive water filter turbulence and water con~amination of the motor bearing elements over a period of time. It is important for the working air in a water filtration system to pass through a sufficient amount of water to draw off the dirt particles from the dirty working air.
Where the dirty working air passes through an inadequate amount of water, the dirt particles are merely transmitted through the system in association with the uncleaned working air. Inadequate water passage has occurred through design limitations o~ through excessive turbulence of the water which created air passageways through the water. Excessive and uncontrolled turbulence can also cause excited impingement of water splashes against the cleaner motor and bearings with consequential harm occurring to such elements.
Another common problem in vacuum cleaner construction is the undesirably high level of noise made by the cleaner during operation from the cleaner motor, the cleaner vacuum fans and the resulting noise from ~3~S 3

-2-turbulent ~orking air. A ~ariety of baffle arrangements have been suggested and employed in the industr~, see U.S. Patcnt No. ~,330,899, to reduce the noise leYel, all ~ith varying degrees of success.
The present inrention contcmplates a new and improved Yacuum cleaner construction which orercomes all of the aboYe referred to problems and oth~rs to provide 8 ncw ~acuum cleaner construction which is simple in design, economical ~o anufacture, prorides i~pro~ed noise reduction, proYides i~proved protection df the otor and bearing elcments against water and contaminants during operation, provides improved water separation operation from working air and which pro~ides improred ~nd controlled operation of water turbulence ant working air operation.

Brief Sumary of the Invention In accordance with the present invention, there is provided a vacuum cleaner having an upper housing and a lower housing, said lower housing having a working air inlet, said upper housing having a by-pass type blower motor and a working air inlet, the improvement comprising:
a water filter system comprising a working air inlet deflector in association with said working air inlet, a bottom pan assembly included in said lower housing and including a preselected amount of water for water filtering of working air and, a static water separator element fixed relative to said working air inlet for separating water from the working air and communicating the working air from said lower s i~273~6~

housing to said upper housing and said working air outleti said water separator element having a bottom wall generally positioned at the water level of the pan assembly, an air porous portion and a generally water non-porous portion for separating water from said w ~ ~ ~ n /

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~273l6a One benefit obtained by use of the present invention is a vacuum cleaner construction which has reduced operational noise.
Another benefit obtained from the present invention is a vacuum cleaner which employs an improved water separator element for separating and condensing water from working sir.
Yet another advantage of the present invention is a water filter vacuum cleaner which controls water turbulence and resulting water contamination of cleaner motor bearing elements over a period of time.
Other benefits and advantages of the subject new vacuum cleaner cons~ruction will become apparent to those skilled in the art upon a reading and understanding of this specification.
Brief DescriPtion of the Drawin~s The invention may take physical form in certain parts and arrangements of parts, the preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein:
FIGURE l is a cross-sectional view of a vacuum cleaner formed in accordance with the present invention showing a water level in the bot~om pan assembly;
FIGURE 2 is a cross-sectional view taken along line 2-2 of FIGURE l particularly showing the configuration of a baffle ring;
FIGURE 3 is a partial cross-sectional view of a sçction of a motor of the present invention particularly illustrating the air pressure sealing of the bearings of the motor against water contamination, PIGURE 4 is a cross-sectional view taken along line 4-4 of PIGURE 1 particularly showing the bottom wall and the bottom wall air outlet port of the working air deflector of the bottom pan assembly; and, 12~3168 FIGURE 5 is a plsn view of a water separator element formed in accordance with the present invention.
Detailed Description of the Invention Referring now to the drawings wherein the 5 showings are for purposes of illustrating the preferred embodiment of the invention only and not for purposes of limiting the same, the FIGURES show a YacUum cleaner A
employing a primary water filter for cleaning air and collecting dirt materials into a water tank or pan receptacle.
More specifically, and wi~h reference to FIGURE
1, vacuum cleaner A comprises an upper housing 10 and a lower housing 12. The upper housing 10 contains a bypass-type blower motor assembly 14 including a fan chamber 16 and a working air inlet port 18 to the fan chamber 16. The motor assembly 14 is supported on a lower mounting plate assembly 24 fastened to the side wall 26 of the upper housing 10 with a plurality of fasteners 28 and brackets 30. The lower mounting plate assembly 24 includes an annular flanged member 32 which is sealingly engaged to annular lower sealing gasket 34. The flanged number 32 and sealing gasket 34 in turn support the fan chamber 16 and ultimately the motor assembly 14. The lower mounting plate assembly 24 includes an inner opening 36 for the communication of working air from the lower housing 12 to the upper housing 10.
Upper mounting plate assembly 44 is of a similar construction to the lower mounting plate assembly and is fastened to the side wall 26. It includes sn upper annular flanged member 46 in sealing ~ngagement to upper sealing gasket 48. The motor 50 of ~otor assembly 14 extends through the upper mounting plate assembly 44 in~o the dome 52 of the upper housing ~7:~68 10. A cover rin8 54 ~s interposed between the dome 52 snd the side walls 26 of the upper housing and includes an annular opening 56 for the egress of motor cooling air as will hereinafter be more fully explained. The cover ring radially innermost edged portions 58 are substantially air-sealed against the motor 50 to segregate motor cooling air intake from the motor cooling air exhaust. The motor cooling air intake is commur.icated through an inlet port (not shown) in the dome 52. Handle 59 is fastened to the dome 52 with fasteners 60 for facilitating transport of the ~acuum cleaner A.
With continued reference to FIGURE 1, and with reference to FIGURE 2, a baffle ring 64 is radially interposed between fan chamber 16 and upper housing side wall 26. The baffle ring extends from the lower mounting plate assembly 24 to the upper mounting plate assembly 44 to define a first air chamber 66 about the fan chamber 16 and a second air chamber 68 adjacent the side wall 26 of the upper housing. The baffle ring provides a tortuous working air exhaust flow pattern from the fan chamber 16 to provide for noise reduction in the operation of the vacuum cleaner A. Working air exhausted from the plurality of fan chamber exhaust ports 70 is immediately communicated into the first air chamber 66. A single baffle ring working air outlet port 72 communicates working air from the first air chamber 66 to the second air chamber 68. The baffle ring ou~let port 72 is spaced 180 from the ultimate working air outlet port 74 of the cleaner A to maximize working air flow travel distance from the first air chamber 66 to the second air chamber 68 and out from the cleaner A. It is within the scope of the invention to include a plurality of spaced radially extending baffle 1273~8 plates 78, a first portion of which depe~d from the side wall 26 and a second portion of which depend from the baffle ring 64. The baffle plates further provide tortuous air flow patterns for noise reduction in the operation of the cleaner A.
The subject cleaner employs a dynamic air seal to better seal the fan bearings and motor against moisture and contaminants that may be intermixed with the working air during operation of the cleaner. The operation cf the air seal shown in FTGURE 3 is more particularly identified in U.S. Patent No. 4,226,575.
In general operation, a working air fan 84 draws working air through the fan chamber working air inle~ port 18 (FIGURE 1) and out the fan chamber exhaust ports 70, To keep the working air away from the bearings 86 of the fan drive, a sealing air fan 88 draws air from sealing air inlet port 90, about check valve 92 along sealing air baffle ring 93 and through the sealing air port 94 which is slightly spaced from the fan drive 96. The sealing air exhaust is similarly expelled through exhaust ports 70. The air pressure seal at sealing air port 94 during operation of the fans 84, 88 effectively seals the bearin8 86 and the motor against the working air sucked into the fan chamber 16 by working air fans 84.
With particular reference to FIGURES 1 and 3, the subject vacuun cleaner A includes a bypass-type fan motor assembly having a fan engaged to the fan drive separate from the main working air fans in the fan chamber 16 for blowing cooling air over the motor. The motor cooling air flow is kept separate from the working air flow passing through the fan chamber 16. The cooling air for the motor 50 is drawn in through the dome 52 through a cooling air inlet port (not shown~ in the side wall of the dome. A fan (not shown~ is typically positioned in the top portion such as indicated at 98 in ehe motor 50 to draw air in rom the dome 52 and is expelled out through the motor through ventilating ports spaced in the motor such as indica~ed at 100. The cooling air is then ultimately expelled through the annular opening 56 in the cover ring 54.
With particular reference to FIGURES 1, 4 and S, the dirt filtra~ion and cleaning operation of the invention will now be particularly discussed. She lower housing 12 includes a dolly assembly 106 for supporting a water pan 108 and for clamping attachment and support of the upper housing 10 through a plurality of clamps 110. The clamps 110 engage a clamping flange 116 depending from the side wall 26 of the upper housing 10 for selective attachment of the lower housing to the upper housing. A sealing gasket 118 facilitates water and air sealin8 of the upper housing to the lower housing. The dolly assembly further includes casters 112 for rolling support of the vacuum cleaner and support legs 114 for supporting the water pan 108.
The water pan 108 is preferably of a clear plastic material such that the water 124, and more particularly the water level, may be viewed by an operator of the cleaner. The pan includes a flanged rim portion 126 which cooperates with sealing gaske~ 118, upper housing flange 116, and clamp 110 to facilitate sealing of the upper housing to the lower housing.
A water separator element 130 is provided in 39 the lower housing 12 to separate and rondense water from the working air during operation of the cleaner. During such operation the working air is passed through the water 124 and quite a bit of water turbulence occurs in the pan water chamber. The separator ele3ent 130 ~273~6a g facilitates separation and condensation of water from working air and filtration of contaminants from the working air. The separator element is preferably constructed of a durable and long-lasting material such as aluminum although it is within the scope of the invention to include other materials such as plastics as the construction ~atérial. It is of a generally frusto-conical configuration including a sloping side wall 132 which tapers towards the bottom of the water pan 108. A bottom wall 134 defines the bottom end portion of a separator element 130 and includes a water outlet aperture or drain hole 136 for the communication of water condensed within the separator element or along the side wall 130. The drain hole is preferably sized to have a one quarter inch diameter. The bottom wall is positioned at the water level in the pan. The side wall 132 includes a water-porous portion and a water nsn-porous portion. The water-porous portion is illustrated as a screen portion 138 including a plurality of stamped or punched holes 140 having an ei8hth of an inch diameter. The screen portion 138 communicates filtered working air from the water chamber towards the fan chamber 16. In the preferred e~bodiment, thirty one rows of holes 140 extend through a 180 seg~ent of the side wall 130 from the bottom wall 134 towards the side wall flange 142. It is preferable that the screen portion is spaced away from the working air inlet port 150 of the bottom pan 108 as the area of greatest water turbulence occurs immediately adjacent the working air inlet port 150. The non-porous portion of the separator ele~ent generally faces towards the working air inlet port lS0 to minimize passage of water through the separator element caused by violent water turbulence. Positioning of the water separator element ~z~3~68 130 relative to the bottom pan 108 is facilitated by a locator device such as mating and locating pin 152 extending from the flanged rim portion 126 of the water pan which is received in the bore 154 in the separator flange 142. By these means, positioning of the separator element 130 in the preferred position is accomplished.
The water pan further includes a deflector element 160 which deflects the working air from the working air inlet port 150 and directs it to the water 124 contained in the water pan. The deflector includes a side wall 162 depending from the water pan 108 and may be integrally formed in the water pan or fastened as a separate element as illustrated in FIGURES 1 and 4. The deflector element side wall 162 deflects the working air towards the deflector element bottom wall 164 which is preferably positioned below the water level in the water pan. The bottom wall includes an opening 166 intermediately disposed in the bottom wall 164 which communicates the working air from the air inlet aperture 150 to the water of the wa$er pan. It may be seen that the bottom wall 164 provides a shelf portion over which working air must pass before passage out of the water and through the separator element. It is through the passage across the shelf portion of the bottom wall 164 that the working air is drawn through the water and primarily washed. The inclusion of a shelf portion in the deflector element 160 provides improved washing over deflector elements which do not include a bottom wall ~nd only provide washing as working ais passes about the bottom ed8e of the side wall of a deflector element. It has been found that such minimal washing provides undesirable results particularly where excessive turbulence oay allow dirty working air to pass to the ~ 3 i~3 separator element without passage through the water of the water pan.
The invention also includes a secondary filtration system for filtering dirty working air containing elements, such as ash, which cannot be picked up by water. Secondary filter 170 comprises a washable type filter element which is air-porous to allow communication of working air to the fan chamber 16. It is mounted on an annular receiving member 172 depending from the lower mounting plate assembly 24. The secondary filter element may be mounted to the recei~ing member 172 in a number of conventional ways such as by an elastomeric band (noe shown) or by compression fitting the filter to the receiving member.
OPeration With particular attention to FIGURE 1, the improved operational characteristics of the new Yacuum cleaner will be specifically discussed.
The invention has a triple filtration system for dirty working air. Water 124 is provided in the pan 108 to a preselected le~el just below the bottom wall 134 of the separator element 130 and above the bottom wall 164 of the deflector 160. Dirty working air sucked in through the working air inlet port 150 of the water pan 108 is initially filtered in the water 124 of the water pan~ Those elements that are picked up by water such as dust and most other types of elements picked up by a Yacuu~ cleaner, are filtered from the working air in this filtration step. During operation, the water 124 is quite turbulent and impinges against the separator element 130 which primarily functions to separate and çondense water particles froM the working air and pre~ents splashing of water towards the upper housing, but also operates as the second dirt filtration ~273~6~3 ~12-system. The area of the plurality of holes 140 in the screen portion is important in that it may not be so limited as to affect the velocity of the air flow through the screen portion. As available area for passage is lessened, the velocity of air flow therethrough must increase. In the preferred embodiment of the inYention, the open area of the holes of the screen portion is 19.35 sq. inches and air flow through the separator is 63 cubic ft./minute. The third filtration system comprises the secondary filtering element 170 which fil;ters those elements not previously filtered by water and the separator element 130. Air flow is controlled in part by the size of the working air inlet port 18 of the fan chamber 16. In the preferred embodiment, the working air inlet port 18 has been reduced to a seven-eights of an inch round aperture to regulate the volume of air being drawn through the system to a prçselected level facilitating efficient perfosmance. By the time the working air has entçred the working air inlet port 18 it has been cleaned and is ready for communication back to the enYironment of the cleaner. The working air is drawn up through the fan chambers 16 and is expelled through fan chamber ports 70 into the first air chamber 66 then out through the baffle ring outlet port 72 into the sesond air chamber 68 and ultimately out through the working air outlet port 74 of the cleaner.
The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon the reading and understanding of the specification. It is my intention to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.

- ~731 68 Ha~ing thus described ~y irlvention, I now clalm:

Claims (6)

1. In a vacuum cleaner having an upper housing and a lower housing, said lower housing having a working air inlet, said upper housing having a by-pass type blower motor and a working air inlet, the improvement comprising:
a water filter system comprising a working air inlet deflector in association with said working air inlet, a bottom pan assembly included in said lower housing and including a preselected amount of water for water filtering of working air and, a static water separator element fixed relative to said working air inlet for separating water from the working air and communicating the working air from said lower housing to said upper housing and said working air outlet; said water separator element having a bottom wall generally positioned at the water level of the pan assembly, an air porous portion and a generally water non-porous portion for separating water from said working air.

2. The improvement as defined in claim 1 wherein said separator element includes an air-porous portion and a generally water-non-porous portion for separating water from said working air.

3. The improvement as defined in claim 2 wherein said air-porous portion faces generally away from said deflector.

4. The improvement as defined in claim 2 wherein said air-porous portion is sized relative to an inlet air aperture of said bypass type blower motor to regulate working air velocity through said air-porous portion to a preselected level whereby water is filtered from said working air by said separator element during operation of said vacuum cleaner.

5. The improvement as described in claim 1 wherein said deflector includes a bottom wall contiguous to the water level of said bottom pan assembly, said bottom wall including a working air outlet port for communicating the working air to said bottom pan assembly.

6. The improvement as described in claim 5 wherein said bottom wall is configured to direct the working air from said deflector bottom wall air outlet port through the water of said bottom pan assembly over the extent of said bottom wall.