EP1815778A1 - Vacuum cleaner with a polypropylene cover - Google Patents

Abstract

The vacuum cleaner, comprising a body with a cover (80) and an inner cavity (40) housing an electric motor, fan and trash separator linked to a hose connector, has the cover made from an expanded polymer material with at least one lengthwise or transverse reinforcing member (82). In a variant the reinforcing member can be in the form of a rigid frame with the expanded polymer injected over it, while a further reinforcing member (42) joins the base and side walls. Lower (4) and upper body sections are also made from the expanded polymer, with the upper body section having a wall thickness of between 15 and 60 mm.

Description

The invention relates to the field of household appliances vacuum cleaners and more particularly the structure of a vacuum cleaner.

Historically, household appliances, including vacuum cleaners, have benefited from the various plastics that became available as polymer processing technology and their differentiated performance were developed, each specifically chosen for a particular function. special: resistance to temperature, rigidity or flexibility, acoustic damping, aesthetic appearance, etc .... Today, there are more than half a dozen different plastics in the body of a vacuum cleaner: ABS, polyamide , polyethylene, polypropylene, PVC, elastomers, etc.

Several elements are thus manufactured separately and fixed to form the body of the device as well as the cover for the housing of the dust collection bag, the supports of the filter elements, etc ...

The plastics used in the vacuum cleaners are as thin as possible so as to limit the weight of the apparatus, and reduce the effort required for handling the vacuum cleaner during its use, this manipulation being a major cause of fatigue, for example when floors are to be climbed or when stairs are to be cleaned.

A first problem encountered during the manufacture of a vacuum cleaner is therefore the reduction of the weight of the device, this problem being a permanent concern for vacuum cleaner manufacturers.

The desired weight reduction results in the thinning of the shell and the body which goes against the strength of the device. In fact, the weight of plastic material used for the manufacture of a vacuum cleaner quickly reaches a limit determined by the strength of the assembly.

A second problem is to maintain the strength of the hull and the body while greatly reducing the weight of plastic material used and that of the vacuum cleaner.

Vacuuming in the home is not usually a very pleasant task, and in fact, the appliance is used without care. It often happens that the device hits furniture, walls or various objects placed in the home. On this occasion, given the rigidity of the frame of the vacuum cleaner, the shocked part is often damaged.

A third problem facing vacuum cleaner manufacturers is thus to combine good mechanical characteristics of the frame with possible shock absorption to limit the effects of imprudent handling. One solution to this problem can be found in particular by rubber bands surrounding, like a belt, the body of the apparatus. Such a solution generates a significant additional cost.

Moreover, in the current situation of the recycling of all types of waste, and in particular end-of-life appliances, all environmentally conscious manufacturers and their efforts towards sustainable development are looking for solutions to limit the weight of materials. to recycle and use as much as possible materials that can be easily recovered. It is known that the environmental impact of a vacuum cleaner comes largely from its constitution.

A fourth problem that arises is to manufacture a vacuum cleaner whose materials can be easily, and if possible completely, recycled.

The invention therefore aims to solve these major difficulties, ie aims to achieve a vacuum cleaner reduced weight, good strength, can absorb shocks and having a high recyclability end of life.

According to the invention, the vacuum cleaner comprises a frame, as well as a cover, said housing accommodating in particular an electric motor-fan and a waste separation device connected to a connector opening out of the frame, said waste separation device being arranged in a housing formed in the frame of the vacuum cleaner, said electric motor-fan being able to depressurize the housing of the waste separation device in order to suck air through the connection inside the frame, said cover constituting one of the closing walls of the housing of the waste separation device, characterized in that the lid is made of expanded polypropylene, and in that it comprises at least one mechanical reinforcement of its structure.

Expanded polypropylene (EPP) is formed of beads which are molded in the object using a press in the presence of steam. Mainly used as shock absorbing material, especially recently in the automobile (shock absorber), the EPP has multiple qualities: temperature resistance up to 110 ° C, excellent stability, lightness, impact resistance, ability to be recycled, etc. which makes it attractive. However, its low mechanical strength is currently only a complementary material when making subsets.

The present invention is thus likely to provide a vacuum cleaner, one of the external parts, in this case the cover, which requires a certain rigidity, strength and mechanical strength, is made of PPE, material that is not provided, originally, for this purpose.

The use of EPP for this member of the vacuum cleaner has, in addition to the advantages resulting from its intrinsic properties described above, the particularity of having an elastic memory, which also has significant advantages in terms of assembly of the cover on the frame of the device. Indeed, it is thus possible to articulate the lid without hinge and simply lock it by "forcing" the material to be deformed, the material resuming its shape after the deformation to maintain the assembly.

Such a lid therefore allows, in addition to a slight reduction in the weight of the entire vacuum cleaner, to provide good environmental protection during shocks in the use of the vacuum cleaner.

However, it appears necessary, in the case where the lid is used to close the waste separation compartment, to mechanically reinforce this lid. Indeed, such a compartment undergoes a depression during operation of the engine, to create an aspiration of air by a nozzle connected to the waste separation compartment. Therefore, the cover, bearing on the frame, generally by its periphery, undergoes a bending force that can be important.

In order not to risk damaging the cover, a mechanical reinforcement, made by a rigid part, is then associated with the cover, in order to limit its deformation during operation of the vacuum cleaner.

The mechanical reinforcement may consist of a rigid piece extending over substantially the width and / or the length of the lid, or a frame made of a rigid material around which is injected polypropylene.

Advantageously, the reinforcement of the cover is supported on one or more walls from the frame, to limit the stress of the EPP constituting the cover.

According to one embodiment of the invention, the frame comprises a lower body and an upper body, the upper body being also made of expanded polypropylene, the lid bearing on said upper body.

By body of the device is meant the visible outer part of the device, which can take various names: housing, shell, frame ....

Since the upper body is an important part of the frame of the vacuum cleaner, the present invention thus dares to present essential constituent parts of the frame of the vacuum cleaner, requiring good mechanical properties, made of PPE.

According to a preferred embodiment of the invention, the lower body is also made of expanded polypropylene. Such an embodiment greatly limits the weight of the apparatus while providing, by the flexibility of the material, excellent shock absorption and non-aggression capabilities to the work environment.

Moreover, such a configuration makes it possible to join another object of the present invention which is to favor polypropylene in the choice of the plastics material, with the objective of using more than 90% of a single type of plastic material. polypropylene, throughout the body of the vacuum cleaner. Polypropylene can then be used in two forms: conventional polypropylene (PP) which is known for its lightness, and average mechanical performance, and expanded polypropylene (EPP). Preferably, homopolymers which are easy to recycle will be used.

In order to avoid deformations of the expanded material constituting in particular the housing of the waste separation device, advantageously, the upper body comprises a mechanical reinforcement of certain walls delimiting the housing of the waste separation device.

Preferably, the mechanical reinforcement consists of a rigid piece of generally U-shaped shape matching the bottom wall and two non-adjacent walls delimiting the housing of the waste separation device. Such a hoop structure is simple in design and is sufficient to considerably reduce the risk of deformation of the walls, risks related to the depression generated by the engine, but may also result from external constraints (shocks, pressure related to certain uses, storage, ...).

It is then interesting to associate such a structure with that constituting the reinforcement of the lid by proposing a lid reinforcement consisting of a rigid piece extending over the width or the length of the lid and resting on the two U-shaped legs. mechanical reinforcement of the housing of the waste separation device to form a frame that stiffens the structure of the frame and the lid.

Other characteristics and advantages of the invention will be given by the description which follows, with reference to the appended figures which constitute only a non-limiting example of embodiment.

Figure 1 is a perspective view of a vacuum cleaner according to the present invention.

Figure 2 is an exploded view of the different main parts of the vacuum cleaner.

Figure 3 is an exploded view of some parts of the vacuum cleaner.

Figure 4 is a perspective view, from below, of the cover of the vacuum cleaner.

Figure 5 is a top view, in perspective, of the upper body of the vacuum cleaner.

Figure 6 is a perspective view of some parts of the vacuum cleaner.

• un petit corps inférieur 2 disposant :
  • o d'un logement 20 de la partie inférieure du moteur,
  • o d'un emplacement pour les organes de manoeuvre arrière tels que roues ou roulettes (non représentées),
  • o d'une sortie d'air 26 de l'aspirateur,
  • o d'un logement 30 de la partie inférieure d'un enrouleur de câble électrique (non représenté),
• un corps supérieur 4 comprenant :
  • o un espace 40 aménagé pour la réception du dispositif de séparation des déchets, qui, selon l'exemple proposé, est un sac constitué d'une ou plusieurs couches filtrantes (non représenté),
  • o un logement de la partie supérieure de l'enrouleur de câble électrique,
  • o un emplacement pour les organes de manoeuvre avant (non représentés) de l'aspirateur,
  • o un évidement de logement de la partie supérieure du moteur, conjointement avec le logement 20 du corps inférieur 2,
  • o un insert 45 permettant le raccordement de tubulures d'aspiration, cet insert coopérant avec un support de sac 46 disposé dans l'espace 40.
• une pièce arrière 50 comportant une large poignée 52 de transport de l'aspirateur.

As shown in Figures 1 and 2, the vacuum cleaner 1 according to the invention consists of a vacuum cleaner body composed of three main parts manufactured separately and assembled thereafter:

• a small lower body 2 with:
  • o a housing 20 of the lower part of the engine,
  • o a location for the rear actuators such as wheels or wheels (not shown),
  • o an air outlet 26 of the vacuum cleaner,
  • o a housing 30 of the lower part of an electric cable reel (not shown),
• an upper body 4 comprising:
  • a space 40 arranged for the reception of the waste separation device, which, according to the proposed example, is a bag consisting of one or more filtering layers (not shown),
  • o a housing of the upper part of the electric cable winder,
  • o a location for the front actuators (not shown) of the vacuum cleaner,
  • a housing recess of the upper part of the motor, together with the housing 20 of the lower body 2,
  • an insert 45 allowing the connection of suction tubes, this insert cooperating with a bag support 46 disposed in the space 40.
• a rear part 50 having a large handle 52 for transporting the vacuum cleaner.

According to the invention, a cover 80 is made of expanded polypropylene and is disposed on the upper body 4. The mechanical strength of the cover on the upper body 4 of the vacuum cleaner is obtained by interlocking the peripheral rim 83 of the cover 80 in a groove 43 of the upper body 4, slightly deforming the material, as previously explained.

This lid allows the closure of the dust bag housing and directs air from the bag to the engine block. Incidentally, this cover can receive, in its thickness, various suction accessories such as small brush, suction lolly, etc.

As is clearly visible in Figures 4 and 6, the cover 80 comprises a mechanical reinforcement, in the form of a cross member 82 preferably made of non-expanded polypropylene to reduce the diversity of plastics used. Any other material can also be used in the context of the present invention, as soon as the crossbar thus obtained has the required qualities of rigidity.

Indeed, during operation of the device, the electric fan motor creates a vacuum in the housing 40 of the dust bag of the order of 26 kPa, to generate an air intake by the insert 45 connection of the vacuum cleaner. The cover 80 closing the housing of said dust bag is thus subjected to a suction force which requires a mechanical reinforcement to overcome the low mechanical strength of the EPP, and thus prevent a deflection of the cover which could lead to its rupture.

Since the use of the EPP for producing the lid requires a relatively large thickness of material relative to the same unexpanded material, the lid will preferably be partially hollowed out from the shape of the cross-member so that the latter completely fits into the inner face of the lid, without additional rim. It may even be expected that this cross is inserted into force in the material, which facilitates its assembly and reduces associated costs. Figure 4 shows that the cross is part of the thickness of the lid.

Advantageously, the material constituting the frame of the vacuum cleaner, ie at least the upper body 4, and preferably also the lower body 2 and the rear part 50, is expanded polypropylene.

However, in order to reinforce the shock resistance of the handle 52, the rear piece 50 has an unexpanded PP core allowing the piece 50 to be mechanically resistant to a possible violent impact on said handle.

The low mechanical strength of the EPP required to considerably increase the thickness of the walls to have sufficient strength. Surprisingly, however, even if the volume of material required then causes a larger vacuum cleaner than normal, the mass of plastic material can be greatly reduced, and the weight of the final vacuum can be halved.

By way of example, as indicated in FIG. 5, the side walls of the housing 40 of the upper body 4 have thicknesses varying from approximately 15 mm for the thickness a of the partition wall with the engine compartment, to more than 50 mm for the largest thickness c of the wall separating said housing with the outside. Indeed, the thickness of this wall is not constant over the entire height of the upper body. It is about halfway up, at the connection, by the insert 45 with the suction pipe, so that the tensile force, when moving the device, is well absorbed by the upper body . The thickness b of this wall at the upper level of the body 4 is about 30 mm.

Figure 5 shows the zone 5 where the thickness of the wall of the upper body 4 is the largest. This thickness can even reach 60 mm at the level of the insert 45. The latter, by sandwiching the body 4 with the support 46 of the bag, creates, during the displacement of the vacuum, a tension important in the front part of the upper body, requiring a significant thickness of the wall at this level.

The cover has, meanwhile, a variable thickness. This thickness is of the order of 8 mm at the edge 83. The thickness of the lid is greater at ribs 85 adjacent the housing of the part 82 reinforcement since it is of the order of 30 mm.

The cover 80 also has a protuberance 84 coming opposite the wall 44 separating the compartment 40 from the motor housing. This protuberance 84 limits the bending of the cover when the latter is physically deformed for any reason, for example an unfortunate support of the user on the cover.

The amount of material remains, however, lower than on a conventional vacuum, which is also advantageous from an economic point of view since the vacuum cleaner is less expensive to manufacture.

Furthermore, the lid, as well as the walls of the housing 40 of the filter bag for waste recovery, comprise reinforcing ribs from the molding of the various parts. Such ribs are areas of extra thickness that help to stiffen these parts.

Thus, the cover has ribs 85 which are extended by ribs 820 of the cross member 82. The walls of the housing 40 of the upper body 4 also have ribs, such as the ribs 440 of the partition wall 44 with the engine compartment, and than the ribs 490 of the bottom wall 49.

Advantageously, the upper body 4 comprises a mechanical reinforcement of the side walls of the housing 40, in the form of a rigid piece 42 in the shape of a U, as shown in FIG.

Like the crosspiece 82, this part is advantageously made of unexpanded polypropylene, in order to limit the diversity of the plastics used. However, it is conceivable, in the context of the invention, to use any material having the required qualities of rigidity.

This piece 42 thus has two vertical branches 420 connected by a spacer 422. This piece 42 is disposed in the housing 40 by inserting into some walls delimiting said housing, like the cross member 82, in order to keep the inner continuity said walls.

Thus, the vertical branches 420 rest on the side walls 47, 48 of the housing 40, while the spacer 422 is supported on the bottom wall 49. Preferably, as shown in FIG. 42 U cooperates with the cross member 82 of the cover to form a frame that reinforces the mechanical strength of the lid, and the holding of the side walls 47, 48.

Advantageously, the cross-member 82 bears on the free ends of the branches 420 of the reinforcement piece 42.

In a manner similar to the configuration of the cover, the ribs 490 of the bottom wall of the housing 40 are associated with ribs 423 of the spacer 422, to create continuity in the different ribs of the walls.

This aspect is all the more important that the ribs, in addition to their role of reinforcement, also make it possible to create air circulation zones, between said ribs. Indeed, the bag, under the effect of the air circulation and the depression created by the motor, tends to come to press against some walls of the housing 40. The ribs then allow, containing the bag envelope , leaving air circulation channels out of the bag towards the engine compartment.

The high flexibility of the EPP allows for improved shock absorption compared to other plastics traditionally used to make vacuum cleaners. This great flexibility is associated, depending on the degree of expansion, an elastic memory of the material, which also has significant advantages in terms of assembly of the different complementary parts fitted to the body of the device. Indeed, it is thus possible to articulate for example the different lids without hinge and simply lock them by deforming the material. This curious particularity also makes it possible to fix inserts, by interlocking, without difficulty.

It suffices to "force" the material to deform to lock or fix an insert, the material resuming its shape after the deformation to maintain the assembly.

According to the example shown, and as shown in Figure 2, the upper body holding on the lower body is provided by rods 12, 13 bearing under the lower body 2. The rods 12 engage with the rear part 50 while the rod 13 is connected to a rigid piece 90 disposed on the upper body 4.

The supports of the rods 12 and 13 under the lower body 2 are preferably associated with the wheels, not shown, of the vacuum cleaner. As regards the central wheel, the latter is associated with a platform 11 for refocusing the wheel relative to the entire vacuum cleaner.

The actual assembly of the upper body on the lower body consists, according to the example shown, in screwing the rods 12 and 13 into corresponding tubes from the parts 90 and 50, such as the tube 14, the tubes and / or the rods advantageously passing through a portion of the upper body 4.

The screwing thus makes it possible to compress, by means of the parts 90 and 50, the upper body on the lower body, the relatively large deformation of the PPE, as previously described, making it possible to seal between the lower and upper bodies, without a specific seal.

The rigid piece 90 also has locations for the on / off control button 60, in connection with an underlying switch, and the knob 68 for rewinding the electric cable on the reel.

The rigid piece 90 also has a housing 92 for a housing 94 containing a pleated filter HEPA type, for filtering the air from the dust bag, before entering the engine.

Indicators, actuators and actuators 60, 68, and the workpiece Rigid 90, the tubes 12, 13 and the wheels, will preferably be made of unexpanded polypropylene.

The motor, not shown, will advantageously be arranged in a housing 120 of protection, advantageously consisting of rigid parts made of unexpanded polypropylene. This casing consists of a cover 122 also having orifices 126 for air inlet, as well as a fairing substantially cylindrical 130, surrounding the motor and on which is fixed the cover 122 by a bayonet type assembly .

Advantageously, the fairing comprises a multitude of openings 132 of air exhaust, these openings, of cylindrical shape, having a diameter of the order of 2.5 mm.

In order to further reduce the noise generated by the engine, a foam 134 is disposed in front of the openings 132, so that the air leaving the shroud 130 passes through such a foam before reaching the outlet 26 of the lower body 2.

This outlet is advantageously made opposite the openings 132 in order to extend the air circuit, which is favorable to the reduction of noise.

As far as expanded polypropylene is concerned, it will be used at degrees of expansion defined by the amount of material (polypropylene) per liter. It will be preferable to use contents of between 40 g and 80 g of material per liter.

Claims (14)

Vacuum cleaner (1) comprising a frame, and a cover (80), said housing including an electric motor-fan and a waste separation device connected to a connector (45) opening out of the frame, said waste separation device being disposed in a housing (40) formed in the frame of the vacuum cleaner, said electric motor-fan being able to depressurize the housing (40) of the waste separation device in order to suck air through the connector (45) inside the frame, said cover (80) constituting one of the closing walls of the housing (40) of the waste separation device, characterized in that the cover (80) is made of expanded polypropylene, and in that it comprises at least one mechanical reinforcement of its structure. Vacuum cleaner (1) according to the preceding claim, characterized in that the mechanical reinforcement consists of a rigid piece (82) extending over substantially the width and / or length of the cover (80). Vacuum cleaner (1) according to claim 1, characterized in that the mechanical reinforcement consists of a frame made of a rigid material around which is injected polypropylene. Vacuum cleaner (1) according to one of the preceding claims, characterized in that the reinforcement is supported on one or more walls from the frame. Vacuum cleaner (1) according to one of the preceding claims, characterized in that the frame comprises a lower body (2) and an upper body (4), and in that the upper body (4) is made of expanded polypropylene, the lid (80) bearing on said upper body (4). Vacuum cleaner (1) according to the preceding claim, characterized in that the upper body (4), made of expanded polypropylene, comprises the housing (40) for receiving the filter dust bag, and in that the thickness of the walls (44, 47, 48, 49) of said housing (40) is between 15 mm and 60 mm. Vacuum cleaner (1) according to the preceding claim, characterized in that the lower body (2) is also made of expanded polypropylene. Vacuum cleaner (1) according to one of claims 5 to 7, characterized in that the upper body (4) comprises a mechanical reinforcement of certain walls defining the housing (40) of the waste separation device. Vacuum cleaner (1) according to the preceding claim, characterized in that the mechanical reinforcement consists of a rigid piece (42) of generally U-shaped shape matching the bottom wall (49) and two non-adjacent walls (47, 48) delimiting the housing (40) of the waste separation device. Vacuum cleaner (1) according to the preceding claim, characterized in that the mechanical reinforcement of the cover (80) consists of a rigid piece (82) extending over the width or the length of the cover (80) and supported on both U-shaped branches of the mechanical reinforcement (42) of the housing (40) of the waste separation device to form a frame that stiffens the structure of the frame and the cover (80). Vacuum cleaner (1) according to one of the preceding claims, characterized in that the mechanical reinforcements of the cover (80) and / or the walls (47, 48, 49) of the housing (40) of the waste separation device are made of unexpanded polypropylene. Vacuum cleaner (1) according to the preceding claim, characterized in that the expanded polypropylene and unexpanded polypropylene are homopolymers. Vacuum cleaner (1) according to any one of the preceding claims, characterized in that the waste separation device is a bag consisting of one or more filter layers. Vacuum cleaner (1) according to one of the preceding claims, characterized in that expanded polypropylene has a content of between 40 g and 80 g of material per liter.

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