EP4635391A1

EP4635391A1 - Cleaning apparatus with sound dampening feature

Info

Publication number: EP4635391A1
Application number: EP25170211.4A
Authority: EP
Inventors: Ryan Phillips; Mitchell J. WESLEY; Chris J. HARMELINK; Renata Ferreira De Paoli
Original assignee: Bissell Inc
Current assignee: Bissell Inc
Priority date: 2024-04-15
Filing date: 2025-04-11
Publication date: 2025-10-22
Also published as: CN120814762A

Abstract

A cleaning apparatus (10) includes suction assembly housing (16) including a floor (18), an intake opening (20), and bypass apertures (22) arranged at least partially around the intake opening (20). A base plate (24) defines an air outlet (26). A suction source (28) includes an impeller cover (30) with an impeller inlet (32) aligned with the intake opening (20) and at least one impeller outlet (34). The at least one impeller outlet (34) is in fluid communication with the bypass apertures (22) via a guide passage (36) at least partially defined by the impeller cover (30) and the floor (18). A sound dampening funnel (38, 260) is disposed in the guide passage (36). The sound dampening funnel (38, 260) includes a lower edge (42) arranged over the bypass apertures (22) to cover a portion of the bypass apertures (22) and reduce an open area (44) of the bypass apertures (22) through which air is directed by the suction source (28) toward the air outlet (26), and, consequently, reduce a noise level generated by said cleaning apparatus (10).

Description

The present disclosure generally relates to a cleaning apparatus with a sound dampening feature, and more particularly, to a cleaning apparatus with a sound dampening funnel disposed about a suction source.

BACKGROUND

Extraction cleaners can be used for cleaning various types of surfaces, including carpet, upholstery, and other fabric surfaces. Many extraction cleaners include systems for storing and delivering cleaning fluid to a surface to be cleaned. Additionally, many extraction cleaners generate a vacuum effect to draw dispensed cleaning fluid and messes into the extraction cleaner for collection and disposal.

BRIEF SUMMARY

According to one aspect of the present disclosure, a cleaning apparatus includes suction assembly housing including a floor, an intake opening, and bypass apertures arranged at least partially around the intake opening. A base plate defines an air outlet. A suction source includes an impeller cover with an impeller inlet aligned with the intake opening and at least one impeller outlet. The at least one impeller outlet is in fluid communication with the bypass apertures via a guide passage at least partially defined by the impeller cover and the floor. A sound dampening funnel is disposed in the guide passage. The sound dampening funnel includes a lower edge arranged over the bypass apertures to cover a portion of the bypass apertures and reduce an open area of the bypass apertures through which air is directed by the suction source toward the air outlet, and, consequently, reduce a noise level generated by said cleaning apparatus.
According to another aspect of the present disclosure, a cleaning apparatus includes a suction assembly housing including a sidewall and a floor that define a receiving space. The floor defines bypass apertures in the receiving space. A base plate defines an air outlet downstream of the bypass apertures. A suction source is disposed in the receiving space. The suction source includes an impeller cover that defines at least one impeller outlet in fluid communication with a guide passage that is defined between the impeller cover, the sidewall, and the floor. A sound dampening funnel is positioned around the impeller cover and extends from proximate the at least one impeller outlet to the floor in the guide passage. The sound dampening funnel extends at an acute angle from the sidewall and over a portion of the bypass apertures to reduce an open area of the bypass apertures through which air is configured to flow towards the air outlet. The air is directed by the suction source through the guide passage and is configured to interact with the sound dampening funnel as the air is guided toward the bypass apertures to reduce noise generated by said cleaning apparatus.
According to yet another aspect of the present disclosure, a cleaning apparatus includes a base enclosure that defines a suction port. A suction assembly housing includes a sidewall, a floor, an intake opening, and bypass apertures. The suction assembly housing includes a motor housing and an impeller housing. A base plate defines an air outlet. An inlet passage and an outlet passage are defined between the suction port and the intake opening. An outlet passage is defined between the bypass apertures and the air outlet. A suction source is operably coupled with the suction assembly housing. The suction source is configured to direct air through the suction port, the inlet passage, the suction source, and the outlet passage. The suction source includes an impeller assembly disposed in the impeller housing and having an impeller cover that defines an impeller inlet and at least one impeller outlet. A motor is disposed in the motor housing and configured to drive the impeller assembly. A guide passage is defined between the impeller cover, the motor housing, and the floor of the base enclosure. A sound dampening funnel is disposed on the floor in the guide passage. The sound dampening funnel extends at an acute angle from a sidewall of the base enclosure proximate to the at least one impeller outlet, toward the impeller cover, and to the floor to extend over the bypass apertures and reduce an airflow portion of the bypass apertures through which the air is directed by the suction source from the guide passage to the outlet passage.
These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a schematic diagram of a cleaning apparatus, according to an aspect of the present disclosure;
FIG. 2 is a side perspective view of a cleaning apparatus, according to an aspect of the present disclosure;
FIG. 3 is a partially exploded side perspective view of a cleaning apparatus with a supply tank assembly and a recovery tank assembly, according to an aspect of the present disclosure;
FIG. 4 is a cross-sectional view of the cleaning apparatus of FIG. 2, taken along lines IV-IV, illustrating a cooling air flow path, according to an aspect of the present disclosure;
FIG. 5 is a cross-sectional view of the cleaning apparatus of FIG. 2, taken along lines V-V, illustrating a working air flow path, according to an aspect of the present disclosure;
FIG. 6 is an enlarged cross-sectional view of the cleaning apparatus of FIG. 5, taken at area IV, illustrating a suction source and a suction assembly housing, according to the present disclosure;
FIG. 7 is an exploded side perspective view of a base enclosure and a base plate of a cleaning apparatus, according to an aspect of the present disclosure;
FIG. 8 is a cross-sectional view of a suction source within a base enclosure of a cleaning apparatus where a sound dampening funnel is positioned about an impeller of the suction source, according to an aspect of the present disclosure;
FIG. 9 is a cross-sectional, side perspective view of a suction source within a base enclosure of a cleaning apparatus where a sound dampening funnel is positioned about the suction source and illustrating a working airflow path through the suction source, according to an aspect of the present disclosure;
FIG. 10 is a partial, cross-sectional, side perspective view of sound dampening features disposed within a guide passage around an impeller assembly, according to an aspect of the present disclosure;
FIG. 11A is a side perspective view of a sound dampening funnel, according to an aspect of the present disclosure;
FIG. 11B is a side elevational view of a sound dampening funnel, according to an aspect of the present disclosure;
FIG. 12 is a graphical representation of sound performance in a combined frequency range of different sound dampening features relative to a baseline in the absence of the sound dampening features, where the sound dampening features cover different portions of bypass apertures in a working air flow path, according to an aspect of the present disclosure;
FIG. 13A is a graphical representation of sound intensity of different sound dampening features relative to a baseline sound level in the absence of the sound dampening features and in a first subset frequency range, according to an aspect of the present disclosure;
FIG. 13B is a graphical representation of percentages of noise intensity improvement of the sound dampening features of FIG. 13A in the first subset frequency range, according to an aspect of the present disclosure;
FIG. 14A is a graphical representation of sound intensity of different sound dampening features relative to a baseline sound level in the absence of the sound dampening features and in a second subset frequency range, according to an aspect of the present disclosure;
FIG. 14B is a graphical representation of percentages of noise intensity improvement of the sound dampening features of FIG. 14A in the second subset frequency range, according to an aspect of the present disclosure;
FIG. 15A is a graphical representation of sound intensity of different sound dampening features relative to a baseline sound level in the absence of the sound dampening features and in a combined frequency range, according to an aspect of the present disclosure; and
FIG. 15B is a graphical representation of percentages of noise intensity improvement of the sound dampening features of FIG. 15A in the combined frequency range, according to an aspect of the present disclosure.

The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles described herein.

DETAILED DESCRIPTION

The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a cleaning apparatus with a sound dampening feature. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.
For purposes of description herein, the terms "upper," "lower," "right," "left," "rear," "front," "vertical," "horizontal," and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. Unless stated otherwise, the term "front" shall refer to the surface of the element closer to an intended viewer, and the term "rear" shall refer to the surface of the element further from the intended viewer. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
The terms "including," "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by "comprises a ..." does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.
With reference to FIGS. 1-15B, reference numeral 10 generally designates a cleaning apparatus 10 or surface cleaning apparatus 10 that includes a base housing or base enclosure 12 defining a suction port 14. The cleaning apparatus 10 also includes a motor/suction assembly housing 16 (which may be referred to as a motor assembly housing 16 and/or a suction assembly housing 16) that includes a floor 18 defining at least one intake opening 20 and bypass apertures 22 arranged at least partially around of the intake opening 20. A base plate 24 defines an air outlet 26. The cleaning apparatus 10 includes a suction source 28, which includes an impeller cover 30 defining an impeller inlet 32 and at least one impeller outlet 34. The impeller inlet 32 is in fluid communication with the intake opening 20, and the impeller outlets 34 are in fluid communication with a chamber or guide passage 36 at least partially defined by the suction assembly housing 16, the impeller cover 30, and the floor 18.
A sound dampening funnel 38 is disposed within the guide passage 36. Working air 40 is directed by the suction source 28 into the guide passage 36 and is directed toward, along, and/or through the sound dampening funnel 38. Additionally, the sound dampening funnel 38 includes a first or lower edge 42 arranged over the bypass apertures 22 to cover or extend over a portion of the bypass apertures 22. In this way, the sound dampening funnel 38 divides the bypass apertures 22 into an open airflow portion 44 or unimpeded portion 44 through which the working air 40 can flow generally unimpeded and a covered portion 46 or impeded portion 46 that at least partially impedes the flow path for the working air 40. Accordingly, the funnel 38 reduces an open area of the bypass apertures 22 through which working air 40 flows unimpeded when being directed by the suction source 28 to the air outlet 26 to, consequently, reduce a noise level generated by the cleaning apparatus 10.
When in operation, the cleaning apparatus 10 generally generates sound or noise resulting from operation of one or more features of the cleaning apparatus 10, such as the suction source 28. For example, noise may be generated by the operation of the suction source 28 (e.g., motor noise) and/or from vibrations that can result from the operation of the suction source 28. In general, the cleaning apparatus 10 can operate with the sound dampening funnel 38 omitted and, in such circumstances, the cleaning apparatus 10 generates a baseline level of noise or sound (measured in decibels or dB). In other words, the baseline level of noise is generated in the absence of the sound dampening funnel 38. The sound dampening funnel 38 is configured to reduce the noise generated by the cleaning apparatus 10 relative to the baseline level, which may be referred to as a reduced or lowered noise level. Moreover, the sound dampening funnel 38 may affect sound level or intensity in different frequency ranges. The frequency ranges include a first frequency range ("Frequency Range 1"), which may be an extended or combined frequency range generally between about 20 Hz and about 48,000 Hz; a second frequency range ("Frequency Range 2"), which may be a subset of Frequency Range 1 with a frequency generally between about 20 Hz and about 20,000 Hz; and a third frequency range ("Frequency Range 3"), which may also be a subset of Frequency Range 1 with a frequency generally between about 20,000 Hz and about 48,000 Hz.
Referring to FIG. 1, the cleaning apparatus 10 may have a variety of configurations. For example, the cleaning apparatus 10 may be an extraction cleaner often used to clean rugs, carpeting, drapes, and upholstered surfaces. In various aspects, the cleaning apparatus 10 includes a suction system 60 and a liquid delivery system 62. The liquid delivery system 62 and the suction system 60 may be used for dispensing liquid, as well as recovering fluid and debris material.
The liquid delivery system 62 includes a supply tank 70 for holding and storing liquid such as a cleaning solution for use in a cleaning process. The liquid may also be water or combinations of cleaning solution(s) and water. For example, many household extraction cleaning tasks can be performed using water along with or in combination with a liquid cleaning solution that contains surfactants, stabilizers, fragrances, and/or other active and inactive ingredients.
The liquid delivery system 62 also includes a pump 72, valves, and/or similar features to direct the liquid out of the supply tank 70 and, consequently, out of the cleaning apparatus 10. The cleaning apparatus 10 may optionally include a heater 74 to heat or warm liquid that is dispensed. The pump 72 is configured to direct the liquid from the supply tank 70 and through a dispensing outlet 76 of the cleaning apparatus 10 to be dispensed onto a surface being cleaned.
The cleaning apparatus 10 also includes the suction system 60 to draw fluid into the cleaning apparatus 10. The suction system 60 can collect liquid or semi-liquid messes from the surface being cleaned, liquid dispensed via the liquid delivery system 62, other debris materials, and/or combinations thereof. The suction system 60 also includes the suction source 28 to generate a suction or vacuum effect at an inlet 78 to draw the fluid and debris material from the surface being cleaned and into a recovery tank 80. The recovered or collected liquids and/or debris materials are recovered and collected in the recovery tank 80. The working air 40 is drawn from the inlet 78, through the recovery tank 80, through the suction source 28, and expelled from the cleaning apparatus 10 via the air outlet 26 as described further herein.
Components of the cleaning apparatus 10 are electrically coupled to a power source 82 such as a battery or by a power cord plugged into a household electrical circuit. A power switch 84 between the power source 82 and the electrical components of the cleaning apparatus 10 can be selectively closed by a user to activate the electrical components. The power source 82 may be utilized for powering the cleaning apparatus 10 and/or components coupled thereto, such as an accessory or tool 90.
With reference to FIGS. 2 and 3, an exemplary cleaning apparatus 10 that includes the sound dampening funnel 38 (FIG. 4) is illustrated. The illustrated cleaning apparatus 10 is a portable cleaning apparatus 10, which is generally smaller and lighter for a user to carry. However, the components and functions described herein may be utilized in upright cleaning apparatuses 10, such as those that are larger, heavier, and maneuvered along the surface for the cleaning process, without departing from the teachings herein.
The cleaning apparatus 10 in FIGS. 2 and 3 includes the base enclosure 12 with a support portion 100 for receiving or otherwise supporting the recovery tank 80 and the supply tank 70. The support portion 100 includes a perimeter wall 102 that at least partially defines a first seat 104 for receiving the supply tank 70 and a second seat 106 for receiving the recovery tank 80.
The support portion 100 can include a hose connector for supporting an accessory hose 110. Various tools 90 may be selectively coupled to the cleaning apparatus 10 via the accessory hose 110. The tool 90, which may include the inlet 78 and/or the dispensing outlet 76, is manually maneuverable by the user relative to the cleaning apparatus 10 and the surface being cleaned. The tool 90 is configured to utilize various features and functions of the cleaning apparatus 10, such as one or both of the suction system 60 and the liquid delivery system 62. When the applicator tool 90 is coupled to the cleaning apparatus 10, the suction system 60 can generate the vacuum effect at the inlet 78 of the tool 90 to draw fluid and debris into the recovery tank 80. Additionally, a wand 112, which couples the tool 90 to the accessory hose 110, may include a trigger for releasing or spraying the liquid from the liquid delivery system 62. As illustrated, the support portion 100 includes a hose support 116 for supporting the accessory hose 110 and an accessory support 118 for coiling and coupling the accessory hose 110 and the tool 90 to the support portion 100, which may assist in transporting the cleaning apparatus 10. Further, the support portion 100 includes cord supports 120 around which the power cord may be coiled for storing the cleaning apparatus 10.
The base enclosure 12 includes a handle 130 to assist the user in carrying or maneuvering the cleaning apparatus 10. The handle 130 is formed by or is coupled to a central support 132. The central support 132 is disposed or extends between the recovery tank 80 and the supply tank 70 when the recovery tank 80 and the supply tank 70 are coupled with the support portion 100.
The supply tank 70 is included in a supply tank assembly 140, which includes a carrying handle 142 for selectively removing and carrying the supply tank 70 separate from the cleaning apparatus 10. The supply tank 70 includes an inlet 144 for receiving cleaning solution. Additionally, the supply tank 70 includes a valve, which is configured to mate with a receiver 148 of the base enclosure 12 when the supply tank assembly 140 is positioned on the first seat 104 of the support portion 100. Positioning the supply tank assembly 140 on the first seat 104 mates the valve with the receiver 148 in a manner that opens the valve to allow the cleaning solution to be directed by the pump 72.
The recovery tank 80 is included in a recovery tank assembly 156, which also includes a cover 158 and a carrying handle 160 for selectively removing the recovery tank 80 from the support portion 100 to dispose of the recovered liquids and debris materials. The recovery tank assembly 156 defines a tank inlet 162 and a tank outlet 164, which are each in fluid communication with a duct assembly 170. The duct assembly 170 is operably coupled to the recovery tank 80 and the base enclosure 12 to provide fluid communication between the recovery tank 80 and the suction source 28. The duct assembly 170 includes an inlet duct 172 in fluid communication with the tank inlet 162 and an outlet duct 174 in fluid communication with the tank outlet 164. The cleaning apparatus 10 may also include one or more separators 176 to separate the liquids and debris material from the working air 40 for collection.
Referring to FIGS. 4-6, the base enclosure 12, including the support portion 100, defines an interior for housing various components of the cleaning apparatus 10. Fluid directing lines and passages, the pump 72, and the suction source 28 are exemplary components included in the interior of the base enclosure 12. The suction assembly housing 16 is operably coupled with the base enclosure 12. The suction assembly housing 16 includes the first wall 18, which may be referred to herein as the floor 18, with a second wall 190, which may be referred to herein as the sidewall 190, extending from the floor 18 to define a receiving space 192 for the suction source 28. Typically, the first and second walls 18, 190 extend generally perpendicularly to one another. While the first wall 18 is illustrated as being horizontal and the second wall 190 is illustrated as being vertical, it is contemplated that the first wall 18 can be vertical and the second wall 190 can be horizontal without departing from the teachings herein.
There are at least two airflow paths through the cleaning apparatus 10, including a cooling flow path, as illustrated in FIG. 4, and a working flow path as illustrated in FIG. 5, which are driven, at least in part, by the suction source 28. The central support 132 defines vents 200, 202 on opposing sides thereof for the cooling flow path. In this way, the vents 200, 202 extend between the first and second seats 104, 106 to remain open and unblocked when the recovery tank 80 and the supply tank 70 are supported on the support portion 100. In certain aspects, the vents 200 on a first side of the cleaning apparatus 10 may be configured as inlet vents 200, and the vents 202 on a second side are configured as outlet vents 202.
The suction assembly housing 16 includes a motor housing 208 and an impeller housing 210. The suction assembly housing 16 is operably coupled with the base enclosure 12. The suction assembly housing 16 can be constructed of one or more separate components, casings, or housings. For example, the motor housing 208 and the impeller housing 210 may be separate components or integrally formed with one another. Further, at least a portion of the suction assembly housing 16 may be separate from the base enclosure 12 or, alternatively, integrally formed with the base enclosure 12.
The suction source 28 includes a motor 212 positioned in the motor housing 208. The motor 212 and the motor housing 208 may be collectively referred to as a motor assembly. A top of the motor housing 208 defines cooling air inlets 214. Activation of the suction source 28 causes cooling air 216 to be drawn along the cooling flow path and through the cooling air inlets 214. The cooling air inlets 214 allow the cooling air 216 to be drawn into and through the motor housing 208 to assist with reducing heat caused by the operation of the motor 212. The motor housing 208 also defines a cooling air outlet 218, which is in fluid communication with a cooling passage 220. The cooling passage 220 is configured to direct the cooling air 216, along with heat from the motor 212, toward and/or through the outlet vents 202.
Referring still to FIGS. 5 and 6, the suction source 28 also includes an impeller assembly 230 positioned in the impeller housing 210. The impeller assembly 230 includes an impeller 232 positioned in the impeller cover 30. The impeller housing 210 is operably coupled to the motor housing 208, and the impeller 232 is operably coupled to the motor 212. The motor 212 is configured to drive rotation of the impeller 232 to direct air through the cleaning apparatus 10. The impeller cover 30 defines at least one impeller inlet 32 and at least one impeller outlet 34. In the illustrated configuration, the impeller cover 30 defines one impeller inlet 32 and multiple impeller outlets 34. The impeller inlet 32 is generally perpendicular to the impeller outlets 34, directing the working air 40 in two perpendicular directions. As illustrated, the impeller outlets 34 are arranged along a side 234 of the impeller cover 30 and around the impeller 232.
The suction assembly housing 16 includes the floor 18 and the sidewall 190 to define the receiving space 192 for receiving at least a portion of the suction source 28. In certain aspects, each of the floor 18 and the sidewall 190 may be part of the impeller housing 210. In the illustrated configuration, the floor 18 may include a recessed portion for supporting the sound dampening funnel 38 and an elevated portion (relative to the recessed portion) that supports the impeller assembly 230.
The sidewall 190 generally extends from the floor 18, proximate to the side 234 of the impeller cover 30, and toward the motor housing 208. A motor seal 236 is provided between the sidewall 190 (e.g., the impeller housing 210) and the motor housing 208 to generally separate the working air 40 from the remainder of the interior of the base enclosure 12.
Referring still to FIG. 6, as well as FIGS. 7 and 8, the suction assembly housing 16 defines the intake opening 20, which provides fluid communication with the impeller inlet 32 for the working flow path. The intake opening 20 may be a single intake opening 20 or multiple intake openings 20 without departing from the teachings herein. Additionally, a gasket 238 is disposed between the impeller cover 30 and the impeller housing 210. This gasket 238 is generally an anti-vibration/noise gasket 238. The gasket 238 may extend partially through the intake opening 20 and around an edge or rim 240 of the portion of the impeller housing 210 that supports the impeller assembly 230. The gasket 238 can also reduce or prevent airflow between the base enclosure 12 and the impeller cover 30.
The suction assembly housing 16 also defines the bypass apertures 22, which are arranged along at least a portion of a perimeter of the intake opening 20. The intake opening 20 is generally aligned with a rotational axis of the impeller assembly 230, and the bypass apertures 22 are arranged about the rotational axis. The intake opening 20 and the bypass apertures 22 are in fluid communication via the impeller assembly 230, allowing the working air 40 to flow through the impeller cover 30.
The intake opening 20 and the bypass apertures 22 may be oriented in one direction to direct the working air 40 in parallel directions, while the impeller outlets 34 may be oriented in a perpendicular direction to direct the working air 40 in a perpendicular direction. In the illustrated example, the intake opening 20 and the bypass apertures 22 are arranged horizontally to allow vertical airflow therethrough, while the impeller outlets 34 are arranged vertically to allow horizontal airflow therethrough. Accordingly, the working air 40 is directed in a first direction through the intake opening 20 and the impeller inlet 32, in a second direction that is perpendicular to the first direction through the impeller outlets 34, and in a third direction that is parallel to the first direction through the bypass apertures 22.
The base enclosure 12 and the suction assembly housing 16 are operably coupled with and/or positioned on the base plate 24. In various aspects, the base plate 24 may be coupled with wheels 244 or rollers to assist with maneuvering the cleaning apparatus 10 along the underlying surface. A dividing wall 250 extends below the floor 18 and between the floor 18 and the base plate 24. The base plate 24 includes a receiving channel 252, and the dividing wall 250 is positioned within the receiving channel 252. The dividing wall 250 being positioned in the receiving channel 252 partially forms an air inlet passage 254 from the suction port 14 to the impeller assembly 230. The air inlet passage 254 is generally defined between the base plate 24 and one or both of the suction assembly housing 16 and/or the base enclosure 12 to guide the working air 40 from the suction port 14 to the intake opening 20 which, consequently, fluidly couples the impeller assembly 230 with the suction port 14.
In addition to the air inlet passage 254, an air outlet passage 256 is defined from the bypass apertures 22 to the air outlets 26. The air outlet passage 256 is generally defined between the base plate 24 and one or both of the suction assembly housing 16 and/or the base enclosure 12. Generally, the dividing wall 250 separates the air inlet passage 254 and the air outlet passage 256. The base plate 24 also defines the air outlets 26, which are generally positioned at a bottom of the cleaning apparatus 10, downstream of the bypass apertures 22, and are in fluid communication with the air outlet passage 256.
Referring still to FIG. 8, as well as FIGS. 9 and 10, the working air 40 is directed through the air inlet passage 254, through the intake opening 20 and the impeller inlet 32, through the impeller outlets 34, and into the guide passage 36. The guide passage 36 is defined between the sidewall 190 of the suction assembly housing 16 and the side 234 of the impeller cover 30. Accordingly, the guide passage 36 is defined by the floor 18, the sidewall 190, and the impeller cover 30. The motor housing 208 and/or the motor seal 236 may also assist with sealing an end or top of the guide passage 36 to direct the working air 40 through the bypass apertures 22. The guide passage 36 generally extends around the impeller cover 30 between the sidewall 190 and the side 234 of the impeller cover 30. When the working air 40 is directed through the impeller outlets 34, the working air 40 flows into and/or through the guide passage 36.
As the working air 40 is directed into the guide passage 36, the working air 40 is directed to or toward a sound dampening feature 260, which is illustrated as the sound dampening funnel 38 that is positioned around the impeller cover 30. Typically, the sound dampening feature 260 is constructed, at least in part, of a porous nanofiber material. The sound dampening funnel 38 is positioned within the guide passage 36 and encircles the impeller cover 30. The working air 40 interacts with the sound dampening funnel 38 as the working air 40 is guided toward the bypass apertures 22, which causes vibrations in the porous nanofiber material.
Referring still to FIG. 10, the sound dampening funnel 38 is positioned on the floor 18 and extends toward the motor housing 208 proximate the impeller outlets 34. There is generally a gap between the motor seal 236 and the sound dampening funnel 38 such that the sound dampening funnel 38 is not constrained by the motor seal 236 or the motor housing 208. Further, the sound dampening funnel 38 extends along the guide passage 36 between the impeller outlets 34 and the bypass apertures 22. In certain aspects, the sound dampening funnel 38 extends beyond or above the impeller outlets 34.
The funnel 38 may guide some of the working air 40 along a path of least resistance to the bypass apertures 22. The path of least resistance may be over, along, and/or below the funnel 38. Additionally or alternatively, the funnel 38 may at least partially intersect the path of the working air 40 so that at least some of the working air 40 has to pass through the funnel 38 before exiting the guide passage 36. The sound dampening funnel 38 is positioned on the recessed portion of the floor 18 where the bypass apertures 22 are defined. Accordingly, the working air 40 may flow above/over, below, and/or through the funnel 38 and then through the bypass apertures 22. Generally, the working air 40 carries the noise in waves, and the working air 40 passes through, above, and below the funnel 38 material, which reduces the amplitude of the waves and, consequently, reduces the noise.
The impeller outlets 34 and the bypass apertures 22 are oriented perpendicular to one another, which results in the working air 40 flowing in the second direction through the impeller outlets 34 and the third direction through the bypass apertures 22. The sound dampening funnel 38 can assist in directing the working air 40 from the second direction from the impeller outlets 34 to the third direction through the bypass apertures 22.
Referring still to FIG. 10, as well as FIGS. 11A and 11B, the sound dampening funnel 38 defines a frusto-conical shape, with a second edge 262, illustrated as an upper edge 262, defining a first width or diameter w₁ and the first edge 42, illustrated as the lower edge 42 on the floor 18, defining a second width or diameter w₂ . The first width w₁ is greater than the second width w₂ such that the sound dampening funnel 38 tapers or becomes narrower from one end (e.g., the edge 262) to the other (e.g., the edge 42, narrowing from top to bottom). In other words, an open-ended cylindrical shape having the same or substantially same upper width w₁ and lower width w₂ (e.g., a ring shape) does not qualify as a funnel shape.
The sound dampening funnel 38 forms a sidewall 264 defining an open top at the upper edge 262 and an open bottom at the lower edge 42 in which a radius of the open top is greater than the radius of the open bottom. In other words, the sound dampening funnel 38 defines a hollow geometric shape having a circular or oval crosssection that varies throughout the height h of the funnel 38. Further, the sound dampening funnel 38 can be described as a hollow cone or truncated cone having a radius that tapers from the open top to the open bottom, with the radius of the open top being greater than the radius of the open bottom.
With the different widths w₁, w₂ of the sound dampening funnel 38, the upper edge 262 is positioned adjacent to or abuts the sidewall 190 of the base enclosure 12, and the lower edge 42 is positioned closer to the impeller cover 30. An acute angle Θ is defined between the sound dampening funnel 38 proximate to the upper edge 262 and the sidewall 190. As described herein the angle Θ may be adjusted to adjust the sound dampening or noise reducing effect provided by the sound dampening funnel 38.
The sound dampening funnel 38 can have different sizes and configurations and provide for different angles Θ, which may depend on a variety of factors such as the configuration of the cleaning apparatus 10, the selected sound reduction, the working flow path, etc. A non-limiting configuration of the sound dampening funnel 38 is illustrated in FIGS. 11A and 11B. In this configuration, the upper width w₁ is between about 90 mm and about 110 mm, or more particularly about 98 mm, and the lower width w₂ is between about 75 mm and about 90 mm, or more particularly about 87 mm. Additionally, in this illustrated configuration, the sound dampening funnel 38 has a height h between about 25 mm and about 35 mm, or more particularly about 31 mm. This configuration of the sound dampening funnel 38 provides the angle Θ between about 5° and about 15°, or more particularly about 9.5°. This configuration, as further discussed herein, divides the bypass apertures 22 to cover 50% of a total area of the bypass apertures 22. As described further herein, the lower width w₂ and, consequently, the angle Θ can be adjusted to adjust performance of the sound dampening funnel 38 (i.e., adjust reduction of noise).
The sound dampening funnel 38 is positioned on the floor 18 over the bypass apertures 22. In this way, the lower edge 42 of the sound dampening funnel 38 extends across the bypass apertures 22 around the impeller cover 30. The sound dampening funnel 38 divides the bypass apertures 22 into the open airflow portions 44, through which the working air 40 is configured to flow unimpeded, and the covered portions 46, which generally at least partially impedes the working flow path such that the working air 40 passes through the sound dampening funnel 38 before exiting through the bypass apertures 22. While some of the working air 40 may flow around or through the sound dampening funnel 38 and through the covered portion 46 of the bypass apertures 22, the substantial portion, or entirety, of the working air 40 flowing through the guide passage 36 is directed through the open airflow portions 44 of the bypass apertures 22. Accordingly, the sound dampening funnel 38 reduces the area of the bypass apertures 22 through which the working air 40 can flow unimpeded.
Generally, the area of the bypass apertures 22 that form the open airflow portions 44 is substantially similar or the same for each bypass aperture 22. In other words, the sound dampening funnel 38 reduces the area of each bypass aperture 22 by the same or similar amount. However, as the sound dampening funnel 38 can generally move within the guide passage 36, the area of the covered portions 46 and the open airflow portions 44 may vary slightly and may adjust during operation of the cleaning apparatus 10.
The sound dampening funnel 38 is generally configured as a porous nanofiber material where air molecules in the porous material are configured to vibrate and rub against the nanofibers, which generally results in the conversion of sound energy to heat energy. The heat energy can be dissipated with the flow of working air 40 through the guide passage 36. In various aspects, the sound dampening funnel 38 has a thickness between about 0.5 mm and about 5 mm to maximize acoustic performance (e.g., sound reduction) while maintaining air performance for exhausting the working air 40 from the cleaning apparatus 10. Further, a gap is generally defined between the suction source 28 and the sound dampening funnel 38 to assist with and/or maximize the airflow from the impeller cover 30 and through the guide passage 36. This gap is generally a minimum of about 0.5 mm to allow for the working air 40 to flow through the impeller outlet 34 and along the sound dampening funnel 38 proximate to the side 234 of the impeller cover 30.
The working air 40 is configured to be directed from the impeller cover 30 and toward or to the sound dampening funnel 38 rather than the sidewall 190 of the base enclosure 12, which assists in reducing the sound generated by the cleaning apparatus 10. In other words, the working air 40 being directed into the sound dampening funnel 38 reduces the noise level generated by the cleaning apparatus 10 compared to the working air 40 being directed into the sidewall 190 of the base enclosure 12, which can be constructed of more rigid materials such as plastic(s).
Referring still to FIGS. 10-11B, the sound dampening funnel 38 is free of mechanical attachments to other components in the cleaning apparatus 10. The sound dampening funnel 38 can rest on the floor 18 and move in response to the working air 40 flowing through the guide passage 36. The sound dampening funnel 38 is floating or suspended in the guide passage 36 with minimal or limited points of contact with surrounding components. Accordingly, the sound dampening funnel 38 is freely movable within the guide passage 36 with movement limited by the shape and size of the guide passage 36. In this way, the sound dampening funnel 38 can shift, lift, drop, spin, etc. within the guide passage 36.
While the sound dampening funnel 38 is generally freely movable within the guide passage 36, it is also contemplated that the funnel 38 may have or include additional positioning or affixing components. These additional positioning or affixing components may include material tabs, tape, glue, etc. In such examples, these components may assist in supporting the material shape and position under the flow of the working air 40 and/or in a static condition.
Referring to FIGS. 1-11B, in operation, the user can use the cleaning apparatus 10 for one or more cleaning processes. The user can activate the suction source 28 to generate the vacuum effect at the inlet 78, which can cause noise to be generated due to operational functions of the various components of the cleaning apparatus 10, including the suction source 28. The user can maneuver or move the tool 90 relative to the surface being cleaned to draw debris materials into the cleaning apparatus 10. In certain aspects, the user can also cause the cleaning solution to be sprayed or delivered to the surface being cleaned with the liquid delivery system 62.
The suction effect generated by the suction source 28 draws the debris material and liquids entrained in the working air 40 through the tool 90, through the accessory hose 110, and into the base enclosure 12. The working air 40, debris materials, and liquids, which may be collectively referred to as recovered materials, are drawn through a connecting conduit in the base enclosure 12 that fluidly couples the accessory hose 110 with the inlet duct 172. The recovered materials travel through the inlet duct 172, through the tank inlet 162, and into the recovery tank 80. Due to gravitational forces, at least most of the debris materials and the liquids fall to a bottom of the recovery tank 80.
The working air 40, which may include some entrained debris materials and liquids, is drawn out of the recovery tank 80, leaving a substantial portion or all of the debris materials and the liquids recovered in the recovery tank 80. The working air 40 is drawn by the suction source 28 through the tank outlet 164 and into the outlet duct 174. In certain aspects, the separator 176 may be disposed at the tank outlet 164 or the outlet duct 174 to retain more debris materials in the recovery tank 80, reducing debris material that travels into the outlet duct 174.
The working air 40 is drawn through the outlet duct 174, the suction port 14, and the air inlet passage 254. The working air 40 is then directed through the impeller inlet 32, through the impeller outlets 34, and into the guide passage 36 where the working air 40 is directed into or toward the sound dampening funnel 38. The working air 40 is directed along the sound dampening funnel 38 and at least primarily through the open airflow portions 44 of the bypass apertures 22. The working air 40 is then directed through the air outlet passage 256 and exhausted from the cleaning apparatus 10 via the air outlets 26. While the working air 40 is generally free of debris materials and liquids, some amount of debris materials and liquid may be entrained in the working flow path through the suction source 28, the bypass apertures 22, and the air outlets 26. Accordingly, the open airflow portions 44 may each have an area to promote the flow of the working air 40 with the entrained materials through the bypass apertures 22.
Referring still to FIGS. 1-11B, when the cleaning apparatus 10 is operating, the cleaning apparatus 10 is configured to generate noise due to operations of the components (e.g., mechanical vibrations caused by operation of certain features) and the airflow through the cleaning apparatus 10, including at least the working air 40. The sound dampening funnel 38 reduces the noise level generated by the cleaning apparatus 10. For example, the working air 40 is directed into the porous nanofiber material rather than the sidewall 190 of the base enclosure 12. Additionally, the porous nanofiber material converts the sound energy to heat energy. Moreover, the funnel shape and the relationship of the sound dampening funnel 38 with the bypass apertures 22 can affect the noise reduction. Further, the funnel or frusto-conical shape can also assist with noise reduction while maximizing efficiency of the manufacturing process, which can be shown in a comparison with other sound dampening features 260 constructed of the same porous nanofiber material. The funnel shape of the sound dampening funnel 38 provides a balance between sound reduction and additional material included in the cleaning apparatus 10, minimizing the effect the sound dampening feature 260 has on the airflow through the cleaning apparatus 10.
Referring again to FIG. 10, as well as FIG. 12, testing was conducted with different portions of the bypass apertures 22 being on opposing sides of the sound dampening feature 260 (e.g., to adjust the size of the unimpeded portion 44 and the covered or impeded portion 46). This testing revealed that different percentages of the bypass apertures 22 being covered resulted in different levels of noise reduction relative to the baseline in the absence of the sound dampening feature 260. Accordingly, it was found that there is a relationship between sound reduction and the percentage of the area of the bypass apertures 22 that is covered versus open.
As illustrated in FIG. 10, the lower edge 42 of the sound dampening funnel 38 is positioned on the floor 18 and can extend across the bypass apertures 22. To change the percentage of the area of the bypass apertures 22 that are covered by the sound dampening funnel 38 (e.g., percentage of the covered portions 46 compared to a total area or 100%) and the percentage of the area left open for the working air 40 (e.g., percentage of the open airflow portions 44 compared to 100%), the lower width w₂ can be adjusted along with the angle Θ.
Testing was conducted with a SpotClean Pro^™ Portable Cleaner, Model Number 3617Z, from BISSELL, Inc. to find sound performance (e.g., noise level in dB) in the extended Frequency Range 1 between about 20 Hz and about 48000 Hz. The SpotClean Pro^™ Portable Cleaner is a non-limiting example of the cleaning apparatus 10 described herein. Initial testing without the sound dampening feature 260 was conducted, which found the SpotClean Pro^™ Portable Cleaner generated about 96.13 dB of noise in the tested frequency range, which is considered the baseline level (e.g., in the absence of the sound dampening funnel 38 or other sound dampening feature 260) of noise or sound for this test.
For each of Example A-Example E of the sound dampening feature 260, the upper width w₁ remained the same or similar, which was generally about 98 mm, and the height h remained the same or similar, which was generally about 31 mm. The bypass apertures 22 generally have a width w₃ (from an outer edge proximate the sidewall 190 to an inner edge proximate to the intake opening 20) between about 5 mm and about 10 mm, or more particularly about 8 mm. The change in the lower width w₂ and the angle Θ adjusts the lower edge 42 relative to the width w₃ of the bypass apertures 22. Accordingly, the lower width w₂ may adjust from at least the outer edge (covering about 0%) to the inner edge (covering about 100 %) of the bypass apertures 22.
Example A, also referred to as Ring A, which is not considered a funnel, covers about 0% of the bypass apertures 22, leaving about 100% of the bypass apertures 22 open for the working air 40 to flow unimpeded. Further, Ring A forms the angle Θ of about 0°, extending along a surface of the sidewall 190. Typically, the upper width and the lower width of Ring A are substantially similar or the same. With Ring A, the SpotClean Pro^™ Portable Cleaner generated about 93.59 dB of noise. Accordingly, Ring A reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 2.5 dB relative to the baseline in this tested frequency range.
Example B, also referred to as Funnel B, covers about 25% of the bypass apertures 22, leaving about 75% of the bypass apertures 22 open for the working air 40 to flow through. The lower width w₂ is less than the lower width w₂ of Ring A, which consequently increases the value of the angle Θ compared to Ring A. Generally, the configuration of Funnel B has a lower width w₂ less than Ring A but greater than Funnel C. Accordingly, the lower width w₂ may be between about 98 mm (substantially equal to the lower width w₂ of Ring A) and about 87 mm (substantially equal to the lower width w₂ of Funnel C). Further, Funnel B generally defines the angle Θ greater than Ring A (where the angle Θ is about 0°) and less than Funnel C (where the angle Θ is about 9.5°). Funnel B covers about 25% of the bypass apertures 22, leaving about 75% of the bypass apertures 22 open for the working air 40 to flow unimpeded. With Funnel B, the SpotClean Pro^™ Portable Cleaner generated about 94.26 dB of noise. Accordingly, Funnel B reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 1.9 dB relative to the baseline in this frequency range.
Example C, also referred to as Funnel C, covers about 50% of the bypass apertures 22, leaving about 50% of the bypass apertures 22 open for the working air 40 to flow through unimpeded. Funnel C is the configuration of the sound dampening funnel 38 illustrated in FIGS. 11A and 11B having the upper width w₁ of about 98 mm, the lower width w₂ of about 87 mm, and the height h of about 31 mm, as well as defining the angle Θ of about 9.5°. With Funnel C, the SpotClean Pro^™ Portable Cleaner generated about 92.19 dB of noise. Accordingly, Funnel C reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 3.9 dB relative to the baseline in this frequency range.
Example D, also referred to as Funnel D, covers about 75% of the bypass apertures 22, leaving about 25% of the bypass apertures 22 open for the working air 40 to flow through unimpeded. The configuration of Funnel D has a lower width w₂ less than Funnel C (of about 87 mm) and defines the angle Θ greater than Funnel C (with the angle Θ of about 9.5°). With Funnel D, the SpotClean Pro^™ Portable Cleaner generated about 93.15 dB of noise. Accordingly, Funnel D reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 3.0 dB relative to the baseline in this frequency range.
Example E, also referred to as Funnel E, covers about 100% of the bypass apertures 22, leaving about 0% of the bypass apertures 22 open for the working air 40 to flow through unimpeded. The configuration of Funnel E has a lower width w₂ less than Funnel D and defines the angle Θ greater than Funnel D. The lower width w₂ is generally between about 75 mm (abutting the rim 240) and about 80 mm (along the inner edge of the bypass apertures 22). The angle Θ depends on the positioning of the lower edge 42 relative to the sidewall 190. The angle Θ may be between about 15° and about 20°, and more particularly about 18.5°. With Funnel E, the SpotClean Pro^™ Portable Cleaner generated about 94.72 dB of noise. Accordingly, Funnel E reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 1.4 dB relative to the baseline in this frequency range.
Referring still to FIG. 12, the use of the sound dampening feature 260 reduced the sound generated by the SpotClean Pro^™ Portable Cleaner. Notably, Funnel C, covering 50% of the area of the bypass apertures 22, resulted in the most sound reduction of the tested examples, reducing the sound by about 4 dB relative to the baseline (e.g., in the absence of the sound dampening funnel 38 or other sound dampening feature 260) between about 20 Hz and about 48 kHz and by about 1dB more than Funnel D, which resulted in the next most reduction in sound. Further, both Funnel C and Funnel D reduced the generated sound greater than Ring A, illustrating that covering a portion of the bypass apertures 22 increases the sound reduction caused by the sound dampening feature 260. Moreover, it was found that Funnel C, with its greatest amount of sound reduction, also balanced the sound reduction with airflow performance for allowing the working air 40 to flow through the cleaning apparatus 10 efficiently.
Referring to FIGS. 13A-15B, the funnel shape and percentage of the bypass apertures 22 covered by the sound dampening feature 260 affected the sound reduction caused by the sound dampening feature 260. Additionally, the sound dampening funnel 38 was also tested and compared with different sound dampening features 260 constructed of the porous nanofiber material. Ring A, Funnel C, and Ring A plus a Disc F, which may be referred to as Ring+Disc G, were tested in a SpotClean Pro^™ Portable Cleaner, Model Number 3617Z, from BISSELL, Inc. to determine the sound reduction provided relative to a baseline level of noise (e.g., in the absence of the sound dampening funnel 38 or other sound dampening feature 260).
Additionally, tests were conducted to determine a reduction in sound intensity (dB) in the combined Frequency Range 1 with a frequency between about 20 Hz and about 48 kHz, in the first subset Frequency Range 2 with a frequency between about 20 Hz and about 20 kHz, and in the second subset Frequency Range 3 between about 20 kHz and about 48 kHz. The Frequency Ranges 1-3 correspond to human and household animal (pet) hearing ranges. For example, Frequency Range 1 includes a combined hearing range for humans and household animals, Frequency Range 2 includes a hearing range for humans, and Frequency Range 3 includes a hearing range for household animals. Typically, household animals include household pets, such as at least cats and dogs. The Frequency Ranges 1-3 were tested to determine sound reduction for humans and pets together and individually.
The Disc F in Ring+Disc G is a generally planar piece of the porous nanofiber material that is positioned on the floor 18, extending from proximate the sidewall 190 and over the bypass apertures 22 to substantially cover the floor 18. The Disc F defines a plurality of holes that are generally circular in shape. The holes are arranged around a central opening for receiving the elevated portion of the impeller housing 210 that supports the gasket 238 and the impeller assembly 230 (see FIG. 10). Further, multiple holes are defined between an outer edge and an inner edge of the Disc F. Accordingly, some of the holes are configured to expose the floor 18, while some of the holes are configured to align with and expose the bypass apertures 22. Accordingly, the Disc F can also reduce the open airflow portions 44 of at least one of the bypass apertures 22. Further, the Disc F can form a barrier between the working air 40 and the floor 18 in certain locations. Ring A is positioned on the Disc F with the lower edge 42 being positioned along the outer edge of the Disc F to form the combination Ring+Disc G.
Referring to FIGS. 13A and 13B, within Frequency Range 2 (20 Hz-20 kHz), the SpotClean Pro^™ Portable Cleaner without the sound dampening feature 260 proximate the suction source 28 generated about 87.32 dB of noise, which is the baseline level of noise within Frequency Range 2 (i.e., Range 2 baseline) that is generated in the absence of the sound dampening funnel 38 or other sound dampening feature 260. With Ring A, the SpotClean Pro^™ Portable Cleaner generated about 85.21 dB of noise. Accordingly, Ring A reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 2.1 dB relative to the Range 2 baseline. This reduction in noise resulted in an improvement in sound intensity of about 38% relative to the baseline within Frequency Range 2.
With Funnel C, the SpotClean Pro^™ Portable Cleaner generated about 83.55 dB of noise. Accordingly, Funnel C reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 3.8 dB relative to the Range 2 baseline. This reduction in noise resulted in an improvement in sound intensity of about 58% relative to the Range 2 baseline.
With Ring+Disc G, the SpotClean Pro^™ Portable Cleaner generated about 83.45 dB of noise. Accordingly, Ring+Disc G reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 3.9 dB relative to the Range 2 baseline. This reduction in noise resulted in an improvement in sound intensity of about 59% relative to the baseline within the Range 2.
Overall, Funnel C and Ring+Disc G reduced the noise generated by the SpotClean Pro^™ Portable Cleaner by about 4 dB, resulting in similar improvements in the noise intensity. Each of Funnel C and Ring+Disc G reduced the generated noise more than Ring A. While Funnel C and Ring+Disc G resulted in similar improvements in sound intensity, Funnel C includes a single component of the nanofiber material, whereas Ring+Disc G utilizes two components of the nanofiber material. Accordingly, Ring+Disc G can increase manufacturing complexity.
Referring to FIGS. 14A and 14B, within Frequency Range 3 (20 kHz-48 kHz), the SpotClean Pro^™ Portable Cleaner without the sound dampening feature 260 proximate the suction source 28 generated about 56.74 dB of noise, which is the baseline level of noise within Frequency Range 3 that is generated in the absence of the sound dampening funnel 38 or other sound dampening feature 260. This baseline is less than the baseline within Frequency Range 2. SpotClean Pro^™ Portable Cleaner generates a greater sound intensity in Frequency Range 2 compared to Frequency Range 3. With Ring A, the SpotClean Pro^™ Portable Cleaner generated about 55.05 dB of noise. Ring A reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 1.7 dB relative to the Range 3 baseline. This reduction in noise resulted in an improvement in sound intensity of about 32% relative to the baseline within Frequency Range 3 ("Range 3 baseline").
With Funnel C, the SpotClean Pro^™ Portable Cleaner generated about 56.69 dB of noise. Accordingly, Funnel C reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 0.05 dB relative to the Range 3 baseline. This reduction in noise resulted in an improvement in sound intensity of about 1% relative to the Range 3 baseline.
With Ring+Disc G, the SpotClean Pro^™ Portable Cleaner generated about 50.2 dB of noise. Accordingly, Ring+Disc G reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 6.5 dB relative to the baseline. This reduction in noise resulted in an improvement in sound intensity of about 78% relative to the Range 3 baseline.
Overall, Ring+Disc G resulted in the most improvement in sound intensity in Frequency Range 3, and Ring A resulted in about half the improvement of Ring+Disc G. In comparison, Funnel C resulted in the least improvement within this range.
Referring to FIGS. 15A and 15B, testing was also conducted within Frequency Range 1 (20 Hz-48 kHz). In this combined sound range, the SpotClean Pro^™ Portable Cleaner without the sound dampening feature 260 proximate the suction source 28 generated about 96.4 dB of noise, which is the baseline level of noise within this combined range ("Range 1 baseline") that is generated in the absence of the sound dampening funnel 38 or other sound dampening feature 260. This baseline is greater than the Range 2 baseline and the Range 3 baseline separately. Further, this Range 1 baseline is almost twice the Range 3 baseline.
With Ring A, the SpotClean Pro^™ Portable Cleaner generated about 93.94 dB of noise. Accordingly, Ring A reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 2.5 dB relative to the combined Range 1 baseline. This reduction in noise resulted in an improvement in sound intensity of about 43% relative to the baseline within the combined Frequency Range 1.
With Funnel C, the SpotClean Pro^™ Portable Cleaner generated about 92.26 dB of noise. Accordingly, Funnel C reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 4.1 dB relative to the Range 1 baseline. This reduction in noise resulted in an improvement in sound intensity of about 61% relative to the combined Range 1 baseline.
With Ring+Disc G, the SpotClean Pro^™ Portable Cleaner generated about 91.42 dB of noise. Accordingly, Ring+Disc G reduced the sound generated by the SpotClean Pro^™ Portable Cleaner by about 5 dB relative to the Range 1 baseline. This reduction in noise resulted in an improvement in sound intensity of about 68% relative to the baseline within the combined Frequency Range 1.
Overall, Funnel C and Ring+Disc G reduced the noise generated by the SpotClean Pro^™ Portable Cleaner by about 4-5 dB, resulting in similar improvements in the noise intensity in the combined Frequency Range 1. Each of Funnel C and Ring+Disc G reduced the generated noise more than Ring A. Additionally, Funnel C provided this improvement in sound intensity using less material and components compared to Ring+Disc G.
Referring again to FIGS. 1-15B, in sum, the sound dampening feature 260 can affect the sound generated by the cleaning apparatus 10. The configuration of the sound dampening feature 260, as well as the percentage of the bypass apertures 22 that is covered both contribute to the reduction in generated sound. The funnel configuration generally provided a greater reduction in sound compared to the ring alone. With the exception of the Frequency Range 3 alone (i.e., separate from Frequency Range 2), the ring and disc combination (i.e., Ring+Disc G) provided similar improvements in sound intensity with the funnel configuration utilizing fewer components and less materials. Moreover, the funnel configuration can be adjusted to change the reduction in sound level and effect on the working air 40 by changing the lower width w₂ and the angle Θ between the funnel 38 and the sidewall 190 of the base enclosure 12. The sound dampening funnel 38 reduces sound intensity generated in the cleaning apparatus 10 in the multiple frequency ranges, which correlate to multiple hearing ranges, while maximizing airflow performance. Accordingly, the funnel-shaped sound dampening feature 38 balances noise reduction with airflow performance. Further, the sound dampening funnel 38 may be movable within the guide passage 36 while providing generally consistent coverage of the bypass apertures 22 to, consequently, provide generally consistent noise reduction.
While the present disclosure focuses on the sound dampening funnel 38 being included in the cleaning apparatus 10, it is contemplated that the ring (Ring A) or the ring in combination with the disc (Ring+Disc G) may be used in the cleaning apparatus 10 without departing from the teachings herein. Further, additional sound dampening features 260 or layers may be used on various components within the working flow path (such as on the base plate 24 under the bypass apertures 22 and/or in the air outlet passage 256) without departing from the teachings herein. In further non-limiting examples, the cleaning apparatus 10 may include multiple sound dampening features 260, including, but not limited to, multiple funnel shapes aligned together or a ring shape and a funnel shape aligned together. It is also contemplated that folds can be added to the sound dampening features 260 to provide additional surface area (e.g., pleats) or shapes for added structure and minimizing separate parts (such as an inner funnel with surrounding ring). The material shape(s) of the sound dampening feature(s) 260 can be accomplished in a variety of processes, such as, for example, cutting and bending to shape with an affixment to hold the selected shape or pressure/thermal forming for the selected shape.
Use of this device may provide for a variety of advantages. For example, the sound dampening funnel 38 can reduce noise generated by the cleaning apparatus 10 that can result from mechanical vibrations, operation of various components, and/or the working air 40 flowing through the cleaning apparatus 10. Additionally, the sound dampening funnel 38 can be constructed as a single component that is placed about the suction source 28 and is able to freely move within the space provided by the guide passage 36. Accordingly, the sound dampening funnel 38 can maximize efficiency of the manufacturing process. Further, the sound dampening funnel 38 constructed from the porous nanofiber material can reduce generated sound. Also, the configuration of the funnel shape can affect the percentage of the bypass apertures 22 that are covered, which can further reduce the generated sound. Moreover, the sound dampening funnel 38 can reduce sound generated in multiple hearing ranges. Also, the sound dampening funnel 38 can be adjusted to change the percentage of the bypass apertures 22 that are covered. Additional benefits and advantages of using this device may be realized and/or achieved.
The device disclosed herein is further summarized in the following paragraphs and is further characterized by combinations of any and all various aspects described herein.
According to one aspect of the present disclosure, a cleaning apparatus includes suction assembly housing including a floor, an intake opening, and bypass apertures arranged at least partially around the intake opening. A base plate defines an air outlet. A suction source includes an impeller cover with an impeller inlet aligned with the intake opening and at least one impeller outlet. The at least one impeller outlet is in fluid communication with the bypass apertures via a guide passage at least partially defined by the impeller cover and the floor. A sound dampening funnel is disposed in the guide passage. The sound dampening funnel includes a lower edge arranged over the bypass apertures to cover a portion of the bypass apertures and reduce an open area of the bypass apertures through which air is directed by the suction source toward the air outlet, and, consequently, reduce a noise level generated by said cleaning apparatus.
According to another aspect of the present disclosure, a suction assembly housing includes an impeller housing having a sidewall extending from a floor. The sidewall at least partially defines a guide passage. A sound dampening funnel extends at an acute angle from an upper edge abutting the sidewall of the base enclosure to the floor to cover a portion of bypass apertures.
According to another aspect of the present disclosure, a sound dampening funnel extends at an acute angle between 5° and 15° relative to a sidewall.
According to another aspect of the present disclosure, a sound dampening funnel reduces a noise level generated by a cleaning apparatus by more than 3 dB relative to a baseline noise level in the absence of the sound dampening funnel within a frequency range between 20 Hz and 20 kHz.
According to another aspect of the present disclosure, a sound dampening funnel reduces a noise level generated by a cleaning apparatus by more than 3 dB relative to a baseline noise level in the absence of the sound dampening funnel within a frequency range between 20 Hz and 48 kHz.
According to another aspect of the present disclosure, a portion of bypass apertures covered by a sound dampening funnel is between 25% and 75% of a total area of the bypass apertures.
According to another aspect of the present disclosure, a portion of bypass apertures covered by a sound dampening funnel is 50% of a total area of the bypass apertures. The sound dampening funnel reduces a noise level generated by a cleaning apparatus by about 4 dB relative to a baseline noise level in the absence of the sound dampening funnel in a frequency range of between 20 Hz and 48 kHz.
According to another aspect of the present disclosure, a cleaning apparatus includes a suction assembly housing including a sidewall and a floor that define a receiving space. The floor defines bypass apertures in the receiving space. A base plate defines an air outlet downstream of the bypass apertures. A suction source is disposed in the receiving space. The suction source includes an impeller cover that defines at least one impeller outlet in fluid communication with a guide passage that is defined between the impeller cover, the sidewall, and the floor. A sound dampening funnel is positioned around the impeller cover and extends from proximate the at least one impeller outlet to the floor in the guide passage. The sound dampening funnel extends at an acute angle from the sidewall and over a portion of the bypass apertures to reduce an open area of the bypass apertures through which air is configured to flow towards the air outlet. The air is directed by the suction source through the guide passage and is configured to interact with the sound dampening funnel as the air is guided toward the bypass apertures to reduce noise generated by said cleaning apparatus.
According to another aspect of the present disclosure, an open area of bypass apertures for air to be directed through is between 25% and 50% of a total area of the bypass apertures.
According to another aspect of the present disclosure, a sound dampening funnel reduces noise generated by a cleaning apparatus more when an open area of bypass apertures is 50% of a total area compared to when the open area of the bypass apertures is 25% of the total area.
According to another aspect of the present disclosure, a sound dampening funnel reduces a noise generated by a cleaning apparatus in a frequency range between 20 Hz and 20 kHz.
According to another aspect of the present disclosure, a sound dampening funnel reduces noise generated by a cleaning apparatus in a frequency range between 20 kHz and 48 kHz.
According to another aspect of the present disclosure, a gap of at least 0.5 mm is defined between a sound dampening funnel and at least one impeller outlet.
According to another aspect of the present disclosure, a sound dampening funnel has a thickness between 0.5 mm and 5 mm.
According to another aspect of the present disclosure, a sound dampening funnel is configured to freely move within a guide passage.
According to another aspect of the present disclosure, a cleaning apparatus includes a base enclosure that defines a suction port. A suction assembly housing includes a sidewall, a floor, an intake opening, and bypass apertures. The suction assembly housing includes a motor housing and an impeller housing. A base plate defines an air outlet. An inlet passage and an outlet passage are defined between the suction port and the intake opening. An outlet passage is defined between the bypass apertures and the air outlet. A suction source is operably coupled with the suction assembly housing. The suction source is configured to direct air through the suction port, the inlet passage, the suction source, and the outlet passage. The suction source includes an impeller assembly disposed in the impeller housing and having an impeller cover that defines an impeller inlet and at least one impeller outlet. A motor is disposed in the motor housing and configured to drive the impeller assembly. A guide passage is defined between the impeller cover, the motor housing, and the floor of the base enclosure. A sound dampening funnel is disposed on the floor in the guide passage. The sound dampening funnel extends at an acute angle from a sidewall of the base enclosure proximate to the at least one impeller outlet, toward the impeller cover, and to the floor to extend over the bypass apertures and reduce an airflow portion of the bypass apertures through which the air is directed by the suction source from the guide passage to the outlet passage.
According to another aspect of the present disclosure, a sound dampening funnel reduces noise generated by a cleaning apparatus in a frequency range between 20 Hz and 48 kHz.
According to another aspect of the present disclosure, a sound dampening funnel reduces noise generated by a cleaning apparatus by about 4 dB compared to a baseline noise level in the absence of the sound dampening funnel.
According to another aspect of the present disclosure, an acute angle is between 5° and 15°.
According to another aspect of the present disclosure, an airflow portion is between 25% and 75% of a total area of the bypass apertures.
It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.
For purposes of this disclosure, the term "coupled" (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.
It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations.
It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

Claims

A cleaning apparatus (10), comprising:
a suction assembly housing (16) including a floor (18), an intake opening (20), and bypass apertures (22) arranged at least partially around the intake opening (20);

a base plate (24) defining an air outlet (26);

a suction source (28) including an impeller cover (30) with at least one impeller inlet (32) aligned with the intake opening (20) and at least one impeller outlet (34), wherein the at least one impeller outlet (34) is in fluid communication with the bypass apertures (22) via a guide passage (36) at least partially defined by the impeller cover (30) and the floor (18); and

a sound dampening funnel (38, 260) disposed in the guide passage (36), wherein the sound dampening funnel (38, 260) includes a lower edge (42) arranged over the bypass apertures (22) to cover a portion (46) of the bypass apertures (22) and reduce an open area (44) of the bypass apertures (22) through which air (40) is directed by the suction source (28) toward the air outlet (26), and, consequently, reduce a noise level generated by said cleaning apparatus (10).
The cleaning apparatus (10) of claim 1, wherein the sound dampening funnel (38, 260) reduces noise generated by said cleaning apparatus (10) in a frequency range between 20 Hz and 48 kHz.
The cleaning apparatus (10) of either of claims 1 or 2, wherein the sound dampening funnel (38, 260) reduces the noise level generated by said cleaning apparatus (10) by more than 3 dB relative to a baseline noise level in the absence of the sound dampening funnel (38, 260) within a frequency range between 20 Hz and 20 kHz.
The cleaning apparatus (10) of any one of claims 1-3, wherein the sound dampening funnel (38, 260) reduces the noise level generated by said cleaning apparatus (10) by more than 3 dB relative to a baseline noise level in the absence of the sound dampening funnel (38, 260) within a frequency range between 20 Hz and 48 kHz.
The cleaning apparatus (10) of any one of claims 1-4, wherein the portion (46) of the bypass apertures (22) covered by the sound dampening funnel (38, 260) is between 25% and 75% of a total area of the bypass apertures (22).
The cleaning apparatus (10) of any one of claims 1-5, the sound dampening funnel (38, 260) positioned around the impeller cover (30) and extending from proximate the at least one impeller outlet (34) to the floor (18) in the guide passage (36), and wherein the air (40) directed by the suction source (28) through the guide passage (36) is configured to interact with the sound dampening funnel (38, 260) as the air (40) is guided toward the bypass apertures (22) to reduce noise generated by said cleaning apparatus (10), and further wherein the open area (44) of the bypass apertures (22) for the air (40) to be directed through is between 25% and 50% of a total area of the bypass apertures (22).
The cleaning apparatus (10) of any one of claims 1-6, wherein the sound dampening funnel (38, 260) reduces the noise generated by said cleaning apparatus (10) more when the open area (44) of the bypass apertures (22) is 50% of the total area compared to when the open area (44) of the bypass apertures (22) that is 25% of the total area.
The cleaning apparatus (10) of any one of claims 1-7, wherein the portion (46) of the bypass apertures (22) covered by the sound dampening funnel (38, 260) is 50% of a total area of the bypass apertures (22), and wherein the sound dampening funnel (38, 260) reduces the noise level generated by said cleaning apparatus (10) by about 4 dB relative to a baseline noise level in the absence of the sound dampening funnel (38, 260) in a frequency range of between 20 Hz and 48 kHz.
The cleaning apparatus (10) of any one of claims 1-8, wherein a gap of at least 0.5 mm is defined between the sound dampening funnel (38, 260) and the at least one impeller outlet (34).
The cleaning apparatus (10) of any one of claims 1-9, wherein the sound dampening funnel (38, 260) has a thickness between 0.5 mm and 5 mm.
The cleaning apparatus (10) of any one of claims 1-10, wherein the sound dampening funnel (38, 260) is configured to freely move within the guide passage (36).
The cleaning apparatus (10) of any one of claims 1-11, wherein the suction assembly housing (16) includes an impeller housing (210) having the floor (18) and a sidewall (190) extending from the floor (18), the sidewall (190) at least partially defining the guide passage (36), and wherein the sound dampening funnel (38, 260) extends at an acute angle (Θ) relative to the sidewall (190) from an upper edge (262) abutting the sidewall (290) to the floor (18) to cover the portion (46) of the bypass apertures (22).
The cleaning apparatus (10) of claim 12, wherein the sound dampening funnel (38, 260) extends at the acute angle (Θ) between 5° and 15° relative to the sidewall.
The cleaning apparatus (10) of either one of claims 12 or 13, further comprising:
a base enclosure (12) defining a suction port (14);

the suction assembly housing (16) including a motor housing (208) and the impeller housing (20), wherein an inlet passage (254) is defined between the suction port (14) and the intake opening (20), and further wherein an outlet passage (256) is defined between the bypass apertures (22) and the air outlet (26); and

the suction source (28) operably coupled with the suction assembly housing (16), wherein the suction source (28) is configured to direct air through the suction port (14), the inlet passage (254), the suction source (28), and the outlet passage (256), the suction source (28) including:
an impeller assembly (230) disposed in the impeller housing (20), the impeller assembly (230) having the impeller cover (30) defining the impeller inlet (32) and at least one impeller outlet (34); and

a motor (212) disposed in the motor housing (208) and configured to drive the impeller assembly (230), wherein the guide passage (36) is defined between the impeller cover (30), the motor housing (208), and the floor (18).
The cleaning apparatus of claim 14, wherein the sound dampening funnel (38, 260) extends at the acute angle (Θ) from the sidewall (190) proximate to the at least one impeller outlet (34), toward the impeller cover (30), and to the floor (18) to extend over the bypass apertures (22) and reduce the open area (44) of the bypass apertures (22) through which the air (40) is directed by the suction source (28) from the guide passage (36) to the outlet passage (256).