FLOOR CLEANING APPARATUS FOR FILTER CLEANING SYSTEM
This application claims the benefit of U.S. Provisional Patent Application Serial No. 60 / 780,211, filed March 8, 2006. Technical Field The present invention relates generally to the field of floor care equipment and, more particularly , with a vacuum cleaner, extractor or the like equipped with a pneumatic mechanism to clean dirt and filter waste including, in particular, fine dust particles from the pores of the filter in order to improve the filter cleaning efficiency and prolong the life of the filter. filter service. BACKGROUND OF THE INVENTION A vacuum cleaner is an electro-mechanical apparatus used to effect the dry removal of dust, dirt and other small litter from carpets, rugs, fabrics or other surfaces in domestic, commercial and industrial environments. In order to achieve the desired removal of dirt and dust, most vacuum cleaners incorporate a rotating agitator. The rotating agitator is provided to hit the dirt and garbage of the hair of the carpet or mat while a pressure drop or vacuum is used to force the air
trapped with this dirt and garbage towards the vacuum cleaner's mouthpiece. The air charged with particles is then attracted to a collection container of dirt. The air is then attracted through a filter before being directed through the suction generator motor to provide cooling. Finally, the air is filtered to remove any fine carbon particles from the brushes of that engine and other debris that could remain in the air stream before being discharged back into the environment. Frequently the dust collection container is designed to produce cyclonic air flow by providing that container with a powder chamber having a cylindrical side wall and a tangentially directed air inlet. This arrangement forces the air to swirl around the dust collection chamber in the manner of a cyclone. The centrifugal force that is produced causes dust and debris to move towards and against the cylindrical side wall of the chamber while relatively clean air can be drawn out of the center of the chamber through the filter to the suction generator. Under most operating conditions the
Most or all dust and debris is removed from the airstream by the cyclonic airflow. Sometimes, however, some dust and debris remains trapped inside the airstream. Typically, that dust and debris is relatively thin lightweight powder particles that are not as susceptible to the centrifugal separation force produced by the cyclonic airflow. Over time these fine particles can get trapped and fill the pores of the filter medium, thereby restricting the air flow and reducing the cleaning efficiency of the vacuum cleaner. Eventually the cleaning efficiency of the vacuum cleaner is so damaged that it is necessary for the operator to clean or change the filter in order to achieve the desired level of cleaning. The present invention relates to a vacuum cleaner, extractor or the like equipped with a filter cleaning mechanism more efficient and effective. Advantageously, the present invention allows the dust and debris of a filter to be quickly and easily cleaned, particularly including the fine particles of the pores of the filter in situ. As a result, each filter has a longer service life and the appliance can be operated at a higher cleaning efficiency through the duration
full of that life of prolonged service. SUMMARY OF THE INVENTION In accordance with the purposes of the present invention described herein, a floor cleaning apparatus is provided. The floor cleaning apparatus includes a housing. A dust collection container is maintained in the housing. The dust collection container includes a dirty air inlet, a clean air inlet, a dust collection chamber and a clean air outlet. A filter is received in the dust collection container. In addition, a suction generator is carried in the housing. The floor cleaning apparatus also includes a flow control valve assembly. The flow control valve assembly is selectively displaceable between (a) a first position where dust and debris are captured in the dirt collection container and (b) a second position where clean air is attracted through when minus one portion of the filter to clean the filter. An activator automatically moves the flow control valve assembly between the first and second positions. More specifically describing the invention, the activator can take the form of a chronometre. In other
mode, the activator is a deposition sensor. That position sensor can be connected to the control handle. In yet another embodiment, the activator is an operating sensor. The operating sensor can take the form of an air pressure sensor or a dirt volume sensor. In yet another embodiment, the trigger is a switch that initiates filter cleaning when the filter cleaner apparatus is first switched on. Alternatively, that switch can initiate filter cleaning when the floor cleaning apparatus is turned off. The housing of the floor cleaning apparatus includes a nozzle assembly and a basket assembly. A suction inlet is provided in the nozzle assembly. A rotating agitator can be carried in the nozzle assembly adjacent to the suction inlet. In addition, the dirt collection container is carried in the basket assembly. That basket assembly is pivotally connected to the nozzle assembly. In addition, the floor cleaning apparatus can include a manual activator so that the operator can clean the filter at any desired time. In addition, the flow control valve assembly includes a first flow valve to selectively open and close the clean air inlet and a second
Flow valve to selectively close and open the dirty air outlet. In accordance with a further aspect of the present invention, there is provided a method for cleaning a filter in situ in a floor cleaning apparatus. The method can be broadly described as including the step of providing the floor cleaning apparatus with two modes of operation. These modes of operation include a floor cleaning mode where dust and debris are collected in a dust collection container and a filter cleaning mode where dust and debris are cleaned from the filter. In addition, the method may include the step of automatically activating the filter cleaning mode upon perceiving a predetermined condition. The activation of the filter cleaning mode can occur when the floor cleaning apparatus is switched off and on. Alternatively, activation of the filter cleaning mode can occur upon perceiving the position of a control handle or the perception of a predetermined operating condition. In addition, activation of the filter cleaning mode may occur during the perception of the operation of the floor cleaning apparatus for a predetermined period of time.
In the following description various preferred embodiments of this invention are shown and described, simply by way of illustration of some of the most appropriate modes for carrying out the invention. As will be appreciated, the invention is capable of other different embodiments and its various details are capable of modification in various evident aspects, all without abandoning the invention. Consequently, the drawings and descriptions will be considered as illustrative in nature and not as restrictive. BRIEF DESCRIPTION OF THE DRAWING The accompanying drawing incorporated in and forming a part of this specification illustrates various aspects of the present invention and, together with the description, serves to explain certain principles of the invention. In the drawing: Figure 1 is a perspective, partially broken away view of the floor cleaning apparatus of the present invention; Figure 2 is a detailed perspective view of the assembled dust collection container; Figure 3 is a detailed perspective view of the dust collection container, filter and assembly
flow control valve of the present invention; Figure 4 is a cross-sectional view of the dust collection container, filter and flow control valve assembly in the first position that allows normal vacuum operation; Figure 5 is a cross-sectional view similar to Figure 4, but illustrating the flow control valve assembly in the second position that allows the cleaning of a section of the filter; and Figure 6 is a detailed top perspective view of the filter assembly. Reference will now be made in detail to the current preferred embodiments of the invention, examples of which are illustrated in the figures of the accompanying drawing. Detailed Description of the Invention Reference is now made to Figure 1 illustrating the floor cleaner apparatus 10 of the present invention. In the illustrated embodiment, the floor cleaning apparatus 10 comprises a vertical vacuum cleaner. It should be appreciated, however, that the apparatus can easily be the same as a basket vacuum, a manual vacuum cleaner or even an extractor.
As illustrated, the apparatus 10 includes a housing 12 that includes both a nozzle assembly 14 and a basket assembly 16. The nozzle assembly 14 includes a suction inlet 18 through which air entrained with dust and debris is attracted to the vacuum 10. A rotary agitator 20 is mounted to the nozzle assembly 14 and extends through the inlet 18. of suction. The basket assembly 16 includes a handle 22 having a handle 24. An actuator switch 26 for connecting and disconnecting the vacuum cleaner is provided adjacent to the handle. In addition, the basket assembly 16 includes a cavity or receiver 28 for receiving and retaining a dust collection receiver 30. A suction generator 32 is mounted in a compartment in the basket assembly 16. During the operation, the rotating agitator 20 hits the dust and debris of the hair of the carpet or carpet being cleaned. The suction generator 32 attracts air trapped with that dust and debris through the suction inlet 18 to the dust collection container 30. The dust and debris are trapped in the dust collection container 30 and now relatively clean air passes through and over the motor of the suction generator 32 to provide
cooling before being discharged through a discharge port (not shown) back into the environment. As best illustrated in Figures 2 and 3, the dust collection container 30 comprises a dust cup section 36 and a lid section 38. The powder cup section 36 comprises a side wall 35, a bottom wall 37 and a packing ring 39. In the illustrated embodiment, the bottom wall 37 is a "drain door" connected by a link 31 to the side wall 35. A bracket 33 and fastener 29 complete the articulated connection. A latch 150 secures the lower wall 37 in the closed position. A slide latch release 152 moves downward to release the latch 150 and open the bottom wall 37 in order to empty the dust and debris from the dust collection container in a manner described in greater detail in the co-pending US patent application. Serial No. 11 / 104,711, filed April 13, 2005. The lid section 38 comprises a first element 40, a second element 42 and a third element 43. The first element 40 includes a dirty air inlet 44 and a filter cavity 46. The second element 42 includes a clean air outlet 48. The third element 43 receives a pivoting handle 51 for conveniently carrying the
container 30 for collecting dust. The first element 40 is connected to the side wall 35 by the screws 160. The third element 43 is connected to the second element 42 by the screws 162. A filter, generally designated by the reference number 52, is received in the cavity 46 of filter of the first element 40. The filter 52 includes a side wall 54, a hub 56 and multiple partitions 58 that extend between the hub and the side wall (see also Figure 6). The divisions 58 serve to divide the filter 52 into multiple sections 60. A filter means 62, of a type well known in the art, extends between the side wall 54, the cube 56 and the divisions 58 defining each section 60. Packaging 166 and 168 provide a seal between the hub 56 and the side wall 54 of the filter 52 and the support cap member 40. A prefilter 66 and an internal support 64 extend downwardly in the powder cup section 36 from the first element 40 to the bottom wall 37. A package 164 provides an air tight seal between the support 64 and the bottom wall 37. The prefilter 66 includes a series of intake openings 68 that allow air flow in a manner that will be described in more detail below.
In the illustrated embodiment, the dust collection container 30 is designed to produce cyclonic air flow and thus use centrifugal force to improve the efficiency with which dust and debris are separated from the air stream. More specifically, as clearly illustrated in Figure 3, the dust cup section 36, the lid section 38, the internal support 64, the prefilter 66 and the filter 52 are all substantially cylindrical in configuration. As illustrated in Figures 4 and 5, the internal support 64 and the prefilter 66 are received concentrically in the side wall 35 of the powder cup section 36. The filter 52 is received concentrically in the filter cavity 46 of the first element 40 of the lid section 38. The dirty air inlet 44 is directed tangentially towards the annular space formed between (a) the first element 40 and the side wall 35 on the outside and (b) the internal support 64 and pre-filter 66 on the inside. The air flow flows around the annular space in a circular or vortex pattern generating centrifugal force that causes the dust and debris in the air stream to move outward towards the side wall 35 thereby causing the dust and debris to flow. collect in section 36 of dust cup. Simultaneously, the air relatively
clean is attracted through the intake openings 68 provided in the prefilter 66 along the inner wall of the annular space where it is then directed upwards through the filter 52. Specifically, the air passes through the medium 62 of filter where any fine dust and debris that remains in the air stream is stopped while clean air passes through the medium through the clean air outlet 48 to the suction generator 32. The direction of air flow during the normal operation of the expiration is shown by the action arrows in Figure 4. The flow control system of the present invention will now be described in detail. The flow control system includes an actuator such as a drive motor 70 which is connected to a first drive gear 72. The first drive gear 74 is meshed with a second drive gear 74 carried in the cover 38. The second drive gear 74 is connected to an air guide 76 by the screws 75. The air guide 76 has a concavity 78 which it retains a clean air inlet valve comprising a valve body 80 and a deflection spring 82. When in the normal operating position illustrated in Figure 4, the body 80 of
valve couples and closes the clean air inlet 50 defined by the central opening in the second drive gear 74. As further illustrated in the figures of the drawing, the air guide 76 includes an air guide passage 84 defining an arc of A °. The airflow control system also includes a static air guide 86 which is retained in the cover 38 by running over the filter 52. A seal 167 is provided between the air guide and the filter 52. The static air guide 86 It includes a central opening 88 and a series of radially arranged divisions 90 that define a series of air paths that also have an arc of A °. As noted above, the filter 52 includes divisions 58 that divide the filter into equal sections 60, each having an arc of A °. It should be appreciated that the partitions 90 in the static air guide 86 are aligned with the partitions 58 in the filter 52. Consequently, the air paths 92 in the static air guide 86 are each aligned with a single filter section 60. 52. In the illustrated embodiment, filter 52 includes eight divisions 58 that divide filter 52 into eight equal sections 60, each expanding an arc of 45 °. Similarly, the static air guide 86 includes eight divisions
90 that divide the guide into eight air paths 92, each expanding an arc of 45 °. In addition, the air guide passage 84 in the air guide 76 also expands an arc of 45 °. As will be described in more detail below, the air guide 76 is rotated precisely to bring the air guide passage 84 in perfect alignment with a single air path 92 of the static air guide 86 and thus a single section 60 of filter 52 during each movement cycle. As further illustrated, the air guide 76 includes a first cam 94 projecting from the bottom wall thereof. The cam 94 includes eight cam profiles, one for each section 60 of the filter 52. The cam 94 couples a cam follower 96 (also with eight matching profiles) which is connected by means of a ticking arrow to a control valve 100 flow. More specifically, the telescopic arrow 98 comprises a first section 102 connected to the cam follower 96 and a second section 104 having a perforation 106 which telescopically receives the first section 102. A compression spring 108 received in the perforation 106 engages the first section 102 of the arrow and deflects the telescopic arrow 98 to an extended position. One second
compression spring 110 is received in hub 112 of element 40. This spring 110 of compression engages the bottom of the cam follower 96 and biases the cam follower 96 into engagement with the cam 94. A seal 170 of cover and expander 172 is sealed around the arrow 98 and the element 40 to prevent any air passage. The flow control valve 100 comprises a flexible tubular diaphragm 114 supported at a first or upper end by a first open air guide 116 and a second or lower end by a second open air guide 118. The air guide 116 is secured to the element 40 and is static. By contrast, the second open air guide 118 is fastened to the distal end of the second section 104 of the telescopic arrow 98. During the normal operation of the vacuum cleaner, the rotary stirrer 20 functions to shake the dust and debris from the hair of an underlying carpet that is being cleaned. That dust and debris is then attracted by the suction generator 32 through the inlet 44 to the dust collection container 30. As the air stream flows cyclonicly around the sidewall 35, dust and debris are collected in the dust collection container 30. The relatively clean air is then attracted through
of the openings 68 in the prefilter 66 (see action arrow A in Figure 4) above through the filter 52. The filter means 62 allows the passage of clean air but prevents the passage of any relatively fine dust particles which can remain in the air stream. The now clean air then passes up through the static air guide 86 (note the action arrow B) and then passes through the air outlet 48. The air then moves through a conduit to the suction generator 32. From there the clean air passes over the motor of the suction generator 32 to provide cooling before being discharged into the environment through a final filter and discharge port (not shown) back into the environment. As the vacuum cleaner 10 operates, fine dust particles not removed from the airstream by the cyclonic action in the dust cup section 36 are separated from the air stream and trapped by the filter filter medium 62. 52. Over time, these fine particles begin to close the pores of the filter medium 62 thus restricting the air flow. This not only causes the motor of the suction generator 32 to operate warmer and at a lower efficiency, also
reduces the air flow, thus adversely affecting the cleaning efficiency of the vacuum 10. Consequently, the air flow may be restricted in order to prevent the vacuum cleaner from cleaning properly. It is then necessary to either clean or replace the filter 52. The present invention allows the filter 52 to be cleaned in situ in a very convenient and efficient manner before any substantial loss of energy or cleaning efficiency occurs. Specifically, the motor 70 is activated to rotate the air guide 76 through a 45 ° arc by means of the take-up gears 72, 74. Precise rotation can be provided by a stepper motor or a permanent magnet current motor in combination with a sensor and sensor target such as a magnet 120 clamped to or retained in a cavity in the drive gear 74. An annular bearing 122 and cooperating bearing plate 124 ensure free rotation of the drive gear 74. As the rotation is completed, the air guide passage 84 in the air guide 76 is aligned with one of the air paths 92 in the static air guide 86 and, consequently, one of the sections 60 of the filter 52. The rotation of the drive gear 74
simultaneously causes the cam 94 at the bottom of the air guide 76 to rotate from the position shown in Figure 4 to the position shown in Figure 5. As this occurs, the cam follower 96 follows the cam 94 causing that the telescopic arrow 98 moves downwards. This in turn causes the second open air guide 118 of the flow control valve 100 to engage the upper part of the support 64. As this occurs, the diaphragm 114 expands and the air path for normal operation illustrated by the action arrow A in Figure 4 is interrupted (compare Figure 5 with Figure 4). The telescopic arrow 98 accommodates any discrepancy that may exist in the height of the cam 94 and the distance in which the second open air guide 118 moves to engage the upper part of the support 64. When the valve 100 closes the flow path of the Normal air, no air can be attracted by the suction generator through the prefilter 66 or the suction inlet 18. As negative pressure builds up, the biasing force of the spring 82 is exceeded and the valve body 80 is displaced to open the clean air inlet 50 in the drive gear 74. As a consequence, clean air is attracted through the inlet 50 beyond the
80 valve body. That clean air then passes through the air guide passage 84 in the air guide 76 and the air path 92 aligned in the static air guide 86 (see action arrow C in Figure 5). The clean air is then attracted through a single section 60 of the filter 52 in the reverse direction to the normal flow so as to remove fine dust particles from the pores of the filter medium 62. As a result of a pressure drop, those fine dust particles settle to the bottom of the support 64 (note the action arrow D) while the air stream moves again through the other sections 62 of the filter 52 not aligned with the passage 84 of the guide 76 of air (note the action arrow E). The air stream then again moves through the air paths 92 of the static air guide 86 (ie, those not aligned with the air guide passage 84) before passing out of the dust collection container 30. through the outlet 48. The air stream is then attracted through the suction generator 32 before being discharged back into the environment. During a cleaning cycle, the sections 60 of the filter 52 are cleaned in sequence in the manner described above and the air guide 76 is rotated toward alignment with
each air path 92 and each filter section 60. The cleaning cycle may last, for example, from about one to about 30 seconds and more typically from about 3 to about 15 seconds. After the air guide 76 is rotated, precisely through 360 °, the drive motor 70 is stopped and the flow control valve 100 is opened as illustrated in Figure 4. When this occurs, the air flow is restores to the suction inlet 18 and the spring 82 biases the valve body 80 so as to close the inlet 50 of clean air and restores the air flow for normal operation of the vacuum cleaner. The motor 70 is activated by means of an activator 30 as schematically illustrated in Figure 3. The activator 300 can assume a number of forms. In a possible embodiment, the trigger 30 is a timer that measures the operation time of the suction generator 32 of the vacuum 10. After the suction generator 32 is operated for a predetermined period of time, such as for example 15 minutes , timer 300 activates motor 70 to start the filter cleaning cycle. In another possible mode, the activator 300 is a position sensor. In this embodiment, the position sensor 300 detects the position of the handle 22. When detecting the
return of the handle 22 to the storage position, vertical from the use position, down, the position sensor activates the motor 70 to initiate the filter cleaning cycle. In yet another embodiment, a stopwatch is added to the position sensor so that the trigger 300 only functions to initiate the cleaning cycle when the handle 22 is returned to the vertical position after a predetermined operating time has elapsed since the last filter cleaning. In yet another embodiment the activator 300 is an operating sensor. The operating sensor 300, for example, may be an air pressure sensor for sensing the air pressure between the dust collection container 30 and the suction generator 32 or a dust volume sensor for detecting the level of dust in the dust cup. Upon reaching a predetermined pressure or powder level, such as an activator 300 operates to activate the engine 70 and initiate the cleaning cycle. In still another alternative mode, the activator 300 is a switch. The switch 300 can operate to initiate the filter cleaning cycle when the vacuum 10 is connected first or when the vacuum cleaner is
disconnect Still further, the vacuum cleaner 10 may include a manual trigger switch 300. The manual switch 300 can be coupled by the user at any desired time in order to start the cleaning cycle. Obviously, a manual switch of this nature can be provided in the vacuum cleaner in addition to any of the other triggers previously discussed if desired, to allow the user to bypass the automatic system to initiate the cleaning cycle. The above description of preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described. Modifications or obvious variations are possible in the light of the previous teachings. The modalities were selected and described to provide the best illustration of the principles of the invention and their practical application in order to allow one of ordinary experience in the field to use the invention in various modalities and with various modifications as appropriate for the use particular contemplated. All these modifications and variations are
within the scope of the invention as determined by the appended claims when interpreted in accordance with the width to which they are justly, legally and equitably entitled. The preferred drawings and embodiments do not limit or are intended to limit the ordinary meaning of the claims and their fair and wide interpretation in any way.