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Vacuum cleaner with improved hygenic performance
US20070209144A1
United States
- Inventor
Joseph A. Fester Aaron P. Griffith James A. Krzeminski Sue A. Potter Daniel M. Heidenga - Current Assignee
- Bissell Homecare Inc
Worldwide applications
Application US11/683,541 events
2007-03-08
2007-03-08
2007-09-13
Status
Abandoned
Description
translated from
-
[0001] This application claims priority to U.S. provisional patent application Ser. No. 60/743,454, filed Mar. 10, 2006, which is incorporated herein by reference in its entirety. -
[0002] 1. Field of the Invention -
[0003] The invention relates generally to vacuum cleaners. In one aspect, the invention relates to a vacuum cleaner having improved filtration and hygienic performance. In another aspect, the invention relates to a vacuum cleaner having an ultraviolet light. In another of its aspects, the invention relates to a vacuum cleaner that has microbe-inhibiting properties. -
[0004] 2. Description of the Related Art -
[0005] Upright vacuum cleaners having cyclone separators are well-known in the art. These vacuum cleaners may employ a frusto-conical shape separator, while others use high-speed rotational motion of the air/dirt in a cylindrical separator to separate the dirt by centrifugal force. Typically, working air enters and exits at an upper portion of the cyclone separator and the bottom portion of the cyclone separator is used to collect dirt. It is further known to employ multiple serial cyclone separators to improve the collection of fine dirt particles that may not be collected by a single separator. -
[0006] Vacuum cleaners further have at least one motor/fan assembly for generating suction to draw air and dirt into the vacuum cleaner, and frequently have a second motor/fan assembly to drive an agitator, such as a brushroll, housed in the foot of the vacuum cleaner. Air to cool to the motor/fan assemblies is drawn into the vacuum cleaner and subsequently exhausted from the housing through separate ports in vacuum cleaner housing. As the air passes through the motor, carbon dust discharged from the motor brushes can become entrained in the air and thus also exhausted from the vacuum cleaner, leading to contamination of the home environment. Some effort has been made to filter the motor cooling air after it has passed through the vacuum cleaner. A filter can be placed at the inlet or exhaust port to remove carbon dust from the motor cooling air, however, this filter adds expense and bulk to the vacuum cleaner. -
[0007] Even those vacuum cleaners having means to collect fine dirt and to filter the motor cooling air after it passes through the motor do not protect the home environment from certain bacteria and molds that may be drawn from a carpet or other surface and rendered airborne by the exhaust form the vacuum cleaner, spreading unpleasant odors and unhealthy bacteria. The vacuum cleaner can suction up bacteria and mold, but then these undesirable items are exhausted back into the home environment because their small size prohibits collection by a cyclone separator. Ultraviolet lights and ion generators have been used in some vacuum cleaners in an attempt to neutralize or destroy odor-causing bacteria and mold. These efforts concentrate on sanitizing the working air as it enters the suction nozzle of the foot, in the cyclone separator (or other collecting means) or as it is exhausted. Bacteria and mold can accumulate in multiple areas of the vacuum cleaner. -
[0008] According to the present invention, a vacuum cleaner comprises a housing, a cleaning head assembly in the housing and having a suction nozzle and a working air path therethrough, a dirt collector in the housing for removing dirt from a dirt-containing airstream, and a suction source having an inlet connected to the dirt collector and adapted to draw the dirt-containing airstream from the suction nozzle and through the dirt collector, and an outlet. A filter is positioned between the dirt collector and the inlet to the suction source. An ultraviolet light source is positioned between the dirt collector and the filter, wherein the ultraviolet light source is positioned to illuminate the filter assembly. -
[0009] In one embodiment, the housing includes a handle assembly pivotally coupled with the cleaning head assembly and the ultraviolet light source is positioned in the handle assembly. The dirt collector and the suction source can also be positioned in the handle assembly. -
[0010] In another embodiment, the vacuum cleaner can further comprise a second filter positioned downstream of the outlet of the suction source. At least one of the first and second filters can be a HEPA filter. -
[0011] In yet another embodiment, the ultraviolet light source is annular and the airstream passes through the open center of the ultraviolet light source. The ultraviolet light source can be mounted in an annular casing. The annular casing can be transparent. The annular casing can further include a plurality of openings. -
[0012] In still another embodiment, the filter is treated with a photocatalyst. Preferably, the photocatalyst is TiO2. -
[0013] Further according to the invention, a vacuum cleaner comprises a working air path formed at least in part from a plastic material that includes at least one anti-microbial agent in an effective amount sufficient to impart microbe-inhibiting properties to the working air path. -
[0014] In one embodiment, the at least one anti-microbial agent can be incorporated in the plastic material. The at least one anti-microbial agent can be selected from the group consisting of: phenol derivatives, organotins, and mixtures thereof. The phenol derivative can be 2,4,4′-trichloro-2′-hydroxydiphenol and the organotin can be Tri-n-butyltin maleate. -
[0015] In another embodiment, the plastic material can be treated with the at least one anti-microbial agent to impart microbe-inhibiting properties to the working air path. The plastic material can be soak-treated in an aqueous solution containing the at least one anti-microbial agent, and the at least one anti-microbial agent comprises stabilized chlorine dioxide. -
[0016] In yet another embodiment, the vacuum cleaner can further comprise a housing, a cleaning head assembly in the housing and having a suction nozzle, a dirt collector in the housing for removing dirt from a dirt-containing airstream, and a suction source having an inlet connected to the dirt collector and adapted to draw the dirt-containing airstream from the suction nozzle and through the dirt collector, and an outlet, wherein the working air path is positioned at least between the cleaning head assembly and the dirt collector. The working air path can include one or more of the dirt collector and a conduit between the dirt collector and the suction source. -
[0017] In the drawings: -
[0018] FIG. 1 is a front perspective view of a vacuum cleaner according to the present invention comprising a handle assembly pivotally mounted to a foot assembly. -
[0019] FIG. 2 is a rear perspective view of a vacuum cleaner according to the present invention. -
[0020] FIG. 3 is a partially exploded view of the vacuum cleaner fromFIG. 1 . -
[0021] FIG. 4 is an exploded view of the foot assembly fromFIG. 1 . -
[0022] FIG. 5 is a partial cut-away view of the foot assembly illustrating a height-adjustment mechanism. -
[0023] FIG. 6 is a side view of the vacuum cleaner, illustrating the foot assembly in a lowered position with respect to a floor surface. -
[0024] FIG. 7 is a side view similar toFIG. 6 , illustrating the foot assembly in a raised position with respect to a floor surface. -
[0025] FIG. 8 is a cross-section view taken through line 8-8 ofFIG. 3 that is partially cut-away to illustrate a detent pedal in an engaged or locked position where the handle assembly is immobile with respect to the foot assembly. -
[0026] FIG. 9 is a view similar toFIG. 8 , illustrating the detent pedal in an unengaged or unlocked position where the handle assembly is movable with respect to the foot assembly. -
[0027] FIG. 10 is a partial cut-away view of the foot assembly illustrating the drive attachment between the brush assembly and a motor/fan assembly. -
[0028] FIG. 11 is a top cross-sectional view of the vacuum cleaner through the foot assembly, illustrating a path for motor cooling air through the foot assembly. -
[0029] FIG. 12 is a rear, close-up view of the vacuum cleaner. -
[0030] FIG. 13 is a partial cut-away of the rear handle assembly illustrating a diverter mechanism. -
[0031] FIG. 14 is a side view of the diverter assembly fromFIG. 13 , where the diverter assembly is in a first orientation. -
[0032] FIG. 15 is a side view similar toFIG. 14 , where the diverter assembly is in a second orientation. -
[0033] FIG. 16 is a rear view of the handle assembly illustrating a second embodiment diverter mechanism. -
[0034] FIG. 17 is a schematic illustration of the air flow path through the diverter mechanism fromFIG. 16 . -
[0035] FIG. 18 is an exploded view of a cyclone module assembly according to the present invention. -
[0036] FIG. 19 is a cross-sectional view taken through line 19-19 ofFIG. 3 . -
[0037] FIG. 20 is a cross-sectional view taken through line 20-20 ofFIG. 3 . -
[0038] FIG. 21 is a perspective view of a separator unit from the cyclone module assembly. -
[0039] FIG. 22 is a cross-sectional view through the middle portion of the vacuum cleaner illustrating a latching mechanism between the handle assembly and the cyclone module assembly. -
[0040] FIG. 23 is a partially exploded perspective view of the cyclone module assembly illustrating an emptying mechanism. -
[0041] FIG. 24 is a perspective view of the cyclone module assembly with the emptying mechanism actuated to empty the dirt collected in the cyclone module assembly. -
[0042] FIG. 25 is a cross-sectional view through line 25-25 ofFIG. 3 illustrating a motor/fan assembly and a UV sanitation assembly -
[0043] FIG. 26 is an exploded view of the motor/fan assembly and the UV sanitation assembly. -
[0044] FIG. 27 is a partially exploded perspective view of the vacuum cleaner illustrating a post-motor filter assembly. -
[0045] FIG. 28 is a perspective view of a telescoping wand for use with the vacuum cleaner in a retracted position. -
[0046] FIG. 29 is a perspective view of the telescoping wand in an extended position. -
[0047] FIG. 30 is a cross-sectional view through the telescoping wand fromFIG. 29 . -
[0048] FIG. 31 is a perspective view of a flexible crevice tool for use with the vacuum cleaner. -
[0049] FIG. 32 is a top view of the flexible crevice tool fromFIG. 31 illustrating the side-to-side flexing of the crevice tool. -
[0050] FIG. 33 is a side view of the flexible crevice tool fromFIG. 31 illustrating the up-and-down flexing of the crevice tool. -
[0051] FIG. 34 is a top perspective view of a turbine-powered brush for use with the vacuum cleaner. -
[0052] FIG. 35 is a bottom perspective view of the turbine-powered brush fromFIG. 34 . -
[0053] FIG. 36 is an exploded view of the turbine-powered brush fromFIG. 34 . -
[0054] FIG. 37 is a bottom perspective view of a second embodiment of a turbine-powered brush for use with the vacuum cleaner. -
[0055] FIG. 38 is a view similar toFIG. 20 illustrating the path of working air through the cyclone assembly. -
[0056] Referring to the drawings, and in particular toFIGS. 1-2 , anupright vacuum cleaner 10 according to the present invention comprises anhandle assembly 12 pivotally mounted to a cleaning head orfoot assembly 14. Thehandle assembly 12 further comprises aprimary support section 16 with a closed-loop handgrip 18 on one end to facilitate movement by a user. Thehandgrip 18 is preferably overmolded with a soft low durometer material for providing a comfortable grip for the user. Amotor cavity 20 is formed at an opposite end of thehandle assembly 12 and houses a source of suction, illustrated herein as a vertically-oriented motor/fan assembly 22 (FIG. 27 ). Thehandle assembly 12 pivots relative to thefoot assembly 14 through an axis of rotation formed perpendicular to a shaft within the motor/fan assembly 22. An electric cord (not shown) extending from the motor/fan assembly 22 is stored on a pair of opposed cord wraps 24 provided on the rear of theprimary support section 16. Afirst push button 26 operating a first switch for actuating the motor/fan assembly 22 and asecond push button 28 operating a second switch for actuating an agitator in the foot assembly are provided near thehandgrip 18. A light bulb 30 (FIG. 27 ) housed in acasing 32 is positioned in front of themotor cavity 20 for illuminating an area to be cleaned in front of thefoot assembly 14. -
[0057] Referring toFIG. 3 , thehandle assembly 12 further receives a removablecyclone module assembly 34 on a slottedplatform 36 within arecess 38 provided on theprimary support section 16. Thecyclone module assembly 34 separates and collects dirt from a working air stream and can be emptied of collected dirt after a cleaning operation is complete. -
[0058] Referring toFIG. 4 , thefoot assembly 14 further comprises alower housing 40 that mates with anupper housing 42 creating abrush chamber 44 in a forward position thereon. Anagitator brush assembly 46 is positioned within thebrush chamber 44 for rotational movement via a bearing assembly (not shown), as is well known in the vacuum cleaner art. Asuction nozzle 48 is formed in the lower housing beneath thebrush chamber 44 and is in fluid communication with a surface to be cleaned. Thesuction nozzle 48 can be overmolded with a soft low durometer material. A transparent orsemi-transparent window 50 can be provided on thebrush chamber 44 to allow the user to view theagitator brush assembly 46. Afoot conduit 52 provides a working air path through thefoot assembly 14, from thesuction nozzle 48 and through acurved conduit 54. In the preferred embodiment, thefoot conduit 52 is a smooth, rigid, blow-molded tube connected to the bendablecurved conduit 54, which coincides with the pivot point between thefoot assembly 14 and thehandle assembly 12 to allow thehandle assembly 12 to pivot relative to thefoot assembly 14. In an alternate embodiment, one or both of thefoot conduit 52 and thecurved conduit 54 is a flexible hose as is commonly known in the vacuum cleaner industry. A pair ofrear wheels 56 are mounted for rotation at a rearward portion of thefoot assembly 14 on respective axle pins 57. Acircuit breaker 58 is provided in thefoot assembly 14 to protect the electrical wiring of thevacuum cleaner 10 from damage caused by an overload or a short circuit. -
[0059] Referring additionally toFIG. 5 , a rotatableheight adjustment knob 60 is provided on thefoot assembly 14 and operates aheight adjustment assembly 62 such as is commonly known to adjust the vertical height of thesuction nozzle 48 relative to the surface to be cleaned. Theheight adjustment knob 60 comprises acylindrical body 64 having ahandle 66 on an upper surface thereof for the user to grip and a steppedportion 68 of incremental steps having a constant height difference formed on the bottom edge of thebody 64. The steppedportion 68 can be formed with aprotrusion 69 at either extreme of rotation to limit the movement of the height adjustment knob. Theheight adjustment assembly 62 comprises acarriage assembly 70 that interacts with theheight adjustment knob 60. Thecarriage assembly 70 comprises a pair ofwheels 72 mounted to asupport 74 that is pivotable with respect to thefoot assembly 14. Thesupport 74 is received in a molded cavity in the bottom of thelower housing 40. Anarm 76 extends upwardly at an angle from thesupport 74 and engages the steppedportion 68 on theheight adjustment knob 60. -
[0060] The height of thesuction nozzle 48 can be adjusted relative to the surface to be cleaned by rotating theheight adjustment knob 60 in either direction, i.e. clockwise or counterclockwise. The steppedportion 68 riding on thearm 76 moves such that thearm 76 engages an adjacent incremental step on theadjustment knob 60. In this way, the height of thesuction nozzle 48 can be adjusted up or down a predetermined height, from a fully lowered position shown inFIG. 6 where thesuction nozzle 48 is close to the surface being cleaned to a fully raised position shown inFIG. 7 where thesuction nozzle 48 is farther from the surface being cleaned. -
[0061] Referring toFIGS. 8-9 , adetent pedal 78 is provided on the rearward portion of thefoot assembly 14, near one of therear wheels 56. Thedetent pedal 78 operates a locking mechanism between thehandle assembly 12 and thefoot assembly 14. Thedetent pedal 78 is pivotally mounted to thelower housing 40 of thefoot assembly 14 through apivot pin 80 formed at one end of ashaft 82 extending downwardly from thedetent pedal 78. Theshaft 82 is received in anangled recess 84 in thelower housing 40. Alatch 86 is formed on a forward portion of thedetent pedal 78 and is selectively received in alatch recess 88 formed onhandle assembly 12. Aspring 90 biases thedetent pedal 78 upwardly to add additional force to the locking mechanism when thelatch 86 is received by thelatch recess 88. To unlock thehandle assembly 12 from thefoot assembly 14, the user depresses thedetent pedal 78 with their foot. The downward force on thedetent pedal 78 causes thepivot pin 80 to rotate counterclockwise, with respect to the orientation ofFIGS. 8-9 , such that theshaft 82 is pivoted rearwardly in therecess 84. This motion causes thelatch 86 to pivot out of engagement with thelatch recess 88, thus unlocking thehandle assembly 12 from thefoot assembly 14. -
[0062] Referring toFIG. 10 , theagitator brush assembly 46 is rotated by a dedicatedagitator motor assembly 92 housed in amotor recess 116 formed in thelower housing 40. Anendless belt 118 is coupled between adrive shaft 120 of themotor assembly 92 and thebelt mounting portion 114 to transmit rotational movement of theshaft 120 to thebrushroll 94. Two pairs of upper andlower retainers 115 on either side of thebelt 118 prevent thebelt 118 from slipping off thebelt mounting portion 1 14. The retainers can be made of a felt material that also helps to prevent dust and dirt from entering the belt area, thus minimizing damage to theagitator brush assembly 46. AU-shaped spring clip 122 positioned between themotor assembly 92 and themotor recess 116 is used during assembly of thevacuum cleaner 10 to keep tension on thebelt 118 before themotor assembly 92 has been tightened into themotor recess 116 with suitable fasteners, such as screws or bolts (not shown). -
[0063] Referring toFIG. 11 , air for cooling theagitator motor assembly 92 is drawn into thefoot assembly 14 through an inlet (not shown) where the air passes through theagitator motor assembly 92 to cool the components of the assembly. The inlet can be formed in thelower housing 40, near theagitator motor assembly 92. After passing through theagitator motor assembly 92, the motor cooling air is then ported into themotor cavity 20 upstream of the suction motor/fan assembly 22 through a firstpost-motor cooling conduit 124, as indicated by arrows. Theconduit 124 extends through apivot 126 forming the axis of rotation between thehandle assembly 12 and thefoot assembly 14, and enters the motor/fan assembly 22 through asecond cooling conduit 315 coupled with an opening 128 (FIG. 26 ) formed in aupper casing 292 that houses the motor/fan assembly 22 where the motor cooling air ported through theconduits cyclone module assembly 34. In this way, any carbon particles from the motor brushes or other dirt that become entrained in the motor cooling air will be filtered out from the air exhausted from thevacuum cleaner 10 by apost-motor filter assembly 300, as described in more detail below. -
[0064] Referring toFIG. 12 , arear conduit 130 is provided on the rear portion of thehandle assembly 12 and extends from thecurved conduit 54 to acyclone inlet housing 132. Aflexible hose 134 is connected at one end to thecyclone inlet housing 132 by a bayonet-type fastener 136 and the other end is removably stored in asocket 138. The middle portion of thehose 134 can be placed on a hose hook 140 (FIG. 1 ) located on the upper front portion of thehandle assembly 12 for storage and can be further engaged by anupper hose guide 142 and alower hose guide 143 located on the rear portion of thehandle assembly 12 to retain the length of thehose 134 substantially against thehandle assembly 12. Referring toFIGS. 2 and 12 , thelower hose guide 143 is positioned below the center of gravity of thehandle assembly 12 so that when the hose is removed from thesocket 138 and pulled in a generally horizontal direction, thevacuum cleaner 10 tends to roll across the surface to be cleaned instead of tipping. -
[0065] Referring additionally toFIG. 13 , removal of thehose 134 from thesocket 138 automatically actuates adiverter mechanism assembly 144 that switches the operational mode of thevacuum cleaner 10 from on-the-floor cleaning, where working air is drawn into thevacuum cleaner 10 through thesuction nozzle 48, to above-the-floor cleaning, where working air is drawn into thevacuum cleaner 10 through thehose 134. Thediverter assembly 144 comprises a pair offlap valves cyclone inlet housing 132. Thefirst flap valve 146 is rotatably mounted to avalve plate 150 positioned within thesocket 138. Thesecond flap valve 148 is rotatably mounted to avalve plate 152 positioned between therear conduit 130 and thecyclone inlet housing 132. Abypass conduit 154 fluidly connects thehose 134 to thecyclone inlet housing 132 downstream of thesecond flap valve 148. Theflap valve 148 is sized to occlude theconduit 130. Theflap valves shafts valve plates flap valves link arm 160 extending between the shafts. Specifically, theshaft 156 has anorthogonal extension arm 162 that is attached to one end of thelink arm 160. The other end of thelink arm 160 is attached to asimilar extension arm 164 on theshaft 158. A spring (not shown) biases thefirst flap valve 146 in an upward direction, where upward is defined as the directed toward the top of the page with respect toFIG. 13 . -
[0066] When thehose 134 is inserted into thesocket 138, theflap valves FIG. 16 , where the end of thehose 134 engages thefirst flap valve 146 and both valves are rotated such that theextension arms rear conduit 130 is unobstructed and working air can flow from thesuction nozzle 48 to thecyclone module assembly 34 through thecyclone inlet housing 132 and the vacuum cleaner can be used for on-the-floor cleaning. Upon removal of thehose 134 from thesocket 138, the spring forces the first flap valve to rotate clockwise, with respect to the orientation ofFIGS. 14-15 , thus also rotating theshaft 156 clockwise to move theextension arm 162 to a generally vertical position. Thelink arm 10 causes theextension arm 164 to move in a corresponding fashion, whereby thesecond flap valve 148 rotates clockwise to the second orientation shown inFIG. 15 . In the second orientation, thesecond flap valve 148 occludes therear conduit 130 such that no suction force is created at thesuction nozzle 48 and working air enters thehose 134, flows through thebypass conduit 154 andcyclone inlet housing 132, and into thecyclone module assembly 34, whereby thevacuum cleaner 10 can be used for above-the-floor cleaning. Reinsertion of thehose 134 into thesocket 138 automatically switches the operational mode of thevacuum cleaner 10 back to on-the-floor cleaning. -
[0067] A second embodiment of adiverter mechanism assembly 166 is shown inFIGS. 16-17 . Thediverter assembly 166 comprises a pair offlap valves cyclone inlet housing 172. Thefirst flap valve 168 is positioned in asocket 174 for receiving thehose 134. Thesecond flap valve 170 is positioned between anair conduit 176 leading from thesuction nozzle 48 to the motor/fan assembly 22 through thecyclone module assembly 34 and abypass air conduit 178 that fluidly connects thehose 134 to theair conduit 176 downstream of thesecond flap valve 170. Theflaps valves shafts flap valves shafts first flap valve 168 in an upward direction, where upward is defined as the directed toward the top of the page with respect toFIG. 16 . -
[0068] When thehose 134 is received in thesocket 174, theflap valves FIG. 17 ) such that thesecond flap valve 170 seals off thebypass conduit 178 and working air flows in a path from thesuction nozzle 48 through theair conduit 176 and into thecyclone module assembly 34 whereby the vacuum cleaner can be used for on-the-floor cleaning. Upon removal of thehose 134 from thesocket 174, the spring forces thefirst flap valve 168 to rotate counterclockwise, with respect to the orientation ofFIG. 17 , thus rotating thegear 184 counterclockwise such that thegear 186 rotates clockwise and thesecond flap valve 170 is rotated clockwise to occlude theair conduit 176 and open thebypass conduit 178 and thevacuum cleaner 10 can be used for above-the-floor cleaning. As thehose 134 is reinserted into thesocket 174, thefirst flap valve 168 is pushed downward by the end of thehose 134 such that the first flap valve pivots clockwise to the first orientation, and thus causing, through the gear transmission, thesecond flap valve 170 to pivot upward to unobstruct the air conduit and close thebypass conduit 178. -
[0069] Referring toFIGS. 18-19 , thecyclone module assembly 34 comprises a unitary cyclone separator and dirt cup assembly having two stages of separation. The first stage, comprising aprimary cyclone separator 200, is housed in alower casing 202 which also forms the dirt cup. The second stage, comprising a plurality ofsecondary cyclone separators 204, is housed in anupper casing 206 above theprimary cyclone separator 200 and dirt cup and is partitioned off from theprimary cyclone separator 200 by a separatingplate 207. Alatch 208 secures thelower casing 202 to theupper casing 206 so that the casings can be separated to provide access to the primary and secondary cyclones separators for repair and maintenance. Agasket 210 is provided at the parting line between the casings and surrounds the separatingplate 207 to ensure an air tight seal when the casings are assembled. Thecasings cyclone module assembly 34. Aninlet opening 212 is formed in thelower casing 202 and is in fluid communication with thecyclone inlet housing cyclone module assembly 34 is removably received on thevacuum cleaner 10, thus providing an inlet for the working air from thesuction nozzle 48 orflexible hose 134 into thecyclone module assembly 34. Theinlet opening 212 is positioned tangentially with respect to the wall of thelower casing 202. -
[0070] Theprimary cyclone separator 202 comprises aprimary cyclone chamber 214 defined between thelower casing 202 and abaffle assembly 216 arranged around afines collector conduit 218. Thebaffle assembly 216 comprises acylindrical portion 220 havingperforations 222 that allow air to flow from theprimary cyclone chamber 214 to thesecondary cyclone separators 204 andmultiple fingers 224 extending downward from the bottom of thecylindrical portion 220. The dirt separated by theprimary cyclone separator 200 is collected in the bottom portion of thecyclone module assembly 34 in afirst collection region 226 defined between thelower casing 202 and thefines collector conduit 218. Thefingers 224 disrupt the circular movement of air in thefirst collection region 226 in order to facilitate the settling of dirt and to reduce re-entrainment of the dirt in swirling air patterns. -
[0071] Referring toFIG. 20 , anair passage 228 from thebaffle assembly 216 to the entrance into thesecondary cyclone separators 204 extends betweenapertures 230 formed in thefines collector conduit 218 and is defined laterally between the outer surface of anair exhaust conduit 246 and the inner surface of anannular wall 231 surrounding theair exhaust conduit 246. Theseparators 204 are frusto-conical in shape, having an uppercylindrical portion 234 and a lowerconical portion 236, and define multiplesecondary cyclone chambers 238 for separating fines dirt particles from the working air. Eachsecondary cyclone separator 204 has atangential air inlet 232 formed in the uppercylindrical portion 234 and adirt outlet 240 formed in the lowerconical portion 236. The uppercylindrical portion 234 has an openupper end 235 for communication with anair outlet tube 242 extending centrally into the uppercylindrical portion 242 to anoutlet passage 244 in communication with anair exit conduit 246. -
[0072] Referring toFIG. 21 , thesecondary cyclone separators 204 can be formed as asingle unit 233, where theunit 233 comprises acircular disc 237 from which thesecondary cyclone separators 204 extend in a circular configuration that is concentric with the outerperipheral edge 239 of thedisc 237. Thesecondary cyclone separators 204 are arranged with their respective central axes parallel to one another and to the central axis of theprimary cyclone separator 202. In one embodiment the number ofsecondary cyclone separators 204 is eight, although theunit 233 can have any number. Theunit 233 has anannular lip 241 bounded exteriorly by the circular configuration ofsecondary cyclone separators 204. Thelip 241 rests on the upper edge of theannular wall 231 and helps guide working air into theair inlets 232, which are formed at regular intervals in anannular inlet wall 243 extending vertically above thelip 241. -
[0073] A pair ofarms 245 attached to opposite sides of a vortex-stabilizer surface 247 extends below each of thedirt outlets 240. The vortex-stabilizer surface 247 is positioned in such a way that the bottom end of the cyclone vortex or the “vortex tail” formed by the airflow through thesecondary cyclone chamber 238 contacts the vortex-stabilizer surface 247. Thevortex stabilizer surface 247 provides a dedicated location for the vortex tail to attach. As a result, thevortex stabilizer surface 247 minimizes a walking or wandering effect that might otherwise occur. Confining the vortex tail improves separation efficiency of thesecondary cyclone separators 204 and further prevents re-entrainment of dirt already separated from the working air. -
[0074] Referring again toFIG. 20 , theair outlet passage 244 is formed by a flaredportion 248 extending radially outward from an upper portion of theair exit conduit 246 and acover portion 250. Theair outlets 242 can be integrally formed with the flaredportion 248 or can be formed separately. Dirt separated by thesecondary cyclone separators 204 fall through thedirt outlets 240 that are in communication withdirt chutes 252 formed between theapertures 230 in thefines collector conduit 218. Asecond collection region 254 is formed in the bottom of thecyclone module assembly 34, between thefines collector conduit 218 and theair exit conduit 246. Theair exit conduit 246 extends from theair outlets 242 of thesecondary cyclone separators 204 to anair exit 256 formed in abottom wall 258 of thecyclone module assembly 34 that is in direct communication with the slottedplatform 36. Afirst gasket 251 is positioned between the upper surface of the flaredportion 248 and the lower surface of thecover portion 250, asecond gasket 253 is positioned between the lower surface of the flaredportion 248 and the upper surface of the secondarycyclone separator unit 233, and athird gasket 255 is positioned between thedirt outlets 240 and thedirt chutes 252 to provide an air-tight working air path through thecyclone module assembly 34. -
[0075] Thevacuum cleaner 10 further comprises anion generator 259, shown schematically inFIGS. 19-20 . Theion generator 259 is preferably located in thecyclone module assembly 34 and emits a stream of ions into the working airstream. The force of the accelerated air in thecyclone module assembly 34 drives ions into substantially every surface and crevice of the working air path therethrough. The ions react with odor-causing molecules to render them inert and thus improve the odor of the air before it is exhausted from thevacuum cleaner 10 into the home environment. In an alternate embodiment not illustrated, theion generator 259 is located outside the working air path, which can be provided with a bleed inlet for introducing ions into the working air path. This configuration advantageously allows for controlling the speed of ion emissions into the working airstream. Exemplary positions for the bleed inlet include, but are not limited to, theinlet 212 of theprimary cyclone separator 200, the inlet of thesecondary cyclone separators 204, themotor casing housing 332 of thepost-motor filter assembly 300. Furthermore,multiple ion generators 259 can be provided, such that ions can be emitted at multiple points within thevacuum cleaner 10. -
[0076] Theion generator 259 can be powered through thevacuum cleaner 10 such that it is in continuous operation when thevacuum cleaner 10 is energized. Alternately, theion generator 259 can be separately powered, such as by a battery, so that it can remain in operation for a period of time after thevacuum cleaner 10 is de-energized. The time of operation can be controlled by a timing circuit, mechanical timer, or thermal switch located near the motor/fan assembly 22. -
[0077] Referring toFIG. 22 , acarry handle 260 is located on theupper casing 206 of thecyclone module assembly 34 that is useful for lifting theentire vacuum cleaner 10 or for lifting thecyclone module assembly 34 when it is separated from thevacuum cleaner 10. Thecarry handle 260 can be overmolded with a low durometer material to provide a comfortable grip to the user. Thecarry handle 260 further has an actuator comprising apush button 262 that operates a latching mechanism that releasably secures thecyclone module assembly 34 within therecess 38. The latching mechanism comprises a movableupper latch 264 received in anupper slot 266 and an immobilelower latch 268 received in alower slot 270. Theupper latch 266 has acatch 272 that engages acomplementary formation 273 on theupper slot 266 to secure thecyclone module assembly 34 within therecess 38. Thelower latch 268 is received in thelower slot 270 to relieve stress on theupper latch 264 caused by the weight of thecyclone module assembly 34. Theupper latch 264 extends laterally from thepush button 262 such that when thepush button 262 is depressed, theupper latch 264 moves downward and out of engagement with theupper slot 266. While thepush button 262 is still depressed, the user can remove thecyclone module assembly 34 from thevacuum cleaner 10 by tilting thecyclone module assembly 34 away from therecess 38, such that both latches 264, 268 are moved from theirrespective slots cyclone module assembly 34 off theplatform 36. -
[0078] Referring toFIG. 23 , thebottom wall 258 of thecyclone module assembly 34 is connected to thelower casing 202 by a hinge 274 (FIG. 19 ) and is further movable through actuation of an emptying mechanism to permit emptying of the collect dirt. Arecess 276 is provided on the rear side of thelower casing 202 for receiving components of the emptying mechanism, specifically for receiving a pivotinglever 278. The pivotinglever 278 comprises an elongatedflat body 280 with apush button 282 at one end, acatch 284 at the opposite end and twopivot pins 286 extending laterally from the midsection of thebody 280. Thecatch 284 engages aslot 288 on thebottom wall 258 to secure thebottom wall 258 in a closed position. Thepins 286 are rotatably received inholes 290 formed in therecess 276 and define the axis about which thelever 278 pivots. -
[0079] Referring toFIG. 24 , when thepush button 282 is depressed, as indicated by the arrow, thebody 280 pivots about the axis defined by the pivot pins 286, such that thecatch 284 is drawn away from theslot 288, and thebottom wall 258 is released to an open position (shown) where the dirt collected in thecyclone module assembly 34 is free to fall into a waste receptacle or equivalent. -
[0080] Referring toFIGS. 25-26 , the motor/fan assembly 22 is housed in a three-part casing, comprising an upper, a lower front, and a lowerrear motor casing motor cavity 20. The motor/fan assembly 22 is oriented vertically in the casing. Theupper casing 292 includes acavity 298 for a pre-motor filter assembly comprising aremovable filter tray 300 and apre-motor filter 302 received in the tray. Ahandle 304 is provided on the front of thefilter tray 300 so that the user may open thefilter tray 300 and replace thepre-motor filter 302 as needed. Theupper casing 292 andfilter tray 300 further have openings orslots opening 128 for porting the motor cooling air in from thesecond cooling conduit 315 is positioned such that the motor cooling air enters theupper casing 292 downstream of the pre-motor filter assembly but upstream of the motor/fan assembly 22. The motor/fan assembly 22 rests on amotor isolator 310 positioned in thelower casing 294. The lowerrear casing 296 includes a motor/fanassembly outlet conduit 312 leading to a post-motor filter assembly 330 (FIG. 27 ). Afirst gasket 314 is positioned between the slottedplatform 36 and theupper casing 292. Asecond gasket 316 is positioned between the motor/fan assembly 22 and the upper casing. Athird gasket 318 is positioned between thehandle 304 of thefilter tray 300 and thecavity 298. Mounted on top of theupper casing 292 and beneath the slottedplatform 36 is an ultraviolet (UV)sanitation assembly 320 for sanitizing thepre-motor filter 302 and, in part, the working air from the cyclone module assembly before it enters the motor/fan assembly. TheUV sanitation assembly 320 comprises anannular casing 322 that houses an annular UVlight bulb 324 through which the working air can pass. Thecasing 322 is open at the bottom to reflect UV light towards thepre-motor filter 302 to sanitize, disinfect and/or neutralize pollutants, such as bacteria, molds, and dust mites, captured by thepre-motor filter 302. Thecasing 322 can further comprise openings orslots 328 through which a portion of UV light from theUV light bulb 324 can pass to partially illuminate a lower region of thecyclone module assembly 34 and create a “glowing” effect in the dirt collection region. Thecasing 322 can be transparent or semi-transparent to allow light from theUV light bulb 324 to shine through thecasing 322. UV light is effective in a direct line of sight only, so for maximum effectiveness, the ribs that form theslots 306 can be eliminated thus exposing the maximum amount ofpre-motor filter 302 surface to theUV light 324. -
[0081] Thepre-motor filter 302 can optionally be treated with a photocatalyst, such as titanium dioxide (TiO2) or compounds of TiO2, for increasing the hygienic performance of theUV sanitation assembly 320. When the photocatalyst is irradiated by UV light from theUV light bulb 324, it behaves as a catalyst and enables oxidation of pollutants on thepre-motor filter 302. For maximum results, the catalyst can be applied to the surface(s) of thepre-motor filter 302 in direct line of sight with theUV sanitation assembly 320. -
[0082] Referring toFIG. 27 , thepost-motor filter assembly 330 comprises afilter housing 332 positioned on one side of thehandle assembly 12 for receiving a removable and replaceablepost-motor filter 334. Anopening 336 in the bottom of thehousing 332 is in communication with the motor/fanassembly outlet conduit 312. Thefilter housing 332 further has aremovable cover 338 having openings orslots 340 forming an air exhaust. Thecover 338 can be removed to replace thepost-motor filter 334 as needed. Thepost-motor filter 334 is preferably a HEPA filter. -
[0083] In addition to the porting of the motor cooling air, the two-stage cyclone separation, theUV sanitation assembly 320, thepre-motor filter 302, thepost-motor filter 334, and theion generator 259, thevacuum cleaner 10 can further promote a sanitary and hygienic home environment by using an anti-microbial material for many of its components, especially the components making up the working air path of thevacuum cleaner 10. In particular, many of the components can be made of a plastic having incorporated therein an anti-microbial compound, such as phenol derivatives, especially 2,4,4′-trichloro-2′-hydroxydiphenol (e.g., Triclosan®, Irgasan®, Microban®), that reduce and/or prevent bacterial and mold growth on surfaces. Other anti-microbial compounds such as organotins, especially Tri-n-butyltin maleate (as in Ultra Fresh DM-50), can also be used to impart antimicrobial activity to plastic molded components Soak-treating in an aqueous solution containing stabilized chlorine dioxide can also be used to impart anti-microbial properties to molded plastic parts. -
[0084] Thevacuum cleaner 10 can further be provided with one or more above-the-floor tools for use in conjunction with theflexible hose 134, such as, but not limited to, a telescoping wand 342 (FIGS. 28-30 ), a flexible crevice tool 344 (FIGS. 31-33 ), and/or a turbine-powered brush 346 (FIGS. 34-37 ). Referring toFIGS. 28-30 , thetelescoping wand 342 comprises first andsecond tube sections locking device 352. Thefirst tube section 248 has a suction orinlet end 353 for ingestion of dirt. Thesecond tube section 350 can be received within thefirst tube section 348 and has anattachment end 354 that is sized to receive a flexible hose by a friction fit. Thetelescoping wand 342 can be adjusted to any length, from a fully retracted length shown inFIG. 30 to a fully extended length shown inFIG. 29 . -
[0085] Referring additionally toFIG. 30 , thelocking device 352 comprises alocking collar 356 that retains asplit ring 358, as is known in the vacuum cleaner wand art. Thelocking collar 356 hasinternal threads 360 that mate with complementaryexternal threads 362 on thefirst tube section 348. Loosening thelocking collar 356 opens thesplit ring 358 and allows thesecond tube section 350 to be moved relative to thefirst tube section 348. When a desired length has been reached, thelocking collar 356 is tightened, whereby thesplit ring 358 is closed to secure thetelescoping wand 342 at the desired length. Markings can be provided on thetelescoping wand 342 to indicate to the user the proper end to attach to the flexible hose and/or the direction to rotate thecollar 356 to loosen or tighten thelocking device 352 when make a length adjustment. -
[0086] Referring toFIG. 31 , theflexible crevice tool 344 comprises an elongatedhollow body 364 that is made of a flexible material that allows thecrevice tool 344 to bend or deform as needed, such as when the user is cleaning a hard to reach area, for example underneath or behind furniture. The material has sufficient resilience to otherwise retain a relatively straight shape. Thebody 364 has asuction opening 366 at one end that can be angled such that user can hold thecrevice tool 344 in an ergonomic manner while maintaining thesuction opening 366 relatively flat against a surface being cleaned. Thebody 364 can further be formed with a plurality ofcircumferential furrows 368 along the length of the body. Thefurrows 368 function to increase the flexing of the crevice tool as illustrated byFIGS. 32-33 , whereby thecrevice tool 344 can be flexed in multiple directions as indicated by the phantom line drawings of thebody 364. Thebody 364 has anattachment end 370 opposite thesuction opening 366 that is sized to receive a flexible hose by a friction fit. A circumferential flange 372 on theattachment end 370 provides a stop for the end of the flexible hose. Theattachment end 370 can be made of a stiffer material than thebody 364 and can be attached to the body using any suitable means. -
[0087] Referring toFIGS. 34-36 , the turbine-poweredbrush 346 is substantially disclosed in U.S. Provisional Application No. 60/594,773, entitled “Vacuum Accessory Tool”, and filed on May 5, 2005, incorporated herein by reference in its entirety, and thus will only be described briefly. The turbine-poweredbrush 346 comprises a nozzle body formed by anupper housing 374 and alower housing 376 secured together by a rotatable andremovable retaining ring 378. Abrush chamber 380 is formed in a forward portion of thelower housing 376 in close proximity to and in fluid communication with asuction nozzle 382 formed in thelower housing 376. A commonly known agitator assembly in the form of abrush roll 386 comprising adowel 388 that supports a plurality ofbristles 390, as is well-known in the vacuum cleaner art, is rotatably mounted within thebrush chamber 380 via bearingassemblies 392, which are located on the ends of thedowel 388. Anagitator pulley 394 is formed on thedowel 388 between the bearingassemblies 392. A working air conduit in the form of aconnector 396 for attachment to a flexible hose is positioned on an end opposite thesuction nozzle 382. Animpeller chamber 398 is formed between thesuction nozzle 382 and theconnector 396 and receives animpeller assembly 400 having a set ofarcuate blades 402. Theimpeller assembly 400 is mounted within theimpeller chamber 398 to freely rotate upon air impinging theblades 402. Abelt 404 is installed between theimpeller assembly 400 and theagitator pulley 394 such that thebrush roll 386 will rotate as theimpeller assembly 400 rotates. -
[0088] A second embodiment of the turbine-poweredbrush 346′ is illustrated inFIG. 37 , where like elements are identified by like numerals bearing a prime (′) symbol. The turbine-poweredbrush 346′ further includes at least onehair removal element 406 in thelower housing 376′ adjacent thesuction nozzle 382′. Thehair removal element 406 can comprise a plurality of spaced, flexible nubs or bristles 408 preferably formed from a suitable polymeric material that can be chosen from natural or synthetic resins, such as nylon, rubber, or the like. The material of thebristles 408 is selected such that it creates an electrostatic charge when in contact with and moving relative to a carpet or other fabric surface. The electrostatic charge attracts pet hair and other dirt on the surface and holds the pet hair and other dirt in the vicinity of thesuction nozzle 382′ for ingestion therethrough. -
[0089] Thetelescoping wand 342,flexible crevice tool 344, and turbine-poweredbrush flexible hose 134. Thecrevice tool 344 and the turbine-poweredbrush suction end 353 of thetelescoping wand 344 by a friction fit. When not in use, the above-the-floor tools can be stored on thevacuum cleaner 10. A recess 410 (FIG. 1 ) is provided on theprimary support section 16 above thecyclone module assembly 34 for mounting the turbine-poweredbrush 346. Therecess 410 has a retaining clip (not shown) that is sized to engage theconnector 396 of the turbine-powered brush. A first tool support 414 (FIG. 2 ) is provided on a side of theprimary support section 16 near themotor cavity 20 for mounting thetelescoping wand 342. Theattachment end 354 of thetelescoping wand 342 is sized to friction fit thetool support 414. Anupper tool clip 416 provided above thefirst tool support 414 encircles thefirst tube section 348 to help retain thetelescoping wand 342 in an upstanding orientation. Asecond tool support 418 is provided above thehose guide 140 for mounting the flexible crevice tool (not shown). -
[0090] The air path through thevacuum cleaner 10 will now be described. Thevacuum cleaner 10 can be operated in two modes: on-the-floor cleaning and above-the-floor cleaning. For on-the-floor cleaning, working air is drawn through thesuction nozzle 48 and enters thecyclone module assembly 34. For above-the-floor cleaning, working air is drawn into thevacuum cleaner 10 through thehose 134 and enters thecyclone module assembly 34. Once the working air enters thecyclone module assembly 34, the air path through the vacuum cleaner is the same, regardless of operational mode. -
[0091] Referring toFIG. 38 , working air enters theprimary cyclone separator 200 through theinlet opening 212. Theprimary cyclone chamber 214 performs centrifugal separation, where larger dirt particles are separated from the working air by centrifugal force acting on the dirt swirling around thebaffle assembly 216, as indicated by arrows A. The working air next passes radially inwardly through theperforations 222 in thebaffle assembly 216, as indicated by arrows B, and then upwardly through theair passage 228, as indicated by arrows C. To enter thesecondary cyclone separators 204, the working air turns outwardly past thelip 241 to pass through thetangential air inlets 232, as indicated by arrows D where the working air enters the cyclone module assembly forming a well-known cyclonic vortex air flow pattern associated with frusto-conical shaped separators, as indicated by arrows E. Dirt particles not separated from the working air by theprimary cyclone separator 200 are separated by the cyclonic action created by the vortex. The vortex tail is in contact with thevortex stabilizer surface 247. At thevortex stabilizer surface 247, the now relatively clean working air abruptly turns upward, as indicated by arrows F, and exits thesecondary cyclone separator 204 through theair outlet tube 242. The secondary cyclone outlet air passes through theoutlet passages 244, as indicated by arrows G, to theair exit conduit 246 where the outlet air combines and flows downwardly through theair exit conduit 246, as indicated by arrows H to exit thecyclone module assembly 34 through theair exit 256. -
[0092] Upon exiting thecyclone module assembly 34, the outlet air passes sequentially through theUV sanitation assembly 320, thepre-motor filter 302, and on to the motor/fan assembly 22. In theupper casing 292, the working air is be joined by brush motor cooling air from thefoot assembly 14. The working air mixes with the motor cooling air and exits the motor/fan assembly 22 through theoutlet conduit 312 and passes through thepost-motor filter assembly 330, whereupon the filtered outlet air is finally exhausted from thevacuum cleaner 10. -
[0093] While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that the description is by way of illustration of one embodiment of the invention and not of limitation. Reasonable variation and modification are possible within the forgoing description and drawings without departing from the spirit of the invention which is defined in the appended claims.
Claims (20)
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Claims (20)
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1. A vacuum cleaner comprising:
a housing;
a cleaning head assembly in the housing and having a suction nozzle and a working air path therethrough;
a dirt collector in the housing for removing dirt from a dirt-containing airstream;
a suction source having an inlet connected to the dirt collector and adapted to draw the dirt-containing airstream from the suction nozzle and through the dirt collector, and an outlet;
a filter positioned between the dirt collector and the inlet to the suction source; and
an ultraviolet light source positioned between the dirt collector and the filter, wherein the ultraviolet light source is positioned to illuminate the filter.
2. The vacuum cleaner according to claim 1 , wherein the housing comprises a handle assembly pivotally coupled with the cleaning head assembly and the ultraviolet light source is positioned in the handle assembly.
3. The vacuum cleaner according to claim 2 , wherein the dirt collector and the suction source are positioned in the handle assembly.
4. The vacuum cleaner according to claim 1 , and further comprising a second filter positioned downstream of the outlet of the suction source.
5. The vacuum cleaner according to claim 4 , wherein at least one of the first and second filters is a HEPA filter.
6. The vacuum cleaner according to claim 1 , wherein the ultraviolet light source is annular and the airstream passes through the open center of the ultraviolet light source.
7. The vacuum cleaner according to claim 6 , wherein the ultraviolet light source is mounted in an annular casing.
8. The vacuum cleaner according to claim 7 , wherein the annular casing is transparent.
9. The vacuum cleaner according to claim 7 , wherein the annular casing comprises a plurality of openings.
10. The vacuum cleaner according to claim 1 , wherein the filter is treated with a photocatalyst.
11. The vacuum cleaner according to claim 1 wherein the photocatalyst is titanium dioxide (TiO2).
12. A vacuum cleaner comprising a working air path formed at least in part from a plastic material that includes at least one anti-microbial agent in an effective amount sufficient to impart microbe-inhibiting properties to the working air path.
13. The vacuum cleaner according to claim 12 , wherein the at least one anti-microbial agent is incorporated in the plastic material.
14. The vacuum cleaner according to claim 13 , wherein the at least one anti-microbial agent is selected from the group consisting of phenol derivatives, organotins, and mixtures thereof.
15. The vacuum cleaner according to claim 14 , wherein the phenol derivative is 2,4,4′-trichloro-2′-hydroxydiphenol and the organotin is Tri-n-butyltin maleate.
16. The vacuum cleaner according to claim 12 , wherein the plastic material is treated with the at least one anti-microbial agent to impart microbe-inhibiting properties to the working air path.
17. The vacuum cleaner according to claim 16 wherein the plastic material is soak-treated in an aqueous solution containing the at least one anti-microbial agent, and the at least one anti-microbial agent comprises stabilized chlorine dioxide.
18. The vacuum cleaner according to claim 12 , and further comprising:
a housing;
a cleaning head assembly in the housing and having a suction nozzle;
a dirt collector in the housing for removing dirt from a dirt-containing airstream; and
a suction source having an inlet connected to the dirt collector and adapted to draw the dirt-containing airstream from the suction nozzle and through the dirt collector, and an outlet;
wherein the working air path is positioned at least between the cleaning head assembly and the dirt collector.
19. The vacuum cleaner according to claim 18 wherein the working air path includes the dirt collector.
20. The vacuum cleaner according to claim 18 wherein the working air path includes a conduit between the dirt collector and the suction source.