United States Patent 191 Fromknect et ah 1 WET/DRY SUCTION CLEANER [75] Inventors: Charles Thomas Fromknect; Martin Edward Harbeck, both of Anderson,
[21] Appl. No.: 320,802
[52] U.S. Cl 15/413, 310/58, 310/88 [51] Int. Cl. A471 5/00, A471 7/00 [58] Field of Search 310/66, 67, 88, 58;
[56] References Cited UNITED STATES PATENTS 2,291,775 4/1942 Tucker 310/66 2,635,277 4/;1953 Belknap ....l5/353 2,953,807 9 /1960 Nilsson .,15/4l3 3,063,082 11/1962 Rosenberg 15/353 3,082,465 3/1963 Wood 15/353 3,165,774 1/1965 Barba 15/353 3,290,865 12/1966 Serou et al 15/353 3,331,090 7/1967 Reiber et a1. 15/413 Primary Examiner-J. D. Miller Assistant Examiner -Patrick R. Salce Attorney, Agent, or Firm-Marshall J. Breen; Chester A. Williams, Jr.; Alan Ruderman 1 June 11, 1974 [57] ABSTRACT A wet/dry suction cleaner having a dirt storage receptacle and a power suction module mounted thereon. The module includes three housings between the lower two of which is mounted a by-pass motorblower unit which together with the intermediate housing is entrapped between the lower and upper housings. An air shut-off valve assembly depends downwardly from the lower housing into the receptacle. The intermediate housing is a separator member having annular walls which separate the blower working airflow from the motor cooling airflow. The upper housing has an exhaust port which communicates with the blower airstream. Motor cooling air enters between the top and bottom housings and must flow under and over a labyrinth of vertical walls formed by the upper and intermediate housings before entering the motor between the upper and intermediate housing. The cooling air exits the motor to a cooling air ex haust chamber formed by annular walls of the intermediate housing and exhausts therefrom between the upper'and intermediate housings up and under a labyrinth similar to its entry.
10 Claims, 5 Drawing Figures us I24 I00 m us '32 so 464 33 1 '11 68 ,nmnjmfimmunimtnnm 5- 6 Mo i z I I1 1 I42 62 52 X 43 4s 64 Y 1 WET/DRY SUCTION CLEANER BACKGROUND OF THE INVENTION This invention relates to utilitysuction cleaners for picking up liquid and other materials and more particularly to an improved casing construction of power suction module for such cleaners which prevents liquid from entering the electrical system thereof. It is particularly well suited for a vertical axis utility type cleaner for use in and out of the home.
In order to prevent moisture from entering the motor section, cleaners of the type capable of vacuuming up both liquid and solid materials generally use by-pass motor-blowers in which the airstream for cooling the motor is maintained separately from the working airstream moving the dirt and/or liquid. Moreover, utility type suction cleaners which are used outside the home, e.g., on patios, driveways, walks, etc., are known to be left outside inadvertently. A problem can therefore result if the weather changes over night and a rainstorm developes. This particularly can be a problem when the cleaner is of the wet/dry type using a by-pass motorblower system, since the cooling air inlet and exhaust lead directly to and from the motor without first passing through the storage receptacle as would a purely dry suction cleaner having a motor-blower in which the cooling airstream is the working airstream that has passed through the blower. If the electrical system is not securely protected against the entry of moisture, an electrical path to ground and a breakdown in motor insulation could result. This situation could result in a hazardous shock to one later attempting to operate the cleaner. The trend toward double insulating to prevent hazardous shock has spurred at least one safety certify- SUMMARY OF THE INVENTION It is therefore a primary object of the present invention to provide in a power suction module for a utility cleaner having a by-pass motor-blower a casing construction which prevents the entry of liquids into the electrical system.
Another object of this invention is to provide in a power suction module for a utility vacuum cleaner having a by-pass motor-blower a casing construction which prevents liquid from entering the electrical system through the motor cooling inlet and exhaust ports.
A further object of this invention is to provide in a power suction module for a utility vacuum cleaner having a by-pass motor-blower a construction in which the working airflow and the motor cooling airflow are maintained separate.
A still further object of this invention is to provide a power suction module for a utility vacuum cleaner capable of wet and dry operation having a plurality of housings constructed to form a casing in which the motor electrical elements are protected from contact with any liquids.
The present invention achieves these objects by providing a power suction module for a utility cleaner in which the working airflow which enters into a dirt receiving receptacle and passes through the blower is maintained separate from the cooling air-flow which separately enters the cleaner through a labyrinth of walls, cools the motor and exhausts through a labyrinth of walls.
DESCRIPTION OF THE DRAWINGS The particular features and advantages of the inven tion as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. I is a vertical cross-sectional view of a vacuum cleaner embodying the novel features of the present invention, the dirt receptacle having been broken away for convenience;
FIG. 2 is a vertical cross-sectional view taken through the vacuum cleaner of FIG. 1 but in a plane normal thereto;
FIG. 3 is a top plan view of the vacuum cleaner of FIG. 1, with the upper housing removed;
FIG. 4 is a bottom plan view of the upper housing; and
FIG. 5 is a cross-sectional view taken along line 55 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the accompanying drawings wherein like reference numerals denote similar parts throughout the various views, there is disclosed a utility vacuum cleaner similar to that disclosed in the applicants co-pending US. Pat. application No. 133,655 (filed Apr. 13, 1971 but provided with both wet and dry cleaning capabilities and incorporating the new and improved power suction module construction of the present invention. The cleaner generally designated 20 comprises an open top substantially cylindrical dirt receptacle 22 and a power suction module comprising a lower or first housing 24, a separator or second housing 26 and a top or third housing 28, which hereafter will be described in detail. The receptacle and each of 'the housings, preferably is comprised of synthetic plastic and is manufactured by molding. Formed adjacent to the open end of the dirt receptacle 22 is an air suction inlet conduit 30 opening into the receptacle and adapted to couple a conventional vacuum cleaner flexible hose (not shown) in the usual manner. Preferably, a styrene baffle 32 may be mounted behind the inlet aperture defined by the conduit 30. The-baffle can be shaped to direct the inlet air and liquid downwardly and circumferentially toward the lower inside walls of the receptacle.
The lower housing 24 is substantially cup shaped having a peripheral flange 33 including a peripheral rim 34 substantially corresponding in shape to the periphery of the top of the dirt receptacle, and includes at its underside an annular groove 36 for receiving the top peripheral portion of the dirt receptacle. In this manner the lower housing is supported on the dirt receptacle with the cup shaped portion of the housing nested therein, and the housing is detachably secured to the receptacle in the same manner as described in the aforesaid copending patent application. At the bottom of the housing 24 there is formed a substantially flat circular seating portion 38 having an aperture 40 formed centrally therein with a downwardly extending neck 42 communicating with the interior of the dirt receptacle. A number of threaded bosses 44 (only two of which are shown) are molded on the bottom of the housing 24 radially outwardly from the aperture 40 for supporting a valve housing assembly generally designated as 46.
The valve housing assembly 46 comprises a substantially cylindrical valve housing 48 extending downwardly from a flanged disc portion 50. A short upstanding cylindrical wall 52 extends upwardly from the disc surface 50 of the housing assembly. Mounting screws 54 pass into the bottom of the disc 50'and are threadedly received into the bosses 44 to secure the assembly 46 to the housing 24. An inverted cup shaped plastic float valve, 56 having a short metal rod 58 centrally secured to the upper surface thereof, is positioned within the housing 48. The rod 58 extends through a substantially central opening 60 in the surface of the disc 50 and is secured at its upper end to a valve member 62 adapted to close off the airflow to the aperture 40. The float 56 is made of a light weight polyethylene material and is capable of floating not only on liquids but also on foam. When the level of liquid and/or'foam in the receptacle 22 reaches a predetermined level, the float 56 moves upwardly until the valve 62 seats against the bottom of the neck 42'to shut off the airflow to the aperture 40. A grid type guard 64 is fitted around the bottom of the housing 48 to protect the float 56 against the entry of large dirt particles.
Mounted on an annular seal 66 positioned in the seat 38 is the blower 68 of a by-pass type motor-blower unit generally indicated as '70. A by-pass motor-blower is one in which an airstream separate from the working airstream is utilized to cool the motor. The blower has a centrally disposed inlet 72 positioned in communication with the aperture40, and includes a plurality of exhaust openings 74 tangentially disposed about the cylindrical housing thereof. Mounted vertically above the blower 68 is the motor portion 76 of the motor-blower unit. A motor-blower shaft 78 is journaled at its upper end in a yoke member 80 and at its lower end in the blower wheel (not shown) of the blower unit. The motor armature (not'shown) is secured to the shaft 78 and provides the power to drive the blower. Two coolsecured to the shaft 78 just below the yoke for provid- 7 ing positive cooling to the motor core and armature.
The separator housing 26 includes a floor or plate surface 84 which may be secured by means of screws 86 to the yoke 80 of the motor-blower unit. Extending downwardly from the floor or plate 84 of the housing 26 is an inner substantially cylindrical annular wall 88 and an outer substantially cylindrical longer annular wall 90. The outer wall 90 engages a seal 92 which abuts the upper surface of the blower housing, while the inner wall 88 engages the upper portion of the motor housing just below the yoke. The cup shaped housing 24 and the downwardly extending annular wall 90 defines therebetween a blower exhaust chamber communicating with the blower ports 74, while the walls 88 and 90 of the housing26 define therebetween a motor cooling air exhaust chamber for receiving cooling air exhausted through the openings 82. Formed in the separator floor or plate 84 is a substantially rectangular opening 94 communicating with the upper end of the motor and defines a cooling air intake in the housing 26. Communicating with the motor cooling air exhaust chamber is a pair of openings 96 formed in the separator housing floor or plate 84. At the peripheral portion of the floor 84 of the intermediate housing is an upstanding annular wall 98 having on its free upper end an outwardly facing flanged lip portion 100. The floor 84 includes an upstanding substantially rectangular bridging or spanning portion 102 between the opening 94 and the openings 96 for purposes which will hereinafter become clear. As best seen in FIGS. 1 and 3 the intermediate housing 26 has an open grid plate structure 104 formed in the floor adjacent to one end of the bridging portion 102, which, as best illustrated in H6. l,'communicates with the blower exhaust chamber. At the other end of the bridging portion 102 there is a narrow upstanding rib 106 fitted with a seal 108. The portion of the wall 98 in the vicinities of the grid structure 104 and the rib 106 being removed. A conventional electrical switch member 110 having a toggle type actuator 111 extending upwardly is mounted in a cavity formed in the floor of the intermediate housing. Electrical wiring 112 extends from the motor 76 to the switch 111 and passes through the floor 84 out the housing 26 as illustrated.
' The third or' upper housing 28 is a substantially truncated dome shaped member having a central recessed floor portion114 bridged by a carrying handle 116. Projecting downwardly from the lower surface of the top v.housing are four bosses 118 into which are threaded a respective screw 120 (only one of which is shown) passing through holes 122 formed in the lower housing 24; This secures the housings 28 and 24 together and entraps the intermediate or separator housing 26 and the motor-blower unit in position therebetween. Theannular side walls 124 about the recess 114 of the housing 28 are formed in the area above the grid 104 with an upwardly projecting annular wall 126 defining an aperture 128. This aperture forms the exhaust port of the vacuum cleaner and communicates through the grid 104 with the blower exhaust chamber. Extending radially outwardly from the upper portion of the wall 124 is a peripheral rim 130 including a peripheral bead 132 spaced above the upper surface of the flange 33 of the housing 24. Spaced from the wall 124 and extending downwardly from the underside of the wall 130 is an annular wall 134 which abuts the top surface portion of the lower housing 24. The annular wall 134 as best illustrated in FIG. 5 has a plurality of slots 136 out therein to form air inlet and exhaust ports for the motor cooling air. The annular space between the wall 124 and the wall 134 is spaced to receive the upstanding annular wall 98 of the intermediate housing 26 without contacting the same. The floor 114 of the upper housing 28, moreover, is spaced above the floor 84 of the intermediate housing except in the central area of the raised rectangular portion 102, which is below the handle 116 of the upper housing. In that portion, the upper housing has an annular rectangular opening 138 which receives the rectangular portion 102 of the intermediate housing. A seal 139 is fitted between the portion 102 and the walls of the opening 138 and extends outwardly between the grid 104 and the wall of the exhaust port. This combination together with the rib 106, seal 108 and the wall 124 in the vicinities of the rib 106 and grid 104 effectively separate the air entering the inlet opening 94 from the air exiting from the exhaust openings 96.
In operation, motor cooling air enters between the peripheral bead 132 and the top of the flange 33 of the lower housing 24 and passes in through the slots 136 inthe annular wall 134 of the upper housing. The cooling air must then pass over the annular wall 98 and the lip 100 which is spaced from the upper housing, and then passes downwardly between the wall 124 and the wall 98 before it can enter the space between the floors 114 and 84. Similarly motor cooling air exhausted from the openings 82 pass through the exhaust openings 96 between the floors 114 and 84 and must pass over the annular wall 98 before exiting from the slots 136 on the side of the cleaner opposite to where it entered. The path of motor cooling air flow is clearly illustrated in FIG. 2. It is obvious therefore that the walls 134, 98, and 124 comprise a labyrinth of vertical walls for diverting the respective intake and exhaust cooling airstreams between the inlets on the right side of FIG. 2, i.e., between the peripheral bead 132 and the upper housing and the intake opening 94, and from the exhaust openings 96 to the cooling air exhaust between the bead 132 and the upper housing on the left side of FIG. 2. v
The working airstream as illustrated in FIG. 1 enters the inlet 30 and may pass through a filter 140 prior to entering the aperture 40 and the blower inlet 72. The filter 104 is described in detail in co-pending Pat. application No. 320,801 filed on even date herewith but for present purposes can be described as being of a substantially hemispherical shape comprising a fabric material, and as having an opening 142 in the lower peripheral portion thereof through which the valve housing 48 protrudes. The upper peripheral portion of the filter 140 includes a resilient gasket 144 to seal the dirt receptacle from the housing 24. Any liquid entering with the dirt through the inlet port 30 drops to the bottom of the receptacle and as the liquid and/or foam level in the receptacle raises to the point where the float 56 is lifted to close the opening 40 by means of the valve 62, the airflow entering the cleaner through the openings 30 is effectively closed off to protect the blower and motor unit from damage by the liquid and- /or foam.
To futher protect against any liquid from entering the cleaner during, for example, a rainstorm if the cleaner is left outside, a switch cap 150 having a plurality of camming surfaces snapping under the floor 144 of the upper housing protects the toggle 1 l 1 and switch housing 110 against the entrance of moisture. The switch cap is fully described in co-pending Pat. application No. 320,800 filed on even date herewith. A plurality of drains such as illustrated at 152 allows any water falling into the recessed floor 114 to drain downwardly into the grid 104 and into the blower exhaust chamber between the wall 90 and the cup shaped lower housing and down through the blower area into the receptacle. It should thus be clear that the cleaner should be left outside in a driving rainstorm any water tending to enter through the cooling inlet or exhaust slots 136 would be prevented from entering the motor and other electrical elements by the annular wall 98. However, any water collecting around the outer walls of the separator housing may be allowed to drain into the working airflow system through a drain 1154 created by interupting the seal 139 in the vicinity of the grid 104.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to a preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
Having thus set forth the nature of the invention what is claimed herein is:
I. In a wet/dry suction cleaner having an open top dirt, liquid and foam collecting receptacle including a working air inlet, and a power suction module mounted on said receptacle for drawing wet and dry dirt laden air through said inlet into said receptacle, said power module comprising: a first housing adapted to be secured onthe top of said receptacle, a seat having an aperture formed in said housing, a by-pass motor-blower unit having the motor mounted above the blower positioned on said seat with the blower inlet communicating with said aperture, a shut-off valve mechanism mounted below the aperture responsive to the foam and liquid level in said receptacle for closing flow communication between said aperture and said receptacle, a second housing positioned on said motor-blower unit having an upstanding annular wall, said first and second housings forming therebetween a blower exhaust chamber, means defining a cooling air exhaust chamher in communication with a cooling air exhaust passage in said second housing, means defining a motor cooling air inlet passage in said second housing, a third housing including an exhaust port communicating with said blower exhaust chamber positioned on said first housing, the second and the third housings forming first and second air passageways therebetween, the first passageway communicating with said motor cooling air inlet passage, the second passageway communicating with said motor cooling air exhaust passage, cooling air inlet means and cooling air exhaust means fomied be tween the first and third housings, said inlet means communicating with the first passageway, a first part of said second housing upstanding annular wall being disposed intermediate said cooling inlet means and said first passageway and terminating at a higher elevation than said inlet means so that incoming cooling air is baffled over said wall, a second part of said annular wall being disposed intermediate said cooling exhaust means and said second passageway and terminating at a higher elevation than said exhaust means so that exhausted cooling air is baffled over said wall.
2. In a cleaner as recited in claim 1 wherein said second housing includes inner and outer downwardly extending spaced annular walls, said blower exhaust chamber being formed between said outer wall and said first housing, said motor cooling air exhaust chamber being formed between said inner and outer walls, said cooling air inlet passage being located radially inwardly of said inner wall, and said cooling air exhaust passage being located intermediate said inner and outer walls.
3. In a cleaner as recited in claim 2 wherein said third housing includes inner and outer upright annular walls, said second housing upstanding wall being radially located intermediate said third housing walls, said cooling air inlet means and cooling air exhaust means being r 7 located at the bottom of said third housing outer annular wall.
4. in a cleaner as recited in claim 2 wherein said second housing inner annular wall is in sealed abutting en- 1 gagement with one end of said motor, and said second housing outer annular wall is in sealed abutting engagement with the motor side of said blower.
5. in a cleaner as recited in claim 3 including means defining a lip on the top of said upstanding wall, said lip being disposed radially outwardly toward said thirdhousing outer wall.
6, in a cleaner as recited in claim 3 wherein said cooling inlet means and said cooling exhaust means comprise slots formed in the bottom of said third housing outer annular wall.
7. A power suction module adapted for use with an open top storage receptacle having an air inlet for drawing wet and dry dirt laden air therethrough, said module comprising a lower housing having an inlet supporting a by-pass motor-blower unit with the blower intake in flow communication with said inlet, the motor of said unit being cooled by an airstream separate from the blower working airstream, a separator housing positioned on the motor-blower unit to form with the lower housing a blower working airstream exhaust chamber for receiving working air exhausted from the blower, said separator housing further forming a motor cooling air exhaust chamber for receiving cooling air which has passed through the motor, an upper housing having an exhaust port in flow communication with the blower exhaust chamber positioned on the lower housing, said .upper housing forming with the separator housing a cooling air intake passageway communicating with the motor for conducting cooling air thereto and a cooling air exhaust passage communicating with the cooling air exhaust chamber, cooling air inlet means and cooling air exhaust means formed in the top housing and communicating respectively with the cooling air intake passage and exhaust passage, and a labyrinth of vertical walls formed in the separator housing and the top housing for diverting the respective intake and exhaust cooling airstreams between said inlet means and the intake passage and between said exhaust means and the exhaust passage 8. A power suction module as recited in claim 7 wherein lower said housing is substantially cup shaped with a blower supporting seat formed on the bottom thereof, said separator housing comprising a member having inner and outer downwardly extending annular walls, the outer wall operatively abutting the blower and forming with said lower housing the blower exhaust chamber, the inner wall operatively abutting the motor and forming with said outer wall the cooling air exhaust chamber.
9. A power suction module as recited in claim 8 wherein said labyrinth of walls includes an annular wall extending downwardly from the upper housing, said cooling air inlet means and cooling air exhaust means comprising a plurality of slots formed in the lower rim of said wall, said intermediate housing including an upstanding annular wall positioned between said upper housing annular wall and each of said cooling air intake passage and cooling air exhaust passage, said upstanding wall terminating 'at a'higher elevation than said slots.
10. A power suction module as recited in claim 9 including means defining a lip on the top of said upstanding wall, said lip being disposed radially towards said upper housing outwardly extending annular wall.