US20110219579A1

Movatterモバイル変換

Info

Publication number: US20110219579A1
Application number: US12/722,895
Authority: US
Inventors: Wayne Ernest Conrad
Original assignee: GBD Corp
Current assignee: GBD Corp
Priority date: 2010-03-12
Filing date: 2010-03-12
Publication date: 2011-09-15

Abstract

An upright surface cleaning apparatus comprises a floor cleaning head having a dirty air inlet, and an air flow passage extending from the dirty air inlet to a clean air outlet. An upright section is moveably mounted to the surface cleaning head between a storage position and an in use position. The upright section comprises a filtration member and a suction motor provided in the air flow passage. The suction motor has an air inlet end, an opposed distal end, and an air inlet direction. The upright section further comprises a motor housing. The motor housing comprises a motor section in which the suction motor is provided. The motor section has a first end at the air inlet end of the suction motor and an opposed second end at the distal end of the suction motor. An openable post motor filter chamber is provided in the motor housing and has an inlet end and an outlet end. At least a portion of the filter chamber is provided in the motor section. The inlet end includes a finger guard and the filter chamber has a direction of airflow that is transverse to the air inlet direction of the suction motor. A post motor HEPA filter is removably mounted in the filter chamber.

Description

FIELD

The disclosure relates to surface cleaning apparatuses, such as vacuum cleaners. Particularly, the disclosure relates to upright surface cleaning apparatuses.

INTRODUCTION

The following is not an admission that anything discussed below is prior art or part of the common general knowledge of persons skilled in the art.

Various constructions for surface cleaning apparatus such as vacuum cleaners are known. Currently, many surface cleaning apparatus are constructed using at least one cyclonic cleaning stage. The air is drawn into the vacuum cleaner through a dirty air inlet and conveyed to a cyclone inlet. The rotation of the air in the cyclone results in some of the particulate matter in the airflow stream being disentrained from the airflow stream. This material is then collected in a dirt collection chamber, which may be at the bottom of the cyclone or in a dirt collection chamber exterior to the cyclone chamber (see for example WO2009/026709 and U.S. Pat. No. 5,078,761). One or more additional cyclonic cleaning stages and/or filters may be positioned downstream from the cyclone.

SUMMARY

The following summary is provided to introduce the reader to the more detailed discussion to follow. The summary is not intended to limit or define the claims.

According to one aspect, an upright surface cleaning apparatus is provided with a suction motor housing that includes a post motor filter chamber. The post motor filter chamber is positioned spaced from but facing the suction motor. The air accordingly will travel from the air treatment member or members to the suction motor inlet. The air will travel through the fan of the suction motor and then by or through the motor section to cool the motor. The air will then travel laterally, and possibly upwardly and laterally, to the post motor filter. This constructions permits a reduction in the size of the suction motor housing.

Traditionally, upright surface cleaning apparatus have had large, bulky frames or upper housings. The upper housing has a recess for removably receiving a cyclone. The housing has also incorporated air flow passages (e.g., from a dirty air inlet to a cyclone inlet and from a cyclone outlet to a suction motor inlet). This structure increases the weight of an upright vacuum cleaner and also reduces the portability of an upright vacuum cleaner for the elderly or the infirm. A reduction in the size of the suction motor housing reduces the weight and increases the portability of the surface cleaning apparatus.

In a preferred embodiment, the suction motor is mounted on the upright section of the vacuum cleaner (e.g., the portion that comprises the push handle) and is spaced from the floor cleaning head. Such a construction is advantageous as it permits the floor cleaning head to extend further under furniture (e.g., floor cleaning head may be passed under furniture until the bottom of the upright section contact the furniture). However, if the components of the vacuum cleaner (e.g., the motor and the cyclone housing) are too high on the handle, then the hand weight of the vacuum cleaner during operation will increase thereby decreasing the usability of the vacuum cleaner. Reducing the height of the suction motor housing permits the suction motor to be provided on the handle, thereby reducing the height of the floor cleaning head and increasing the ability of the floor cleaning head to clean under furniture. At the same time, the components on the vacuum cleaner may be mounted lower thereby reducing hand weight.

According to this aspect, an upright surface cleaning apparatus comprises a floor cleaning head having a dirty air inlet, and an air flow passage extending from the dirty air inlet to a clean air outlet. An upright section is moveably mounted to the surface cleaning head between a storage position and an in use position. The upright section comprises a filtration member and a suction motor provided in the air flow passage. The suction motor has an air inlet end, an opposed distal end, and an air inlet direction. The upright section further comprises a motor housing. The motor housing comprises a motor section in which the suction motor is provided. The motor section has a first end at the air inlet end of the suction motor and an opposed second end at the distal end of the suction motor. An openable post motor filter chamber is provided in the motor housing and has an inlet end and an outlet end. At least a portion of the filter chamber is provided in the motor section. The inlet end includes a finger guard and the filter chamber has a direction of airflow that is transverse to the air inlet direction of the suction motor. A post motor HEPA filter is removably mounted in the filter chamber.

The inlet end of the filter chamber may be positioned adjacent the suction motor. At least a portion of the inlet end of the filter chamber may be laterally spaced from and may face the suction motor.

The surface cleaning apparatus may further comprise a pre-motor filter positioned at the air inlet end of the suction motor. The pre-motor filter may have a direction of airflow that is aligned with the air inlet direction of the suction motor.

The filtration member may comprise a cyclone. The cyclone may comprise an air inlet and an air outlet, and the air outlet of the cyclone may be spaced from and may face the pre-motor filter. The air inlet end of the filter chamber may be spaced less than 3 inches from the suction motor, more specifically less than 1.5 inches from the suction motor.

According to another aspect, another upright surface cleaning apparatus is provided. The surface cleaning apparatus comprises a floor cleaning head having a dirty air inlet. An air flow passage extends from the dirty air inlet to a clean air outlet. An upright section is moveably mounted to the surface cleaning head between a storage position and an in use position, and includes a motor housing. A filtration member and a suction motor are provided in the air flow path. The suction motor has an air inlet end, an opposed distal end, and an air inlet direction. An openable post motor filter chamber is provided in the motor housing and has an inlet end and an outlet end. At least a portion of the inlet end is laterally spaced from and faces the suction motor. The inlet end includes a finger guard. A post motor HEPA filter is removably mounted in the filter chamber.

The inlet end of the filter chamber may be positioned adjacent the suction motor.

The motor housing may comprise a motor section in which the suction motor is provided. The motor section may have a first end at the air inlet end of the suction motor and an opposed second end at the distal end of the suction motor. At least a portion of the filter chamber may be provided in the motor section.

The filter chamber may have a direction of airflow that is transverse to the air inlet direction of the suction motor.

The filtration member may comprise a cyclone. The cyclone may comprise an air inlet and an air outlet, and the air outlet may be spaced from and may face the pre-motor filter. For example, the air inlet end of the filter chamber may be spaced less than 3 inches from the suction motor, more specifically less than 1.5 inches from the suction motor.

DRAWINGS

Reference is made in the detailed description to the accompanying drawings, in which:

FIG. 1ais a perspective illustration of an embodiment of a surface cleaning apparatus in a storage position;

FIG. 1bis a perspective illustration of the surface cleaning apparatus ofFIG. 1a, in an in-use position;

FIG. 2 is a cross section taken along line2-2 inFIG. 1;

FIG. 3 is a top perspective illustration of a motor housing of the surface cleaning apparatus ofFIG. 1a;

FIG. 4 is a top perspective illustration of the surface cleaning apparatus ofFIG. 1a, with a filtration member housing removed, and a pre-motor filter exploded from the motor housing;

FIG. 5 is a perspective illustration of the surface cleaning apparatus ofFIG. 1, showing a grate and a post-motor filter removed from the surface cleaning apparatus;

FIG. 6A is a cross section taken alongline6A-6A inFIG. 1; and

FIG. 6B is a cross section taken alongline6B-6B inFIG. 1; and

DETAILED DESCRIPTION

Referring toFIG. 1a, a first embodiment of asurface cleaning apparatus100 is shown. In the embodiment shown, thesurface cleaning apparatus100 is an upright surface cleaning apparatus (otherwise referred to as an upright vacuum cleaner). In alternate embodiments, the surface cleaning apparatus may be another suitable type of surface cleaning apparatus, such as a canister type vacuum cleaner, and hand vacuum cleaner, a stick vac, a wet-dry type vacuum cleaner or an carpet extractor.

Referring still toFIG. 1a, thesurface cleaning apparatus100 has adirty air inlet102, aclean air outlet104, and an air flow passage extending therebetween. In the embodiment shown, thedirty air inlet102 is provided in afloor cleaning head106. From thedirty air inlet102, the airflow passage extends through thefloor cleaning head106, and through anair conduit108, to anupright section110. Theclean air outlet104 is provided in theupright section110. In the embodiment shown, theair conduit108 includes a pivotingjoint member112 connected to thefloor cleaning head106, alower upflow duct114, anupper upflow duct116, ahose117, and anelbow joint118. The elbow joint118 is in airflow communication with theupright section110. In alternate embodiments, theair conduit108 may be of another configuration. For example, only a pivotingjoint member112, alower upflow duct114, and an elbow joint118 may be provided.

Ahandle119 is mounted to theupper upflow duct116, for manipulating thesurface cleaning apparatus100.

Theupright section110 is moveably mounted to thesurface cleaning head106 between a storage position, shown inFIG. 1a, and an in-use position, shown inFIG. 1b. In order to move the upright section from the storage position to the in-use position, the pivotingjoint member112 may be pivoted about a horizontal axis.

Referring now toFIG. 2, theupright section110 includes afiltration member housing120, and amotor housing122. Thefiltration member housing122

houses filtration member

124, which is positioned in the airflow passage downstream of thedirty air inlet102 for removing particulate matter from air flowing through the airflow passage. Themotor housing122 houses asuction motor126, which is provided in the airflow passage downstream of thefiltration member124 for drawing air through the airflow passage.

In the embodiment shown, theupright section110 is supported by and mounted to thelower upflow duct114. Particularly, amount128 is provided which mounts theupright section110 to thelower upflow duct114. Themount128 may be of any suitable configuration. In the embodiment shown, themount128 is integrally formed with themotor housing122, and is mountable to thelower upflow duct114. Themount128 may be mountable to thelower upflow duct114 in any suitable manner, and is preferably removably mountable to thelower upflow duct114.

In the embodiment shown, thefiltration member housing120 includes asidewall130, atop wall132, and abottom wall134. Themotor housing122 includes asidewall136 and abottom wall138, and anopen top140. Thesidewall136 of themotor housing122 is removably mounted to thebottom wall134 of thefiltration member housing120, so that thebottom wall134 of thefiltration member housing120 seals theopen top140 of themotor housing122. Thesidewall136 of themotor housing122 may be removably mounted to thebottom wall134 of thefiltration member housing120 in any suitable manner, such as by one ormore latch members142.

In the embodiment shown, as themotor housing122 is mounted to thelower upflow duct114, and thefiltration member housing120 is removably mounted to themotor housing122 above themotor housing122, thefiltration member housing120 may be removed from the motor housing by unlatching the one ormore latch members142, and lifting thefiltration member housing120 off of themotor housing122. When this is done, thefiltration member housing120 will be generally sealed, except for any airflow passages leading to or from thefiltration member housing120, and the top140 of themotor housing122 will be open.

Referring still toFIG. 2, in the embodiment shown, thefiltration member124 is a cyclone144. In alternate embodiments, thefiltration member124 may be, for example, a filter, such as a filter bag or a foam filter. In further alternate embodiments, thefiltration member124 may include a plurality of cyclones, or a plurality of cyclonic stages.

The cyclone144 may be of any suitable configuration. In the embodiment shown, the cyclone144 extends along a longitudinal axis146, which is generally vertically extending, and includes a generallycylindrical cyclone wall148, which defines acyclone chamber150. The upper end152 of thecyclone wall148 is open, and thelower end154 of the cyclone wall includeslower wall156. Thecyclone wall148 is positioned in thefiltration member housing120 such that it is spaced from thesidewall130,top wall132, andbottom wall134 of thefiltration member housing120. A plurality ofstruts158 support thecyclone wall148 within thefiltration member housing120. The space between thelower wall156 of the cyclone144 and thebottom wall134 of thefiltration member housing122 forms adirt collection chamber160.

The cyclone144 further includes acyclone air inlet162, and acyclone air outlet164. Thecyclone air inlet162 extends from a first end (not shown) that is in communication with thehose117, through thesidewall130 of thefiltration member housing120, to a second end (not shown) that is in communication with thecyclone chamber150. Thecyclone air outlet164 extends along the axis146, from afirst end170 that is positioned within thecyclone chamber150, through thelower wall156, and to asecond end172 that is in communication with the interior of themotor housing122. A screen (not shown) is preferably mounted over thefirst end170 of the cyclone air outlet.

In use, air flows from thehose117 into thecyclone chamber150 through thecyclone air inlet162. In thecyclone chamber150, the air flows within thecyclone wall148 in a cyclonic pattern, and particulate matter is separated from the air. The particulate matter exits thecyclone chamber150 through the first end152, and settles in thedirt collection chamber160. The air exits thecyclone chamber150 through thecyclone air outlet164, and enters themotor housing122.

Thedirt collection chamber160 may be emptied in any suitable manner. In the embodiment shown, thebottom wall134 is pivotally mounted to thesidewall130, and serves as an openable door. Thedirt collection chamber160 may be emptied by removing thefiltration member housing120 from thesuction motor housing124, as described hereinabove, and pivoting thebottom wall134 away from thesidewall130.

Referring still toFIG. 2, themotor housing122 houses thesuction motor126, a pre-motor filter176 (shown inFIGS. 5 and 6A and6B) upstream of thesuction motor126 and downstream of the cyclone144, and apost-motor filter178 downstream of thesuction motor126 and upstream of theclean air outlet104.

Thepre-motor filter176 extends across theopen top140 of themotor housing122, and has anupstream side180 that faces and is spaced from thecyclone air outlet164, and an opposeddownstream side182 that faces thebottom wall138 of themotor housing122. Thepre-motor filter176 is supported within themotor housing122 by an apertured support wall184 (seen most clearly inFIG. 3), which extends across themotor housing122. Thepre-motor filter176 is sized to be generally snugly received within themotor housing122, such that air entering themotor housing122 from thecyclone air outlet164 passes through thepre-motor filter176 in a direction indicated by arrow A (i.e. the pre-motor filter has a direction of airflow indicated by arrow A). Thepre-motor filter176 may be any suitable type of filter. Preferably, the pre-motor filter includes afoam layer186 and a feltlayer188.

Referring toFIG. 4, when thefiltration member housing120 is lifted off of themotor housing122, thepre-motor filter176 is exposed, and may be removed, replaced, or cleaned.

Referring back toFIG. 2, thesuction motor126 is housed within themotor housing122, in amotor section173. Themotor section173 is beneath theapertured support wall184. Themotor section173 has afirst end175 and an opposedsecond end177.

Thesuction motor126 may be any suitable type of suction motor, and preferably has afan portion199 and amotor portion197. In the embodiment shown, thesuction motor126 extends along a longitudinal axis190 that is generally vertically extending. Thesuction motor126 has anair inlet end179, an opposed distal end181, and an air inlet direction, indicated by arrow A3. Thefirst end175 of themotor section173 is at theair inlet end179 of thesuction motor126, and thesecond end177 is at the distal end181 of thesuction motor126. Preferably, thepre-motor filter176 is positioned at theair inlet end179 of thesuction motor126, and the direction of airflow of thepre-motor filter176 is aligned with the air inlet direction of thesuction motor126.

Thepost motor filter178 is housed in apost-motor filter chamber183. In the example shown, the postmotor filter chamber183 is entirely within themotor section173. In alternate embodiments, only a portion of the postmotor filter chamber183 may be within themotor section173, or the postmotor filter chamber183 may be outside of themotor section173. Preferably at least a third, more preferably at least two thirds and most preferably at least 75% of the postmotor filter chamber183 is positioned within themotor section173. An advantage of this design is that the height of the motor housing may be shortened, this permits the suction motor, and other components positioned on top of the motor housing, to be located lower on the upper section but still spaced from the top of the floor cleaning head.

The postmotor filter chamber183 has aninlet end185, which is adjacent thesuction motor126, and anoutlet end187, which is adjacent theclean air outlet104. Preferably, at least a portion of theinlet end185 is laterally spaced from and faces thesuction motor126. For example, theair inlet end185 of thefilter chamber183 may be spaced less than 3 inches from thesuction motor126, and preferably less than 1.5 inches from the suction motor. The direction of airflow through postmotor filter chamber183, indicated by arrow A4, is transverse to the air inlet direction of the suction motor, indicated by arrow A3.

The postmotor filter chamber183 is preferably openable, and thepost-motor filter178 is preferably removably mounted in the postmotor filter chamber183. For example, as shown inFIG. 5, theclean air outlet104 may be defined in agrate189 that is removably mountable to thesuction motor housing122. For example, one ormore latch members191 may be provided to removably latch thegrate189 to thesuction motor housing126. Alternately, thegrate189 may be pivotally openable with respect to thesuction motor housing126. When thegrate189 is opened or removed from thesuction motor housing122, thepost motor filter178 may be removed from the postmotor filter chamber183, and may optionally be replaced or cleaned, for example.

Referring toFIGS. 5,6A, and6B, theinlet end185 of the postmotor filter chamber183 includes afinger guard191. The finger guard generally prevents or minimizes the risk of a users fingers contacting thesuction motor126 when the postmotor filter chamber183 is open and thepost motor filter178 is removed from the postmotor filter chamber183. Thefinger guard191 may be of any suitable configuration. In the embodiment shown, thefinger guard191 is in the form of a grate, which extends partially around thesuction motor126 and is integral with thesuction motor housing122.

Thepost-motor filter178 may be any suitable type of filter, such as a HEPA filter.

It is possible that in some instances, the airflow passage may become fully or partially clogged. For example, a large object, such as a ball of hair, may become lodged anywhere in the airflow passage, such as in thefloor cleaning head106. For further example, thepre-motor filter176 may become clogged with particulate matter. If this occurs, thesuction motor126 may burn out. Referring still toFIG. 2, a bleed-valve101 is provided in themotor housing122. If a clog occurs in the airflow passage, the pressure in themotor housing122 will decrease. Thebleed valve101 is preferably configured to open when the pressure decreases, and allow air to flow through themotor housing122 to the clean air.

Various apparatuses or methods are described above to provide an example of each claimed invention. No example described above limits any claimed invention and any claimed invention may cover processes or apparatuses that are not described above. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described above or to features common to multiple or all of the apparatuses described above.

Claims

1. An upright surface cleaning apparatus comprising:

(a) a floor cleaning head having a dirty air inlet;

(b) air flow passage extending from the dirty air inlet to a clean air outlet;

(c) an upright section moveably mounted to the surface cleaning head between an storage position and an in use position and comprising a filtration member and a suction motor provided in the air flow passage, the suction motor having an air inlet end, an opposed distal end and an air inlet direction; and a motor housing, the motor housing comprising a motor section in which the suction motor is provided, the motor section having a first end at the air inlet end of the suction motor and an opposed second end at the distal end of the suction motor;

(d) an openable post motor filter chamber provided in the motor housing and having an inlet end and an outlet end, at least a portion of the filter chamber is provided in the motor section, the inlet end includes a finger guard and the filter chamber has a direction of airflow that is transverse to the air inlet direction of the suction motor; and,

(e) a post motor HEPA filter removably mounted in the filter chamber.

2. The surface cleaning apparatus ofclaim 1 wherein the inlet end of the filter chamber is positioned adjacent the suction motor.

3. The surface cleaning apparatus ofclaim 1 wherein at least a portion of the inlet end of the filter chamber is laterally spaced from and faces the suction motor.

4. The surface cleaning apparatus ofclaim 1 further comprising a pre-motor filter positioned at the air inlet end of the suction motor.

5. The surface cleaning apparatus ofclaim 4 further comprising a pre-motor filter positioned at the air inlet end of the suction motor and the pre-motor filter has a direction of airflow that is aligned with the air inlet direction of the suction motor.

6. The surface cleaning apparatus ofclaim 5 wherein the filtration member comprises a cyclone, the cyclone comprises an air inlet and an air outlet and the air outlet of the cyclone is spaced from and faces the pre-motor filter.

7. The surface cleaning apparatus ofclaim 1 wherein the air inlet end of the filter chamber is spaced less than 3 inches from the suction motor.

8. The surface cleaning apparatus ofclaim 1 wherein the air inlet end of the filter chamber is spaced less than 1.5 inches from the suction motor.

9. An upright surface cleaning apparatus comprising:

(a) a floor cleaning head having a dirty air inlet;

(b) air flow passage extending from the dirty air inlet to a clean air outlet;

(c) an upright section moveably mounted to the surface cleaning head between an storage position and an in use position and including a motor housing;

(d) a filtration member and a suction motor provided in the air flow path, the suction motor having an air inlet end, an opposed distal end and an air inlet direction;

(e) an openable post motor filter chamber provided in the motor housing and having an inlet end and an outlet end, at least a portion of the inlet end is laterally spaced from and faces the suction motor, the inlet end including a finger guard; and,

(f) a post motor HEPA filter removably mounted in the filter chamber.

10. The surface cleaning apparatus ofclaim 9 wherein the inlet end of the filter chamber is positioned adjacent the suction motor.

11. The surface cleaning apparatus ofclaim 9 wherein the motor housing comprises a motor section in which the suction motor is provided, the motor section having a first end at the air inlet end of the suction motor and an opposed second end at the distal end of the suction motor and at least a portion of the filter chamber is provided in the motor section.

12. The surface cleaning apparatus ofclaim 9 further comprising a pre-motor filter positioned at the air inlet end of the suction motor.

13. The surface cleaning apparatus ofclaim 9 wherein the filter chamber has a direction of airflow that is transverse to the air inlet direction of the suction motor.

14. The surface cleaning apparatus ofclaim 13 further comprising a pre-motor filter positioned at the air inlet end of the suction motor and the pre-motor filter has a direction of airflow that is aligned with the air inlet direction of the suction motor.

15. The surface cleaning apparatus ofclaim 14 wherein the filtration member comprises a cyclone, the cyclone comprises an air inlet and an air outlet and the air outlet is spaced from and faces the pre-motor filter.

16. The surface cleaning apparatus ofclaim 9 wherein the air inlet end of the filter chamber is spaced less than 3 inches from the suction motor.

17. The surface cleaning apparatus ofclaim 9 wherein the air inlet end of the filter chamber is spaced less than 1.5 inches from the suction motor.