Note: Descriptions are shown in the official language in which they were submitted.
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VACUUM CLEANER HAVING DIRT COLLECTION VESSEL
WITH A LABYRINTHINE AIR FLOW PATH
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0001] The present invention relates generally to the floor care equipment
field and,
more particularly, to a new and improved vacuum cleaner incorporating a dirt
collection
vessel having a labyrinthine air flow path for enhanced cleaning performance.
BACKGROUND OF THE INVENTION
[0002) A vacuum cleaner is an electro-mechanical appliance utilized to effect
the dry
removal of dust, dirt and other small debris from carpets, rugs, fabrics or
other surfaces in
domestic, commercial and industrial environments. In order to achieve the
desired dirt
and dust removal, most vacuum cleaners incorporate a rotary agitator. The
rotary agitator
is provided to beat dirt and debris from the nap of the carpet or rug while a
pressure drop
or vacuum is used to force air entrained with this dirt and debris into the
nozzle of the
vacuum cleaner. The particulate laden air is then drawn into a dirt collection
vessel
before being directed through the motor of the suction generator to provide
cooling.
Finally, the air is filtered to remove any fine particles of carbon from the
brushes of that
motor or other dirt that might remain in the airstream before being exhausted
back into
the environment.
[0003) Dirt collection vessels on vacuum cleaners typically comprise a dirt
cup
having a cylindrical sidewall, a tangentially directed air inlet for receiving
dirt and debris
from the nozzle of the vacuum cleaner, and an axially oriented outlet for
discharging
clean air from the dirt collection vessel. Such a structural arrangement
allows for
cyclonic air flow in the dirt cup. Such air flow causes dirt and debris to
move outwardly
toward the side wall of the dirt cup under the centrifugal force generated by
the cyclonic
air flow. That dirt and debris is then collected in the dirt cup as the clean
air is drawn
toward and through the axially directed outlet.
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[0004] In many vacuum cleaners a filter of some type is provided over the
discharge
outlet to eliminate any dirt and debris not removed from the air stream by the
cyclonic air
flow. In other, more recent designs, one or more secondary cyclones are
provided to
remove any fine dust particles that may have escaped the first or primary
cyclone
cleaning stage.
100051 The present invention relates to a vacuum cleaner incorporating a dirt
collection vessel of novel design that includes a labyrinthine air flow path
that provides
enhanced cleaning performance without the need for a fine particle filter in
the dirt
collection vessel.
SUMMARY OF THE INVENTION
[0006] In accordance with the purposes of the present invention as described
herein,
an improved vacuum cleaner is provided. That vacuum cleaner comprises a body
including (a) a nozzle assembly having a suction inlet, (b) a control assembly
including a
control stalk, (c) a suction generator carried on the body, and a dirt
collection vessel
carried on the body. The dirt collection vessel is characterized by a housing
having a
dirty air inlet, a clean air outlet, a labyrinthine air flow path connecting
the dirty air inlet
with the clean air outlet, and a dirt collection chamber opening to the
labyrinthine air
flow path. As the air stream follows the labyrinthine air flow path it moves
in the shape
of a sign wave.
[0007] More specifically describing the invention, the dirt collection vessel
includes a
series of spaced baffles forming a series of interconnected passageways. This
series of
spaced baffles comprises a first ring shaped baffle, a second ring shaped
baffle, and a
third ring shaped baffle. The first, second and third ring shaped baffles are
concentrically
disposed with respect to one another.
[0008] A first airflow pathway is defined between the dirty air inlet and the
first ring
shaped baffle. A second airflow pathway is defined between the first and
second ring
shaped baffles. A third air flow passageway is defined between the second and
third ring
shaped baffles.
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[0009] Still further describing the invention, the dirt collection chamber
includes a
first divider, a second divider and a cylindrical outer wall. The first and
second dividers
are ring shaped and concentrically received within the cylindrical outer wall.
The first
divider projects between the first and second ring shaped baffles so that the
second air
flow passageway is u-shaped. Similarly, the second divider projects between
the second
and third ring shaped baffles so that the third air flow passageway is u-
shaped. A first
blind channel is formed in the first divider while a second blind channel is
formed in the
second divider. Still further, a third blind channel is formed adjacent the
cylindrical outer
wall. A clean air outlet is formed between the third ring shaped baffle and
the third blind
channel. All of the blind channels open toward the dirt collection chamber and
away
from the labyrinthine air flow path.
[0010] The dirt collection chamber includes a first dirt compartment formed
between
the dirty air inlet and the first divider, a second dirt compartment formed
between the first
and second dividers, and a third dirt compartment formed between the second
divider and
the cylindrical outer wall. In addition, a ring shaped air deflector is
positioned in the
second dirt compartment. The ring shaped deflector is aligned with the second
ring
shaped baffle.
[0011] In an alternative embodiment of the invention, the dirt collection
vessel
further includes a primary cyclone separator upstream from the labyrinthine
air flow path.
In this embodiment, air flows through the dirty air inlet, into the primary
cyclone
separator, and from the primary cyclone separator into the labyrinthine air
flow path, and
then from the labyrinthine air flow path to the clean air outlet. Thus, the
labyrinthine air
flow path acts as a secondary cleaning means for removing fine dirt and debris
from the
air stream.
[0012] In the following description, therein describes multiple embodiments of
the
invention, simply by way of illustration of some of the modes best suited to
carry out the
invention. As it should be realized, the invention is capable of other
different
embodiments, and its several details are capable of modification in various,
obvious
aspects departing from the invention. Accordingly, the drawings and
descriptions will be
regarded as illustrative in nature, but not as restrictive.
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BRIEF DESCRIPTION OF THE DRAWINGS
[00131 The accompanying drawings incorporated herein and forming a part of the
specification, illustrate several aspects of the present invention and
together with the
description serve to explain certain principles of the invention. In the
drawings:
100141 Figure 1 is a perspective view of an upright vacuum cleaner
incorporating the
novel dirt collection vessel of the present invention;
[0015] Figure 2 is a cross-sectional view, illustrating a first embodiment of
the dirt
collection vessel of the present invention;
[0016] Figure 3 is a schematical cross-sectional view of an alternative
embodiment of
the dirt collection vessel of the present invention.
[0017] Reference will now be made in detail of the present invention, examples
of
which are illustrated in the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION
100181 Reference is now made to Figure 1 illustrating an upright vacuum
cleaner 10
incorporating the novel dirt collection vessel 12 of the present invention.
The vacuum
cleaner 10 includes a body, generally designated by reference numeral 14. The
body 14
includes a nozzle assembly 16 and a control assembly 18. As is known in the
art, the
control assembly 18 is pivotally connected to the nozzle assembly 16 to aid
the operator
in manipulating the vacuum cleaner 10 back and forth across the floor. Wheels
(not
shown) carried on the body 14 allow the vacuum cleaner 10 to be moved smoothly
across
the floor. As illustrated, the nozzle assembly 16 is equipped with a suction
inlet 20. A
rotary agitator 22, including bristle tufts, wipers or cleaning ribs 23, is
mounted on the
nozzle assembly 16 and extends across the suction inlet 20. The rotary
agitator 22 rotates
relative to the nozzle assembly 16 in a manner well known in the art.
[0019] The control assembly 18 carries a suction generator 28 (i.e. a fan and
motor
assembly) and the collection vessel 12. The details of the dirt collection
vessel will be
described in greater detail below. The control assembly 18 also includes a
control stalk
30 and an actuator switch 32 for turning the vacuum cleaner 10 on and off. The
vacuum
cleaner 10 may be powered by electricity from an electrical wall outlet
through a power
cord (not shown) or by means of an onboard battery.
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[0020] In operation, the rotary agitator 22 quietly and efficiently brushes
dirt and
debris from the nap of an underlying carpet. That loosened dirt and debris is
first drawn
into the suction inlet 20 before being delivered to the dirt collection vessel
12 by means
of the suction generator 28. Dirt and debris is trapped in the dirt collection
vessel 12 and
the now clean air is directed over the motor of the suction generator 28 to
provide cooling
before being exhausted into the environment through the exhaust vent or port
34.
[00211 A first embodiment of the dirt collection vessel 12 of the present
invention is
illustrated in Figure 2. As illustrated, the dirt collection vessel 12
includes a housing 40,
including a cylindrical outer wall 42, as well as a cylindrical inner wall 44
concentrically
received within the cylindrical outer wall 42. The cylindrical inner wall 44
defines the
dirty air inlet 46. Dirty air inlet 46 opens into a labyrinthine air flow
path, generally
designated by reference numeral 48. A dirt collection chamber, generally
designated by
reference numeral 50, opens to the labyrinthine air flow path 48. The dirt
collection
chamber 50 is closed at one end by an annular bottom wall 52 that may be
connected by
means of a hinge 54 to the outer side wall 42. A latch mechanism of a type
known in the
art and generally designated by reference numeral 56, holds the bottom wall 52
closed.
When the latch mechanism 56 is unlatched, the bottom wall 52 pivots about the
hinge 54
to allow one to empty dirt and debris from the dirt collection chamber 50.
[00221 The labyrinthine air flow path 48 is formed by a series of spaced
baffles 58,
60, 62, that project from the top wall 64 of the dirt collection vessel 12. As
illustrated,
the ring shaped baffles 58, 60, 62 are concentrically disposed with respect to
one another.
A first air flow passageway 66 is defined between the dirty air inlet 42 or
cylindrical
inner wall 44 and the first ring shaped baffle 58. A second air flow
passageway 68 is
defined between the first ring shaped baffle 58 and the second ring shaped
baffle 60. A
third air flow passageway 70 is defined between the second ring shaped baffle
60 and the
third ring shaped baffle 62.
[0023] The dirt collection chamber 50 includes a first divider 72 and a second
divider
74. The dividers 72, 74 are ring shaped and concentrically received within the
cylindrical
outer wall 42. As illustrated, the first divider 72 projects between the first
and second
ring shaped baffles 58, 60 so that the second air flow passageway 68 is u-
shaped.
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Similarly, the second divider 74 projects between the second and third ring
shaped baffles
60, 62 so that the third air flow passageway 70 is u-shaped.
[0024] A first blind channel 76 is formed in the first divider 72, and a
second blind
channel 78 is formed in the second divider 74. In addition, a third blind
channel 80 is
formed adjacent to the cylindrical outer wall 42. All of the blind channels
76, 78, 80
open toward the bottom wall 52 of the dirt collection chamber 50 and away from
the
labyrinthine air flow path 48. The clean air outlet 82 is formed between the
third ring
shaped baffle 62 and the third blind channel 80.
[0025] The dirt collection chamber 50 includes a first dirt compartment 84
formed
between the dirty air inlet 42 and the first divider 72, a second dirt
compartment 86
formed between the first and second dividers 72, 74, and a third dirt
compartment 88
formed between the second divider 74 and the cylindrical outer wall 42. An
annular or
ring shaped deflector 90 is positioned in the second dirt compartment and
aligned with
the second ring shaped baffle 60. Ribs 95 connect the inner wall 44, first
divider 72,
second divider 74 and deflector 90 to the sidewall 42.
10026] The movement of air through the dirt collection vessel 12 will now be
described in detail. Suction generator 28 draws an air stream entrained with
dirt and
debris through the suction inlet 20. That air stream is delivered by duct work
(not shown)
to the dirty air inlet 46 provided in the cylindrical inner wall 44. At this
point, the air
stream enters the labyrinthine air flow path 48. For purposes of this
document, the
terminology "labyrinthine air flow path" shall mean an air flow path having
intricate
passageways. Upon entering the labyrinthine air flow path 48, the air stream
passes
through the first air flow passageway 66 between the cylindrical inner wall 44
or dirty air
inlet 46 and the first ring shaped baffle 50. That air stream then makes a
sharp 180
degree turn around the first ring shaped baffle 58 before entering the second
air flow
pathway 68 (note action arrows A). As the air stream turns 180 degrees around
the first
ring shaped baffle 58, centrifugal forces act upon dirt and debris in the air
stream, forcing
that dirt and debris downward where it is collected within the first dirt
compartment 84.
The air stream now minus the dirt and debris collected in the first dirt
compartment 84
travels through the second air flow passageway 68. The air stream then makes
another
180 degree turn around the second ring shaped baffle 60 (Note action arrow B).
Here, the
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air stream passes through the annular gap 92 provided between the second ring
shaped
baffle 60 and the air deflector 90. Once again, centrifugal forces are
generated on any
remaining dirt and debris in the air stream as the air stream moves around the
second ring
shaped baffle 60 to enter the third air flow passageway 70. Thus, any
remaining fine
particles of dirt are acted upon by centrifugal force that tends to capture
those particles in
the second dirt compartment 86. The air stream, minus the particles captured
in second
dirt compartment 86, then passes through the third air flow passageway 70
until making
yet a third 180 degree turn around the third ring shaped baffle 62 (note
action arrows C).
At this point, only a relatively few of the finest dirt particles, if any, are
remaining in the
air stream. Centrifugal forces generated by the 180 degree turn of the air
stream force
any remaining particles outwardly toward the bottom of the third dirt
compartment 86
where those particles are collected while the now clean air stream passes
through the
clean air outlet 82. As should be appreciated, the air stream moves along a
sine wave
shaped path as it moves through the passageways 66, 68, 70 of the labyrinthine
air path
48.
[0027] It should be appreciated that the unique combination of ring shaped
baffles 58,
60, 62 that force the air stream to make a 180 change of direction, blind
channels 76, 78,
80 that help capture dirt particles and prevent their return to the air stream
traveling
through the labyrinthine air path 48, dirt compartments 84, 86, 88, and air
deflector 90
function to clean the air free of dirt and debris including fine dirt
particles. Thus, there is
no need to provide a fine particle filter media in the dirt collection vessel
12 of the
present invention. This eliminates the need to service/replace such a filter.
It also
eliminates any possibility of operating the vacuum cleaner at less than top
efficiency due
to the presence of such a filter when it is partially clogged with particles.
[0028] As is further illustrated in Figure 2, the air stream travels from the
clean air
outlet 82 into the internal chamber 94 of the discharge manifold 96. A
discharge port 98
in the manifold 96 is connected by duct work (not shown) to the suction
generator 28 (see
action arrows D). Accordingly, the air stream, now clean of particles, is
drawn over the
motor of the suction generator 28 to provide cooling before being exhausted
back into the
environment through the exhaust port 34. If desired, it should be appreciated
that a filter,
such as a HEPA filter, may be provided between the suction generator 28 and
the exhaust
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port 34 in order to filter any carbon particles from the coils of the motor,
or from any
other source that might remain in the air stream.
[0029] An alternative embodiment of dirt collection vessel 100 is illustrated
in Figure
3. As illustrated, the dirt collection vessel 100 includes a primary cyclone,
generally
designated by 102, and a secondary cyclone generally designated by reference
numeral
104.
[0030] Primary cyclone 102 includes a dirt collection chamber 106 having an
outer or
side wall 108, of substantially cylindrical shape, a tangentially directed
inlet 110 and an
axially directed outlet 112. A bottom wall 116 is pivotally connected to the
outer side
wall 108 by means of a hinge 118. A latching arrangement 120 of a type known
in the
art, secures the bottom wall 116 in the closed position, but may be unlatched
by the
operator to allow the bottom wall 116 to hinge open so that dirt and debris
may be
removed from the dirt collection vessel 100.
100311 The axial outlet 112 of the dirt collection chamber 106 is covered by a
shroud
122. The upper portion 124 of the shroud 122 provides smooth continuous inner
and
outer surfaces to promote smooth air flow. The lower portion 126 of the shroud
122
includes a series of apertures 128. The shroud 122 is supported in the center
of the dirt
collection chamber 106 by the top wall 114 of the primary cyclone 102.
[0032] During vacuum cleaner operation, the suction generator 28 draws dirt
and
debris through the suction inlet 20. That dirt and debris is then conveyed by
duct work
(not shown) to the tangentially directed inlet 110. The air stream with
entrained dirt and
debris then moves in a cyclonic air flow pattern through the dirt collection
chamber 106
(note action arrows E). This flow pattern creates centrifugal forces that
force dirt and
debris in the air stream outwardly toward the side wall 108. That dirt and
debris then
gradually falls downwardly toward the bottom of the dirt collection chamber
106, where
it collects. Relatively clean air is then drawn through the apertures 128
(only some of
which are illustrated in Fig. 3 for simplicity) of the shroud 122 and passes
through the
axially directed outlet 112, connected directly from the inlet 46 of the
secondary cyclone
104 (not action arrow F). The secondary cyclone 104 is identical to the dirt
collection
vessel 12 discussed above.
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[0033] Thus, the air stream exiting the axially directed outlet 112 of the
primary
cyclone flows through the inner cylindrical wall 44, past the dirty air inlet
46, into the
labyrinthine air flow path 48. Any relatively fine particles of dirt and
debris remaining in
that air stream are removed from the air stream by centrifugal force as the
air stream
travels along the labyrinthine air flow path 48, making 180 degree turns
around the first,
second and third ring shaped baffles 58, 60, 62 (note action arrows A, B and
C). That
fine dirt and debris is collected in the first, second and third dirt
compartments 84, 86, 88.
The clean air then passes through the clean air outlet 82, entering the
discharge manifold
chamber 94 before passing through the outlet port 98 and then through duct
work to the
suction generator 28. The air stream is then exhausted back into the
environment through
the exhaust vent 34. The air stream may, of course, be directed through a
final filter,
such as a HEPA filter, before exhausting through the air vent 34 if desired.
[00341 The foregoing description of the preferred embodiments of the present
invention have been presented for purposes of illustration and description. It
is not
intended to be exhaustive or to limit the invention to the precise form
disclosed. Obvious
modifications or variations are possible in light of the above teachings. The
embodiments were chosen and described to provide the best illustration of the
principles
of the invention and its practical application to thereby enable one of
ordinary skill in the
art to utilize the invention in various embodiments and with various
modifications as are
suited to the particular use contemplated. All such modifications and
variations are
within the scope of the invention as determined by the appended claims when
interpreted
in accordance with the breadth to which they are fairly, legally and equitably
entitled.
The drawings and preferred embodiments do not and are not intended to limit
the
ordinary meaning of the claims in their fair and broad interpretation in any
way.
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