Note: Descriptions are shown in the official language in which they were submitted.
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ADAPTER RING FOR VACUUM CLEANER FILTERS
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to vacuum cleaners, and, more
specifically, to
devices for filtering dirt and other debris suctioned into vacuum cleaners.
Description of the Related Art
[0002] Vacuum cleaners are well known. They are devices that use an air pump
to
create a partial vacuum to suck up dirt and other debris, usually to clean
floors and other
surfaces. Vacuum cleaners come in a variety of configurations, e.g., upright,
canister,
robotic, central, etc. Upright vacuum cleaners typically take the form of a
cleaning head,
onto which a handle and bag or cyclone are attached. Upright designs usually
employ a
rotating brushroll or beater bar, which removes dirt through a combination of
sweeping and
vibration movements. Canister vacuum cleaners, on the other hand, have a
vacuum head
with a suction inlet (which may have a brushroll) connected to a wand, and a
motor and
dust collector housed in a separate unit. Typically, the separate unit is
mounted on wheels
and is connected to the vacuum head by a flexible hose.
[0003] Filters are used in vacuum cleaners to remove the dirt and other debris
from air.
One common type of filter found in vacuum cleaners is a planar filter. The
planar filter is
installed in a closed passage of the vacuum cleaner and is used to supplement
the primary
filtration device, e.g., a bag or a cyclone. A vacuum cleaner may have two or
more planar
filters located in separate chambers of the vacuum cleaner. For example, a
"pre-motor"
filter may be mounted in the airstream upstream of the suction fan, and a
"post-motor"
filter may be mounted in the airstream downstream of the suction fan. Planar
filters
typically do not have a separate dirt collection chamber associated with
them¨rather, they
generally trap the dirt in the filter material itself.
[0004] Planar filters come in a variety of sizes and configurations, e.g.,
flat or curved.
Such filters can use any variety of filter material. For example, filter
material may be foam
or pleated filter paper. Combinations of layers and materials are also
frequently used.
Filter material typically comes in different grades in relation to particle
sizes that will be
filtered by the filter material. For example, relatively coarse open-cell foam
filter material
may be used for filtering large particles. Conversely, filter material passing
High-Efficiency
Particulate Air (HEPA) or Ultra-Low Penetration Air (ULPA) standards may be
used for
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removing smaller particles. Such filters may comprise paper or non-woven
fabrics that may
be impregnated with chemicals, as known in the art.
[0005] Conventionally, details of the filter to be used must be considered
when designing
a vacuum cleaner. Each filter in a respective vacuum cleaner is typically
designed to meet
the dimensional and operational specifications of the particular vacuum
cleaner. These
specifications may include the filter size, shape, airflow rate, dirt
capacity, and filter grade
of the filter.
[0006] The filter specifications can be critical to obtain proper vacuum
cleaner operation.
For example, if filter dimensions are not correct, the filter may be too large
or too small to
properly fit into the vacuum cleaner. In such cases, the user may think that
the filter is
properly installed, but the poor fit will may cause air leaks that result in
decreased filtering
efficiency, and the filter may jostle, rattle, or otherwise move in the
chamber during
operation of the vacuum cleaner causing unnecessary noise and possible damage.
Even if
the dimensions are correct, other operational characteristics may not properly
match the
vacuum cleaner. For example, a vacuum cleaner may be designed to operate with
filter
having a relatively low air impedance (i.e., the filter allows the air to pass
relatively freely),
and if the filter has a high impedance, it may unduly restrict the suction
motor leading to
higher operating temperatures, reduced cleaning efficiency, or other problems.
The filter's
dirt capacity also should match the vacuum cleaner's recommended maintenance
schedule,
so if the filter has a relatively low capacity and clogs sooner than expected,
the user may be
dissatisfied with the vacuum's performance.
[0007] As a result of the foregoing, vacuum cleaner filters typically are
constructed to
dimensionally and operationally match specific vacuum cleaner models. The
inventors have
found that this causes a significant burden on the process of designing and
manufacturing
vacuum cleaner filters. Thus, there exists a need for providing alternative
approaches to
providing vacuum cleaner filters.
SUMMARY
[0008] In one embodiment, there is provided a filter adapter for engaging a
filter to fit
the filter into a vacuum cleaner chamber. The filter adapter may include an
adapter ring
having an inner ring perimeter and an outer ring perimeter, and a number of
protrusions
extending from the outer perimeter of the ring.
[0009] In another embodiment, there is provided an adapter ring and filter
assembly for
use in a vacuum cleaner chamber. The assembly may include a filter having an
outer filter
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perimeter, and an adapter ring having an inner ring perimeter configured to
surround the
outer filter perimeter and an outer ring perimeter configured to contact an
inner surface of
the vacuum cleaner chamber.
[0010] The recitation of this summary of the invention is not intended to
limit the claims
of this or any related or unrelated application. Other aspects, embodiments,
modifications
to, and features of the claimed invention will be apparent to persons of
ordinary skill in view
of the disclosures herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention is best understood from the following detailed
description when
read in connection with the accompanying drawings, with like elements having
the same
reference numerals. Included in the drawings are the following figures:
[0012] Figure 1 is an isometric view of an exemplary ring assembly that may be
used to
adapt a filter to a particular vacuum cleaner.
[0013] Figure 2 is an isometric view of a filter that engages with the
exemplary ring
assembly of Figure 1.
[0014] Figure 3 is an isometric view of the exemplary ring assembly of Figure
1 engaged
with the filter of Figure 2.
[0015] Figure 4 is an isometric view of an embodiment of a rib-less ring
assembly.
[0016] Figure 5 is an isometric view of an embodiment of a ring assembly
having a
plurality of clamps for engaging the filter of Figure 2.
[0017] Figure 6 is an top view of an alternative ring assembly having a
rectangular
shape.
DETAILED DESCRIPTION
[0018] It has been found that the process of designing and manufacturing
vacuum
cleaner filters can be expedited and simplified by modifying vacuum cleaner
filters to
operate in multiple different vacuum cleaners. The following embodiments
describe unique
exemplary arrangements for providing adapter rings for vacuum cleaner filters.
It will be
appreciated that embodiments may be used upright, canister, robotic, stick,
central, and
other kinds of vacuum cleaner, and also that embodiments may be used for pre-
motor or
post-motor filters.
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[0019] Figure 1 illustrates an exemplary adapter ring 100. The adapter ring
100 is
configured to engage a filter that removes dirt and other debris suctioned by
a vacuum
cleaner. In an exemplary embodiment, adapter ring 100 will engage with a
filter to enlarge
the effective circumference of the frame of the filter. By enlarging the
circumference of the
filter, the filter may be adapted to properly fit into a particular vacuum
cleaner, other than
the vacuum cleaner in which the filter was originally designed to fit. For
example, a filter
having a diameter that is otherwise too small for a particular vacuum cleaner
filter chamber
may be adapted by the adapter ring 100 to properly fit within the chamber. The
shown
embodiment increases the effective circumference of a circular filter to fit
into a larger
circular chamber, but other embodiments may change the effective perimeter
shape, such
as by converting a circular filter to fit into a square chamber.
[0020] As depicted in Figure 1, adapter ring 100 includes an outer perimeter
102 and an
inner perimeter 104. The inner perimeter 104 is configured to engage a filter
having a
similar outer surface shape. In the embodiment of Figure 1, the inner
perimeter 104 is
annular, to engage a filter also having an annular outer surface. However, an
adapter ring
may be shaped (and sized) in any manner necessary to engage a particular
filter. For
example, alternative embodiments of the present invention may include a ring
that is
rectangular (Figure 6), square, polygon, oval, etc. Further, an adapter ring
100 may be
sized to engage with a filter of various sizes to fit within particular vacuum
cleaners and
may be formed of any material that suitably engages with a filter. For
instance, inner
perimeter 104 may be formed of plastic, metal, rubber, etc., to engage with
outer perimeter
202 of filter 200 (Figure 2). It will be appreciated that inner perimeter 104
need not exactly
match the entire outer perimeter 202 of the filter 200, but it should match
enough of the
outer perimeter 202 to engaged the filter 200 to remain in place during
installation into the
vacuum cleaner and during use.
[0021] In an exemplary embodiment, at least one rib extends outwardly from
outer
perimeter 102 of adapter ring 100. In a preferred embodiment, at least three
ribs, e.g.,
ribs 106, 108, 110 extend outwardly from adapter ring 100. Ribs 106, 108, 110
may be
spaced about the adapter ring 100 equidistantly from each other. In other
embodiments,
ribs may be spaced from each other in varying distances. Ribs 106, 108, 110
may extend
perpendicularly from the outer perimeter 102 of adapter ring 100. However,
ribs may
extend in any direction or formation, e.g., horizontally, diagonally, cross-
wise, etc. Ribs
106, 108, 110 are intended to enlarge the circumferential size of filter 200
to adapt filter
200 to properly fit into a particular vacuum cleaner. In one embodiment, ribs
106, 108,
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110 are a plastic material. However, adapter ring 100 may be made of any other
suitable
material, such as metal, rubber, etc.
[0022]
The ribs may have any size or shape to adapt a filter to a particular chamber
of
a vacuum cleaner. In the embodiment of Figure 1, the ribs 106, 108 extend
between an
upper edge 112 and a lower edge 114 of the adapter ring 110, and have rounded
corners
116 at each end where the ribs 106, 108, 110 terminate ad the upper and lower
edges 112,
114. Other ribs, however, may be have different shapes, and may include
straight lines,
jagged edges, curves, angles, etc. The ribs also may not extend entirely from
the upper
edge 112 to the lower edge 114, or may extend beyond one or both edges 112,
114. The
ribs also may be angled or perpendicular to the shown ribs (e.g., a rib may be
provided as
an annular wall that extends from the outer perimeter 102 around all or some
of the outer
perimeter 102). One of ordinary skill in the art will understand the sizes and
shapes that
the ribs may take to adapt a filter for properly fitting the filter into a
particular vacuum
cleaner.
[0023] Inner perimeter 104 of adapter ring 100, and outer perimeter 102 of
adapter ring
100, may be shaped and sized similarly. For instance, both inner perimeter 104
and outer
perimeter 102 may be shaped annularly. However, in alternative embodiments,
inner
perimeter of ring and outer perimeter of ring may take on shapes and sizes
that are
different from one another. Such difference in size between inner perimeter
104 and outer
perimeter 102 may result in various thicknesses of the ring (and the adapted
filter). This
thickness between outer perimeter 102 and inner perimeter 104 may be
configured to vary
according to the particular vacuum cleaner that the filter is being adapted to
fit. For
example, if a large spacing is present between filter 200 and a wall of the
vacuum cleaner
chamber, the thickness of adapter ring 100 may be increased accordingly.
[0024] Adapter ring 100 engages filter 200 when inner perimeter 104 of adapter
ring
100 contacts outer perimeter 202 of filter 200 (Figure 2). In an exemplary
embodiment,
outer perimeter 202 of filter 200 defines the circumferential size of filter
200. The
circumferential size of outer perimeter 202 may be used to determine the
sizing of filter 200
with respect to a particular vacuum cleaner. If the circumference of outer
perimeter 202 is
too large, for example, filter 200 will not be placeable into the chamber of
the vacuum
cleaner. Conversely, if the circumference of outer perimeter 202 is too small
for a particular
vacuum cleaner, filter 200 will jostle, rattle, or otherwise move laterally or
vertically within
the vacuum cleaner. As it does so, it may no longer seal properly with the
airflow passages
that direct air to or from the filter 200.
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[0025] In the shown embodiment, the filter's outer perimeter 202 is defined by
the
filter's frame 206. Frame 206 may be formed of any material typically used for
frames of a
filter, such as plastic. The frame 206 may extend the full height of the
filter 200, and may
include other features, such as a cross-shaped structure at the top of the
filter 200 having a
handle 208 that may be used to insert and remove the filter 200 from the
filter chamber.
The handle 208 also may be used to orient the filter 200 or for other purposes
as known in
the art.
[0026] The filter 200 also includes a filter element 204. Filter element 204
may be
formed of any material typically used for filtering dust or other debris. For
example, filter
element 204 may be paper, fiberglass, foam, etc. As depicted in Figures 2,
filter element
204 is located within frame 206. The performance of a particular filter is
typically defined
by the filter grade of filter element 204. A foam filter element 204, for
example, may be
graded to filter relatively large particles, whereas a filter element 204
conforming to High-
Efficiency Particulate Air (HEPA) or an Ultra-Low Penetration Air (ULPA)
standards, may be
graded to filter relatively small particles. The filter element 204 may
include multiple layers
of similar or dissimilar filter material, as known in the art. In some cases,
the filter element
204 may have sufficient structural properties that a frame 206 is not
necessary or used.
[0027] In the example if Figure 2, the filter 200 also includes a bottom
portion 210 made
from an extension of the frame 206. The bottom portion 210 may be provided to
seal
against a chamber wall, and may include a lower seal 212 that seals around an
exhaust or
inlet passage of a vacuum fan. In an exemplary embodiment, depicted on Figure
2, bottom
portion 210 may flare away from filter 200. In such an embodiment, bottom
portion 210
will have a circumference larger than the circumference of outer perimeter
202.
[0028] As shown in Figure 3, adapter ring 100 engages with filter 200. In
particular,
inner perimeter 104 of adapter ring 100 engages with outer perimeter 202 of
filter 200.
The circumference of inner perimeter 104 is configured to be slightly larger
than the
circumference of outer perimeter 202 so that adapter ring 100 slides into
place around
outer perimeter 202. The sizes of the parts may be selected to provide a
removable
connection (e.g., a slight friction fit or deformable snaps), or to provide a
permanent
connection (e.g., a tight friction fit or snaps that do not permit removal).
In an exemplary
embodiment, adapter ring 100 is engaged with filter 200 by lightly pressing
adapter ring
100 upon and about outer perimeter 202 of filter 200. When adapter ring 100 is
engaged to
filter 200, adapter ring 100 preferably fits snugly upon filter 200 so that it
does not jostle,
rattle, or otherwise be displaced from filter 200 during normal use and
handling. When
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inner perimeter 104 of adapter ring 100 is fit upon outer perimeter 202 of
filter 200, the
lower edge 114 of adapter ring 100 abuts against the upper part of bottom
portion 210 of
filter 200.
[0029] As noted above, the exemplary adapter ring 100 includes a plurality of
ribs 106,
108, 110 that extend outwardly from adapter ring 100 to enlarge the effective
circumference of adapter ring 100. When adapter ring 100 is engaged with
filter 200, filter
200 will also have a larger effective circumference. Where it is desired to
fit the filter 200 to
a larger circular chamber, the use of three or more ribs 106, 108, 110 is
preferred, as
making three contact points to the inner surface of the circular chamber will
effectively
resist movement in any direction in the plane of the filter 200. However, two
diametrically-
opposed ribs alternatively may be used, which may provide good support, but
also may be
more subject to forces applied perpendicular to the line formed between the
two ribs. The
use of more than three ribs may be used in any event, and may be helpful to
hold the filter
200 in a chamber that has an irregular or non-circular shape. Other variations
and
modifications will be apparent to persons of ordinary skill in the art in view
of the present
disclosure.
[0030] In alternative embodiments, such as the example of Figure 4, an adapter
ring
may have no ribs. Adapter ring 400 is sized and shaped such that it expands
the
circumference of filter 200 without one or more ribs extending from the
adapter ring 400.
Rather, the thickness of adapter ring 400 determines whether a filter 200 will
be adapted to
properly fit into a vacuum cleaner. In such cases, the circumference of outer
perimeter 402
of adapter ring 400 is sized such that filter 200 will properly fit inside a
particular vacuum
cleaner chamber. In this case, the outer perimeter 402 may be a smooth shape
(i.e.,
uninterrupted by ribs or the like) that continuously contacts a
correspondingly-shaped
vacuum cleaner chamber, and may also provide an air seal. As a result, the
filter will not
jostle, rattle, or otherwise move in an undesired way. Adapter ring 400 may be
formed of
foam, although other materials may be used for the ring.
[0031] In the embodiment of Figure 4, adapter ring 400 engages filter 200 by
wrapping
around the enlarged bottom portion 210 of filter 200. In this embodiment, the
adapter ring
400 has a bottom portion 406 that extends around the lower edge of the
filter's bottom
portion 210, and an inner surface 404 that overlies the vertical side of the
filter's bottom
portion 210, and an upper portion 408 that extends around an upper side of the
filter's
bottom portion 210. Thus, adapter ring 400 engages with filter 200 to that
they will not
separate during handling or use. Instead, ring 400 will only disengage when
the user pulls
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top portion 408 and/or bottom portion 406 of ring 400 far enough to allow the
filter 200 to
be removed. The top and/or bottom portion 408, 406 may be formed of a pliable
material,
such as foam, rubber or soft plastic, to allow installation and removal.
[0032] In another embodiment, the adapter ring 400 may comprises a simple ring
that
fits over the upper part of the filter 200. For example, the adapter ring 400
may comprise a
circular foam block with a hole sized to fit over filter 200. Other variations
and
modifications will be apparent to persons of ordinary skill in the art in view
of the present
disclosure.
[0033] Another alternative embodiment of an adapter ring 500 is depicted in
Figure 5.
Adapter ring 500 includes at least one clamp for attaching adapter ring 500 to
filter 200. In
a preferred embodiment, adapter ring 500 will have at least three clamps 506,
508, 510 for
engaging adapter ring 500 to filter 200. Clamps 506, 508, 510 attach to bottom
portion
210 of filter 200. Clamps 506, 508, 510 are used to securely affix adapter
ring 500 to filter
200. Clamps 506, 508, 510 are also used to enlarge the effective circumference
of filter
200. To securely affix each clamp 506, 508, 510 to filter 200, adapter ring
500 includes, on
clamp inner surface 518, a flange or other member for affixing adapter ring
500 to filter
200. For example, as depicted on Figure 5, clamp 508 includes a horizontally
extending
coupling member 516 for engaging adapter ring 500 to bottom portion 210 of
filter 200.
However, coupling member 516 may affix to the side, bottom, or any other
surface of filter
200.
[0034] Clamps 506, 508, 510 also include clamp outer surface 520. In an
exemplary
embodiment, clamp outer surface 520 includes at least one rib extending
outwardly from
clamp outer surface 520 (e.g., vertically extending ribs 512, 514 of clamp
510). Ribs 512,
514 may be used to enlarge the effective circumferential size of adapter ring
500. Thus,
when adapter ring 500 is engaged with filter 200, the effective circumference
of filter 200 is
enlarged by way of the outwardly extending ribs. As discussed above, by
enlarging the
effective circumference of filter 200, adapter ring 500 permits filter 200 to
be properly sized
for a particular vacuum cleaner, e.g., adapter ring 500 prevents filter 200
from jostling,
rattling, or otherwise moving when the vacuum cleaner is in operation.
[0035] In some embodiments, inner perimeter 504 of adapter ring 500 may assist
in
coupling adapter ring 500 to filter 200. In particular, inner perimeter 504
will fit over, and
engage with, outer perimeter 202 of filter 200. To ensure a snug fit of
adapter ring 500,
inner perimeter 504 of adapter ring 500 should be slightly larger than outer
perimeter 202
of filter 200, as discussed above for adapter ring 100. Thus, inner perimeter
504, in
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combination with clamps 506, 508, 510, will ensure adapter ring 500 is snugly
fit upon filter
200. Thus, adapter ring 500 will not disengage from filter 200 during normal
operation of
the vacuum cleaner. To release adapter ring 500 from filter 200, clamps 506,
508, 510
may be pulled away from bottom portion 210 of filter. This movement of clamp
will
separate coupling member 516 from bottom portion 210 of filter.
[0036] Although Figures 1 and 3-5 have depicted rings having an annular shape,
alternative embodiments for a ring of the present invention should not be so
limited.
Alternative embodiments of the ring of present invention may include, for
example, many
different shapes and sizes for adapting a filter to a particular vacuum
cleaner. For example,
a ring may be shaped as a parallelogram, oval, rhombus, etc. As depicted on
Figure 6, an
adapter ring 600 may be rectangular (i.e., approximately the shape of a
geometric
rectangle). Thus, in this embodiment, adapter ring 600 may be used to engage
with a filter
(not shown) that is rectangular.
[0037] Figure 6 depicts adapter ring 600 having an inner perimeter 604 and
outer
perimeter 602. Inner perimeter 604 engages the outer perimeter of a
rectangular filter. An
embodiment of adapter ring 600 will be sized and shaped such that it will
snugly engage the
rectangular filter, e.g., ring will be sized and shaped so that it will not
jostle, rattle, or
otherwise move during use of the vacuum cleaner. In one embodiment, inner
perimeter
604 of adapter ring 600 should be substantially the same size as its
corresponding filter,
although adapter ring 600 should be a predetermined size larger than the outer
perimeter
of a corresponding rectangular filter. Such sizing of adapter ring 600 will
ensure that
adapter ring 600 is properly engaged with the filter.
[0038] Adapter ring 600 also includes a plurality of ribs, e.g., 604, 606,
608, 610,
attached to outer perimeter 602. In an exemplary embodiment, at least four
ribs will
extend outwardly from adapter ring 600. Ribs 604, 606, 608, 610 are sized to
ensure that
the filter engaged with adapter ring 600 properly fits into a chamber of a
particular vacuum
cleaner. As such, the filter will be snugly held into place within a vacuum
cleaner. The
outwardly extending ribs 604, 606, 608, 610 will contact the housing within
the vacuum
cleaner to ensure the filter provides a proper fit for a particular vacuum
cleaner.
[0039] The present disclosure describes a number of new, useful, and
nonobvious
features and/or combinations of features that may be used alone or together.
The
embodiments described herein are all exemplary, and are not intended to limit
the scope of
the inventions. Persons of ordinary skill in the art will appreciate and
understand that the
inventions described herein can be modified and adapted in various and
equivalent ways,
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and such modifications and adaptations are intended to be included in the
scope of this
disclosure and the appended claims.
