Patent Application
20140196605
This invention relates to bagless vacuum cleaners and cyclonic air separators used therewith.
Numerous configurations for bagless cleaning devices have been developed that effectively separate debris from an airflow when such cleaning devices are used with respect to a cleaning surface or medium. Such devices include a variety of bagless vacuum cleaners that successfully ensure enhanced suction levels. Inherent in the obviation of bags is the difficulty in disposing collected particulates and debris. Such particulates and debris include, but are not limited to, dust, dirt, fibers, food particles, buttons, small lids and caps (such as bottle caps), fur, hair, epidermis particles and the like.
Certain cyclonic separator devices have been developed for such vacuum cleaners, as is known in the art. Such devices create centrifugal airflow so that inherent centrifugal forces separate debris within that airflow for eventual disposal from a debris collection device (including, but not limited to debris collection devices that incorporate dust-collecting chambers such as dirt cups.
Despite these known devices, a need persists to effectively separate both coarse debris and fine debris from dirty air prior to expelling separated air from a surface cleaning device. For example, many existing devices effect coarse debris accumulation while neglecting efficient fine debris accumulation, thereby resulting in vacuum devices that have poor functionality. At least these deficiencies are overcome, and additional attributes are imparted, by the devices presently disclosed herein.
A dual-stage cyclonic separator is provided for separating debris from air in a bagless surface cleaning apparatus. The cyclonic separator includes a cyclonic frustum having a frustum wall with an outer frustum wall for directing a preliminary centrifugal airflow thereabout and an inner frustum wall for directing ultimate centrifugal airflow therein. The frustum wall tapers generally inwardly from a frustum extent disposed adjacent a frustum extent opening toward an opposed frustum extent disposed adjacent a frustum egress. The cyclonic frustum also includes a cylindrical wall depending upwardly from an interface with the frustum extent opening and terminating in a cylindrical ingress. An airflow turret is provided at the cylindrical ingress that facilitates transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow.
The airflow turret incorporates at least two similarly configured and evenly spaced sails that are circumferentially arranged relative to the cylindrical ingress. Each sail has a guide surface to guide incoming air from the preliminary centrifugal airflow toward the cylindrical ingress. In preferred embodiments, the airflow turret comprises five sails and the guide surface of each sail exhibits a generally radial profile. Such profile includes an impact surface of predetermined concavity against which the incoming air strikes, and a terminal restraining edge for piloting the incoming air toward the cylindrical ingress. The terminal restraining edge includes a lead surface that leads the incoming air toward the impact surface. The terminal restraining edge also includes a trail surface that pilots the incoming air toward the cylindrical ingress during the transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow.
The lead surface of the terminal restraining edge leads the incoming air that enters through an adjacent velocity slot provided between adjacent sails. The velocity slot includes an entry ramp of predetermined camber that is configured to deliver the preliminary centrifugal airflow from the coarse debris collection area toward the cylindrical ingress. In exemplary embodiments, each guide surface exhibits a radius of about 38°; each lead surface exhibits a radius of about 14°; each trail surface exhibits a radius of about 14°; each velocity slot exhibits a cross-sectional area in a range from about 120 mm2 to about 130 mm2; and each entry ramp exhibits a grade of about 48°.
In addition, the cyclonic separator includes a debris collection cup having a cup wall with an outer cup wall that, together with a debris collection device and the outer frustum wall, provides a coarse debris collection area within which debris is deposited by the preliminary centrifugal airflow. An inner cup wall provides a fine debris collection area within which debris is deposited by the ultimate centrifugal airflow. At least a portion of the opposed frustum extent depends inwardly into the debris collection cup such that the ultimate centrifugal airflow deposits debris directly within the fine debris collection area.
The cyclonic separator further includes a cyclonic sieve having a sieve wall coextensive with a turret extent for placement adjacent the airflow turret and an opposed debris restriction extent. A debris restriction flange may be provided adjacent the debris restriction extent of the cyclonic sieve and configured to deflect debris in the preliminary centrifugal airflow into the course debris collection area.
The sieve wall has a continuous portion for directing the preliminary centrifugal airflow about the frustum wall wherein the sieve wall is positioned relative to the debris collection device such that dirty air that enters the debris collection device tangentially impinges the continuous portion of the sieve wall. The sieve wall also includes a louvered portion incorporating a plurality of apertures for delivering airflow to the airflow turret. At least some of the apertures have rounded upstream edges and rounded downstream edges past which the preliminary centrifugal airflow is delivered to the velocity slot. The sieve wall exhibits a generally frustoconical geometry, and in some embodiments, the apertures are provided in a predetermined pattern along the louvered portion of the sieve wall.
In some embodiments, the airflow turret includes a turret seating flange having an upper turret seat and a lower turret seat. The cyclonic sieve may incorporate a corresponding sieve seating flange having an upper sieve seat and a lower sieve seat. In such embodiments, the cyclonic sieve is positioned relative to the cyclonic frustum such that the upper sieve seat is disposed adjacent the lower turret seat.
The cyclonic separator also includes an airflow outlet configured to deliver air from the debris collection device after depositing debris in the fine debris collection area. The airflow outlet may be provided in a support member that is disposed adjacent the upper turret seat and configured to direct outgoing air from the cyclonic separator.
In operation of the presently disclosed cyclonic separator, debris that is not deposited in the coarse debris collection area by the preliminary centrifugation airflow is deposited by the ultimate centrifugal airflow into the fine debris collection area through the frustum egress. In some embodiments, an optional sifter is disposed near the frustum egress and configured to direct debris that is deposited from the frustum through the frustum egress into the fine debris collection area.
A bagless surface cleaning apparatus is also provided that includes a base suction unit, an apparatus handle and a main body provided intermediate the base suction unit and the apparatus handle and operably supporting a debris collection device thereby. The cleaning apparatus incorporates a cyclonic separation system as presently disclosed such that dirty air that enters the debris collection device tangentially impinges the continuous portion of the sieve wall.
A debris collection device is also provided that is used with a bagless surface cleaning apparatus to separate debris from air. The debris collection device includes a debris collection canister, a debris collection cover coupled with the debris collection canister and a centrifugal separation system as presently disclosed.
A method of separating debris from air is provided that uses a bagless surface cleaning apparatus. The method includes providing a cyclonic separator as presently disclosed in a debris collection device that is operably mounted in the cleaning apparatus. The cyclonic separator is positioned so that dirty air that enters the debris collection device tangentially impinges the continuous portion of the sieve wall. The cyclonic sieve of the cyclonic separator is positioned so that the preliminary centrifugal airflow traverses the louvered portion of the sieve wall toward the cylindrical ingress during the transition of the preliminary centrifugal airflow to the ultimate centrifugal airflow. The airflow outlet is configured to direct separated air from the cyclonic separator.
Additional aspects of the presently disclosed methods, devices and systems will be made apparent from the following detailed description.
The nature and various advantages of the present invention will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
Now referring to the figures, wherein like numbers represent like elements,
Main body 12 includes apparatus handle 16 that facilitates grasping and maneuvering of cleaning apparatus 10 by a user. Handle 16 may include at least a power button 18 integral therewith and in operational communication with a power source that actuates a vacuum motor (not shown). Such a power source, for example, may be electricity provided through a power cord 19 (shown in partial view in
As used herein, “cleaning surface”, “surface” and “cleaning medium” are used interchangeably to include any area, region, substrate, surface and other medium that can be acted upon by cleaning apparatus 10. Examples of “cleaning surfaces” and “cleaning media” include, but are not limited to, carpets, floors (including floors fabricated from hardwood, linoleum, ceramic, marble and other complementary and equivalent materials), mattresses (including mattresses for humans and pets), furniture (including fully or partially upholstered furniture, wooden furniture, metal furniture, patio and sunroom furniture and the like), accessories (including textile accessories such as pillows, throw pillows and seat cushions), drapery, walls and ceilings (including walls and ceiling made from drywall, having textured and/or painted surfaces, incorporating wainscoting and having a covering secured thereon), stuffed animals, textiles and other surfaces and media. The term “carpet” as used herein includes all textile floor coverings, including but not limited to those having fibers (e.g., whether looped, tufted, hooked, needlefelt, woven or of other design), indoor or outdoor, of natural or synthetic materials, wall-to-wall textiles or roll goods.
One or more visual, tactile, audio and other indices may be provided with power button 18 (and/or any other actuator provided on handle 16) not only to help a user identify the power source activation means for cleaning apparatus 10, but also to indicate a current state of cleaning apparatus 10 (e.g., “on” or “off”). Such indices may include visual indices, such as one or more LED lights or other illumination means provided proximate power button 18. Other visual indices may include one or more letters, numbers, symbols and combinations that readily identify power button 18. Still other indices may include raised protrusions (or indentations) providing tactile guidance of the activation source for cleaning apparatus 10.
In some embodiments, handle 16 may include at least one cord retention member 20 that enables retention of power cord 19 thereby. Cord retention member 20 may be provided as a hook member as shown in the figures or alternatively provided as a retractable element extendable relative to handle 16. At least one supplementary cord retention member 20a may be incorporated anywhere along main body 12, and the disposition of such supplementary cord retention members is not limited to that illustrated herein (for example, a supplementary cord retention member may be disposed at or near a motor shroud 29 instead of, or in addition to, supplementary cord retention member 20a shown in
A hose connector 22 may be formed on at least a portion of main body 12 that communicates with a suction port 24 and facilitates removable fastening of an extendable hose 26. Main body 12 may have a hose carrier 28 provided thereon that permits storage of hose 26 when either the hose or the cleaning apparatus is not in use. At least one of hose connector 22 and hose carrier 28 may be integral with at least a portion of main body 12 or detachably mounted thereto by one or more fastening means as known in the art. Optional accessories for hose 26 may also be removably fastened to corresponding structure on main body 12, including but not limited, to, a brush 30, a crevice tool 32 and a hose wand 34 that permits a user to guide the hose for removal of particulates from a variety of cleaning surfaces. Additional tools may include one or more brushes, squeegees, beater bars, nozzles, etc. It is understood that the incorporation of accessories and tools as shown and described herein is purely optional and does not limit the scope of the presently disclosed invention.
Main body 12 is at least supportable by abuse suction unit 14 that may include fascia 40 having a leading edge 40a and one or more side edges 40b. One or more of fascia 40, leading edge 40a and side edges 40b may have one or more designs, colors, textures and/or embellishments incorporated therewith to enhance the aesthetic features of main body 12. Alternatively, one or more of fascia 40, leading edge 40a and side edges 40b may be fabricated from one or more materials having an antimicrobial additive for treatment of infestation agents during a cleaning operation. Such materials may alternatively, or also, incorporate additives that impart easy-clean characteristics to base suction unit 14.
Leading edge 40a may include a bumper 42 thereon (or integral therewith) to protect cleaning apparatus 10 and floor and wall surfaces from inadvertent marks and impacts. One or more of fascia 40, leading edge 40a, side edges 40b and bumper 42 may include optional indicia for indicating a steering direction of base suction unit 14. For example, one or more illumination means (such as LED or fiber optic lights, not shown) may be used to illuminate at least a portion of base suction unit 14 and thereby direct a path along which cleaning apparatus 10 may be guided. Illumination means may also be used to indicate a state of cleaning apparatus 10 (e.g., “on” or “off”, “carpet mode”, “floor mode”, “need to empty debris collection cup”, etc.).
Base suction unit 14 may support an agitation member such as a beater bar (not shown) for lifting debris from a surface being cleaned. Such a beater bar may be selected from numerous beater bar embodiments, including but not limited to those beater bar embodiments disclosed by co-owned U.S. Ser. No. 10/646,233, the entire disclosure of which is incorporated by reference herein. The beater bar may be positioned within base suction unit 14 and configured to rotate during a beater bar operational mode of cleaning apparatus 10. The beater bar (or equivalent agitation member) may be in operative communication with a drive motor (not shown), such as through a belt drive (not shown) to enable rotation of the beater bar. It is contemplated that an agitation member such as a beater bar can be configured to rotate with sufficient speed to effectively impact the cleaning surface on which cleaning apparatus 10 is employed. For example, one or more actuators may be incorporated with handle 16 (as described hereinabove to control the agitation member (or associated drive motor) for effective agitation of carpet fibers in both higher knap and lower knap carpeting.
Equivalent structure to a beater bar may be suitable for lifting debris from a cleaning surface for delivery of the lifted debris through a suction port (not shown) supported by base suction unit 14. In some embodiments, additional particulate removal features may complement the beater bar or agitation member. Such features may include, but are not limited to, one or more brushes (not shown) along an undercarriage of fascia 40. Such features may also include corrugations (not shown) provided along at least a portion of bumper 42 for disrupting particulates from a cleaning surface and eventual collection of the disrupted particulates in cleaning apparatus 10 (as further described herein).
In an embodiment where cleaning apparatus 10 is a steerable vacuum cleaner, a coupling may be provided between main body 12 and base suction unit 14. Wheels 46 can be disposed on (or in steerable communication with) the coupling to facilitate linear and non-linear travel paths that cleaning apparatus may traverse during use. In some embodiments, the coupling may comprise a yoke having wheels disposed thereon (an example of which is disclosed by co-owned U.S. Ser. No. 12/771,865, the entire disclosure of which is incorporated by reference herein). In some embodiments, the coupling may comprise a swivel joint (shown generally as swivel coupling 48 in
Main body 12 incorporates a carapace 50 having a base extent 50a proximate base suction unit 14 (shown in
Carapace 50 also includes a handle extent 50b proximate handle member 16 (as shown in
Referring further to
Debris collection device 100 may include a device handle 102 that is readily grasped by a user for removal of the debris collection device from, and insertion of the debris collection device into, main body 12. Handle 102 may be an integral component or an assembly of interchangeable components that may be thrilled on or coupled with at least one of a debris collection canister 106 and a debris collection cover 107. In an embodiment where handle 102 is incorporated with cover 107, a user may grasp handle 102 to effect separation and coupling of the debris collection cover relative to canister 106 (e.g., via frictional fit, complementary threaded engagement and the like). Although debris collection device handle 102 is shown as a generally arcuate member, it is understood that such handle may assume any geometry amenable to practice of the presently disclosed invention.
A user may grasp handle 102 to remove debris collection device 100 from main body 12 and carry the debris collection device and its contents to another location (e.g., for disposal of accumulated debris into a disposal vessel such as a dustbin or trash receptacle). Debris collection device 100 (and therefore cyclonic separator 200) may alternatively be carried and inserted into a chamber of another cleaning apparatus that operatively receives debris collection device 100 (and therefore separator 200) thereby. In exemplary embodiments where debris collection device 100 is removably secured with complementary engagement structure (e.g., one or more engagement teeth), a user may remove debris collection device 100 from main body 12 simply by grasping debris collection device handle 102 and applying a pulling force sufficient to overcome the retention force between the engagement structure and the debris collection device. Instead of, or in addition to, engagement structure that releasably secures debris collection device 100 in main body 12, handle 102 may include one or more retractable pins (not shown) that cooperate with corresponding recesses (not shown) in a chamber wall of main body 12 Such pins retract from their corresponding recesses upon depression of one or more optional actuators, such as an optional actuator button 104 provided on handle 102.
Further referring to
At least one air ingress 105 (see
Referring additionally to
Cyclonic separator 200 also includes an airflow turret 212, the details of which are further shown in
Each sail 214 includes a guide surface 214a to guide incoming air from the preliminary centrifugal airflow toward cylindrical ingress 208h. Guide surface 214a of each sail 214 includes an impact surface 214a′ of predetermined concavity against which the incoming air strikes (for example, as shown by arrows I in
Each terminal restraining edge 214a″ includes a lead surface 214b that leads the incoming air (for example, in the direction of arrows I′ shown in
Each velocity slot 216 conveys the incoming air that is delivered along an entry ramp 218 of predetermined camber. In some embodiments, each entry ramp 218 exhibits a grade of about 48°. Each entry ramp 218 is configured to deliver the preliminary centrifugal airflow from a coarse debris collection area 300 (shown in
Referring again to
At least a portion of sieve wall 228a is a continuous portion 228a′ (i.e., having no apertures therein) for directing the preliminary centrifugal airflow about frustum wall 208a and depositing debris into coarse debris collection area 300. When sieve wall 228a is positioned in debris collection device 100, continuous portion 228a′ is disposed relative to air ingress 105 such that dirty air entering the debris collection device tangentially impinges the continuous portion of the sieve wall. This striking trajectory initiates the preliminary centrifugal airflow along outer frustum wall 208a that carries unseparated debris and air and deposits debris in coarse debris collection area 300.
Sieve wall 228a includes an opposed debris restriction extent 228d at which a debris restriction flange 233 is electively provided to deflect debris in the preliminary centrifugal airflow into course debris collection area 300. Debris restriction flange 233 may be integral with frustum wall 208a or sieve wall 228a and have a flange lip 233a that helps to deflect debris into course debris collection area 300. Flange lip 233a may be rounded along a periphery thereof to guide debris into course debris collection area 300 after impingement against continuous portion 228a′ of sieve wall 228a. Debris that remains unseparated from the preliminary centrifugal airflow strikes a deflection surface 233b of debris restriction flange 233 for deflection into coarse debris collection area 300. A predetermined clearance 235 between flange lip 233a and inner canister wall surface 106c″ (see
A remaining louvered portion 228a′ of sieve wall 228a incorporates a plurality of apertures 240 for delivering airflow to toward airflow turret 212. Each aperture 240 includes a rounded upstream edge 240a and a rounded downstream edge 240b past which the preliminary centrifugal airflow is generally directed toward each airflow entrance 216. In some embodiments, sieve wall 228a exhibits a generally frustoconical geometry along which apertures 240 are provided in a predetermined pattern along louvered portion 228a″. In an exemplary embodiment as shown in
In some embodiments, locking structure is provided along or near debris restriction extent 228d for engagement with corresponding locking structure presented along frustum wall 208a, such locking structure may include one or more locking teeth (not shown) provided as diametrically opposed members that engage at least a portion of a securement flange 245 provided around at least a portion of frustum outer wall 208a′. In such embodiments, a gap may remain when cyclonic sieve 228 and cyclonic frustum 208 are in locking engagement that permits an additional opportunity for the deposit of debris into coarse debris collection area 300 prior to transition to the secondary centrifugal airflow.
Cyclonic separator 200 additionally includes a debris collection cup 250 that collects debris remaining after the preliminary and ultimate centrifugal airflows. Debris collection cup 250 includes a generally frustoconical or annular cup wall 250a having an outer wall surface 250a′ that, together with debris collection device 100 and outer frustum wall surface 208a′, provides coarse debris collection area 300 within which debris is deposited by the preliminary centrifugal airflow. Debris collection cup wall 250a also includes an inner wall surface 250a″ within which debris is deposited by the ultimate centrifugal airflow in a fine debris collection area 350.
A frustum extent 250a of debris collection cup wall 250a has an aperture 252 that accommodates removable insertion of at least a portion of opposed frustum extent 208d therein. As shown in
Securement structure may be selectively provided on at least one or both of debris collection cup 250 and cyclonic frustum 208 to preserve both portions of the centrifugal airflow during operation of cleaning apparatus 10. Such securement structure may include diametrically opposed locking slots (not shown) disposed at or near aperture 252 of debris cup wall 250a. Such locking slots engage corresponding locking tabs 265 disposed at or near frustum egress 208e at a predetermined distance above optional sifter 255. A circumferential seating flange 267 may be provided at or near locking tabs 265 that engages a complementary frustum seat 269 provided at a periphery of aperture 252. When seating flange 267 is positioned adjacent frustum seat 267, locking tabs 265 may contact a locking guide groove in debris collection cup 250 that guides locking tabs 265 into engagement with the corresponding locking slots. Additional indicia, including but not limited to visual indicia (e.g., arrows 275 in
Debris collection device 100 includes a platform that supports debris collection cup 250 and provides at least a partial boundary for each of coarse debris collection area 300 and fine debris collection area 350. Such a platform can help control the collective release of debris from both collection areas through a collective release outlet 375 at open canister extent 106b. An exemplary platform may be a flapper 380 rotatably coupled with debris collection canister 208 (see
Cyclonic separator 200 includes an airflow outlet 400 configured to deliver air from debris collection device 100 after depositing debris in fine debris collection area 350. Airflow outlet 400 may be provided as a duct or conduit in a support member 402 that is disposed adjacent upper turret seat 230a. Support member 402 is configured to direct outgoing air from cyclonic separator 200 and includes one or more optional gaskets 404, 406 positioned in sealing relationship therewith. Support member 402 may incorporate a finger grip 403 (see
During operation of cleaning device 10, cyclonic separator 200 is housed in debris collection device 100 that is supported within main body 12. Upon actuation of cleaning apparatus 10, a suction source inhales a combination of air and debris (“dirty air”) into an intake conduit (not shown) for delivery through air ingress 105. Referring to
Separated air thereafter traverses clearance 235 for delivery through apertures 240 of louvered portion 228a″ (see arrow E of
Lead surfaces 214b guide the incoming air that enters through an adjacent velocity slot 216 toward cylindrical ingress 208h. The ultimate centrifugal airflow is piloted from cylindrical ingress 208h in region 209 along inner frustum wall surface 208a″. The ultimate centrifugal airflow is generally a vortex that rotates through region 209 and thereby accelerates any residual debris for delivery through frustum egress 208e and eventual deposit in fine debris collection area 350. Thus, debris that is not deposited in coarse debris collection area 300 by the preliminary centrifugation airflow is deposited by the ultimate centrifugal airflow into fine debris collection area 350 through the frustum egress.
As the ultimate centrifugal airflow continues to accelerate along inner frustum wall surface 208a″ (see arrow F of
When disposal of the accumulated debris within debris collection device 100 is needed, a user may execute an operation by which at least a portion of the accumulated debris is released through collective debris release outlet 375. Referring to
One or more of cyclonic frustum 208, cyclonic sieve 228 and debris collection cup 250 may be fabricated from materials that are amenable to repeated use and also to related assembly and disassembly. Such materials should also be amenable to being held and cleaned by users. Such materials may be selected from a variety of materials, including but not limited to plastics and composites that are well known for use in temporally and fiscally efficient manufacturing processes
As used herein, a “user” or an “operator” may be a single user or operator or multiple users and operators (for example, multiple users within a shared residence or multiple members of a cleaning service sharing use of one or more devices incorporating the presently disclosed invention). As used herein, the term “process” or “method” may include one or more steps performed at least by one user or operator. Any sequence of steps is exemplary and is not intended to limit methods described herein to any particular sequence, nor is it intended to preclude adding steps, omitting steps, repeating steps, or performing steps simultaneously.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value as well as equivalent units of that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm” as well as “1.58 inches”. The disclosure of such dimensions and values, however, shall not preclude use of any of disclosed devices having dimensions and values outside of the prescribed ranges.
Every document cited herein, including any cross-referenced or related patent or application is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While the presently disclosed invention has been described in a preferred form, it will be understood that changes, additions, and modifications may be made to the respective articles forming the invention. Accordingly, no limitation should be imposed on the scope of this invention, except as set forth in the accompanying claims.
