Information
-
Patent Grant
-
6637068
-
Patent Number
6,637,068
-
Date Filed
Friday, September 7, 200122 years ago
-
Date Issued
Tuesday, October 28, 200320 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
- Marshall, Gerstein & Borun, LLP
-
CPC
-
US Classifications
Field of Search
US
- 015 353
- 015 3276
- 015 339
- 096 406
- 096 FOR 107
-
International Classifications
-
Abstract
A vacuum cleaner is provided having a tank with an inlet for receiving liquid material and defining an interior. An air impeller housing has an opening in air flow communication with the tank interior, and an air impeller is disposed inside the air impeller housing. A motor is disposed inside a motor housing and operatively coupled to the air impeller, and a switch is provided having a first position in which power is provided to the motor and a second position in which power to the motor is interrupted. A float is disposed in the tank and a float rod extends between the tank and the switch, the float rod being capable of moving the switch from the first position to the second position. A seal is positioned intermediately along the float rod to create a water-tight barrier between opposite ends of the float rod.
Description
FIELD OF THE INVENTION
The present invention relates to vacuum cleaners, and more particularly to wet/dry vacuum cleaners.
BACKGROUND ART
Tank-type vacuum cleaners are capable of receiving dry materials such as debris or dirt and may also be used for suctioning liquids. Such vacuum cleaners typically include an air impeller disposed inside an air impeller housing that is in fluid communication with an interior of the tank, thereby to create a low pressure area in the tank for vacuuming both dry materials and liquid. A motor is operatively coupled to the air impeller. While some wet/dry vacuum cleaners are provided with a pump to facilitate emptying liquid from the tank, such a pump is not required during normal vacuum operation of the vacuum cleaner.
Whether or not the vacuum cleaner includes a pump, once the liquid level in the tank reaches a maximum height, it is important to prevent additional liquid from entering the tank. Accordingly, it is known to provide a switch for stopping the motor in response to a high liquid level. A float is typically provided inside the tank for detecting the liquid level in the tank, and a float rod extends between the float and an actuator for the switch. Accordingly, as the float is raised in response to increasing liquid level, the float rod also moves to actuate the switch, thereby to turn the motor off.
The float rod creates a path from the tank to the switch. Because the switch is often located with or near the motor, and the risk exists that liquid may reach the switch, motor, or other electrical components. For example, if the high liquid level switch fails, the liquid level in the tank may reach the air impeller, which may expel the liquid under significant force. Such liquid may follow the float rod path to the switch or motor. In addition, if the tank is tipped, the liquid may flow along the float rod path to the switch, motor, or other electrical components.
SUMMARY OF THE INVENTION
In accordance with the teachings of the present invention, a vacuum cleaner is provided having a tank with an inlet for receiving liquid material and defining an interior. An air impeller housing has an opening in air flow communication with the tank interior, and an air impeller is disposed inside the air impeller housing. A motor is disposed inside a motor housing and operatively coupled to the air impeller, and a switch is provided having a first position in which power is provided to the motor and a second position in which power to the motor is interrupted. A float is disposed in the tank and a float rod extends between the float and the switch, the float rod being capable of moving the switch from the first position to the second position. A seal is positioned intermediately along the float rod to create a water-tight barrier between opposite ends of the float rod.
Further in accordance with the teachings of the present invention, a vacuum cleaner is provided having a tank with an inlet for receiving liquid material and defining an interior. A lid closes a top of the tank, a motor housing is attached to the lid, and a motor is disposed inside the motor housing. A switch is disposed inside the motor housing and has a first position in which power is provided to the motor and a second position in which power to the motor is interrupted. An air impeller is disposed in an air impeller housing defined by the motor housing and the lid, the air impeller housing having an opening in air flow communication with the tank interior and the air impeller being operatively coupled to the motor. A float is disposed in the tank, and a float rod extends between the float and the switch, the float rod being capable of moving die switch from the first position to the second position. A seal is supported by the motor housing and positioned intermediately along the float rod to create a water-tight barrier between opposite ends of the float rod.
Still further in accordance with the teachings of the present invention, a vacuum cleaner is provided having a tank with an inlet for receiving liquid material, the tank defining an interior. A lid closes a top of the tank, a motor housing is attached to the lid and includes a downwardly depending boss, and a motor is disposed inside the motor housing. A switch is disposed inside the motor housing and has a first position in which power is provided to the motor and a second position in which power to the motor is interrupted. An air impeller is disposed in an air impeller housing defined by the motor housing and the lid, the air impeller housing having an opening in air flow communication with the tank interior and the air impeller being operatively coupled to the motor. A float is disposed in the tank, and a float rod extends between the float and the switch, the float rod being capable of moving the switch from the first position to the second position. A seal is supported by the motor housing and positioned intermediately along the float rod to create a water-tight barrier between opposite ends of the float rod, and a hollow tube portion is attached to the lid and has an upper end sized to engage the motor housing boss, wherein the float rod passes through the tube portion.
Other features and advantages are inherent in the vacuum cleaner claimed and disclosed or will become apparent to those skilled in the art from the following detailed description in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a top plan view of a vacuum cleaner in accordance with the teachings of the present invention;
FIG. 2
is a side elevation view, partially in section, taken along line A—A in
FIG. 1
;
FIG. 3
is a side elevation view, partially in section, taken along line B—B in
FIG. 1
, with the tank removed;
FIG. 4
is an enlarged side elevation view, partially in section, of a portion of
FIG. 2
showing the float rod seal; and
FIG. 5
is an enlarged side elevation in section, of an alternate embodiment of a diaphragm as shown in FIG.
4
.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to
FIGS. 1 and 2
, a vacuum cleaner of the present invention, indicated generally at
10
, has a tank
12
and an upper vacuum assembly, indicated generally at
14
. The tank
12
includes a pair of handles (not shown), which may be used to assist the user in lifting and moving the vacuum cleaner
10
. The tank
12
further defines an inlet
18
that may be fitted with a vacuum hose (not depicted) for applying suction at desired locations.
The upper vacuum assembly
14
includes a lid
22
releasably attached to the tank
12
. Attached to the lid are a cover
20
, a motor housing
24
, and a baffle
25
. A motor
26
is disposed inside the motor housing
24
. The lid
22
makes up the bottom of the upper vacuum assembly
14
and may carry one or more latches (not shown) for attaching the upper vacuum assembly
14
to the tank
12
. The motor housing
24
is disposed between the lid
22
and the cover
20
. When a user wishes to connect the upper vacuum assembly
14
to the tank
12
, the user lifts the upper vacuum assembly
14
above the tank
12
, aligns the latches with latch recesses (not shown) formed in the tank, lowers the upper vacuum assembly
14
until the lid
22
rests on top of the tank
12
, and then, fastens the latches to the tank
12
. A handle
28
is provided on the upper vacuum assembly for facilitating transportation of the assembled vacuum cleaner
10
.
Disposed in the upper vacuum assembly
14
, among other things, is an air impeller assembly
30
. The air impeller assembly
30
includes an impeller housing
32
defining an opening
34
, an air impeller
36
, a motor shaft
38
extending from the motor
26
, and a shaft extension
40
. (If desired, the vacuum cleaner
10
may alternatively use multiple air impellers.) In the illustrated embodiment, the air impeller housing
32
is defined by a lower portion of the motor housing
24
and a central portion of the lid
22
, as best shown in FIG.
2
. The air impeller
36
is disposed within the impeller housing
32
.
The shaft extension
40
is secured to the motor shaft
38
. From the motor shaft
38
, the shaft extension
40
extends through the opening
34
of the housing
32
and connects to a pump impeller
42
. As such, the motor
26
supports the air impeller
36
and the pump impeller
42
and drives both via the motor shaft
38
and the shaft extension
40
. Alternatively, the shaft extension
40
may be formed integral with the motor shaft
38
so that a unitary structure drives the air impeller
36
and the pump impeller
42
. Another alternative is for the shaft extension
40
to be offset from the motor shaft
38
, and torque is then transferred from the motor shaft
38
to the shaft extension
40
via a transmission or a gear train.
Referring to
FIG. 2
, the upper vacuum assembly
14
also includes a filter cage
44
which may be integrally formed with or fastened to the lid
22
and extends downward therefrom. The air impeller assembly
30
is in fluid communication with the filter cage
44
so that the air impeller
36
draws air through the filter cage
44
. The filter cage
44
includes several braces
46
that support a bottom plate
48
. One or more filters (not shown) may surround the circumference of the filter cage
44
as needed during dry and wet pickup.
The pump impeller
42
is disposed in a pump housing
50
(FIG.
2
). A housing inlet
52
is connected to an inlet tube
54
leading to a fluid inlet filter assembly
56
. The pump impeller
42
may be primed using any known priming mechanism or arrangement, such as those described in commonly assigned U.S. Pat. Nos. 5,920,955, 6,119,304, and 6,226,831, incorporated herein by reference. The vacuum cleaner
10
further includes an outlet for discharging liquid transported by the pump, as described in greater detail in the '955, '304, and '831 patents incorporated herein.
In the illustrated embodiment, a switch actuation assembly
60
is disposed inside the motor housing
24
and includes a switch
62
and a toggle member
64
. The switch
62
and toggle
64
are similar to those disclosed in commonly assigned U.S. Pat. No. 5,918,344, incorporated herein by reference, and therefore are not described in detail. The switch
62
has a first position in which power is provided to the motor
26
and a second position in which power to the motor is interrupted. The toggle member
64
engages the switch and is operable to place the switch in either the first or the second position. A user engagable switch actuator
66
is provided on an outside of the lid
20
for initially placing the switch
62
in the first or second position.
While, in the illustrated embodiment, the switch actuation assembly
60
(including the switch
62
and toggle member
64
) is disposed in the motor housing
24
, the assembly
60
may be located in other portions of the vacuum cleaner
10
. For example, the switch actuation assembly may be enclosed by the baffle
25
, a separate switch housing, or any other suitable location.
A high liquid level override assembly is provided for automatically stopping operation of the air impeller
36
in response to a high liquid level. The override assembly includes a float
70
disposed in the cage
44
and a float rod
72
that passes through the lid
22
and motor housing
24
to provide a linkage between the switch actuation assembly
60
and the float
70
. The float
70
is hollow and may be made of any suitable material, such as copolymer polypropylene. The float
70
defines a rod receptacle
74
in which the float rod
72
sits.
In operation, if the level of liquid in the tank
12
gets too high, the high level override assembly will automatically shut-off the motor
26
. When the liquid in the tank
12
gets to the level of the float
70
, the liquid pushes the float
70
upward. Simultaneously, the float
70
pushes the float rod
72
upward against a rod receiving extension
76
of the toggle member
64
. Eventually, the rising liquid reaches a level high enough to create an upward force so that the float rod
72
pushes the toggle
64
so that the switch
62
is in the second position, which stops the motor
26
and, consequently, stops the air impeller
36
and the pump impeller
42
from rotating. The float
70
should be placed at a height low enough so that the motor
26
is turned “OFF” before the level of liquid is high enough to begin entering the air impeller
36
.
In accordance with certain aspects of the present invention, a float rod seal
80
is provided to prevent liquid from traveling along the float rod path. As best shown in
FIG. 4
, the motor housing
24
is formed with an outer upwardly extending wall
82
and an inner upwardly extending wall
84
. The outer and inner upwardly extending walls
82
,
84
are spaced to define an annular gap
86
therebetween. A flexible diaphragm
88
has an outer diameter inserted into the annular gap
86
that is sufficiently thick so that it is frictionally held between the walls
82
,
84
. An upper portion of the outer wall
82
may be crimped inwardly to retain the diaphragm
88
in place. An inner portion of the diaphragm
88
is formed with an aperture sized to engage the float rod
72
to form a water-tight seal therebetween. As shown in
FIG. 4
, the diaphragm
88
may be curved to accommodate vertical movement of the float rod
72
. The motor housing
24
may further be formed with an upwardly projecting seat
90
having an upper end engaging a bottom surface of the diaphragm
88
. With the float rod seal
80
in place, liquid from the tank
12
is prevented from entering the motor housing
24
along the path followed by the float rod
72
.
While, in the illustrated embodiment, the float rod
72
comprises a single rod that is engaged by the diaphragm
88
, it will be appreciated that other seal arrangements may be provided. For example, as illustrated in
FIG. 5
, the float rod
72
may be formed of a first rod extending below the diaphragm
88
to the float
70
, and a second rod extending above the diaphragm to the switch
62
. The first and second rods are attached to opposite surfaces of the diaphragm
88
, which may be continuous (i.e., does not include an aperture as in the previous embodiment). As a result, movement of the first rod is transferred through the diaphragm
88
to the second rod, and the diaphragm
88
provides an uninterrupted seal between the rods.
To further prevent liquid from traveling into the motor housing
24
and to reduce the exposure of the float rod
72
to liquid from the air impeller
36
, the lid
22
is provided with a hollow tube portion
92
. The tube portion
92
extends from a bottom surface of the lid to an upper end
94
positioned near the motor housing
24
. The motor housing
24
is preferably formed with a downwardly depending boss
96
having an inner diameter sized to frictionally receive the tube portion upper end
94
. The tube portion
92
has an inner diameter sufficient to receive the float rod
72
without restricting vertical travel of the rod. A bottom end of the tube portion
92
may be formed with a neck
98
sized to more closely fit the float rod
72
, thereby to reduce the amount of liquid passing into the tube portion
92
. As a result, a portion of the float rod
72
located near the air impeller
36
is entirely enclosed, thereby preventing liquid which may be expelled from the air impeller
36
from following the float rod path to the motor housing.
The foregoing detailed description has been given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications would be obvious to those skilled in the art.
Claims
- 1. A vacuum cleaner comprising:a tank having an inlet for receiving liquid material, the tank defining an interior; an air impeller housing having an opening in air flow communication with the interior; an air impeller disposed inside the air impeller housing; a motor disposed inside a motor housing and operatively coupled to the air impeller; a switch having a first position in which power is provided to the motor and a second position in which power to the motor is interrupted; a float disposed in the tank; a float rod extending between the float and the switch, the float rod being capable of moving the switch from the first position to the second position; and a seal attached intermediately along and to the float rod to create a water-tight barrier between opposite ends of the float rod, at least a portion of the seal being adapted to travel with the float rod.
- 2. The vacuum cleaner of claim 1, in which the switch is disposed inside the motor housing.
- 3. The vacuum cleaner of claim 2, in which the seal comprises a flexible diaphragm supported by the motor housing.
- 4. The vacuum cleaner of claim 3, in which the float rod passes through a wall separating the switch from the float, wherein the diaphragm is supported by the wall.
- 5. The vacuum cleaner of claim 4, in which the wall forms at least a portion of the motor housing.
- 6. The vacuum cleaner of claim 1, in which a toggle member engages the switch to move the switch to the first and second positions.
- 7. The vacuum cleaner of claim 6, in which the toggle member includes an extension adapted to engage the float rod.
- 8. A vacuum cleaner comprising:a tank having an inlet for receiving liquid material, the tank defining an interior; a lid attached to the tank; an air impeller housing having an opening in air flow communication with the tank interior, the impeller housing being defined by a space between the motor housing and the lid; an air impeller disposed inside the air impeller housing; a motor disposed inside a motor housing and operatively coupled to the air impeller; a switch having a first position in which power is provided to the motor and a second position in which power to the motor is interrupted; a float disposed in the tank; a float rod extending between the float and the switch, the float rod being capable of moving the switch from the first position to the second position; a boss depending from the motor housing, wherein the lid includes a tube portion having an upper end sized to engage the boss, and a portion of the float rod passes through the tube portion; and a seal positioned intermediately along the float rod to create a water-tight barrier between opposite ends of the float rod.
- 9. A vacuum cleaner comprising:a tank having an inlet for receiving liquid material, the tank defining an interior; a lid for closing a top of the tank; a motor housing attached to the lid; a motor disposed inside the motor housing; a switch disposed inside the motor housing and having a first position in which power is provided to the motor and a second position in which power to the motor is interrupted; an air impeller disposed in an air impeller housing defined by the motor housing and the lid, the air impeller housing having an opening in air flow communication with the interior and the air impeller being operatively coupled to the motor; a float disposed in the tank; a float rod extending between the float and the switch, the float rod being capable of moving the switch from the first position to the second position; and a seal supported by the motor housing and attached intermediately along and to the float rod to create a water-tight barrier between opposite ends of the float rod, at least a portion of the seal being adapted to travel with the float rod.
- 10. The vacuum cleaner of claim 9, in which the motor housing includes inner and outer upwardly projecting walls defining an annular space therebetween, and in which the seal comprises a flexible diaphragm having an outer edge inserted into the annular space and sized so that the inner and outer upwardly projecting walls frictionally hold the outer edge of the diaphragm.
- 11. The vacuum cleaner of claim 10, in which an upper portion of the outer upwardly projecting wall is crimped inwardly to retain the diaphragm.
- 12. The vacuum cleaner of claim 10, in which the motor housing further includes an upwardly projecting seat adapted to engage an inner portion of the diaphragm.
- 13. The vacuum cleaner of claim 9, in which a toggle member engages the switch to move the switch to the first and second positions.
- 14. The vacuum cleaner of claim 13, in which the toggle member includes an extension adapted to engage the float rod.
- 15. A vacuum cleaner comprising:a tank having an inlet for receiving liquid material, the tank defining an interior; a lid for closing a top of the tank, the lid including a tube portion having an upper end sized to engage a boss; a motor housing attached to the lid, the motor housing including the boss, the boss being downwardly depending from the motor housing; a motor disposed inside the motor housing; a switch disposed inside the motor housing and having a first position in which power is provided to the motor and a second position in which power to the motor is interrupted; an air impeller disposed in an air impeller housing defined by the motor housing and the lid, the air impeller housing having an opening in air flow communication with the tank interior and the air impeller being operatively coupled to the motor; a float disposed in the tank; a float rod extending between the float and the switch, the float rod being capable of moving the switch from the first position to the second position, wherein a portion of the float rod passes through the tube portion; and a seal supported by the motor housing and positioned intermediately along the float rod to create a water-tight barrier between opposite ends of the float rod.
- 16. A vacuum cleaner comprising:a tank having an inlet for receiving liquid material, the tank defining an interior; a lid for closing a top of the tank, the lid including a tube portion having an upper end sized to engage a boss; a motor housing attached to the lid, the motor housing including the boss, the boss being downwardly depending from the motor housing; a motor disposed inside the motor housing; a switch disposed inside the motor housing and having a first position in which power is provided to the motor and a second position in which power to the motor is interrupted; an air impeller disposed in an air impeller housing defined by the motor housing and the lid, the air impeller housing having an opening in air flow communication with the tank interior and the air impeller being operatively coupled to the motor; a float disposed in the tank; a float rod extending between the float and the switch, the float rod being capable of moving the switch from the first position to the second position, wherein a portion of the float rod passes through the tube portion; and a seal supported by the motor housing and positioned intermediately along the float rod to create a water-tight baffler between opposite ends of the float rod.
- 17. The vacuum cleaner of claim 16, in which the motor housing includes inner and outer upwardly projecting walls defining an annular space therebetween, and in which the seal comprises a flexible diaphragm having an outer edge inserted into the annular space and sized so that the inner and outer upwardly projecting walls frictionally hold the outer edge of the diaphragm.
- 18. The vacuum cleaner of claim 17, in which an upper portion of the outer upwardly projecting wall is crimped inwardly to retain the diaphragm.
- 19. The vacuum cleaner of claim 17, in which the motor housing further includes an upwardly projecting seat adapted to engage an inner portion of the diaphragm.
- 20. The vacuum cleaner of claim 16, in which the seal includes an aperture through which the float rod passes, the aperture being sized to create a water-tight engagement with the float rod.
- 21. The vacuum cleaner of claim 16, in which a toggle member engages the switch to move the switch to the first and second positions.
- 22. The vacuum cleaner of claim 21, in which the toggle member includes an extension adapted to engage the float rod.
US Referenced Citations (7)