Low-profile and highly-maneuverable vacuum cleaner having a headlight, a sidelight, anti-ingestion bars, side brushes, a squeegee, and a scent cartridge

Abstract
A low-profile and highly-maneuverable vacuum cleaner having improved functionality including, alone or in combination, a headlight, a sidelight, anti-ingestion bars, side brushes, a squeegee, and a scent cartridge for use in cleaning floors, floor coverings, carpets, upholstery, and other surfaces. One embodiment includes a tortuous air flow path created by baffles that divert air flow. The tortuous path creates quieter air flow through the vacuum housing. The tortuous air flow arrangement is for cooling the internal parts of a vacuum cleaner. Another embodiment includes an indicator light assembly for the vacuum cleaner visually providing the user with the vacuum's current operation status. In another embodiment, the rear wheels are recessed within the head housing and slightly offset rearwardly of the rear wall of the head housing to provide enhanced maneuverability.
Description




BACKGROUND OF THE INVENTION




a. Field of the Invention




The present invention relates to cleaning machines. More specifically, it relates to low-profile and highly-maneuverable vacuum cleaners having a headlight, a sidelight, anti-ingestion bars, side brushes, a squeegee, a scent cartridge, and other performance enhancing features for use in cleaning floors, floor coverings, carpets, upholstery, and other surfaces.




b. Background Art




Individuals often use cleaning machines, such as vacuum cleaners or carpet sweepers, to clean floors, floor coverings, carpets, upholstery, and other surfaces. The typical cleaning machine has a base or head, such as a power nozzle on a vacuum cleaner, that is moved over the surface to be cleaned. In some cleaning machines, suction is provided, which draws particles and debris from a section of the surface being cleaned into the cleaning machine, where the dirty air is passed through a bag in which the entrained particles are captured.




An agitator is often rotatably attached to the base or head to improve the effectiveness of the cleaning machine. The agitator typically has one or more projections that impinge on the surface being cleaned as the agitator rotates. A vacuum cleaner, for example, may have a roller brush with bristles that brush the surface as the base or head is moved across the surface to be cleaned. As the vacuum cleaner moves over the surface, the roller brush rapidly rotates and the bristles repeatedly impinge on the surface. This contact between the bristles and the surface agitates dirt and other particles from the surface and improves the effectiveness of the vacuum cleaner. A carpet sweeper has a rotating blade that similarly impinges the surface being cleaned. An example of such a device is illustrated in U.S. Pat. No. 4,646,380.




In the past there have been few attempts to control the flow of cooling air through a vacuum head. Thus, a large noise source during vacuum cleaner operation stems from the uncontrolled flow of working and cooling air through the vacuum head. Thus, there remains a need for controlled flow of both working and cooling air through the vacuum head to reduce the amount of noise generated by the vacuum during operation.




In powered vacuums, it is know to shape or contour the bottom cover to improve the efficiency of air movement from the edges of the vacuum to the intake aperture. An example of such contouring of the bottom cover is shown in U.S. Pat. No. 4,219,902. There remains a need, however, for improvement in both the design and location of these channels to further enhance the air flow from the outer edges of the vacuum head housing to the intake aperture of the vacuum.




In the art of vacuum cleaner design, it is desirable to maximize the surface area cleaned with respect to the surface area covered by the footprint of the vacuum head. One such way to maximize the surface area cleaned is to includes side brushes on the vacuum to draw in debris laterally outside the surface area covered by the footprint of the vacuum head.




Prior art side brushes generally consist of tufts of bristles designed to sweep the debris toward the vacuum's suction inlet. An example of such side brushes is disclosed in U.S. Pat. No. 4,219,902. While these prior art bristle side brushes do generally increase the surface area cleaned with respect to the surface area covered by the footprint of the vacuum head, in addition to other drawbacks, they often fail to maximize the desired cleaning effect. These bristle-type side brushes are generally straight or only angled in one direction. Such a design often acts like a snow-plow, merely piling or pushing debris along the surface of the floor, or “flicking” the debris ahead of the vacuum rather than desirably directing the debris into the suction inlet. In addition, prior art side brushes are often designed to work in only one direction (i.e., they only work to sweep the debris when the vacuum is moving in a forward motion).




Other drawbacks to prior art bristle side brushes include the fact that the prior art side brushes often wear rapidly and require frequent service. Such service is often complicated by the fact that the prior art bristle side brushes are often mounted from the inside of the vacuum head and cannot be serviced from the outside of the vacuum. Additionally, prior art side brush designs are often not interchangeable from one lateral side to the other lateral side of the vacuum (i.e., the right side brush cannot be used on the left side of the vacuum and vice versa). Finally, the prior art bristle side brushes often fail to offer any protection for the wall or wall molding when the vacuum inadvertently comes in contact with the wall or wall molding.




There is a need for a vacuum side brush that more effectively directs debris toward the vacuum's suction inlet to help maximize the surface area cleaned with respect to the vacuum's footprint. There is a need for a vacuum side brush that directs debris toward the suction inlet both when the vacuum is being moved forward and backward (i.e., being pushed and pulled). There is a need for a vacuum side brush that is easily serviceable from the outside of the vacuum head. There is a need for a vacuum side brush that is interchangeable from one lateral side of the vacuum head to the other (i.e., a single side brush that can be used on either lateral side of the vacuum head). Finally, there is a need for a vacuum side brush that can serve as a de facto bumper to help protect the wall or wall molding when the vacuum inadvertently comes in contact with the wall or wall molding.




In the art of vacuum cleaners, most vacuum cleaners include some form of roller brush surrounded by a suction inlet. When vacuuming, the roller brush comes in contact with the floor surface to help guide debris into the vacuum's suction inlet. Most debris encountered by the roller brush and ultimately the suction inlet is of a particle size that is easily guided by the roller brush into the suction inlet. However, occasionally the operator of the vacuum will encounter larger sized debris, such as articles of clothing, paper items, children's toys, and the power cord of the vacuum.




The introduction of larger sized items can cause the roller brush to become entangled with the items or cause the suction inlet of the vacuum to become plugged. Entanglement of the roller brush can lead to severe damage of the vacuum motor. In addition, a vacuum will fail to operate correctly with a plugged suction inlet and can also be damaged if either the plug is not promptly removed or the vacuum power terminated.




Prior art vacuums often rely on the operator of the vacuum to prevent larger sized debris from being introduced to either the roller brush or the suction inlet. Prior art vacuums often fail to provide safeguards to prevent roller brush entanglement or clogging of the suction inlet.




There is a need for an apparatus to be included in a vacuum cleaner assembly that will prevent the introduction of larger sized debris to both the vacuum roller brush and the suction inlet.




Because in most vacuum cleaners, the roller brush and suction inlet are located towards the front portion of the vacuum head housing, the front portion of most vacuum head housings is apertured. As a result, the structural integrity of the front portion of most vacuum head housings is weakened.




The squeegee structure on a vacuum serves an important role in the efficacy of the vacuum's performance. Past squeegee structures were permanently or semi-permanently attached to the bottom of the vacuum, and were not meant to be replaced or repaired. In addition, the channel that the squeegee was located within was often made of metal, which could become nicked or burred, which in turn increased the chances of scratching the floor when the vacuum was used. Further, the blade was attached to the bottom of the vacuum by a separate flexible material, such as tape, in only a few discrete locations. The discreet attachment points are prone to wear and tear, and did not provide a consistent flex across the length of the blade. There is a need in the art for a squeegee structure that is integral to the vacuum structure, and that is securely attached to the bottom of a vacuum, that does not wear to scratch the vacuumed surfaces, and that is easily replaceable.




Oftentimes vacuuming is performed in poorly lit areas such as under furniture, within closets, and the like. Lighting is necessary when vacuuming to allow the user to determine if the area being vacuumed is dirty, and if the area, after it has been vacuumed, has been cleaned successfully.




Prior art vacuum lighting systems generally include only a headlight situated near the front of the vacuum head cover. These prior art lighting systems have several drawbacks. First, prior art lighting systems generally project light well in front of the vacuum and not directly in front of the vacuum where debris is about to be vacuumed. Projecting light well in front of the vacuum detracts from the user's ability to see what is directly in the path of the vacuum.




Second, the light from prior art systems is generally cast over a wide area because the light is projected well in front of the vacuum. This diminishes the effectiveness of the lighting system. One solution to this problem is providing a vacuum with brighter lights. Brighter lights, however, require more power, which in turn requires a more powerful and generally heavier motor than vacuums with less powerful lights. Adding weight to the vacuum is undesirable because it generally reduces the mobility of the vacuum, and it generally causes the user of the vacuum to fatigue quicker than using a lighter vacuum.




A third drawback is that prior art lighting systems do not have side lighting. Oftentimes, vacuums are fitted with side brushes that clean the area directly to the sides of the vacuum. Without side lighting the debris to the sides of the vacuum in dimly lit areas is difficult to see. Hence, the user will have a difficult time determining if the area to the side of the vacuum is dirty and if vacuuming the area cleaned the area successfully. Moreover, when vacuuming in areas such as under a desk where the user may not be able to see directly in front of the vacuum, a sidelight would illuminate the area to the side of the vacuum that the user can see and hence allow the user to determine visually if the area under the desk is dirty and if the area has been cleaned successfully.




Accordingly, there is a need for a vacuum with a lighting system that lights the area directly in front of the vacuum and the area to the side of the vacuum. Moreover, there is a need for a vacuum that optimizes the brightness of the lighting system without adding weight to the vacuum.




During the operation of prior art vacuums, it is known to direct the air flow through one or more different filters as the air is drawn into, through and out from the vacuum. It remains desirable, however, to take fuller advantage of the possibilities for improving the desirability of using a vacuum by maximizing the benefit obtained from the air flow already present in the vacuum head.




Although it is well-known in the prior art to put a plurality of wheels on the underside of the vacuum head to facilitate ease of use and reduce wear to the surface being vacuumed, there remains a need for further optimization in the placement of such wheels. For example, the placement of the wheels on the underside of the head can effect the maneuverability of the vacuum and how convenient it is to use the vacuum and to move the vacuum from one working location to another.




BRIEF SUMMARY OF THE INVENTION




It is desirable to have a low-profile and highly-maneuverable vacuum cleaners having improved functionality including, alone or in combination, a headlight, a sidelight, anti-ingestion bars, side brushes, a squeegee, and a scent cartridge for use in cleaning floors, floor coverings, carpets, upholstery, and other surfaces. Accordingly, it is an object of the disclosed invention to provide such an improved vacuum cleaner.




In one embodiment of the present invention the head housing of the vacuum defines a tortuous air flow path. The path is made tortuous by placement of baffles that divert air flow. The tortuous path creates quieter air flow through the vacuum housing. The tortuous air flow arrangement is for cooling the internal parts of a vacuum cleaner. The air flow arrangement includes air intake slots on the top cover. The arrangement further includes at least one baffle attached to an interior portion of the head housing and positioned in the path of the air flow entering the intake slots. Finally, the arrangement also includes cooling vanes attached to the drive shaft and positioned in the path of the air flow in said head housing, wherein the at least one baffle and the cooling vanes slow the air flow and direct the air flow towards said internal parts thereby cooling the parts.




In yet another form, the vacuum cleaner of the present invention includes side brushes that employ spring-action blades similar to windshield wiper blades instead of tufts of bristles to overcome the drawbacks of prior art side brushes and to maximize the surface area cleaned. The combination of rubberized blade-like materials and dual-angled blades helps minimize the “snow-plowing” and “flicking” problems often encountered in prior art side brushes. The dual-angled blades serve to more effectively direct debris towards the vacuum's suction inlet. In addition, the dual-angled blades perform effectively during both pulling and pushing strokes of the vacuum. All of the above features of the present invention vacuum side brush design combine to maximize the surface area cleaned by the vacuum with respect to the surface area covered by the footprint of the vacuum.




The present invention side brushes also solve the service difficulties often found in the prior art. The present invention side brushes are easily serviced or replaced from the outside of the vacuum head housing by removing one screw. In addition, to further ease serviceability, the present invention dual-blade design is also interchangeable with respect to the vacuum head housing (i.e., a right-side blade can be used on the left side of the vacuum head housing and vice-versa) thereby reducing necessary parts inventory. Finally, the rubberized construction of the present invention side brushes effectively acts as a de facto bumper when the vacuum inadvertently comes into contact with surfaces that are lower than the height of the actual vacuum bumper.




The vacuum cleaner side brush is comprised of a substantially flat connection surface having a length, a width, a top connection surface, a bottom connection surface, and at least one blade. The blade is joined to and extends down from the bottom connection surface and includes a bottom blade surface. The side brush also includes a connection means for connecting the side brush to the head housing of the vacuum cleaner. In a preferred embodiment, the connection means is an aperture and a screw for screwing the side brush to the head housing.




In one embodiment of the present invention, an anti-ingestion bar for the vacuum includes at least two side arms including anti-ingestion portions with a front bar portion extending between the side arms. The front portion includes at least one lateral support portion.




In one embodiment of the present invention, a squeegee is attached to the bottom of a vacuum head. The squeegee includes a main body attached having a front edge, a rear edge and a middle portion. The middle portion of the squeegee defines a wiper and a flexible hinge continuously attaching the wiper to the middle portion. The squeegee is attached to the bottom of a vacuum head.




Another embodiment of the present invention includes a light assembly for a vacuum. The light assembly includes a reflector assembly having at least one light source. The light assembly further includes a headlight optically coupled with the reflector assembly wherein the at least one light source provides light for the headlight. The light assembly further includes a sidelight optically coupled with the reflector assembly wherein the at least one light source provides light for the sidelight. The light assembly generally illuminates the area to the front and the area to the side of the vacuum. The reflector assembly further includes a headlight reflector optically coupled with the light source and a headlight lens. The headlight reflector defines a generally vertical reflective surface defining at least one plane of curvature, the generally vertical reflective surface defining a focal region wherein the light source is positioned generally within the focal region. Light from the light source is reflected from the generally vertical reflective surface toward the headlight lens.




Another embodiment of the present invention includes a vacuum having a light assembly having a reflector assembly having a light source. The light assembly further includes a sidelight optically coupled to the reflector assembly, wherein the light source is adapted to provide light to the sidelight, and whereby the sidelight is adapted to illuminate the area downwardly and to the side of the vacuum. In yet another embodiment of the present invention, a lens for the light assembly includes a front face and a rear face defining a refraction contour, the refraction contour adapted to direct light incident on the refraction contour downwardly and forwardly of the vacuum.




Another embodiment of the present invention includes a vacuum having a headlight. The vacuum including a vacuum head housing defining a headlight cavity with a rear wall and a front portion. The vacuum further includes a reflector assembly attached with the vacuum head housing within the headlight cavity and a headlight lens housing releasably attached with the vacuum head housing adjacent the front portion of the vacuum head housing. The vacuum further includes a headlight lens releasably attached with the headlight lens housing.




In yet another embodiment of the present invention, a scent cartridge assembly for a vacuum cleaner includes a scent cartridge compartment disposed in the upper housing of the vacuum proximate the motor. A scent cartridge is positioned in the scent cartridge compartment. There is a scent cartridge cover removably attached to the upper housing to secure the scent cartridge housing into the scent cartridge compartment. The scent cartridge also includes a pair of exhaust vents disposed through said scent cartridge compartment.




Another embodiment of the present invention includes an indicator light assembly for the vacuum cleaner. The indicator light assembly includes a light pipe indicator unit and a circuit board. The light assembly further includes an elliptical recess in the top cover of the vacuum head for receiving the light pipe indicator unit. LEDs on the circuit board are operable to selectively illuminate upon the occurrence of a predetermined condition. The light assembly further includes at least one light pipe disposed above and slightly displaced from the LEDs, wherein upon illumination of one of the LEDs light from the LED is transmitted to the upper surface for observation by the user.




In another embodiment of the present invention the rear wheels are recessed within the head housing and slightly offset rearwardly of the rear wall of the head housing. This provides enhanced maneuverability and a generally lower overall vertical profile of the vacuum head housing. The rear wheel assembly includes at least one rear wheel positioned adjacent to the front-to-back center line of said vacuum head, with the at least one rear wheel projecting slightly from the back end.




The foregoing and other aspects, features, details, utilities, and advantages of the present invention will be apparent from reading the following description and claims, and from reviewing the accompanying drawings.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is an isometric view looking downwardly at the front and top of an upright vacuum according to the present invention;





FIG. 2

is an exploded isometric view of the vacuum depicted in

FIG. 1

;





FIG. 3

is an enlarged fragmentary isometric view of the head of the vacuum depicted in

FIG. 1

;





FIG. 4

is a front elevation of the head depicted in

FIGS. 1 and 3

, including a portion of the impeller housing;





FIG. 5

is a left elevation of the head and impeller housing depicted in

FIG. 4

;





FIG. 6

is an enlarged, bottom plan view of the head and impeller housing depicted in

FIGS. 4 and 5

;





FIG. 7

is an isometric view of the head housing top cover positioned above the head housing bottom cover, exposing the interior of the vacuum head;





FIG. 8

is a top plan view of the head with the top cover removed and showing the air path through the head;





FIG. 9

is a front isometric view of a vacuum side brush in accordance with one embodiment of the present invention;





FIG. 10

is a rear isometric view of the vacuum side brush depicted in

FIG. 9

;





FIG. 11

is a fragmentary, partially-exploded isometric view of the vacuum side brush depicted in

FIGS. 9 and 10

and a portion of the vacuum to which it attaches;





FIG. 12

is a partially-exploded top isometric view of the vacuum cleaner head with an anti-ingestion bar according to a first embodiment below its insertion point, and a squeegee positioned below the anti-ingestion bar;





FIG. 13

is a partially-exploded bottom isometric view of the vacuum cleaner head, the anti-ingestion bar of

FIG. 12

below its insertion point, and the squeegee below the anti-ingestion bar;





FIG. 14

is a partially-exploded bottom isometric view of the vacuum cleaner head with the anti-ingestion bar of

FIG. 12

inserted in the housing, and the squeegee below the anti-ingestion bar;





FIG. 15

is a bottom plan view of the head with the anti-ingestion bar of FIG.


12


and the squeegee installed;





FIG. 16

is a side elevation of the head with the anti-ingestion bar installed (represented by dashed lines);





FIG. 17

is a top isometric view of the bottom cover of the head housing with the anti-ingestion bar of

FIG. 12

installed therein;





FIG. 18

is a top isometric view of an alternative embodiment of the anti-ingestion bar;





FIG. 19

is a top plan view of the alternative embodiment of the anti-ingestion bar depicted in

FIG. 18

;





FIG. 20

is a front elevation of the alternative embodiment of the anti-ingestion bar taken along line


20





20


of

FIG. 18

;





FIG. 21

is a side elevation of the alternative embodiment of the anti-ingestion bar taken along line


21





21


of

FIG. 18

;





FIG. 22

is a bottom plan view of the vacuum cleaner head of the present invention showing the positioning of the integrated runner squeegee with respect to the roller brush;





FIG. 23

is an isometric view of the integrated runner squeegee;





FIG. 24

is a cross-sectional view taken along lines


24





24


of FIG.


23


and showing the different portions of the runner squeegee in section;





FIG. 25

is a bottom isometric view of the vacuum head, showing the squeegee both installed (solid lines) in and during mounting (dashed lines);





FIGS. 26-28

are representative cross-sectional views showing the squeegee prior to mounting, during mounting, and as mounted on the bottom plate;





FIG. 29

is an exploded isometric view of a light assembly according to the present invention, including a headlight and a sidelight;





FIG. 30

is an isometric front view of a reflector assembly comprising part of the light assembly depicted in

FIG. 29

;





FIG. 31

is an isometric rear view of the reflector assembly depicted in

FIG. 30

;





FIG. 32

is a top plan view of the reflector assembly depicted in

FIG. 30

;





FIG. 33

is a cross-sectional view of the reflector assembly depicted in

FIG. 30

taken along line


33





33


of

FIG. 32

;





FIG. 34

is a partially cut-away, isometric view of the top side and rear side of the head, showing the rear side of the reflector assembly installed in the head;





FIG. 35

is an isometric view of the top and front of a headlight lens housing comprising part of the light assembly depicted in

FIG. 29

;





FIG. 35



a


is an enlarged isometric view of a headlight lens snap in engagement with a recess in a channel of the headlight lens housing;





FIG. 35



b


is an enlarged, partially cut-away, isometric view of the a top edge of the headlight lens in engagement with a channel in a downwardly extending flange in a front portion of a cover of the headlight lens housing;





FIG. 36

is a rear isometric view of the headlight lens depicted in

FIGS. 29

,


35


, and


35




b;







FIG. 37

is a side elevation of the reflector assembly with the light bulbs turned on, and the light from the light bulbs incident on the headlight lens;





FIG. 38

is a side elevation of the vacuum with the headlights turned on, showing the light being refracted by the headlight lens and illuminating the area downwardly and forwardly of the vacuum;





FIG. 39

is a top plan view of the vacuum head with the light assembly installed, showing the rearward offset of the headlight lens and of the headlight lens housing;





FIG. 40

is a fragmentary isometric view of the right front of the vacuum head with the light assembly installed;





FIG. 41

is a partially cut-away, isometric view of the top and front of the vacuum head, showing the light assembly and the general pattern of light distribution from the light bulbs incident on both the sidelight lens and the headlight lens;





FIG. 42

is a front elevation of the vacuum head with the lights turned on, showing the light being refracted by the sidelight lens and illuminating the area downwardly and to the side of the vacuum;





FIG. 43

is a side elevation of the sidelight lens, showing a possible light refraction pattern therefrom;





FIG. 44

is a fragmentary isometric view of the top side and rear side of the top cover of the head housing with the scent cartridge cover removed;





FIG. 45

is similar to

FIG. 44

, but is slightly enlarged and depicts the scent cartridge cover in position and closed;





FIG. 46

is similar to

FIG. 45

, but depicts the scent cartridge cover being removed from the vacuum head;





FIG. 47

is a fragmentary, exploded isometric view depicting the scent cartridge cover and scent cartridge holder removed from the vacuum head;





FIG. 48

is a fragmentary, partially-exploded isometric view of the top surface of the headrail housing, depicting the light pipe indicator unit and its associate circuit board;





FIG. 49

is a fragmentary cross-sectional view depicting the light pipe indicator unit projecting through the top surface of the head housing and mounted to its associated circuit board; and





FIG. 50

is a fragmentary left-side elevation depicting the vacuum head tilted away from the working surface so that the vacuum may be transported from one working location to another.











DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS




The present invention is directed toward the features of a low-profile and highly-maneuverable vacuum cleaner


100


(

FIG. 1

) for moving a flow of air and debris or particulate matter


500


(e.g.,

FIGS. 5 and 22

) into the vacuum cleaner


100


, where the particulate matter


500


is separated from the air. The illustrated vacuum cleaner


100


is an upright vacuum cleaner, but need not be. Several of these features, which provide improved functionality for the vacuum cleaner


100


when it is used to clean floors


404


(e.g., FIG.


40


), floor coverings, carpets, upholstery, and other surfaces, are described below. Included among these features and described further below are velocity slots


412


(


a


),


412


(


b


),


412


(


c


), and


412


(


d


) (

FIGS. 4-6

and


22


), side brushes


410


(

FIGS. 4

,


5


, and


9


-


14


), anti-ingestion bars


1200


(

FIGS. 12-14

) or


1200


′ (FIGS.


18


-


20


), a squeegee


1202


(

FIGS. 12-14

and


23


-


28


), a headlight


102


(FIG.


1


), a sidelight


104


(FIG.


1


), a scent cartridge


234


(FIGS.


46


and


47


), and a light pipe indicator unit


4800


(FIGS.


48


and


49


). These new and improved features may be used alone or in combination.




Referring first to

FIGS. 1 and 2

, the upright vacuum cleaner


100


may include a vacuum head housing


106


having an intake nozzle or aperture


200


positioned close to the floor surface


404


(e.g., FIG.


4


), and a handle


108


that extends upwardly from the head housing


106


so that a user may move the head housing


106


along the floor surface


404


. An airflow propulsion device


202


may be disposed within the head housing


106


to create suction at the intake nozzle


200


to draw the particulate matter


500


from the floor surface


404


. The airflow propulsion device


202


may then drive or propel a particulate-laden airstream through an exhaust conduit which may, for example, be included within a portion of the handle


108


. The particulate-laden airstream may exit from the exhaust conduit into a filter bag (not shown). An outer bag


110


may be disposed about the filter bag to protect the filter bag from blows or contact, which might otherwise damage the filter bag and allow the particulate matter therein to undesirably escape.




In one preferred form, the air flow propulsion device


202


includes a motor


204


having a drive shaft


206


. A drive belt


208


is coupled to a first end


210


of the drive shaft


206


and to a rotatable roller brush


212


so that, as the motor


204


turns the drive shaft


206


, the roller brush


212


also turns. An impeller


214


is coupled to a second end


216


of the drive shaft


206


and is disposed within a two-piece impeller housing


218


. The two-piece impeller housing


218


is slippingly coupled to a suction duct


220


.




As shown to good advantage in

FIG. 2

, and as discussed further below, there are a plurality of wheels rotatably attached to the bottom surface of the head housing bottom cover


222


. In the preferred embodiment, there are two rear wheels


224


, each of which is rotatably mounted to the bottom cover


222


by rear axles


226


. Similarly, a pair of smaller front wheels


228


are rotatably attached to the bottom cover


222


by front axles


230


.




A removable access panel


209


covers the drive belt


208


during operation, but permits ready access to the drive belt


208


when required.




As shown in

FIG. 2

, and as discussed further below in connection with

FIGS. 29

,


34


and


44


-


48


, the vacuum head housing


106


defines a scent cartridge compartment


232


, which accommodates a scent cartridge assembly


234


. The scent cartridge assembly includes a scent cartridge or fragrance patch


236


, an exhaust air post filter


238


, a scent cartridge housing


240


, and a scent cartridge compartment cover


242


. The scent cartridge compartment is formed in the vacuum head housing


106


adjacent to the motor


204


. The scent cartridge cover


242


is removably attached to the head housing top cover


244


to removably secure the scent cartridge housing


240


in the scent cartridge compartment


232


.




As also shown in

FIG. 1

, the vacuum head housing


106


includes a slight projection or protuberance


112


. The side light


104


is mounted on this protuberance


112


. As discussed further below, the protuberance


112


in the side light


104


improve edge cleaning. For example, when running a vacuum parallel to the face of a cabinet having a toe kick, the side light


104


illuminates the toe kick area, while the protuberance


112


extends into the toe kick area.




As further described below in connection with

FIGS. 48 and 49

, a light pipe indicator unit


114


is present on the curved upper surface


116


of the top cover


244


.




Also shown in

FIG. 2

are the components of the headlight assembly, including a reflector assembly


2904


, a headlight lens housing


2906


, and a headlight lens


2908


. As further described below, this headlight assembly fits in the headlight cavity


2902


. A side light lens


2912


, which is also discussed further below in connection with, for example,

FIG. 29

, is mounted in a side light cavity


2910


.




In the following sections, the components and operational aspects of the improved features of the vacuum cleaner


100


mentioned above are described in greater detail.




Lower Surface of Bottom Cover




As shown to good advantage in

FIG. 6

, the lower surface


1308


of the bottom cover


222


has many features including a storage compartment


602


for a spare or back-up drive belt


604


, a pair of rear wheels


224


, a pair of front wheels


228


, a downwardly bulbous protrusion


632


, and velocity slots


412


(


a


),


412


(


b


),


412


(


c


), and


412


(


d


). Other features of the lower surface


1308


of the bottom cover


222


including the anti-ingestion bar, the squeegee, and the brush are discussed further below.




Referring to

FIG. 7

, the rear portion


700


of the head housing bottom cover


222


defines a left rear wheel housing


702


and a right rear wheel housing


704


. The rear wheel housings


702


,


704


are recessed upwardly from the lower surface


1308


of the bottom cover


222


. Each rear wheel housing defines a pair of axle apertures


710


, that rotatably support the rear wheel axles


226


of the rear wheels


224


. In the preferred embodiment, the rear wheels


224


are recessed within the rear wheel housings


702


,


704


so that a portion of each of the rear wheels


224


extends past the rear edge of the head housing


106


. This may be seen to good advantage in, for example,

FIGS. 5 and 50

. Also, nearly half of the front and rear wheels


228


,


224


, respectively, extends downwardly past the lower surface


1308


of the bottom cover


222


. This configuration reduces the overall vertical profile of the vacuum head housing


106


, and thus allows the vacuum


100


to be maneuvered under low surfaces such as sofas, desks, and beds. Additionally, having a portion of the rear wheels


224


extend rearwardly of the rear edge of the vacuum head housing


106


enhances the maneuverability of the vacuum, especially when the vacuum


100


is pulled rearwardly with the front end of the vacuum raised as shown in FIG.


50


. For example, if the user were to tilt the vacuum rearwardly slightly (i.e., enough to take the pressure off of the front wheels), the user would experience less resistance to pivotal motion about an axis through the handle and down tube. Also, when the vacuum cleaner is tilted rearwardly as shown in, for example,

FIG. 50

, the vacuum may be more easily transported from a first working surface to a second working surface (e.g., from a first bedroom to a second bedroom.) Additionally, the rear wheels


224


are placed in close proximity to one another near the lateral centerline of the head housing


106


to improve the turning radius of the vacuum


100


.




The front wheels


228


are rotatably mounted to the lower surface


1308


of the bottom cover


222


forwardly of the rear wheels


224


and adjacent to the outside lateral edges of the squeegee


1202


. The lower surface


1308


of the bottom cover


222


defines a left front wheel housing


713


and a right front wheel housing


715


recessed upwardly from the lower surface of the bottom cover


222


. The axles


230


of the front wheels


228


are rotatably supported in apertures defined within the front wheel housings


713


,


714


.




The belt storage compartment


602


is generally boomerang shaped and extends upwardly from the lower surface


1308


of the bottom cover


222


, which is best illustrated in

FIGS. 6 and 7

. The back-up drive belt


604


is stored within the belt storage compartment


602


so that in case the drive belt


208


breaks during use the user will have the back-up belt


208


handy. The boomerang shaped storage compartment


602


generally defines a long radius wall


606


and a short radius wall


608


intersecting together at both of their respective ends with sweeping radius walls


610


,


611


. A first belt-mounting nub


612


and a second belt mounting nub


614


are positioned within the space defined by the sweeping radius walls


610


,


611


. The belt mounting nubs


612


,


614


are generally tear drop shaped and are dimensioned so as to provide a relatively constant width channel


616


,


618


between the belt mounting nubs


612


,


614


and the sweeping radius walls


610


,


611


. The channels


616


,


618


are generally only slightly wider than the thickness of the back-up drive belt


604


.




A friction finger


620


extends outwardly from a midpoint


622


of the short radius wall


608


. The friction finger


620


has a generally convex wall


624


and a generally concave wall


626


that intersect at a tip


630


adjacent a midpoint


628


of the long radius wall


606


, and thereby form a space between the tip


630


and the long radius wall


606


slightly larger than two thicknesses of the belt


604


. The concave wall


626


provides space for the finger of a user to grasp the belt


604


and remove it from the storage compartment


602


.




The back-up drive belt


604


is held in place within the storage compartment


602


by placing the belt


604


around the first belt mounting nub


612


and the second belt mounting nub


614


, within the channels


616


,


618


and across the tip


630


of the friction finger


620


. Once within the compartment, the belt


604


is held in place by frictional interaction with the walls


606


,


608


, the nubs


612


,


614


, and the friction finger


620


. Accordingly, the belt


604


is in a relaxed position, i.e., without tension, when stored in the storage compartment


602


. Prior art systems generally store belts in a tensioned or stretched state which causes the belts to degrade and lose their elasticity over time.




As shown in

FIGS. 5-7

, a bulbous protrusion


632


protrudes downwardly from the lower surface


1308


of the bottom cover


222


. The bulbous protrusion


632


defines a bottom surface


706


of an impeller fan housing chamber


708


within the vacuum head housing


106


. The impeller fan housing


218


generally occupies the impeller fan housing chamber


708


. The bulbous protrusion


632


allows the impeller fan housing


218


to rest lower within the vacuum head housing


106


, and thus reduces the overall vertical profile of the vacuum head housing


106


. As discussed above with respect to recessing the front and rear wheels


228


,


224


, respectively, reducing the vertical profile allows the vacuum to be maneuvered under low lying surfaces such as sofas, desks, and beds, while minimizing contact with such low lying surfaces.




Velocity Slots




Referring most particularly to

FIGS. 4-6

and


22


, front velocity slots


412


(


a


),


412


(


b


), and rear velocity slots


412


(


c


),


412


(


d


) formed in the lower surface


1308


of the bottom cover


222


are described next. These front velocity slots


412


(


a


),


412


(


b


), and rear velocity slots


412


(


c


),


412


(


d


) provide suctional communication between the area adjacent to the side brushes


410


and the suction inlet


200


. The side brushes


410


, as described elsewhere, assist in cleaning debris


500


along the sides of the vacuum


100


. In particular, the debris


500


along the sides of the head housing


106


is moved by the side brushes


410


toward the velocity slots


412


(


a


),


412


(


b


),


412


(


c


),


412


(


d


). During a forward stroke with the vacuum, the debris impacting the most forward inside and outside blades


900


,


902


, respectively, of each side brush


410


is pushed by these blades


900


,


902


into one of the forward velocity slots


412


(


a


),


412


(


b


). Similarly, during a rearward stroke with the vacuum


100


, the debris


500


impacting the most rearward inside and outside blades


900


,


902


, respectively, of each side brush is pushed by these blades


900


,


902


into one of the rearward velocity slots


412


(


c


),


412


(


d


). Accordingly, debris


500


that is loosened by the side brushes


410


is moved from the areas adjacent the brushes and directed through one or more velocity slot


412


(


a


),


412


(


b


),


412


(


c


),


412


(


d


) into the suction inlet


200


.




The forward left velocity slot


412


(


a


) is defined by a recessed area


2203


bounded by a first short downwardly projecting wall


2204


oriented at an oblique angle with respect to the longitudinal axis of the roller brush


212


and a second short downwardly projecting wall


2206


orientated generally transversely to the first downwardly projecting wall


2204


. The forward right velocity slot


412


(


b


) is defined by a recessed area


2208


bounded by a first short downwardly projecting wall


2210


having a portion


2212


generally parallel to the longitudinal axis of the brush


212


and a portion


2214


orientated at an oblique angle with respect to the longitudinal axis of the brush


212


, and by a second short downwardly projecting wall


2216


oriented generally transversely to the oblique portion


2214


of the first downwardly projecting wall


2210


.




The rear left velocity slot


412


(


c


) is defined by a recessed area


2218


bounded by a first downwardly projecting wall


2220


oriented generally parallel to the longitudinal axis of the brush


212


and a second downwardly projecting wall


2222


oriented generally transversely to the first wall


2220


. Finally, the rear right velocity slot


412


(


d


) is defined by a recessed area


2224


bounded by a first downwardly projecting wall


2226


orientated generally parallel with the longitudinal axis of the brush


212


and a second downwardly projecting wall


2228


that is curved having a portion, adjacent the side brush


410


, that is generally parallel to the longitudinal axis of the brush


212


and then curving forwardly into a portion that is generally orientated at an oblique angle with respect to the longitudinal axis of the brush


212


.




Generally, with respect to the velocity slots


412


(


a


),


412


(


b


),


412


(


c


),


412


(


d


), the flow of air into the suction inlet


200


along with the rotation of the brush


212


creates a flow of air from the area adjacent to the velocity slots, through the velocity slots, and into the suction inlet


200


. Integrating both forward velocity slots


412


(


a


),


412


(


b


) and rearward velocity slots


412


(


c


),


412


(


d


) into the lower surface of the bottom cover


222


provides enhanced cleaning capability in both the forward and rearward direction. Accordingly, debris


500


loosened by the side brushes


410


in the forward stroke is generally routed through the forward velocity slots


412


(


a


),


412


(


b


) and debris that is loosened by the side brushes


410


in the rearward stroke is generally routed through the rearward velocity slots


412


(


c


),


412


(


d


).




The oblique angles of the sidewalls


2204


,


2214


of the forward left velocity slot


412


(


a


) and the forward right velocity slot


412


(


b


), respectively, take advantage of the forward motion of the vacuum to guide debris


500


into the suction inlet


200


. Debris that enters the forward velocity slots


412


(


a


),


412


(


b


), will generally contact the sidewalls


2204


,


2214


and be moved rearwardly and inwardly in the forward velocity slots


412


(


a


),


412


(


b


). The walls


2204


,


2214


by virtue of their angular orientation funnel the debris rearwardly and laterally along the walls


2204


,


2214


and into the suction inlet


200


.




Side Brushes




Referring to

FIGS. 3-5

, side brushes


410


are attached to both sides


408


of vacuum head housing


106


adjacent velocity slots


412


(


a


),


412


(


b


),


412


(


c


), and


412


(


d


) (as described above) and proximate the front end


402


of vacuum head housing


106


. The side brushes


410


serve to direct debris


500


from floor surface


404


, but outside the surface area covered by the vacuum's footprint, to the velocity slots


412


(


a


),


412


(


b


),


412


(


c


), and


412


(


d


). The velocity slots


412


(


a


),


412


(


b


),


412


(


c


), and


412


(


d


) are in communication with the suction inlet


200


(see FIGS.


2


and


22


), thereby drawing in any debris


500


introduced to the velocity slots


412


(


a


),


412


(


b


),


412


(


c


), and


412


(


d


) towards the inlet


200


. As shown in

FIGS. 4 and 5

, the side brushes


410


are in contact with the floor surface


404


to help direct debris


500


toward the vacuum's suction inlet


200


.





FIG. 22

, a bottom view of the vacuum head housing


106


, provides a more detailed view of the path that the debris


500


takes en route to suction inlet


200


. Side brushes


410


help direct the debris


500


into the velocity slots


412


(


a


),


412


(


b


),


412


(


c


), and


412


(


d


) and towards the powered roller brush


212


. The debris


500


is ultimately directed into the suction inlet


200


by the mechanical forces of the powered roller brush


212


and the low pressure or suction forces created by the vacuum motor


274


. The suction inlet


200


actually surrounds the powered roller brush


212


.





FIGS. 9 and 10

are front and rear isometric views, respectively, of a side brush


410


. Generally, each side brush


410


is comprised of two dual-angled blade pairs, each blade pair including an inside blade


900


and an outside blade


902


. A connection aperture


912


is present between the blade pairs and receives a connection screw


1100


(

FIG. 11

) to connect the side brush


410


to a mounting bracket


1102


on the bottom cover


222


of the vacuum head housing


106


(see FIG.


11


). The shape and design of the blades


900


and


902


help direct debris


500


toward collection channels


906


,


908


, and


910


and into the suction inlet


200


.




In a preferred embodiment depicted in

FIGS. 9 and 10

, the side brush


410


includes two slightly curved or bowed, dual-angled outside blades


902


suspended from a connection surface


914


. Inward of these outside blades


902


are two slightly curved, dual-angled inside blades


900


, which are also suspended from the connection surface


914


. Central to the side brush


410


and between the inside blades


900


is the connection aperture


912


. A more detailed description of the connection aperture


912


is provided below in connection with FIG.


11


. Each blade includes a bottom surface


904


, an elongated outwardly facing edge


916


, and an inwardly facing edge


1000


. The connection surface


914


of each blade is angled downwardly and inwardly with respect to the floor surface


404


and the head housing


106


, respectively. To account for the angle of the connection surface


914


and ensure that the bottom surfaces of each respective blade is substantially parallel to the floor surface


404


when connected to the vacuum


100


, the outwardly facing edge


916


of each blade is elongated in relation to the inwardly facing edge


1000


of each blade.




As mentioned previously, each side of the connection aperture


912


includes a pair of dual-angled blades, an inside blade


900


and an outside blade


902


. The first angle included in the blades


900


and


902


can be described in relation to the edges


916


,


1000


of each blade, the ends


400


and


402


of the vacuum


100


, and the connection aperture


912


(see FIGS.


9


-


15


). Each respective pair of blades is tilted from the portion of each blade adjacent to the connection surface


914


to the bottom surface


904


away from the connection aperture


912


toward the end


400


,


402


of the head housing


106


closest to the side of the connection aperture


912


that includes the respective pair of blades.




As mentioned previously, the blades


900


and


902


are dual-angled with the first angle being the tilt angle of each blade as described above. The second angle included in the blades


900


and


902


is the angle of axial rotation and can be described in relation to the edges


916


,


1000


of each blade


900


,


902


, and the connection aperture


912


(see FIGS.


9


-


15


). In a preferred embodiment, the general rule is that each blade is axially rotated such that the inwardly facing edge


1000


of each respective blade is closer to the connection aperture


912


than the outwardly facing edge


916


of each respective blade.




As a result, with respect to the horizontal dimension of each blade taken along the side


408


of the head housing


106


when the side brush


410


is installed on the head housing


106


, each blade's outwardly facing edge


916


extends transversely away from the connection aperture


912


while its inwardly facing edge


1000


extends transversely toward the connection aperture


912


.




The blades


900


and


902


are both spaced slightly apart and are slightly curved or bowed in the direction they are angled. The effect of the spacing and the curvature is that the debris collection channels


906


,


908


, and


910


are formed. The debris


500


is guided along the collection channels


906


,


908


, and


910


into the suction inlet


200


. The geometry of the blades


900


and


902


more effectively directs the debris


500


thereby helping to increase the surface area cleaned.




In

FIG. 11

, an exploded view of the side brush


410


depicting the manner of installation is provided. The mounting bracket


1102


is fixed to the side surface


408


of the head housing


106


adjacent the front end


402


. The mounting bracket


1102


includes the mounting surface


1104


which lies substantially in a plane parallel to the connection surface


914


and also lies above and opposite the floor surface


404


. In a preferred embodiment, the outline of the mounting surface


1104


is configured to substantially match the outline of the connection surface


914


. Central to the mounting surface


1104


is the threaded aperture


1106


. The threaded aperture


1106


is configured to receive the mounting screw


1100


for attaching the side brush


410


to the mounting bracket


1102


. As shown in

FIG. 11

, the side brush


410


is attached to the mounting bracket


1102


(and head housing


106


) by inserting the mounting screw


1100


up through the connection aperture


912


and into the threaded aperture


1106


. By tightening the mounting screw


1100


, the mounting surface


1104


and the connection surface


914


are brought in contact with each other. In other embodiments of the side brush


410


, the mounting screw


1100


may be integral to the side brush


410


thereby eliminating the need for the connection aperture


912


. In still further embodiments of the side brush


410


, connection tabs or other known means may be used to connect the side brush


410


to the mounting bracket


1102


.




While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made without departing from the spirit and scope of the invention.




Anti-ingestion Bars





FIGS. 12-17

illustrate a first preferred embodiment of anti-ingestion bar


1200


and its placement in the bottom cover


222


of the head housing


106


of the vacuum cleaner


100


. When installed, the anti-ingestion bar


1200


resides on the lower surface


1308


of the bottom cover


222


, as best seen in

FIGS. 13 and 14

.




As shown in

FIGS. 13 and 14

, the anti-ingestion bar


1200


includes rear anchor portions


1304


on both free ends of side arm portions


1306


. The rear anchor portions


1304


are inserted into anchor slots


1300


formed on the lower surface


1308


of the bottom cover, thereby removably joining the ends of the side arm portions


1306


to the head housing


106


. A front bar portion


1302


of the anti-ingestion bar


1200


engages the front of the bottom cover


222


, as described below in connection with FIG.


17


.




In

FIGS. 15 and 16

, the anti-ingestion bar


1200


is connected to the bottom cover, and a squeegee


1202


covers the rear anchor portions


1304


. The squeegee is described further below. As shown in

FIGS. 15 and 16

, when the anti-ingestion bar


1200


is installed, anti-ingestion portions


1400


of the anti-ingestion bar


1200


reside beneath power roller brush


212


, thereby acting as a guard to prevent larger-sized debris from either becoming entangled with the power roller brush


212


or entering and clogging the vacuum suction inlet (not shown). The front bar portion


1302


is not visible from the bottom of the vacuum


100


and is, therefore, shown in phantom in FIG.


15


.





FIG. 17

is an isometric view looking downwardly on the bottom cover


222


and illustrates the placement of the anti-ingestion bar


1200


within the bottom cover


222


. A fragmentary portion of the agitator or roller brush


212


is shown in FIG.


17


. If the front roller brush


212


were shown, its mid portion would ride above the side arm portions


1306


. The front bar portion


1302


of the anti-ingestion bar


1200


is engaged with the bottom cover


222


. In particular, as described in greater detail below, the front bar portion


1302


is weaved between and releasably held by holding tabs


1700


,


1702


, and


1704


.





FIGS. 18-21

depict an alternative embodiment


1200


′ of the anti-ingestion bar. In this alternative embodiment


1200


′, only the rear anchor portions


1304


′ are different from those


1304


depicted in, for example,

FIGS. 13 and 14

. The rear anchor portions


1304


′ include loops that can accommodate screws or heat stakes to affix the alternative embodiment of the anti-ingestion bar


1200


′ to the bottom cover


222


.




Since the remaining features of the two anti-ingestion bars


1200


,


1200


′ are the same, additional anti-ingestion bar details will be described next with reference to

FIGS. 18-21

. The anti-ingestion bar


1200


or


1200


′ serves to add lateral support to the front wall


402


of the bottom cover


222


and prevents the introduction of larger-sized debris into the vacuum's suction inlet


200


. As best seen in

FIG. 18

, anti-ingestion bar


1200


or


1200


′ is generally U-shaped and includes a front bar portion


1302


connected to at least two identical side arm portions


1306


. As shown in

FIG. 17

, front bar portion


1302


is configured to be releasably secured by the alternating holding tabs


1700


,


1702


, and


1704


along the front wall


402


.




Each side arm portion


1306


terminates at a rear anchor portions


1304


. The rear anchor portions


1304


are adapted to be releasably secured to the vacuum body. In a preferred embodiment, each rear anchor portions


1304


faces the same direction in an “L-shape” (i.e., one faces inwardly and the other faces outwardly) and is held by an anchor slot


1300


. In other embodiments, the rear anchor portions


1304


could face in opposite directions. In an alternative embodiment shown in

FIG. 18

, the rear anchor portions


1304


′ define loops at each end of the anti-ingestion bar


1200


′. The looped rear anchor portions


1304


′ are configured to fit over stubs protruding from the lower surface of the bottom cover


222


.




In both embodiments of the rear anchor portions


1304


and


1304


′, each rear anchor portions is joined to a horizontally directed upper connecting portion


1800


. As shown in

FIG. 21

, each upper connecting portion


1800


resides in the same plane as the rear anchor portions


1304


or


1304


′ and extends forwardly towards the front bar portion


1302


. Each upper connecting portion


1800


is joined to a ramp portion


1802


that extends forwardly and downwardly from the upper connecting portion


1800


toward the front bar portion


1302


. Each ramp portion


1802


is joined to a substantially horizontal anti-ingestion portion


1400


that resides in a plane lower than but parallel to the plane containing the corresponding rear anchor portion


1304


and upper connecting portion


1800


. This is clearly visible in FIG.


21


. As mentioned above, the anti-ingestion portions


1400


serve as a guard to prevent the introduction of larger sized debris into the vacuum's suction inlet


200


. As shown in

FIGS. 18 and 21

, anti-ingestion portion


1400


extends forwardly and substantially horizontally from a lower end of a ramped portion and joins a forwardly extending, upwardly-curved corner portion


1804


. As best seen in

FIG. 19

, each corner portion


1804


terminates at the forward end


1812


of its respective side arm


1306


and is joined to an inwardly and generally perpendicularly directed outside lateral support portion


1806


of the front bar portion


1302


.




The top view (

FIG. 19

) of the front bar portion


1302


and its side view (

FIG. 21

) show that the front bar portion


1302


generally comprised of a joined series of co-planar, lateral support portions


1806


,


1808


, and


1810


as illustrated to good advantage in

FIGS. 19 and 20

. As best illustrated in

FIG. 17

, the lateral support portions


1806


,


1808


, and


1810


are configured so as to weave between and be releasably secured by the offset alternating holding tabs


1700


,


1702


, and


1704


. Holding tabs


1700


,


1702


, and


1704


are forwardly and rearwardly offset to allow the front bar portion


1302


to weave around holding tabs


1700


,


1702


, and


1704


. As mentioned above, the anti-ingestion bar


1200


also serves to structurally reinforce the front wall


402


of the bottom cover


222


.




In the preferred embodiment and as illustrated in

FIGS. 17 and 18

, each outside lateral support portion


1806


extends laterally inwardly and resides in front of an outside, rearwardly-offset holding tab


1704


. Each outside lateral support portion


1806


is joined to an inside lateral support portion


1808


. The inside lateral support portion


1808


extends laterally inwardly and resides behind an interior, frontwardly-offset holding tab


1702


. Finally, the inward ends of the two inside lateral support portions


1808


are joined to a central lateral support portion


1810


. The central lateral support portion


1810


extends laterally between the inside lateral support portions


1808


and resides in front of the central rearwardly offset holding tab


1700


.




Additional embodiments of the anti-ingestion bar


1200


may include various configurations of lateral support portions along the front bar portion


1302


, providing they are configured to be releasably secured by holding tabs along the front wall of the bottom cover. Additionally, the dimensions of the anti-ingestion bar


1200


may vary depending on the dimensions of the vacuum head housing


106


.




Squeegee





FIGS. 12-15

and


22


-


28


show the integrated runner squeegee


1202


portion of the vacuum head housing


106


of the present invention. The integrated runner squeegee


1202


is attached to the lower surface


1308


of the bottom cover


222


, adjacent to and behind the roller brush


212


, and extends laterally substantially from edge to edge of the vacuum head housing


106


. The squeegee


1202


includes a wiper blade


2402


, which extends downwardly from the bottom cover


222


and contacts the surface


404


being cleaned. The wiper blade


2402


flexes rearwardly when the vacuum


100


is being pushed forwardly during use, and the wiper blade


2402


flexes forwardly when the vacuum


100


is moved rearwardly, all the while maintaining contact with the surface


404


being cleaned (see, e.g. FIG.


24


). The squeegee


1202


has several functions, including enhancing the suction force of the vacuum head around the area of the roller brush


212


, and helping collect debris


500


missed by the roller brush


212


in the forward pass by pushing the particles along in front of the squeegee


1202


until the vacuum is moved in a rearwardly direction. Generally, the wiper blade


2402


works on hard surfaces (hardwood, tile, etc.) to push large debris


500


forward and along behind the brush roll area so that when the vacuum head


106


is pulled rearwardly, the large debris


500


can be picked up by the roller brush


212


and suction. The wiper blade


2402


also helps keep debris


500


from being pushed out behind the vacuum by the roller brush


212


. The wiper blade


2402


also works on carpeting to lay the carpet pile over so that the bristles on the roller brush can get further down into the carpet for better deep cleaning. The structure and function of the squeegee


1202


is described in more detail below.




Referring first to

FIG. 12

, the vacuum head


106


of the present invention incorporating the integrated runner squeegee


1202


is shown in a partially-exploded isometric view. Referring to

FIGS. 12

,


23


and


24


, the squeegee


1202


includes a rear portion


1204


, a front portion


1206


, and an intermediate portion


1208


. The rear portion


1204


is a flat member that defines attachment apertures


1210


and a positioning notch


1212


. The attachment apertures


1210


are used with fasteners


1211


to connect the rear portion


1204


to the bottom cover


222


. The positioning notch


1212


receives a positioning pin


2202


(

FIG. 22

) on the bottom cover


222


and ensures the proper lateral positioning of the squeegee


1202


on the lower surface


1308


of the bottom cover


222


.





FIG. 22

shows the squeegee


1202


positioned on the lower surface


1308


of the bottom cover


222


, adjacent to and just behind the roller brush


212


. The positioning pin


2202


is shown received in the positioning notch


1212


, and the two attachment apertures


1210


are shown being used to attach the squeegee


1202


to the lower surface


1308


of the bottom cover


222


.





FIGS. 23 and 24

show the squeegee


1202


disconnected from the vacuum head


106


. The squeegee


1202


is a generally elongated extruded part including primarily a main body


2300


, a wiper blade


2402


, and a flexible hinge


2404


attaching the wiper blade


2402


to the main body


2300


. Preferably, the main body


2300


and the wiper blade


2402


are made of hard plastic material, and the hinge


2404


is made of relatively soft rubber material to allow the wiper blade


2402


to deflect forwardly or rearwardly depending on the motion of the vacuum head


106


. It is contemplated that the wiper blade


2402


could be made of soft material, or that the main body


2300


could be made of soft material, but what is important in this instance is that the wiper blade


2402


is connected to the main body


2300


in a manner that allows the wiper blade


2402


to deflect forwardly or rearwardly as needed.




The main body


2300


includes the front portion


1206


, the rear portion


1204


, and the intermediate portion


1208


. As best shown in

FIG. 24

, the front portion


1206


of the main body


2300


, which is positioned adjacent to the roller brush


212


in the fully-assembled vacuum head housing


106


, defines an upwardly hooked portion


2406


forming a generally L-shaped groove


2408


, which opens upwardly. This L-shaped groove


2408


receives a correspondingly shaped protrusion


2602


formed on the lower surface


1308


of the bottom cover


222


of the vacuum head


106


and assists in attaching the squeegee


1202


to the lower surface


1308


of the bottom cover


222


, in combination with the flat attachment flange


2412


defined in more detail below. The bottom surface of the front portion


1206


, when mounted, is spaced away from the floor but is close enough to push larger objects along with the vacuum head


106


as the vacuum head


106


is moved along the surface


404


being cleaned. The front portion


1206


has an exterior generally rounded lobe shape. The rear edge of the lobe slopes upwardly to the bottom surface of the intermediate portion


1208


, thereby forming a forward deflection stop


2410


for the wiper blade


2402


.




The rear portion


1204


of the main body


2300


defines the flat attachment flange


2412


. The two attachment apertures


1210


(

FIG. 23

) are formed therein, as well as the positioning slot


1212


. The attachment flange


2412


is relatively thin and does not define any features extending from its bottom surface. The intermediate portion


1208


of the main body


2300


extends between the inner edge


2414


of the attachment flange


2412


and the inner edge


2416


of the C-shaped connector hook


2406


. The top surface of the intermediate portion


1208


simply rests against the lower surface


1308


of the bottom cover


222


. The bottom surface of the intermediate portion


1208


defines a rearward deflection stop


2418


and the flexible hinge


2404


for supporting the wiper blade


2402


.




The flexible hinge


2404


extends along the entire bottom surface and is formed of a soft rubber material. The hinge


2404


has a relatively smaller width dimension than does the wiper blade


2402


, and is relatively shorter than the wiper blade


2402


in a vertical section, as shown in FIG.


24


. The wiper blade


2402


extends continuously along the bottom surface of the hinge


2404


and is preferably formed of a hard material such as hard plastic. The bottom edge of the wiper blade


2402


engages the surface


404


being cleaned when the vacuum head


106


is not being moved. The height of the wiper blade


2402


, as shown in

FIG. 24

, is designed to allow the wiper to extend down from the main body


2300


in combination with the height of the hinge


2404


and to engage the surface


404


being cleaned. The wiper blade


2402


is shown in

FIG. 24

as having a rectangular cross-section, however, the forward and rearward edges of the wiper blade


2402


adjacent the surface


404


being cleaned could be angled to facilitate an easier transition between the forward and rearward deflection of the wiper blade


2402


depending on the movement of the vacuum head


106


. The bottom edge of the wiper blade


2402


could also be rounded.




The rearward deflection stop


2418


is formed between the wiper blade


2402


and the attachment flange


2412


and extends from the bottom surface of the intermediate portion


1208


of the main body


2300


. The rearward deflection stop


2418


has a sloped rearward surface


2420


and a vertical forward surface


2422


, which form a generally triangular cross-sectional shape. The rearward deflection stop


2418


acts to restrict the amount of deflection possible by the wiper blade


2402


when the vacuum head


106


is moved in the forward direction and the wiper blade


2402


is deflected rearwardly. Thus, the rearward deflection stop


2418


keeps the wiper blade


2402


from deflecting too far rearwardly in order to maintain the desired contact between the wiper blade


2402


and the surface


404


being cleaned. When the vacuum head


106


is moved in a rearward direction, the wiper blade


2402


deflects forwardly until it contacts the forward deflection stop


2410


.




The integral co-extrusion of the main body


2300


, hinge


2404


, and wiper


2402


has several benefits. One of these benefits is the consistent and continuous attachment of the wiper blade


2402


to the main body


2300


, which creates an evenly distributed force along the wiper blade


2402


as the wiper blade


2402


engages the floor, regardless of the direction the wiper blade


2402


is deflected. This is an advantage over the prior known attachment structures, which attach the wiper blade at discrete locations along the width of the head as opposed to the continuous attachment disclosed herein. The co-extrusion of the main body


2300


, hinge


2404


, and wiper blade


2402


allows for the use of polyurethane as the wiper blade material, and optionally as the main body material, while a flexible rubber can be used as the hinge material. This helps prevent scratching and marring of the surface


404


being cleaned when compared to the burrs developed on the metal wiper blades of previous designs. In addition, the wiper blade


2402


has a self-adjusting height regardless of whether the vacuum head


106


is being moved forwardly or rearwardly since the squeegee


1202


can deflect forwardly or rearwardly along its entire length, as required by the motion of the vacuum head


106


. Further, the positive engagement of the wiper blade


2402


along the surface


404


being cleaned helps provide a seal against that surface, which creates a smaller suction area and accentuates the suction from the airflow propulsion device


202


along the front and side areas of the vacuum head


106


as opposed to directly behind the roller brush


212


.





FIGS. 25-28

show the runner squeegee


1202


being attached to the bottom cover


222


. The two attachment locations


1210


of the integrated runner squeegee


1202


provide secure attachment and easy replacement. The L-shaped recess


2408


is continuous along the front edge


1206


of the integrated runner squeegee


1202


and receives a similarly shaped protrusion


2602


extending from the lower surface


1308


of the bottom cover


222


. The squeegee


1202


is oriented relative to the bottom cover


222


to allow the L-shaped protrusion


2602


to enter the open end of the recess


2408


. The squeegee


1202


is then moved straight back to further insert the L-shaped protrusion


2602


therein. Referring to

FIG. 27

, the main body


2300


of the squeegee


1202


is then pivoted around the engagement of the L-shaped protrusion


2602


and the L-shaped recess


2408


so that the top surface of the main body


2300


engages the lower surface


1308


of the bottom cover


222


. The L-shaped protrusion


2602


is thus seated in the L-shaped recess


2408


, creating the L-shaped tongue and groove interlocking connection


2604


shown in FIG.


28


. The flat attachment flange


2412


is then attached by fasteners, such as screws, to the bottom cover


222


. The squeegee


1202


is held firmly in all dimensions by the L-shaped tongue and groove interlocking connection


2604


and fasteners


1211


. Any lateral sliding is eliminated by the fasteners


1211


, as well as the engagement of the positioning notch


1212


with the positioning pin


2202


(FIG.


22


).




When attached to the vacuum head


106


, the integrated squeegee


1202


also secures the rear free ends of the anti-ingestion bar


1200


or


1200


′.




Headlight, Sidelight, and Refractor




The vacuum


100


of the present invention, illustrated in

FIG. 1

, includes a light assembly


2900


(

FIG. 29

) having a headlight


102


and a sidelight


104


, that direct light to the front of the vacuum and to the side of the vacuum, respectively.

FIG. 29

is an exploded isometric view of the light assembly including a headlight cavity


2902


in the vacuum head


106


, a reflector assembly


2904


, a headlight lens housing


2906


, a headlight lens


2908


, a sidelight cavity


2910


, and a sidelight lens


2912


. In the preferred embodiment, the headlight


102


and the sidelight


104


are optically connected to a common or shared light source that optimizes both the forward and side lighting without comprising weight. Additionally, the headlight


102


and the sidelight


104


of the present invention do not cast a shadow in front of vacuum


100


and to the side of the vacuum


100


respectively because of the there orientation on the head housing top cover


244


and because the light from the lights


102


,


102


is projected outwardly and downwardly.




The upper front portion of the vacuum head


106


defines the headlight cavity


2902


wherein the headlight


102


is operably connected with the vacuum head


106


. The headlight cavity


2902


defines structure for engaging and retaining the reflector assembly


2904


, the headlight lens housing


2906


, and the headlight lens


2908


. The structure for engaging and retaining the reflector assembly


2904


includes a downwardly sloped reflector assembly surface


2914


, a left locating wall


2916


, a right locating wall


2918


, a guide rail


2920


, a rear wall


2922


, and a snap hole


2924


. Generally, the reflector assembly


2904


snaps into place and rests on the downwardly sloped reflector assembly surface


2914


between the left


2916


and right locating walls


2918


. Note, “left” and “right” orientation as discussed within this section is from the perspective of facing the front of the vacuum.




The structure for engaging and retaining the headlight lens housing


2906


includes a rear edge


2926


, a left side edge


2928


, a right side edge


2930


, and a front ledge


2932


. The rear edge


2926


of the headlight cavity


2902


defines a ledge


2934


to support the headlight lens housing


2906


. There are three guide slots


2936


along the rear edge


2926


of the headlight cavity


2902


that are used to guide the headlight lens housing


2906


into position during assembly. The side edges


2928


,


2930


of the headlight cavity


2902


also define a ledge


2934


to support the lens housing


2906


. The left and right locating walls


2916


,


2918


each define a bolthole


2938


(only the right bolthole


2938


is shown) for engaging corresponding bolts or screws that secure the headlight lens housing


2906


to the vacuum head


106


. Generally, the headlight lens housing


2906


is removably attached with the top cover


244


(

FIG. 2

) to provide easy access to the headlight lens


2908


and to the reflector assembly


2904


as discussed in more detail below.




The front ledge


2932


of the headlight cavity


2902


includes a left side portion


2940


, a right side portion


2942


, and a lower middle portion


2944


therebetween. The left and right side portions


2940


,


2942


are generally flat areas, and the middle portion


2944


is lower than the side portions, with downwardly sloping portions


2946


between the middle and side portions. A pair of tabs


2948


project upwardly from the lower middle portion


2944


of the front ledge


2932


. Generally, the headlight lens


2908


defines the same contour as the front ledge


2932


of the headlight cavity


2902


and rests atop the front ledge


2932


when assembled.




The headlight


102


includes the reflector assembly


2904


, the headlight lens housing


2906


, and the headlight lens


2908


. In the preferred embodiment, the reflector assembly


2904


, illustrated in

FIG. 30

, includes a first bulb


3002


and a second bulb


3004


, which are the common light source for the headlight


102


and the sidelight


104


. Utilizing the common light source provides for less heat build up, less energy consumption, and reduced weight as compared with a configuration that does not use a common light source. In addition, by using less energy for lighting, less energy is diverted from the vacuum motor to power the light bulbs, and hence a smaller motor may be used to achieve the desired vacuuming power.




The reflector assembly


2904


includes a headlight reflector


3006


and a sidelight reflector


3009


. The sidelight reflector


3009


is discussed in more detail below. The headlight reflector


3006


defines a generally vertical reflective surface


3008


and a generally horizontal reflective surface


3010


. A first reflective surface


3012


and a second reflective surface


3014


make up the vertical reflective surface


3008


. Each reflective surface


3012


,


3014


is curved or contoured in two directions. In other words, with respect to the coordinate axes shown in

FIG. 30

, each reflective surface


3012


,


3014


is curved in the vertical plane about the y axis (i.e., the x-z plane) and in the horizontal plane about the z axis (i.e., the x-y plane). Accordingly, each reflective surface


3012


,


3014


is generally hyperbolic. The generally hyperbolic reflective surfaces


3012


,


3014


are configured to direct light from the first bulb


3002


and the second bulb


3004


toward the headlight lens


2908


. As is generally known, a hyperbola defines a dish-like shape that includes a focal point. The first and second generally hyperbolic reflective surfaces were designed with the general concepts of a hyperbola in mind. However, unlike a hyperbola, the generally hyperbolic reflective surfaces


3012


,


3014


do not conform to precise mathematical definition. The goal of the generally hyperbolic reflective surfaces


3012


,


3014


is to reflect and concentrate light from the bulbs


3002


,


3004


toward the headlight lens


2908


. Accordingly, optimal use of available light from the bulbs


3002


,


3004


is utilized for lighting the area directly in front of the vacuum. Note, optimal use of available light is also utilized for lighting the area to the side of the vacuum, as discussed in more detail below with reference to the sidelight


104


.




Each generally hyperbolic reflective surface


3012


,


3014


defines a focal region


3016


,


3018


. The focal regions


3016


,


3018


are located forwardly of the generally reflective surfaces


3012


,


3014


. The first light bulb


3002


and the second light bulb


3004


, plugged into a first socket assembly


3020


and a second socket assembly


3022


, respectively, are located generally within the focal regions


3016


,


3018


of the corresponding generally hyperbolic reflective surfaces


3012


,


3014


. Each generally hyperbolic reflective surface


3012


,


3014


also defines apertures


3102


(

FIG. 31

) adjacent to the respective focal region


3016


,


3018


wherein the first socket assembly


3020


and the second socket assembly


3022


and associated wiring


3402


,


3404


(

FIG. 34

) are snapped into place. Generally, light transmitted from the focal regions


3016


,


3018


toward the associated generally hyperbolic reflective surfaces


3012


,


3014


is reflected so as to intersect the headlight lens generally transversely to the rear face of the headlight lens


2908


as discussed in further detail below.




As mentioned above, each generally hyperbolic reflective surface


3012


,


3014


is curved in two directions. In

FIG. 32

, which is a top view of the reflector assembly


2904


, the curvature of the first reflective surface


3012


in the horizontal plane is emphasized with a first dashed line


3202


, and the curvature of the second reflective surface


3014


in the horizontal plane is emphasized with a second dashed line


3204


. In

FIG. 33

, which is a cross-sectional view taken along line


33





33


of

FIG. 32

, the curvature of the first reflective surface


3012


in the vertical plane is emphasized with a third dashed line


3302


. This section is also representative of the curvature defined in the vertical plane by the second generally hyperbolic reflective surface


3014


.




Generally, in a preferred embodiment, the radii of the curvature in the horizontal plane for each generally hyperbolic reflective surface


3012


,


3014


along dashed lines


3202


,


3204


may vary from about 2.5 inches to about 8 inches. Generally, in a preferred embodiment, the radii of the curvature in the vertical plane for each generally hyperbolic reflective surface


3012


,


3014


along dashed line


3302


may vary from about 3 inches to about 4 inches. As mentioned above, for any embodiment of the reflector assembly


2904


, the curvature in the vertical plane and the curvature in the horizontal plane should be designed to reflect light transmitted from the bulbs


3002


,


3004


toward the headlight lens


2908


.




In a most preferred embodiment, the radius of the curvature of the dashed line


3202


varies from about 2.6 inches adjacent to the first socket assembly


3020


to about 7.8 inches adjacent the intersection


3024


between the first


3012


and second


3014


hyperbolic reflective surfaces. Accordingly, the curvature flattens out as one moves along the dashed line


3202


from adjacent to the first socket assembly


3020


to the intersection


3024


. Referring to the second hyperbolic reflective surface


3014


, in the most preferred embodiment the radius of the curvature of the dashed line


3204


in the horizontal plane varies from about 3.8 inches adjacent to the second socket assembly


3022


to nearly flat, i.e., no radius, adjacent to the intersection


3024


, and to about 7.5 inches adjacent a guide slot


3026


(FIG.


30


). Accordingly, the curvature flattens out from the second socket assembly


3022


to the intersection


3024


, and from the second socket assembly


3022


to the guide slot


3026


.




In the most preferred embodiment, if a series of vertical cross-sections were taken, each parallel to the vertical plane containing line


33





33


, and if dashed lines similar to dashed line


3302


were placed in each of those cross-sections, the radius of the curvature of the dashed lines in the vertical plane would vary from about 3.2 inches adjacent to the first socket assembly


3020


to about 3.3 inches adjacent the intersection


3024


. Similarly, the radius of the curvature in the vertical plane of those dashed lines would vary from about 3.8 inches adjacent the second assembly


3022


to about 3.1 inches adjacent the intersection


3024


, and to about 3.2 inches adjacent to the guide slot


3026


.




In addition to the generally vertical reflective surface


3008


, the reflector assembly includes a generally horizontal reflective surface


3010


. The generally horizontal reflective surface


3010


defines a generally flat reflective surface adjacent a bottom edge


3028


of the generally vertical reflective surface


3008


. Moving forward (i.e., away from the vertical reflective surface


3008


), the horizontal reflective surface


3010


defines a generally flat surface until just forward of the intersection


3024


. Moving forward from the intersection


3024


, the horizontal reflective surface


3010


begins to curve downwardly. As shown to good advantage in

FIG. 37

, the horizontal reflective surface


3010


thereby reflects both direct light and diffuse light from the bulbs


3002


,


3004


toward the headlight lens


2908


.




Both the generally vertical reflective surface


3008


and the generally horizontal reflective surface


3010


are reflective. Preferably, the reflector assembly


2904


is fabricated from plastic. In the preferred embodiment, the reflector assembly is coated with chrome to provide the reflective characteristic. A coating tab


3030


extends rearwardly from the reflector assembly


2904


and is used to hold the reflector assembly


2904


during the coating process.




Referring to

FIG. 31

, the rear side


3106


of the reflector assembly


2904


defines a hook


3108


and at least one pressure tab


3110


. To assemble the reflector assembly


2904


with the headlight cavity


2902


, the reflector assembly


2904


is placed between the locating walls


2916


,


2918


with the bottom side of the horizontal reflective surface


3010


on the downwardly curved


2914


reflector assembly surface. The reflector assembly


2904


is then pushed rearward until the pressure tabs


3110


abut the rear wall


2922


of the cavity


2902


, and with the guide slot


3026


(

FIG. 30

) engaging the guide rail


2920


. When the tabs


3110


abut the rear wall


2922


of the cavity


2902


, the hook


3108


will be adjacent the hook snap hole


2924


. The reflector assembly


2904


is seated within the headlight cavity


2902


by pressing rearwardly on the reflector assembly


2904


until the hook


3108


engages the hook snap hole


2924


(see FIG.


34


). When the reflector assembly


2904


is seated in the headlight cavity


2902


, the bottom of the horizontal reflective surface


3010


will generally lie on the top of the downwardly sloped reflector assembly surface


2914


with the bottom of the downwardly curving portion of the horizontal reflective surface


3010


following the downwardly curved contour of the reflector assembly surface


2914


. In the seated position, the reflector assembly


2904


is canted somewhat downwardly.





FIG. 34

is a cut-away isometric view of the reflector assembly


2904


within the light assembly cavity


2902


of the vacuum top cover


244


. As can be seen from this figure, the wiring harnesses


3404


extend through the apertures


3102


in the vertical reflective surface


3008


and through cut-outs


3406


in the rear wall


2922


of the cavity


2902


, and the sockets


3020


,


3022


on the forward end of the wiring harnesses


3404


are secured within the apertures


3102


in the vertical reflective surface


3008


. As can be further seen, the hook


3108


engages the backside of the rear wall


2922


of the headlight cavity


2902


, and the pressure tabs


3110


(shown in phantom) abut the front of the rear wall


2922


of the headlight cavity


2902


.




Referring again to FIG.


30


and to

FIG. 8

, the reflector assembly


2904


includes at least one left ventilation recess


3032


along the top edge of the vertical reflector, and at least one right ventilation recess


3034


along the top edge


3036


of the vertical reflector


3008


. The ventilation recesses


3032


,


3034


provides a pathway for air to circulate around the socket assemblies


3020


,


3022


and the light bulbs


3002


,


3004


, and hence remove heat therefrom. The air flow within the reflector assembly


2904


and within the vacuum head is discussed in detail below. Cooling the bulbs


3002


,


3004


provides for longer bulb life. In the preferred embodiment, there are two left ventilation recesses


3032


and two right ventilation recesses


3034


in the top edge


3036


of the vertical reflector


3008


, wherein at least one left vent recess and at least one right vent recess are adjacent the left and right socket assemblies


3020


,


3022


, respectively. This provides greater cooling to the socket assemblies


3020


,


3022


and the corresponding bulbs


3002


,


3004


.




The headlight


102


, as mentioned above, also includes a headlight lens housing


2906


, which is illustrated to best advantage in FIG.


35


. The headlight lens housing


2906


secures the headlight lens


2908


within the headlight cavity


2902


of the vacuum head housing


106


. The headlight lens housing


2906


defines a cover


3502


having a rear edge


3504


, and two side edges


3506


. The front of the cover defines a short downwardly extending flange


3508


, which defines the front wall of a channel


3510


(

FIG. 35



b


) adapted to engage and retain a top edge


3602


of the headlight lens


2908


. The downwardly extending flange


3508


, along the leftmost and rightmost portion of the headlight lens housing


2906


, extends downwardly defining a left front sidewall


3512


and a right front sidewall


3514


. The left and right front sidewalls


3512


,


3514


are adapted to rest on the front ledge


2932


(

FIG. 29

) of the headlight cavity


2902


when assembled with the vacuum head housing


106


. The left and right front sidewalls


3512


,


3514


each also define a channel (not shown) adapted to engage and retain the side edges


3604


,


3605


(

FIG. 36

) of the headlight lens


2908


. The channels in the sidewalls


3512


,


3514


define a recess


3516


(shown in hidden line in

FIG. 35



a


) adapted to engage a left headlight light lens snap


3606


and a right headlight lens snap


3608


, discussed below with reference to

FIG. 36

, and thereby secure the headlight lens


2908


within the channel


3510


of the headlight housing


2906


.




There are three guide tabs


3518


(

FIG. 35

) along the rear edge


3504


of the cover


3502


. The guide tabs


3518


are adapted to engage the guide slots


2936


(

FIG. 29

) along the rear ledge


2934


of the headlight cavity


2902


. In addition, there are two bolt housings


3520


,


3522


in the front left and right portions of the headlight lens housing


2906


. The bolt housings


3520


,


3522


extend downwardly from the cover


3502


of the headlight lens housing


2906


and are adapted to rest on the front left locating wall


2916


and front right locating wall


2918


, respectively, of the light assembly cavity


2902


. The headlight lens housing


2906


is assembled with the vacuum head housing


106


by guiding the guide tabs


3518


into the corresponding guide slots


2936


until the rear edge


3504


of the headlight lens housing


2906


rests on the rear ledge


2934


of the headlight cavity


2902


. In the assembled position, the bolt housings


3520


,


3522


seat directly over the left and right bolt holes


2938


. Accordingly, a bolt or screw (not shown) is inserted through the bolt housings


3520


,


3522


and tightened into the corresponding bolt holes


2938


, securing the headlight lens housing


2906


to the vacuum head housing


106


. Before securing headlight lens housing


2906


to the vacuum head housing


106


, the headlight lens


2908


, as discussed below, should be assembled with the headlight lens housing


2906


.




The headlight lens


2908


, illustrated in

FIG. 36

, is a generally rectangular lens defining a top edge


3602


, a left side edge


3604


, a right side edge


3605


, and a bottom edge


3610


. The headlight lens


2908


is made from Polycarbonate, preferably LEXAN™. The bottom edge


3610


of the headlight lens is contoured to fit along the lower front ledge


2932


of the headlight cavity


2902


. Accordingly, the bottom edge


3610


has a downwardly sloping contour from the side edges


3604


,


3605


toward a lower middle portion


3612


between the side edges


3604


,


3605


. The front view of the vacuum, illustrated in

FIG. 4

, most clearly illustrates the contour of the bottom edge


3610


of the headlight lens


2908


.




The front side


3524


(

FIG. 35

) of the headlight lens


2908


is generally flat. The rear side


3614


(

FIGS. 36 and 37

) of the headlight lens


2908


defines a refraction contour


3612


that redirects a portion of the light


3800


from the bulbs


3002


,


3004


and the reflector assembly


2904


outwardly and downwardly toward the area directly in front of the vacuum as shown in FIG.


38


. In cross section, as illustrated in

FIG. 37

, the refraction contour


3612


defines a saw tooth pattern


3702


. Each tooth in the saw tooth pattern


3702


has a long face


3704


and a short face


3706


. The saw tooth pattern


3702


is configured so that when the headlight lens


2908


is assembled with the headlight


102


, the long face


3704


of the saw tooth


3702


forms an angle of greater than


90


degrees as compared with light transmitted directly from the bulbs


3002


,


3004


, and the short face


3706


is about transverse the long face


3704


. Therefore, a portion of the light


3708


striking the refraction contour


3612


directly from the bulbs


3002


,


3004


or after reflecting off the vertical


3008


or horizontal reflective


3010


reflective surfaces is transmitted downwardly and forwardly directly in front of the vacuum. Accordingly, the surface about to be vacuumed, directly in front of the vacuum, is illuminated. A portion of the diffuse light


3710


reflected from the downwardly sloping portion


3011


of the horizontal reflective surface


3010


is also refracted directly in front of the vacuum.




A left snap


3606


and a right snap


3608


along the left edge


3604


and the right edge


3605


of the headlight lens


2908


are adapted to snap into the corresponding left recess


3516


and right recess (not shown) in the channel


3510


of the headlight lens housing


2906


. The top edge


3602


and side edges


3604


,


3605


of the headlight lens


2908


fits within the channel


3510


defined by the downwardly extending flange


3508


of the headlight lens housing


2906


and the left and right sidewalls


3512


,


3514


of the lens housing


2906


. Accordingly, the headlight lens


2908


is assembled with the headlight lens housing


2906


by sliding the headlight lens upwardly into the channels


3510


of the left and right sidewalls


3512


,


3514


of the until the snaps


3606


,


3608


engage the corresponding recesses


3516


in the left and right channels. When the headlight lens


2908


is snapped into the headlight lens housing


2906


, the top edge


3602


of the headlight lens is within the channel


3510


defined by the downwardly extending flange


3508


. The headlight lens


2908


may be removed from the headlight lens housing


2906


by flexing the headlight lens housing


2906


until the snaps


3606


,


3608


disengage and then sliding the headlight lens


2908


out of the channel


3510


.




As can be seen most clearly in FIG.


39


and

FIG. 40

, the headlight lens


2908


is offset rearwardly from the front of the vacuum head housing


106


. This protects the headlight lens


2908


from collision with various objects during vacuuming. The rearward offset of the headlight lens is achieved by rearwardly offsetting the channel


3510


in the headlight lens housing


2906


in which the headlight lens


2908


is inserted, and rearwardly offsetting the headlight lens housing


2906


itself so that the headlight lens housing


2906


is recessed slightly within the top cover


244


of the vacuum head housing


106


. In the most preferred embodiment, these offsets and recesses are a few thousandths of an inch.




Referring again to

FIG. 29

, the light assembly


2900


of the present invention also includes the sidelight


104


(FIG.


1


), which includes the reflector assembly


2904


, and the sidelight lens


2912


. Referring to

FIG. 30

, the reflector assembly


2904


includes the sidelight reflector


3009


. Light transmitted directly from the left bulb


3002


, and light reflected from the vertical reflective surface


3008


and horizontal reflective surface


3010


is transmitted directly and by way of the sidelight reflector


3009


, to a sidelight lens


2912


. The sidelight lens is affixed within a recess


2950


in the left sidewall of the vacuum head housing


106


. The sidelight cavity


2910


, mentioned above, extends between the recess


2950


and the headlight cavity


2902


. The sidelight lens


2912


is fixed, preferably by ultrasonic welding, within the recess


2950


. Accordingly, as shown to good advantage in

FIG. 41

, the sidelight


104


and the headlight


102


use a common light source, which, in the preferred embodiment, are the light bulbs


3002


,


3004


.




A section view of the sidelight lens


2912


, taken along line


43





43


of

FIG. 29

, is shown in FIG.


43


. The rear


4302


of the sidelight lens


2912


defines a refraction contour


4304


. The refraction contour


4304


defines a saw tooth pattern


4306


, with each tooth having a long face


4308


and short face


4310


. Light incident on the long faces


4308


is directed downwardly and outwardly from the sidelight lens


2912


.

FIG. 42

generally illustrates a preferred light distribution pattern


4202


from the sidelight


104


. As can be seen, light is directed downwardly and outwardly from the left side of the vacuum head housing


106


. Accordingly, the area that will be swept by the side brushes


410


is illuminated.




The sidelight reflector


3009


is a part of the reflector assembly


2904


and includes an upper sidelight reflector


3038


and a lower sidelight reflector


3040


. The upper sidelight reflector


3038


is generally vertical and is adjacent the left most portion of the first hyperbolic reflective surface


3012


. The lower sidelight reflector


3040


is generally transverse the upper sidelight reflector


3038


and canted upwardly from the horizontal reflective surface


3010


toward the sidelight lens


2912


. When installing the reflector assembly


2904


within the headlight cavity


2902


, the sidelight reflector portion


3009


is inserted into the sidelight cavity


2910


. The sidelight reflector portion


3009


of the reflector assembly


2904


gathers light from the reflector assembly


2904


and transmits it toward the sidelight lens


2912


.




The headlight


102


and the sidelight


104


of the present invention provide several advantages over the prior art headlight systems. For example, because the vertical reflective surface


3008


is contoured in two planes of curvature, the light from the light bulbs


3002


,


3004


is generally more concentrated and may provide improved illumination of the floor surface in front of the vacuum head housing


106


. This also allows the wattage of the light bulbs


3002


,


3004


to be reduced to reduce the buildup of unwanted heat within the front headlight cavity


2902


. Also, because the reflective assembly includes the horizontal reflective surface


3010


with the downwardly-sloped forward portion


3011


, the headlight


102


provides improved illumination of the floor surface in front of the vacuum head housing


106


. Because the headlight lens housing


2906


, including the headlight lens


2908


, is removable, the light assembly


2900


is easier to clean and maintain. The sidelight


104


advantageously lights the floor surface proximate the lateral side of the vacuum head housing


106


, allowing the operator to better view this area of the floor surface


404


in dimly-lighted conditions.




Air Flow





FIG. 8

illustrates a schematic cross-sectional view of the vacuum head housing


106


with the head housing top cover


244


connected with the head housing bottom cover


222


. The arrows shown in

FIG. 8

generally illustrate a primary tortuous path


802


(shown as solid arrows) and a secondary tortuous path


804


(shown as dashed arrows) by which air flows through the vacuum head housing


106


. Air flow through the vacuum head housing


106


advantageously provides cooling for the motor


204


, provides cooling for the bulbs


3002


,


3004


, and provides cooling for the socket assemblies


3020


,


3022


.




The air flow is considered tortuous because the air is not allowed, by design, to flow in the most direct path from the air intake port


3902


(FIG.


39


), which preferably comprises a plurality of slots, past the various components that need cooling, and out the air exhaust port


3904


, which also preferably comprises a plurality of slots having the air intake port


3902


on a different side of the vacuum head housing


106


from the side having the air exhaust port


3904


helps to reduce the likelihood that hot air exiting the air exhaust port


3904


will be immediately drawn back into the air intake port


3902


. Creating one or more tortuous air flow paths


802


,


804


slows the air flow, which in turn allows the vacuum to run quieter than vacuums with a nontortuous air flow pattern. The tortuous air flow path, however, does not sacrifice cooling.




Referencing most specifically

FIG. 8

, air flow through the primary tortuous path


802


is driven primarily by the rotation of the exposed cooling vanes


801


attached with the drive shaft


206


of the motor


204


. Air enters through the air intake port


3902


on the side of the head housing top cover


244


. After entering the vacuum head housing


106


, the air strikes a baffle plate


806


. The baffle plate


806


diverts the air flow around the baffle plate, slowing the air flow down, and generally quieting the cooling operation. The baffle plate


806


also helps ensure that exhaust air, discussed below, will not be inadvertently exhausted through the air intake port


3902


.




After passing the baffle plate


806


, the air flows into and through the motor


204


generally along the drive shaft. Air flow through the motor


204


provides cooling for the motor and related electronic components. The air is pulled through the motor


204


along the drive shaft


210


by operation of the cooling vanes


801


, which rotate along with the drive shaft


210


. The air then flows transversely away from the drive shaft


210


. For the primary tortuous path


802


, the air flows rearwardly in the vacuum head housing


106


toward the air exhaust port


3904


. Before exhausting, however, the air encounters at least one exhaust baffle


810


. As with the baffle


806


, the exhaust baffle


810


slows and diverts the air flow and hence quiets the air flow. Finally, after passing the exhaust baffle


810


, the air flows past the scent cartridge assembly


234


and out through the air exhaust port


3904


. The scent cartridge is discussed further below.




Air flow along the primary tortuous path


802


is generally restricted to a motor chamber area


808


. The motor chamber


808


generally includes the space bounded by the rear wall of the headlight cavity


2902


, the back end of the vacuum head housing


106


, the side surface of the vacuum head housing, and the abutting cooperation between an upper motor retaining wall


712


projecting downwardly from the head housing top cover


244


and a lower motor retaining wall


714


projecting upwardly from the head housing bottom cover


222


. The retaining walls


712


,


714


define an aperture that helps secure the motor


204


in place.




Air flow through the secondary tortuous path


804


is also driven primarily by the cooling vanes. The air flow path through the air intake port


3902


, past the baffle


806


, and through the motor


204


is generally the same as the primary tortuous path


802


. The air flow of the secondary tortuous path


804


, unlike the primary tortuous path


802


, is forced forwardly toward the right wiring harness aperture


3102




a.


The air flow then passes through the cut-out


3406


(see also

FIG. 34

) in the rear wall


2922


of the headlight cavity


2902


, and then through the right ventilation recesses


3034


. The air must flow non-linearly, upward and somewhat laterally, from the cut-out


3406


to the ventilation recesses


3034


. Accordingly, as with the baffles


806


,


810


the nonlinear air flow path causes the air to slow down somewhat and hence provides a quieting effect. The air flow then moves past the right socket assembly


3022


and past the right bulb


3004


removing heat therefrom. Air then moves from the right to the left in

FIG. 8

, through the inner area defined by the reflector assembly


2904


, the headlight lens housing


2906


, and the headlight lens


2908


. Air then exits the reflector assembly


2904


through the ventilation recesses


3032


, and passes through the cut-out


3406


behind the bulb


3002


. The warm air finally flows into the generally chamber like area


812


of the vacuum head housing


106


, behind the rear wall


2922


of the headlight cavity


2902


. The warm air then generally seeps outwardly from the vacuum head housing


106


. The generally chamber like area


812


includes the space bounded by the rear wall of the headlight cavity


2902


, the back end of the vacuum head housing


106


, a side surface of the vacuum head housing, and the abutting cooperation between an upper impeller fan housing retaining wall


716


and a lower impeller fan housing retaining wall


718


.




Scent Cartridge




As previously discussed and as best shown in

FIGS. 5

,


8


, and


40


, the air intake port


3902


is disposed through the left side of the top cover


244


. As best shown in

FIGS. 8

,


34


,


39


, and


44


-


47


, an air exhaust port


3904


is disposed through the rear side of the top cover


244


. In operation, a flow of cooling air (represented by the series of arrows in

FIG. 8

) is generated by the motor


204


as previously discussed. This cooling air flows through the intake port


3902


, along one or more tortuous paths


802


,


804


through the vacuum head housing


106


, through the scent cartridge assembly


234


, and out of the air exhaust port


3904


. The scent cartridge assembly


234


may advantageously impart a fragrance to the cooling air, which then passes through the air exhaust port


3904


into the surrounding environment. In an alternate embodiment, the scent cartridge assembly


234


may include a filter member


238


(FIGS.


2


and


8


). Preferably, the filter member


238


is capable of filtering carbon from the cooling air flow that may be emitted from the motor


204


. Thus, the scent cartridge assembly


234


may advantageously improve the fragrance of the cooling air, while reducing particulates borne in the cooling air, thereby improving the operator's satisfaction with the vacuum cleaner


100


.




Indicator Lights




As shown to best advantage in

FIGS. 1

,


29


,


48


, and


49


, the vacuum head housing


106


includes a light pipe indicator unit


114


that engages into an elliptical recess


2952


(

FIGS. 29 and 48

) in the curved upper surface


116


of the top cover


244


.

FIG. 48

shows an enlarged, fragmentary top isometric view of the light pipe indicator unit


114


exploded above the elliptical recess


2952


. As shown, the light indicator unit


114


has four light pipes


4800


, which ride above and slightly displaced from LEDs


4900


on a circuit board


4802


. The LEDs


4900


could selectively illuminate upon the occurrence of a predetermined condition (e.g., belt broken, vacuum clogged, bag full). Upon illumination of a particular LED, light from the LED would be transmitted or “piped” to the upper surface


116


of the top cover


244


, where it would be observed by the user. When the light pipe indicator unit


114


is installed in the elliptical recess


2952


and retained in position by the retention clips


4901


, the light pipes


4800


extend below the inside of the curved upper surface


116


. The circuit board


4802


, which is mounted to stalactite bosses


4904


extending downwardly from the inside of the curved upper surface


116


by mounting screws


4906


, is positioned adjacent to, but displaced slightly from, the free distal ends of the light pipes


4800


. Thus, if the upper surface of the top cover


244


flexed downwardly during operation or abuse of the vacuum


100


, the possibility of that causing damage to the circuit board


4802


is reduced.




Although various embodiments of this invention have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.



Claims
  • 1. A squeegee attached to a bottom of a vacuum head proximate a suction inlet, the squeegee comprising:(a) a main body having a front portion, a rear portion, and an intermediate portion; (b) a flexible hinge attached to the intermediate portion, wherein said intermediate portion comprises a bottom surface defining a rearward deflection stop; and (c) a wiper blade continuously attaching to the flexible hinge.
  • 2. The squeegee as defined in claim 1, wherein said front portion further having a rear portion defining a forward deflection stop.
  • 3. A squeegee as defined in claim 1, wherein said intermediate portion and said front portion define a downwardly open channel, and said flexible hinge is positioned in said channel.
  • 4. A squeegee as defined in claim 2, wherein a channel is formed by the rearward deflection stop and the forward deflection stop.
  • 5. A squeegee as defined in claim 1, wherein said main body is formed by co-extrusion, with said main body and said wiper blade being a relatively hard material, and said hinge being a relatively flexible material.
  • 6. The squeegee as defined in claim 1, wherein said front portion and said rear portion attaching to said bottom of said vacuum head.
  • 7. A squeegee as defined in claim 6, wherein said front portion attaching to said bottom of said vacuum head by an interlocking structure.
  • 8. A squeegee as defined in claim 7, wherein said bottom of said vacuum head defines a protrusion, and wherein said front portion defines a recess matching the protrusion, and further wherein said protrusion is received in said recess to secure said squeegee to said vacuum head.
  • 9. A squeegee as defined in claim 8, wherein said protrusion is curved, and wherein said recess is curved to match and receive the protrusion.
  • 10. A squeegee as defined in claim 9, wherein said protrusion is L-shaped, and wherein said recess is L-shaped to match and receive the protrusion.
  • 11. A squeegee as defined in claim 7, wherein said interlocking structure is a tongue-in-groove structure.
  • 12. A squeegee as defined in claim 6, wherein said intermediate portion and said wiper blade are connected by a hinge.
  • 13. A squeegee as defined in claim 12, wherein said main body is made of a relatively hard material and said hinge is made of a relatively soft material.
  • 14. A squeegee as defined in claim 13, wherein said main body is an extrusion.
  • 15. A squeegee as defined in claim 14, wherein said hinge is an extrusion.
  • 16. A squeegee as defined in claim 15, wherein said extrusion is a co-extrusion to form the relatively hard material and the relatively soft material simultaneously.
  • 17. A squeegee as defined in claim 6, wherein said main body and said wiper blade are one integral part.
US Referenced Citations (8)
Number Name Date Kind
3079623 Congdon Mar 1963 A
4219902 DeMaagd Sep 1980 A
4475265 Berfield Oct 1984 A
4864682 Bewley et al. Sep 1989 A
5054159 Richardson Oct 1991 A
5517717 Haberli May 1996 A
5794297 Muta Aug 1998 A
6094776 Fish Aug 2000 A
Foreign Referenced Citations (1)
Number Date Country
885613 Dec 1960 GB