Vacuum cleaner with noise suppression features

• US 7,114,216 B2
• Filed: 12/30/2003
• Issued: 10/03/2006
• Est. Priority Date: 01/12/2001
• Status: Expired due to Term

• Current Assignee: Royal Appliance Manufacturing Company (Techtronic Industries Company Limited)
• Original Assignee: Royal Appliance Manufacturing Company (Techtronic Industries Company Limited)
• Inventors: Paliobeis, Steven J., Kalman, Jeffrey M., Stephens, Paul D., Thur, Charles J.
• Primary Examiner(s): Till, Terrence R.
• Application Number:
  US10/751,077
• Publication Number:
  US 20040139573A1
• Time in Patent Office: 1,008 Days
• Field of Search: 153/47, 15350-353, 153/271, 153/272, 153/276, 153/277, 553/37, 554/29, 554/591, 55D/IG.3, 554/82
• US Class Current: 15/326
• CPC Class Codes: A47L 5/28 Suction cleaners with handles and nozzles fixed on the casings, e.g. wheeled suction cleaners with steering handle A47L5/24 takes precedence
• CPC Class Codes: A47L 9/0081 Means for exhaust-air diffusion; Means for sound or vibration damping
• CPC Class Codes: A47L 9/127 tube- or sleeve-shaped
• CPC Class Codes: A47L 9/1409 Rigid filtering receptacles dust collecting receptacles for cyclones A47L9/1683
• CPC Class Codes: A47L 9/165 Construction of inlets
• CPC Class Codes: A47L 9/1666 with filtering means
• CPC Class Codes: A47L 9/22 Mountings for motor fan assemblies
• CPC Class Codes: Y10S 55/03 Vacuum cleaner

Abstract

A vacuum cleaner includes a cyclonic airflow chamber that facilitates the separation of contaminants from a suction airstream. The airflow chamber includes a chamber inlet and a chamber outlet, with the chamber inlet being fluidically connected with at least one of a suction nozzle and an above-the-floor cleaning tool. An exhaust filter housing includes a suction duct and an exhaust plenum, with the suction duct communicating with the chamber outlet. A suction source housing includes an open end communicating with the exhaust plenum and a closed end. A suction source is positioned within the suction source housing to define an annular exhaust flow passageway surrounding the suction source from the housing closed end to the housing open end. The suction source includes a suction inlet communicating with the suction duct and an exhaust outlet communicating with the housing closed end.

Claims

1. A vacuum cleaner comprising:

a cyclonic airflow chamber that facilitates the separation of contaminants from a suction airstream, said airflow chamber including a chamber inlet and an axial chamber outlet, said chamber inlet being fluidically connected with at least one of a suction nozzle and an above-the-floor cleaning tool;

an exhaust filter housing including an exhaust plenum;

a primary filter assembly mounted in said cyclonic airflow chamber upstream from said suction source for filtering contaminants from said suction airstream;

a suction source housing;

a suction duct connecting said axial chamber outlet with said suction source housing, said suction duct surrounded by said exhaust filter housing and extending downward along an axis of said cyclonic airflow chamber;

a suction source positioned within said suction source housing, said suction source including a suction inlet communicating with said suction duct and an exhaust outlet communicating with said exhaust filter housing; and

a diverter located at said chamber inlet, wherein said diverter directs said suction airstream to flow tangentially within said chamber.

2. The vacuum cleaner of claim 1, wherein said primary filter assembly includes a filter element with a polytetrafluoroethylene (PTFE) filter medium.

3. The vacuum cleaner of claim 1, wherein said diverter is associated with a lid that is removable from said chamber.

4. The vacuum cleaner claim 1, further comprising an exhaust filter positioned within said exhaust filter housing.

5. The vacuum cleaner of claim 4, wherein said exhaust filter comprises a high efficiency particulate arrest (HEPA) filter medium.

6. The vacuum cleaner of claim 4, wherein the cyclonic airflow chamber, exhaust filter housing, and suction source housing are associated with a vacuum cleaner upper assembly, and the vacuum cleaner upper assembly is pivotally secured to a nozzle base.

7. The vacuum cleaner of claim 1, wherein said cyclonic airflow chamber is defined by a dirt cup that retains debris separated from said suction airstream, said dirt cup being removable from the exhaust filter housing.

8. The vacuum cleaner of claim 7, further including a primary filter assembly centrally mounted within said dirt cup, said cyclonic airflow chamber being defined between said dirt cup and said primary filter assembly.

9. A vacuum cleaner comprising:

a cyclonic airflow chamber that facilitates the separation of contaminants from a suction airstream, said airflow chamber including a first chamber inlet, a second chamber inlet spaced from said first chamber inlet, and an axial chamber outlet, wherein said first chamber inlet communicates with a suction nozzle and said second chamber inlet communicates with an above-the-floor cleaning tool;

an exhaust filter housing including an exhaust plenum;

a suction source housing;

a suction source positioned within said suction source housing, said suction source including a suction inlet communicating with a suction duct and an exhaust outlet communicating with said exhaust filter housing; and

a diverter located at said chamber inlet, wherein said diverter directs said suction airstream to flow tangentially within said chamber.

10. A vacuum cleaner comprising:

a cyclonic airflow chamber that facilitates the separation of contaminants from a suction airstream, said airflow chamber including a chamber inlet and an axial chamber outlet, said chamber inlet being fluidically connected with at least one of a suction nozzle and an above-the-floor cleaning tool;

an exhaust filter housing including an exhaust plenum;

a suction source housing;

a suction duct connecting said axial chamber outlet with said suction source housing, said suction duct extending along an axis of said cyclonic airflow chamber;

a suction source positioned within said suction source housing, said suction source including a suction inlet communicating with said suction duct and an exhaust outlet communicating with said exhaust filter housing; and

a diverter located at said chamber inlet, wherein said diverter directs said suction airstream to flow tangentially within said chamber, wherein the cyclonic airflow chamber, exhaust filter housing, and suction source housing are associated with a vacuum cleaner upper assembly, and the vacuum cleaner upper assembly is pivotally secured to a nozzle base and said chamber outlet, said suction duct, and said suction inlet are axially positioned parallel to a central longitudinal axis of the upper assembly.

11. A vacuum cleaner comprising:

a cyclonic airflow chamber that facilitates the separation of contaminants from a suction airstream, said airflow chamber including a chamber inlet and an axial chamber outlet, said chamber inlet being fluidically connected with at least one of a suction nozzle and an above-the-floor cleaning tool;

an exhaust filter housing including an exhaust plenum;

a suction source housing;

a suction source positioned within said suction source housing, said suction source including a suction inlet communicating with a suction duct and an exhaust outlet communicating with said exhaust filter housing;

a bleed air port communicating with said suction duct; and

a diverter located at said chamber inlet, wherein said diverter directs said suction airstream to flow tangentially within said chamber.

12. A vacuum cleaner comprising:

a base unit;

a housing pivotally mounted on said base unit;

a suction source mounted to one of said base unit and said housing;

a dirt receptacle mounted to said housing, said dirt receptacle comprising a base wall, a side wall and an open upper end;

a filter removably mounted in said dirt receptacle;

a lid selectively covering said open upper end of said dirt receptacle, wherein said lid comprises a diverter wall to channel an airstream flowing into said dirt receptacle into a cyclonic flow; and

a stem extending from said base wall of said dirt receptacle.

13. The vacuum cleaner of claim 12 wherein said stem surrounds an opening extending through said base wall.

14. The vacuum cleaner of claim 12 wherein said filter is mounted on said stem.

15. The vacuum cleaner of claim 14 wherein said filter sealingly engages said stem.

16. The vacuum cleaner of claim 15 wherein said filter comprises a filter ring engaging said stem.

17. The vacuum cleaner of claim 12 wherein said filter comprises a pleated filter medium.

18. The vacuum cleaner of claim 12 further comprising a frame for supporting said filter.

19. The vacuum cleaner of claim 12 wherein said stem is of one piece with said dirt receptacle.

20. The vacuum cleaner of claim 12 wherein said stem extends approximately parallel to said side wall of said dirt receptacle.

21. The vacuum cleaner of claim 12 further comprising a raised area located on said dirt receptacle base wall.

22. The vacuum cleaner of claim 21 wherein said stem protrudes from said raised area.

23. The vacuum cleaner of claim 12 wherein said filter is approximately cylindrical in shape.

24. The vacuum cleaner of claim 23 wherein said filter comprises a thermoplastic material.

25. A vacuum cleaner comprising:

a nozzle base comprising a suction inlet;

a housing pivotally mounted on said nozzle base;

a suction source mounted to one of said nozzle base and said housing, said suction inlet communicating with said suction source;

a dirt receptacle mounted to said housing, said dirt receptacle comprising a base wall, a side wall and an open upper end;

a stem protruding from said base wall;

a filter assembly, comprising a first filter, removably mounted on said stem; and

,

a lid selectively covering an open upper end of said dirt receptacle, wherein said lid comprises a diverter wall for directing airflow into said dirt receptacle.

26. The vacuum cleaner of claim 25 further comprising a second filter, spaced from said first filter.

27. The vacuum cleaner of claim 26 wherein at least one of said first and second filters comprises a high efficiency particulate arrest (HEPA) filter material.

28. The vacuum cleaner of claim 25 wherein said stem surrounds an opening extending through said base wall.

29. The vacuum cleaner of claim 25 wherein said filter assembly sealingly engages said stem.

30. The vacuum cleaner of claim 29 wherein said filter assembly comprises a filter ring engaging said stem.

31. The vacuum cleaner of claim 25 wherein said filter assembly comprises a closed upper end.

32. The vacuum cleaner of claim 31 wherein said upper end comprises a cap.

33. The vacuum cleaner of claim 25 wherein said first filter comprises a pleated filter medium.

34. The vacuum cleaner of claim 25 wherein said filter assembly further comprises a frame for supporting said first filter.

35. The vacuum cleaner of claim 25 wherein said stem is of one piece with said dirt receptacle.

36. The vacuum cleaner of claim 25 wherein said stem extends approximately parallel to said side wall of said dirt receptacle.

37. The vacuum cleaner of claim 25 further comprising a raised area located on said dirt receptacle base wall.

38. The vacuum cleaner of claim 37 wherein said stem protrudes from said raised area.

39. The vacuum cleaner of claim 25 wherein said filter assembly is approximately cylindrical in shape.

40. A vacuum cleaner comprising:

a base unit, including a nozzle opening;

a housing pivotally mounted on said base unit;

a suction source mounted to said housing and communicating with said nozzle opening;

a dirt receptacle mounted to said housing, said dirt receptacle comprising a base wall, a side wall and an open upper end, said dirt receptacle comprising a filtration chamber;

a filter removably mounted in said filtration chamber, the filter comprising a closed upper end;

a lid selectively covering said open upper end of said dirt receptacle;

an inlet to said filtration chamber, said inlet being located in said lid; and

,

an outlet from said filtration chamber, said outlet being located on said dirt receptacle base wall.

41. The vacuum cleaner of claim 40 wherein said upper end comprises a cap.

42. The vacuum cleaner of claim 40 wherein said filter comprises a pleated filter medium.

43. The vacuum cleaner of claim 40 further comprising a frame for supporting said filter.

44. A vacuum cleaner comprising:

a base unit, including a nozzle opening;

a housing pivotally mounted on said base unit;

a suction source mounted to one of said base unit and said housing and communicating with said nozzle opening;

a dirt receptacle mounted to said housing, said dirt receptacle comprising a base wall, a side wall and an open upper end, said dirt receptacle comprising a filtration chamber;

a filter removably mounted in said filtration chamber;

a lid selectively covering said open upper end of said dirt receptacle;

an inlet to said filtration chamber, said inlet being located in said lid; and

,

an outlet from said filtration chamber, said outlet being located on said dirt receptacle base wall said outlet of said filtration chamber comprises a stem protruding from said dirt receptacle base wall.

45. The vacuum cleaner of claim 44 wherein said stem surrounds an opening extending through said base wall.

46. The vacuum cleaner of claim 44 wherein said filter sealingly engages said stem.

47. The vacuum cleaner of claim 46 wherein said filter comprises a filter ring engaging said stem.

48. The vacuum cleaner of claim 44 wherein said stem is of one piece with said dirt receptacle.

49. The vacuum cleaner of claim 44 wherein said stem extends approximately parallel to said side wall of said dirt receptacle.

50. The vacuum cleaner of claim 44 further comprising a raised area located on said dirt receptacle base wall.

51. The vacuum cleaner of claim 44 wherein said lid comprises a diverter wall to channel an airstream flowing into said filtration chamber into a cyclonic flow.

52. The vacuum cleaner of claim 44 wherein said filter comprises a closed upper end.

53. A vacuum cleaner comprising:

a base unit, including a nozzle opening;

a housing pivotally mounted on said base unit;

a dirt receptacle mounted to said housing, said dirt receptacle comprising a base wall, a side wall and an open upper end, said dirt receptacle comprising a filtration chamber;

a filter removably mounted in said filtration chamber;

a suction source mounted to one of said base unit and said housing and communicating with said nozzle opening via said filtration chamber;

a lid selectively covering said open upper end of said dirt receptacle;

a tangential inlet to said filtration chamber, said inlet being located in said lid; and

,

an axial outlet from said filtration chamber, said outlet being located on said dirt receptacle base wall, said outlet of said filtration chamber comprising a stem protruding from said dirt receptacle base wall.

54. The vacuum cleaner of claim 53 wherein said stem surrounds an opening extending through said base wall.

55. The vacuum cleaner of claim 54 wherein said filter sealingly engages said stem.

56. The vacuum cleaner of claim 53 wherein said axial outlet from said filtration chamber communicates with an inlet of said suction source.

57. The vacuum cleaner of claim 53 wherein said stem is of one piece with said dirt receptacle.

58. The vacuum cleaner of claim 53 wherein said stem extends approximately parallel to said side wall of said dirt receptacle.

59. The vacuum cleaner of claim 53 wherein said stem extends approximately parallel to said side wall of said dirt receptacle.

60. The vacuum cleaner of claim 53 further comprising a raised area located on said dirt receptacle base wall.

61. The vacuum cleaner of claim 60 wherein said stem is positioned on said raised area.

62. The vacuum cleaner of claim 53 wherein said filter comprises a pleated filter medium.

63. The vacuum cleaner of claim 53 further comprising a frame for supporting said filter.

64. The vacuum cleaner of claim 53 wherein said tangential inlet to said filtration chamber comprises a diverter wall located on said lid.

65. A vacuum cleaner comprising:

a base unit, including a nozzle opening;

a housing pivotally mounted on said base unit;

a dirt receptacle mounted to said housing, said dirt receptacle comprising a base wall, a side wall and an open upper end, said dirt receptacle comprising a filtration chamber;

a filter removably mounted in said filtration chamber, said filter comprising a closed upper end;

a suction source mounted to one of said base unit and said housing and communicating with said nozzle opening via said filtration chamber;

a lid selectively covering said open upper end of said dirt receptacle;

a tangential inlet to said filtration chamber, said inlet being located in said lid; and

,

an axial outlet from said filtration chamber, said outlet being located on said dirt receptacle base wall.

66. The vacuum cleaner of claim 65 wherein said upper end comprises a cap.