AC/DC hand portable wet/dry vacuum having improved portability and convenience

• US 7,653,963 B2
• Filed: 08/13/2003
• Issued: 02/02/2010
• Est. Priority Date: 11/12/2002
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Goger, Jason M, Potter, Christine H, Lopano, Daniel N, Watson, James B, Cochran, John R
• Primary Examiner(s): Redding; David A
• Application Number:
  US10/640,267
• Publication Number:
  US 20040088817A1
• Time in Patent Office: 2,365 Days
• Field of Search: 153/01, 153/14, 153/23, 153/271, 153/272, 153/275, 153/276, 153/39, 15D/IG.1
• US Class Current: 15/323
• CPC Class Codes: A47L 11/4019 Fill level sensors; Security means to prevent overflow, e.g. float valves
• CPC Class Codes: A47L 5/14 cleaning by blowing-off, also combined with suction cleaning
• CPC Class Codes: A47L 5/24 Hand-supported suction cleaners
• CPC Class Codes: A47L 5/36 Suction cleaners with hose between nozzle and casing; Suction cleaners for fixing on staircases; Suction cleaners for carrying on the back
• CPC Class Codes: A47L 7/0028 Security means, e.g. float valves or level switches for preventing overflow
• CPC Class Codes: A47L 7/0038 with means for emptying the tanks
• CPC Class Codes: A47L 7/0042 Gaskets; Sealing means
• CPC Class Codes: A47L 9/0009 Storing devices winding devices for electric cables A47L9/26; Supports, stands or holders
• CPC Class Codes: A47L 9/0027 specially adapted for holding the suction cleaning tools
• CPC Class Codes: A47L 9/0045 specially adapted for holding the suction tube
• CPC Class Codes: A47L 9/22 Mountings for motor fan assemblies
• CPC Class Codes: A47L 9/242 Hose or pipe couplings
• CPC Class Codes: A47L 9/26 Incorporation of winding devices for electric cables devices specially adapted for repeatedly paying-out or re-storing cables B65H75/34; arrangements of electrical cables or lines between relatively-movable parts H02G11/00
• CPC Class Codes: A47L 9/2878 Dual-powered vacuum cleaners, i.e. devices which can be operated with mains power supply or by batteries
• CPC Class Codes: A47L 9/2889 Safety or protection devices or systems, e.g. for prevention of motor over-heating or for protection of the user
• CPC Class Codes: H02J 2207/40 adapted for charging from various sources, e.g. AC, DC or multivoltage
• CPC Class Codes: Y10S 15/01 Rechargeable batter

Abstract

A wet/dry utility vacuum with a canister, a powerhead assembly with a fan, a shut-off device that prevents the fan from drawing liquids into the fan inlet when a volume of the liquid in the canister exceeds a predetermined volume. The powerhead assembly includes a controller that permits the utility vacuum to be operated in a desired power mode so that the user may employ either an AC power source or a DC power source, such as a battery pack, for example. In some applications, the battery pack may be interchangeable with the battery packs of various cordless tools, including drill/drivers and saws. A tool set and a method for operating a battery-powered tool set are also provided.

Claims

1. A method for operating a battery-powered tool set, the tool set including a utility vacuum and a power tool, the utility vacuum having a powerhead assembly and a canister removably coupled to the powerhead assembly, the powerhead assembly including a powerhead housing, a fan inlet, a fan, a motor for providing rotary power to the fan, a receptacle assembly and an electric circuit, the method comprising:

coupling a filter to the powerhead assembly such that the filter is located upstream and in fluid communication with the fan inlet;

uncoupling the battery pack from the power tool;

moving a lid that is movably coupled to the powerhead housing to expose the receptacle assembly;

coupling the battery pack to the utility vacuum by sliding the battery pack into the receptacle assembly such that a plurality of battery pack terminals couple to a plurality of receptacle terminals associated with the receptacle assembly to thereby provide the utility vacuum with a cordless source of electrical power; and

moving the lid to cover the battery pack and the receptacle assembly;

wherein the receptacle assembly includes a receptacle housing that is coupled to and extends outwardly from the powerhead housing.

2. A utility vacuum comprising:

a canister;

a powerhead assembly coupled to the canister and having a fan inlet, a fan, a motor for providing rotary power to the fan, a receptacle assembly and an electric circuit for distributing electrical power to the motor, the fan being in fluid communication with the fan inlet;

a filter coupled to the powerhead assembly and in fluid communication with the fan inlet upstream of the motor;

a shut-off device associated with the powerhead assembly, the shut-off device being configured to prevent the fan from drawing a liquid into the fan inlet when a volume of the liquid in the canister exceeds a predetermined volume; and

a flexible hose assembly that is configured to be coupled to the powerhead assembly;

wherein the electric circuit is adapted to receive a source of direct current power from a direct current power source and to provide the direct current power to the motor;

wherein the receptacle assembly includes a receptacle housing and a connector, the receptacle housing defining at least a portion of an exterior surface of the powerhead assembly and being adapted to receive a battery pack, the connector having a plurality of terminals that are configured to electrically detachably couple the battery pack to the electric circuit;

wherein the powerhead assembly includes an inlet and an outlet and wherein the hose assembly includes a hook that engages the powerhead assembly when the hose assembly is coupled to at least one of the inlet and the outlet to resist removal of the hose from the at least one of the inlet and the outlet;

wherein the hose assembly further includes a body that is configured to be received into the at least one of the inlet and the outlet; and

wherein the hook includes at least one post that is disposed generally perpendicular to a longitudinal axis of the body.

11. The utility vacuum of claim 2, wherein a cooling air intake aperture and a cooling air discharge aperture are formed in the powerhead assembly, the cooling air discharge aperture being associated with the outlet so that air flowing through the outlet blows across the cooling air discharge aperture to set up a zone of relatively low pressure that causes air to be drawn out of the cooling air discharge aperture to thereby cool the motor.

12. The utility vacuum of claim 11, wherein the cooling air intake aperture is positioned proximate the inlet.

13. The utility vacuum of claim 11, wherein the cooling air intake aperture is positioned concentric about the inlet.

3. A utility vacuum comprising:

a canister;

a powerhead assembly coupled to the canister and having a fan inlet, a fan, a motor for providing rotary power to the fan, a receptacle assembly and an electric circuit for distributing electrical power to the motor, the fan being in fluid communication with the fan inlet;

a flexible hose that is configured to be coupled to the powerhead assembly;

a filter coupled to the powerhead assembly and in fluid communication with the fan inlet upstream of the motor; and

a shut-off device associated with the powerhead assembly, the shut-off device being configured to prevent the fan from drawing a liquid into the fan inlet when a volume of the liquid in the canister exceeds a predetermined volume;

wherein the electric circuit is adapted to receive a source of direct current power from a direct current power source and to provide the direct current power to the motor; and

wherein the receptacle assembly includes a receptacle housing and a connector, the receptacle housing defining at least a portion of an exterior surface of the powerhead assembly and being adapted to receive a battery pack, the connector having a plurality of terminals that are configured to electrically detachably couple the battery pack to the electric circuit;

wherein the powerhead assembly includes a housing in which the fan, the motor and the electric circuit are housed, the housing including an inlet and an outlet, wherein operation of the utility vacuum draws an intake flow of air into the canister through the inlet and discharges a discharge flow of air through the outlet, wherein a compartment is defined by the housing and a lid, the lid being rotatable relative to the housing between an open condition and a closed condition, and wherein the battery is adapted to be received in the compartment;

wherein the utility vacuum further comprise a latch that can be engaged to maintain the lid in the second condition, the latch including a first latch element that is coupled to the lid and a second latch element that is coupled to the housing, the first and second latch elements being engaged to one another to engage the latch, and wherein the second latch element is not threaded; and

wherein the inlet and the outlet are located on opposite sides of the housing and the flexible hose is positionable in a storage position wherein a first end of the flexible hose is coupled to the inlet and a second end of the flexible hose opposite the first end is received in the outlet.

4. A utility vacuum comprising:

a canister;

a powerhead assembly coupled to the canister and having a fan inlet, a fan, a motor for providing rotary power to the fan, a receptacle assembly and an electric circuit for distributing electrical power to the motor, the fan being in fluid communication with the fan inlet;

a flexible hose that is configured to be coupled to the powerhead assembly;

a filter coupled to the powerhead assembly and in fluid communication with the fan inlet upstream of the motor;

a shut-off device associated with the powerhead assembly, the shut-off device being configured to prevent the fan from drawing a liquid into the fan inlet when a volume of the liquid in the canister exceeds a predetermined volume; and

at least one accessory that is removably coupled to the hose;

wherein the electric circuit is adapted to receive a source of direct current power from a direct current power source and to provide the direct current power to the motor; and

wherein the receptacle assembly includes a receptacle housing and a connector, the receptacle housing defining at least a portion of an exterior surface of the powerhead assembly and being adapted to receive a battery pack, the connector having a plurality of terminals that are configured to electrically detachably couple the battery pack to the electric circuit;

wherein the powerhead assembly includes a housing in which the fan, the motor and the electric circuit are housed, the housing including an inlet and an outlet, wherein operation of the utility vacuum draws an intake flow of air into the canister through the inlet and discharges a discharge flow of air through the outlet, wherein a compartment is defined by the housing and a lid, the lid being rotatable relative to the housing between an open condition and a closed condition, and wherein the battery is adapted to be received in the compartment; and

wherein the utility vacuum further comprise a latch that can be engaged to maintain the lid in the second condition, the latch including a first latch element that is coupled to the lid and a second latch element that is coupled to the housing, the first and second latch elements being engaged to one another to engage the latch, and wherein the second latch element is not threaded.

5. A utility vacuum comprising:

a canister;

a powerhead housing that includes a handle, a pair of tubular members and a fan inlet, the handle being configured to permit the utility vacuum to be hand carried;

a receptacle assembly coupled to the powerhead housing;

a motor coupled to the powerhead housing;

an electric circuit coupled to the powerhead housing and electrically coupled to the motor;

a fan driven by the motor to produce a discharge flow that is routed to the outlet, the fan being in fluid communication with the fan inlet;

a pair of latches coupled to one of the canister and the powerhead housing, the latches being configured to releasably latch the canister and the powerhead housing together;

a shut-off device that includes a plenum and a float, the plenum being in fluid communication with the housing proximate the fan inlet, the float being disposed in the plenum and being configured to close the fan inlet when the powerhead housing is releasably latched to the canister and a volume of a liquid in the canister exceeds a predetermined volume;

a filter coupled to the shut-off device; and

a flexible hose that is removably coupled to at least one of the inlet and the outlet;

wherein a debris-laden air flow is adapted to be drawn into a first one of the pair of tubes during operation of the fan;

wherein an exhaust flow of air is adapted to be expelled from the second one of the pair of tubes during operation of the fan;

wherein an annular space is formed about one of the first and second tubes and a flow of air that is employed for cooling the motor is moved through the annular space;

wherein the receptacle assembly includes a receptacle housing and a connector, the housing being is adapted to receive a battery pack, the connector having a plurality of terminals that are configured to electrically detachably couple the battery pack to the electric circuit.

6. The utility vacuum of claim 5, wherein the flow of air for cooling the motor enters the powerhead housing through the annular space.

7. A utility vacuum comprising:

a canister;

a drain plug that is removably coupled to the canister;

a powerhead assembly coupled to the canister and having a fan inlet, a fan, a motor for providing rotary power to the fan, a receptacle assembly and an electric circuit for distributing electrical power to the motor, the fan being in fluid communication with the fan inlet;

a flexible hose that is configured to be coupled to the powerhead assembly;

a shut-off device associated with the powerhead assembly, the shut-off device being configured to prevent the fan from drawing a liquid into the fan inlet when a volume of the liquid in the canister exceeds a predetermined volume; and

a filter coupled to the shut-off device;

wherein the electric circuit is adapted to receive a source of direct current power from a direct current power source and to provide the direct current power to the motor; and

wherein the receptacle assembly includes a receptacle housing that is adapted to receive a battery pack and a connector with a plurality of terminals that are configured to electrically detachably couple the battery pack to the electric circuit;

wherein the powerhead assembly includes a housing in which the fan, the motor and the electric circuit are housed, the housing including an inlet and an outlet, wherein operation of the utility vacuum draws an intake flow of air into the canister through the inlet and discharges a discharge flow of air through the outlet , wherein a compartment is defined by the housing and a lid, the lid being movable relative to the housing between an open condition and a closed condition, and wherein the battery is received in the compartment;

wherein the flexible hose has a first end, a second end opposite the first end and a body interconnecting the first and second ends, the flexible hose being positionable in a storage position wherein the first end is coupled to the inlet and the body is wrapped about the utility vacuum;

wherein the second end of the flexible hose is received in the outlet when the flexible hose is positioned in the storage position;

wherein the powerhead assembly includes an inlet and an outlet and wherein the hose assembly includes a hook that engages the powerhead assembly when the hose assembly is coupled to at least one of the inlet and the outlet;

wherein the hose assembly further includes a body that is configured to be received into the at least one of the inlet and the outlet;

wherein the hook includes at least one post that is disposed generally perpendicular to a longitudinal axis of the body.

wherein the inlet and the outlet are located on opposite sides of the housing and the flexible hose is positionable in a storage position wherein a first end of the flexible hose is coupled to the inlet and a second end of the flexible hose opposite the first end is received in the outlet;

wherein the powerhead assembly includes a housing in which the fan and the motor are housed and wherein the shut-off device includes a plenum that is disposed in fluid communication with the fan inlet;

wherein one of the power head and the canister includes an over-center latch to detachably couple the canister to the power head assembly;

wherein the utility vacuum further comprises a lid that cooperates with the housing to define a compartment, wherein the lid is movably coupled to the housing; and

wherein the canister has a capacity of about 2 gallons.

8. A utility vacuum comprising:

a canister;

a powerhead assembly coupled to the canister and having a fan inlet, a fan, a motor for providing rotary power to the fan, a receptacle assembly and an electric circuit for distributing electrical power to the motor, the fan being in fluid communication with the fan inlet;

a filter in fluid communication with the fan inlet;

a shut-off device associated with the powerhead assembly, the shut-off device being configured to prevent the fan from drawing a liquid into the fan inlet when a volume of the liquid in the canister exceeds a predetermined volume; and

a battery pack providing a source of direct current electrical power for powering the motor, the battery pack including a housing and having a plurality of battery pack terminals;

wherein the receptacle assembly includes a receptacle housing, which is configured to receive the battery pack, and a connector with a plurality of terminals that are configured to electrically couple the battery to the electric circuit; and

wherein the battery is detachably coupled to the powerhead assembly;

wherein the powerhead assembly includes a housing in which the fan, the motor and the electric circuit are housed, the housing including an inlet and an outlet, wherein operation of the utility vacuum draws an intake flow of air into the canister through the inlet and discharges a discharge flow of air through the outlet;

wherein the battery pack is housed in a compartment, the compartment being defined by the housing and a lid, the lid being movable relative to the housing between a first condition, which permits ingress of the battery to the compartment and egress of the battery pack from the compartment, and a second condition, in which ingress of the battery pack to the compartment and egress of the battery pack from the compartment is inhibited; and

wherein a cooling air intake aperture and a cooling air discharge aperture are formed in the powerhead assembly, the cooling air discharge aperture being associated with the outlet so that air flowing through the outlet blows across the cooling air discharge aperture to set up a zone of relatively low pressure that causes air to be drawn out of the cooling air discharge aperture to thereby cool the motor.

9. The utility vacuum of claim 8, wherein the cooling air intake aperture is positioned proximate the inlet.

10. The utility vacuum of claim 9, wherein the cooling air intake aperture is positioned concentric about the inlet.