An apparatus and method for transporting a flow of air and particulates through a vacuum cleaner. In one embodiment, the apparatus includes an intake body having an intake opening configured to receive the flow of air into particulates. An airflow propulsion device is coupled to the intake opening to draw the flow through the intake opening and through a flow passage having an approximately constant flow area. The flow continues through one or more conduits from the propulsion device to a filter element housed in a filter housing where the particulates are separated from the flow of air.
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1. A vacuum cleaner, comprising:
an intake body having an intake opening configured to be positioned proximate to a floor surface for receiving a flow of air and particulates;
a filter element for separating the particulates from the flow of air;
at least one conduit coupled between the intake body and the filter element; and
an airflow propulsion device coupled between the intake opening and the at least one conduit to draw the flow of air and particulates through the intake opening and toward the filter element, wherein the intake opening, the propulsion device and the conduit define a flow path for the flow of air and particulates and the flow path has an approximation constant flow area from the intake opening to the propulsion device.
11. A vacuum cleaner, comprising:
an intake body having an intake opening configured to be positioned proximate to a floor surface for receiving a flow of air and particulates from the floor surface;
a filter element for separating the particulates from the flow of air;
at least one conduit coupled between the intake body and the filter element; and
an airflow propulsion device coupled between the intake opening and the at least one conduit, wherein the intake opening, the propulsion device and the conduit define a flow path, the flow path having an approximately constant flow area from the intake opening to the propulsion device, the flow path from the intake opening through the propulsion device having a radius of curvature not less than approximately 0.29 inches to provide smooth flow along the flow path.
17. A vacuum cleaner, comprising:
an intake body having an intake opening for receiving a flow of air and particulates, the intake body further having an intake flow area and at least two exit openings;
a filter element to separate the particulates from the flow of air;
at least two conduits, each having a first aperture coupled to one of the exit openings of the intake body and a second aperture in fluid communication with the filter element, and with each conduit of the at least two conduits having a conduit flow area wherein the sum of the conduit flow areas is less than the intake flow area in order to accelerate the flow through the conduits; and
an airflow propulsion device coupled between the intake opening and the exit openings for moving the flow of air from the intake opening to the filter element.
22. A vacuum cleaner, comprising:
an intake body having an intake opening configured to be positioned proximate to a surface for receiving a flow of air and particulates, the intake body further having at least two exit openings for simultaneously directing the flow of air and particulates out of the intake body;
a filter element for separating at least some of the particulates from the flow of air and particulates;
at least two conduits in fluid communications with the intake body and the filter element ; and
a manifold in fluid communication with the filter element and in fluid communication with the at least two conduits, with the manifold including a first portion coupled to a first conduit and a second portion coupled to a second conduit and wherein at least two air flows in the at least two conduits are merged in the manifold and provided to the filter element;
an airflow propulsion device for moving the flow of air and particulates from the intake opening to the filter element.
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0. 30. A vacuum cleaner, comprising:
an intake body having an intake opening configured to be positioned proximate to a floor surface for receiving a flow of air and particulates, the intake body having a lower surface proximate to the floor surface and a vent for exhausting cooling flow for cooling a component within the intake body;
a filter element of separating the particulates from the flow of air;
a flow channel coupled between the intake body and the filter element; and
at least one wheel coupled to the intake body and projecting below at least a portion of the lower surface of the intake body to elevate the portion of the intake body above the floor surface, the wheel being positioned in a path of the cooling air passing outwardly through the vent to diffuse the cooling air.
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The present invention relates to methods and apparatuses for transporting a flow of air and particulates through a vacuum cleaner.
Conventional upright vacuum cleaners are commonly used in both residential and commercial settings to remove dust, debris and other particulates from floor surfaces, such as carpeting, wood flooring, and linoleum. A typical conventional upright vacuum cleaner includes a wheel-mounted head which includes an intake nozzle positioned close to the floor, a handle that extends upwardly from the head so the user can move the vacuum cleaner along the floor while remaining in a standing or walking position, and a blower or fan. The blower takes in a flow of air and debris through the intake nozzle and directs the flow into a filter bag or receptacle which traps the debris while allowing the air to pass out of the vacuum cleaner.
One drawback with some conventional upright vacuum cleaners is that the flow path along which the flow of air and particulates travels may not be uniform and/or may contain flow disruptions or obstructions. Accordingly, the flow may accelerate and decelerate as it moves from the intake nozzle to the filter bag. As the flow decelerates, the particulates may precipitate from the flow and reduce the cleaning effectiveness of the vacuum cleaner and lead to blocking of the flow path. In addition, the flow disruptions and obstructions can reduce the overall energy of the flow and therefore reduce the capacity of a flow to keep the particulates entrained until the flow reaches the filter bag.
Another drawback with some conventional upright vacuum cleaners is that the blowers and flow path can be noisy. For example, one conventional type of blower includes rotating fan blades that take in axial flow arriving from the intake nozzle and direct the flow into a radially extending tube. As each fan blade passes the entrance opening of the tube, it generates noise which can be annoying to the user and to others who may be in the vicinity of the vacuum cleaner while it is in use.
Still another drawback with some conventional upright vacuum cleaners is that the filter bag may be inefficient. For example, some filter bags are constructed by folding over one end of an open tube of porous filter material to close the one end, and leaving an opening in the other end to receive the flow of air and particulates. Folding the end of the bag can pinch the end of the bag and reduce the flow area of the bag, potentially accelerating the flow through the bag. As the flow accelerates through the bag, the particulates entrained in the flow also accelerate and may strike the walls of the bag with increased velocity, potentially weakening or breaking the bag and causing the particulates to leak from the bag.
The invention relates to methods and apparatuses for transporting a flow of air and particulates through a vacuum cleaner. In one embodiment, the apparatus includes an intake body having an intake opening configured to be positioned proximate to a floor surface for receiving the flow of air and particulates. The vacuum cleaner can further include a filter housing configured to receive a filter for separating the particulates from the flow of air, and at least one conduit coupled between the intake body and the filter housing. An airflow propulsion device is coupled between the intake opening and the conduit to draw the flow of air and particulates through the intake opening and toward the filter housing. The intake opening, the propulsion device, and the conduit define a flow path for the flow of air and particulates and in one embodiment, the flow path has an approximately constant flow area from the intake opening to the propulsion device.
In another embodiment, a radius of curvature of the flow path from the intake opening through the propulsion device has a radius of a curvature not less than approximately 0.29 inches to provide smooth flow along the flow path. In still another embodiment, the flow path is divided between two conduits, each extending from the intake body toward the filter housing. In one aspect of this embodiment, the combined flow area through the two conduits is less than the flow area through the intake opening.
The present invention is directed toward methods and apparatuses for moving a flow of air and particulates into a vacuum cleaner and separating the particulates from the air. The apparatus can include an intake passage and an airflow propulsion device having an approximately constant flow area to reduce pressure losses to the flow. Many specific details of certain embodiments of the invention are set forth in the following description and in
As shown in
In yet a further aspect of this embodiment, the rear wheels 90b extend rearwardly of the intake body 100 by a distance at least as great as the thickness of a power cord 43 that couples the intake body 100 to the handle 45 (FIG. 1). Accordingly, the power cord 43 will not be pinched between the intake body 100 and the riser when the vacuum cleaner 10 is moved between steps. In an alternate embodiment, for example, where users move the vacuum cleaner 10 in a forward direction between steps, the forward wheels 90a can have an increased diameter and can extend beyond the forward edge of the intake body 100.
The outer cover 130 can include intake vents 125a for ingesting cooling air to cool the airflow propulsion device 200. The baseplate 110 can include exhaust vents 125b for exhausting the cooling air. Accordingly, cooling air can be drawn into the intake body 100 through the intake vents 125a (for example, with a cooling fan coupled to the airflow propulsion device 100), past the propulsion device 200 and out through the exhaust vents 125b. In one aspect of this embodiment, the exhaust vents 125b are positioned adjacent the rear wheels 90b. Accordingly, the cooling air can diffuse over the surface of the rear wheels 90b as it leaves the intake body 100, which can reduce the velocity of the cooling air reduce the likelihood that the cooling air will stir up particulates on the floor surface 20.
The intake aperture 111 has an elongated rectangular shape and extends across the forward portion of the baseplate 110. A plurality of ribs 119 extend across the narrow dimension of the intake aperture 111 to structurally reinforce a leading edge 121 of the baseplate 110. The skid plate 116 can also include ribs 120 that are aligned with the ribs 119. Accordingly, the flow of air and particulates can be drawn up through the skid plate 116 and into the intake aperture 111. In one embodiment, the intake aperture 111 can have a width of approximately 16 inches and in other embodiments, the intake aperture can have a width of approximately 20 inches. In still further embodiments, the intake aperture 111 can have other suitable dimensions depending on the particular uses to which the vacuum cleaner 10 is put.
An agitation device, such as a roller brush 140, is positioned just above the intake aperture 111 to aid in moving dust, debris, and other particulates from the floor surface 20 and into the intake aperture 111. Accordingly, the roller brush 140 can include an arrangement of bristles 143 that sweep the particulates into the intake aperture 111. The roller brush 140 can be driven by a brush motor 142 via a flexible belt 141 or other mechanism.
In one embodiment, both the intake aperture 111 and the roller brush 140 are symmetric about a symmetry plane 122 (shown in
The intake body 100 further includes a flow channel 112 positioned downstream of the intake aperture 111 and the roller brush 140. The flow channel 112 includes a lower portion 112a positioned in the baseplate 110 and a corresponding upper portion 112b positioned in the inner cover 150. When the inner cover 150 joins with the baseplate 110, the upper and lower portions 112b and 112a join to form a smooth enclosed channel having a channel entrance 113 proximate to the intake aperture 111 and the roller brush 140, and a channel exit 114 downstream of the channel entrance 113.
In one embodiment, the flow channel 112 has an approximately constant flow area from the channel entrance 113 to the channel exit 114. In one aspect of this embodiment, the flow area at the channel entrance 113 is approximately the same as the flow area of the intake aperture 111 and the walls of the flow channel 112 transition smoothly from the channel entrance 113 to the channel exit 114. Accordingly, the speed of the flow through the intake aperture 111 and the flow channel 112 can remain approximately constant.
As shown in
The forward housing 230 includes the entrance aperture 231 that receives the flow of air and particulates from the flow channel 112. In one embodiment, the flow area of the entrance aperture 231 is approximately equal to the flow area of the flow channel 112 so that the flow passes unobstructed and at an approximately constant speed into the forward housing 230. The forward housing 230 further includes two exit apertures 232 (shown as a left exit aperture 232a and a right exit aperture 232b) that direct the flow radially outwardly after the flow of air and particulates has passed through the fan 210. The exit apertures 232 are defined by two wall portions 239, shown as a forward wall portion 239a in the forward housing 230 and a rear wall portion 239b in the rear housing 260. The forward and rear wall portions 239a, 239b together define the exit apertures 232 when the forward housing 230 is joined to the rear housing 260.
In one embodiment, the forward housing 230 includes a plurality of flexible resilient clasps 233, each having a clasp opening 234 that receives a corresponding tab 264 projecting outwardly from the rear housing 260. In other embodiments, other devices can be used to secure the two housings 230, 260. Housing gaskets 235 between the forward and rear housings 230, 260 seal the interface therebetween and prevent the flow from leaking from the housings as the flow passes through the fan 210.
The fan 210 includes a central hub 211 and a fan disk 212 extending radially outwardly from the hub 211. A plurality of spaced-apart vanes 213 are attached to the disk 212 and extend radially outwardly from the hub 211. In one embodiment, the vanes 213 are concave and bulge outwardly in a clockwise direction. Accordingly, when the fan 210 is rotated clockwise as indicated by arrow 253, the fan 210 draws the flow of air and particulates through the entrance aperture 231, pressurizes or imparts momentum to the flow, and directs the flow outwardly through the exit apertures 232.
Each vane 213 has an inner edge 214 near the hub 211 and an outer edge 215 spaced radially outwardly from the inner edge. Adjacent vanes 213 are spaced apart from each other to define a channel 216 extending radially therebetween. In one embodiment, the flow area of each channel 216 remains approximately constant throughout the length of the channel. For example, in one embodiment, the width W of each channel 216 increases in the radial direction, while the height H of each channel decreases in the radial direction from an inner height (measured along the inner edge 214 of each vane 213) to a smaller outer height (measured along the outer edge 215 of each vane). In a further aspect of this embodiment, the sun of the flow areas of each channel 216 is approximately equal to the flow area of the entrance aperture 231. Accordingly, the flow area from the entrance aperture 231 through the channel 216 remains approximately constant and is matched to the flow area of the inlet aperture 111, discussed above with reference to FIG. 2.
The fan 210 is powered by the fan motor 250 to rotate in the clockwise direction indicated by arrow 253. The fan motor 250 has a flange 255 attached to the rear housing 260 with bolts 254. The fan motor 250 further includes a shaft 251 that extends through a shaft aperture 216 in the rear housing 260 to engage the fan 210. A motor gasket 252 seals the interface between the rear housing 260 and the fan motor 250 to prevent the flow from escaping through the shaft aperture 261. One end of the shaft 251 is threaded to receive a nut 256 for securing the fan 210 to the shaft. The other end of the shaft 256 extends away from the fan motor, so that it can be gripped while the nut 254 is tightened or loosened.
In the embodiment shown in
As discussed above, the number of vanes 213 can be selected to be an odd number when the exit apertures 232 are spaced 180° apart. In another embodiment, the exit apertures 232 can be positioned less than 180° apart and the number of vanes 213 can be selected to be an even number, so long as the vanes are arranged such that when the rightmost vane 213b is aligned with the right exit aperture 232b, the vane closest to the left exit aperture 232a is not aligned with the left exit aperture. The effect of this arrangement can be the same as that discussed above (where the number of vanes 213 is selected to be an odd number), namely, to smooth out the distribution of noise generated at the exit apertures 232.
In one embodiment, the fan 210 is sized to rotate at a relative slow rate while producing a relatively high flow rate. For example, the fan 210 can rotate at a rate of 7,700 rpm to move the flow at a peak rate of 132 cubic feet per minute (cfm). As the flow rate decreases, the rotation rate increases. For example, if the intake aperture 111 (
In other embodiments, the fan 210 can be selected to have different flow rates at selected rotation speeds. For example, the fan 210 can be sized and shaped to rotate at rates of between about 6,500 rpm and about 9,000 rpm and can be sized and shaped to move the flow at a peak rate of between about 110 cfm and about 150 cfm. In any case, by rotating the fan 210 at relatively slow rates while maintaining a high flow rate of air through the airflow propulsion device 200, the noise generated by the vacuum cleaner 10 can be reduced while maintaining a relatively high level of performance.
In a further aspect of this embodiment, the performance of the airflow propulsion device 200 (as measured by flow rate at a selected rotation speed) can be at least as high when the airflow propulsion device 200 is uninstalled as when the airflow propulsion device is installed in the vacuum cleaner 10 (FIG. 1). This effect can be obtained by smoothly contouring the walls of the intake aperture 111 (
Returning now to
Each conduit 30 can include an elbow section 31 coupled at one end to the exit aperture 232 and coupled at the other end to an upwardly extending straight section 36. As was described above with reference to
In one embodiment, the radius of curvature of the flow path through the elbow section 31 is not less than about 0.29 inches. In a further aspect of this embodiment, the radius of curvature of the flow path is lower in the elbow section than anywhere else between the airflow propulsion device 200 and the filter element 80 (FIG. 1). In still a further aspect of this embodiment, the minimum radius of curvature along the entire flow path, including the portion of the flow path passing through the airflow propulsion device 200, is not less than 0.29 inches. Accordingly, the flow is less likely to become highly turbulent than in vacuum cleaners having more sharply curved flow paths, and may therefore be more likely to keep the particulates entrained in the flow.
Each elbow section 31 is sealed to the corresponding exit aperture 232 with an elbow seal 95. In one embodiment, the elbow sections 31 can rotate relative to the airflow propulsion device 200 while remaining sealed to the corresponding exit aperture 232. Accordingly, users can rotate the conduits 30 and the handle 45 (
In one embodiment, each elbow seal 95 can include two rings 91, shown as an inner ring 91a attached to the airflow propulsion device 200 and an outer ring 91b attached to the elbow section 31. The rings 91 can include a compressible material, such as felt, and each inner ring 91a can have a surface 92 facing a corresponding surface 92 of the adjacent outer ring 92b. The surfaces 92 can be coated with Mylar or another non-stick material that allows relative rotational motion between the elbow sections 31 and the airflow propulsion device 200 while maintaining the seal therebetween. In a further aspect of this embodiment, the non-stick material is seamless to reduce the likelihood for leaks between the rings 91. In another embodiment, the elbow seal 95 can include a single ring 91 attached to at most one of the airflow propulsion device 200 or the elbow section 31. In a further aspect of this embodiment, at least one surface of the ring 91 can be coated with the non-stick material to allow the ring to more easily rotate.
Each elbow section 31 can include a male flange 32 that fits within a corresponding female flange 240 of the airflow propulsion device 200, with the seal 95 positioned between the flanges 32, 240. Retaining cup portions 123, shown as a lower retaining cup portion 123a in the base plate 110 and an upper retaining cup portion 123b in the inner cover 150, receive the flanges 32, 240. The cup portions 123 have spaced apart walls 124, shown as an inner wall 124a that engages the female flange 240 and an outer wall 124b that engages the male flange 32. The walls 124a, 124b are close enough to each other that the flanges 32, 240 are snugly and sealably engaged with other, while still permitting relative rotational motion of the male flanges 32 relative to the female flanges 240.
As shown in
Each straight section 36 extends upwardly on opposite sides of the filter housing 70 from the corresponding elbow section 31 into the manifold 50. Accordingly, the straight sections 36 can improve the rigidity and stability of the vacuum cleaner 10 (
The manifold 50 includes a lower portion 51 attached to an upper portion 52. The lower portion 51 includes two inlet ports 53, each sized to receive flow from a corresponding one of the straight sections 36. A flow passage 54 extends from each inlet port 53 to a common outlet port 59. As shown in
In the embodiment shown in
Each flow passage 54 turns through an angle of approximately 180° between a plane defined by the inlet ports 53 and a plane defined by the outlet port 59. Each flow passage 54 also has a gradually increasing flow area such that the outlet port 59 has a flow area larger than the sum of the flow areas of the two inlet ports 53. Accordingly, the flow passing through the flow passages 54 can gradually decelerate as it approaches the outlet port 59. As a result, particulates can drop into the filter element 80 rather than being projected at high velocity into the filter element 80. An advantage of this arrangement is that the particulates may be less likely to pierce or otherwise damage the filter element 80.
As shown in
In one embodiment, the filter element 80 includes a generally tubular-shaped wall 81 having a rounded rectangular or partially ellipsoidal cross-sectional shape. The wall 81 can include a porous filter material, such as craft paper lined with a fine fiber fabric, or other suitable materials, so long as the porosity of the material is sufficient to allow air to pass therethrough while preventing particulates above a selected size from passing out of the filter element 80. The wall 81 is elongated along an upwardly extending axis 85 and can have opposing portions that curve outwardly away from each other. In one embodiment, the wall 81 is attached to a flange 82 that can induce a rigid or partially rigid material, such as cardboard and that extends outwardly from the wall 81. The flange 82 has an opening 83 aligned with the outlet port 59 of the manifold 50. In one embodiment, the opening 83 is lined with an elastomeric rim 84 that sealably engages the lip 58 projecting downwardly from the outlet port 59 of the manifold 50. In one aspect of this embodiment the flange 82 formed from two layers of cardboard with an elastomeric layer in between, such that the elastomeric layer extends inwardly from the edges of the cardboard in the region of the outlet port 59 to form the elastomeric ring 84.
In one embodiment, the lower end of the filter element 80 is sealed by pinching opposing sides of the wall 81 together. In another embodiment, the end of the filter element 80 is sealed by closing the opposing sides of the wall 81 over a mandrel (not shown) such that the cross-sectional shape of the filter element is generally constant from the flange 82 to a bottom 86 of the filter element 80. An advantage of this arrangement is that the flow passing through the filter element 80 will be less likely to accelerate, which may in turn reduce the likelihood that the particles within the flow or at the bottom of the filter element 80 will be accelerated to such a velocity as to pierce the wall 81 or otherwise damage the filter element 80. In this manner, lighter-weight particles may be drawn against the inner surface of the wall 81, and heavier particles can fall to the bottom 86 of the filter element 80.
As shown in
Each of the supports 71, 72 includes an upper portion 73a and a lower portion 73b fastened together with screws 74. As is best seen in cross-section in
Returning to
The upper and lower supports 71, 72 also include handle apertures 76 that receive a shaft 47 of the handle 45. The lowermost aperture 76a has a ridge 79 that engages a slot 44 of the handle shaft 47 to prevent the shaft from rotating. The handle 45 includes a grip portion 48 which extends upwardly beyond the filter housing 70 where it can be grasped by the user for moving the vacuum cleaner 10 (
The upper support 71 includes two gaskets 57 for sealing with the manifold 50. In one embodiment, the manifold 50 is removably secured to the upper support 71 with a pair of clips 60. Accordingly, the manifold 50 can be easily removed to access the filter element 80 and the spare belt or belts 141a. In another embodiment, the manifold 50 can be secured to the upper support 71 with any suitable releasable latching mechanism, such as flexible, extendible hands 60a show in hidden lines in FIG. 6.
From the foregoing it will be appreciated that, although specific embodiment of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.
Embree, Michael E., Roberts, Terrance M., McCain, James F.
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