Power head for vacuum systems

Abstract

A vacuum system comprises a vacuum source, an energy-storage device, a handle operatively connected to the vacuum source, an extension tube operatively connected to the handle, and a power head. The power head comprises a housing assembly and a brush assembly. The brush assembly comprises a brush defining an axle chamber, a motor assembly, and a transmission system. At least part of the motor assembly is arranged within the axle chamber, and a fixed portion of the motor assembly is supported relative to the housing assembly. The transmission system transmits rotation of the rotating portion of the motor assembly to the brush. At least part of the transmission system is arranged within the axle chamber. Operation of the vacuum source causes air to be drawn into the handle. The rotating portion of the motor assembly rotates the brush through the transmission system relative to the brush housing.

Claims

1. A vacuum system comprising: a vacuum source; a battery assembly; a handle operatively connected to the vacuum source; an extension tube operatively connected to the handle; a power head comprising a main body assembly a main chamber and a main outlet, a brush assembly comprising a brush defining first and second ends and an axle chamber defining an axle longitudinal axis, first and second bearings, where the first and second bearings are supported by the main body and support the first and second ends of the brush, respectively, such that the brush is supported for rotation relative to the main body assembly, a motor assembly defining a fixed portion and a rotating portion, where the battery assembly is operatively connected to the motor assembly, a motor mount supported by the main body assembly adjacent to the first bearing, where the motor mount engages the fixed portion of the motor assembly such that, at least part of the motor assembly is arranged within the axle chamber, the fixed portion of the motor assembly is supported relative to the main body assembly, and the rotating portion of the motor assembly is arranged within the axle chamber, and a transmission system for transmitting rotation of the rotating portion of the motor assembly to the brush, where at least part of the transmission system is arranged within the axle chamber; wherein the transmission system engages the rotating portion of the motor assembly such that rotating portion of the motor assembly is supported in axial alignment with the axle longitudinal axis solely by the transmission system; the power head is detachably attached to the extension tube such that operation of the vacuum source causes air to be drawn through the main chamber, through the main outlet, through the extension tube, and into the handle; and the battery assembly supplies power to the motor such that operation of the motor assembly causes the rotating portion of the motor assembly to rotate the brush through the transmission system to rotate the brush relative to the brush housing.

2. A vacuum system as recited in claim 1, in which the transmission system comprises: a first transmission portion supported by the rotating portion of the motor, a second transmission portion supported relative to the brush; and a plurality of planetary gears; where the first transmission portion engages the second transmission portion through the plurality of planetary gears such that rotation of the rotating portion of the motor causes rotation of the first transmission portion, rotation of the first transmission portion causes rotation of the second transmission portion, and the second transmission portion is supported relative to the brush such that rotation of the second transmission portion causes rotation of the brush.

3. A vacuum system as recited in claim 2, in which: the first transmission portion comprises a drive gear member; the second transmission portion comprises at least one driven gear member; and rotation of the at least one drive gear member causes rotation of the at least one driven gear member through the plurality of planetary gears.

4. A vacuum system as recited in claim 1, in which the transmission system comprises: a drive gear operatively connected to the motor shaft; and a ring gear formed on an interior surface of the brush; a plurality of planetary gears; wherein rotation of the drive gear is transmitted to the ring gear through the plurality of planetary gears.

5. A vacuum system as recited in claim 4, in which the ring gear is rigidly secured to the interior surface of the brush.

6. A vacuum system as recited in claim 1, in which the battery assembly is supported by the power head.

7. A vacuum system as recited in claim 1, in which the main body assembly comprises: a main housing that is adapted to be attached to the extension tube; and a brush housing that is adapted to be attached to the main housing, where the brush housing defines a brush chamber; wherein a portion of the brush is arranged within the brush chamber; and the fixed portion of the motor assembly is supported relative to the brush housing.

8. A vacuum system comprising: a vacuum source; a battery assembly; a handle operatively connected to the vacuum source; an extension tube operatively connected to the handle; a power head comprising a main body assembly defining a main chamber, a main inlet, and a main outlet, a brush assembly comprising a brush housing defining a brush chamber, a brush defining first and second ends and an axle chamber defining an axle longitudinal axis, first and second bearings, where the first and second bearings are supported by the main body and support first and second ends of the brush, respectively, such that the brush is supported for rotation relative to the brush housing, and a portion of the brush is arranged within the brush chamber, a motor assembly defining a fixed portion and a rotating portion, where the battery assembly is operatively connected to the motor assembly, a motor mount supported by the main body assembly adjacent to the first bearing, where the motor mount engages the fixed portion of the motor assembly such that at least part of the motor assembly is arranged within the axle chamber, the fixed portion of the motor assembly is supported by the brush housing, and the rotating portion of the motor assembly is arranged within the axle chamber, and a transmission system for transmitting rotation of the rotating portion of the motor assembly to the brush, where at least part of the transmission system is arranged within the axle chamber; wherein the transmission system engages the rotating portion of the motor assembly such that rotating portion of the motor assembly is supported in axial alignment with the axle longitudinal axis solely by the transmission system; the power head is detachably attached to the extension tube such that operation of the vacuum source causes air to be drawn through the brush inlet, through the brush chamber, through the brush outlet, through the main inlet, through the main chamber, through the main outlet, through the extension tube, and into the handle; and the battery assembly supplies power to the motor such that operation of the motor assembly causes the rotating portion of the motor assembly to rotate the brush through the transmission system to rotate the brush relative to the brush housing.

9. A vacuum system as recited in claim 8, in which the transmission system comprises: a first transmission portion supported by the rotating portion of the motor, a second transmission portion supported relative to the brush; and a plurality of planetary gears; where the first transmission portion engages the second transmission portion through the planetary gears such that rotation of the rotating portion of the motor causes rotation of the first transmission portion, rotation of the first transmission portion causes rotation of the second transmission portion, and the second transmission portion is supported relative to the brush such that rotation of the second transmission portion causes rotation of the brush.

10. A vacuum system as recited in claim 8, in which: the first transmission portion comprises a drive gear member; the second transmission portion comprises at least one driven gear member; and rotation of the at least one drive gear member causes rotation of the at least one driven gear member through the plurality of planetary gears.

11. A vacuum system as recited in claim 8, in which the transmission system comprises: a drive gear operatively connected to the motor shaft; a ring gear formed on an interior surface of the brush; a plurality of planetary gears; wherein rotation of the drive gear is transmitted to the ring gear through the plurality of planetary gears.

12. A vacuum system as recited in claim 11, in which the ring gear is rigidly secured to the interior surface of the brush.

13. A vacuum system as recited in claim 8, in which the battery assembly is supported by the brush housing.

14. A vacuum method comprising the steps of: providing a vacuum source; providing a battery assembly; operatively connecting a handle to the vacuum source; operatively connecting an extension tube to the handle; providing a power head housing assembly defining a main chamber and a main outlet; providing a brush first and second ends and defining an axle chamber defining an axle longitudinal axis; supporting first and second bearings on the power head housing assembly to engage the first and second ends of the brush to support the brush for rotation relative to the main housing assembly; providing a motor assembly defining a fixed portion and a rotating portion; supporting a motor mount from the main body assembly adjacent to the first bearing, where the motor mount engages the fixed portion of the motor assembly such that, at least part of the motor assembly is arranged within the axle chamber, the fixed portion of the motor assembly is supported relative to the main body assembly, and the rotating portion of the motor assembly is arranged within the axle chamber; operatively connecting the battery assembly connected to the motor assembly; arranging a transmission system to transmit rotation of the rotating portion of the motor assembly to the brush such that at least part of the transmission system is arranged within the axle chamber, and the transmission system engages the rotating portion of the motor assembly such that rotating portion of the motor assembly is supported in axial alignment with the axle longitudinal axis solely by the transmission system; detachably attaching the main housing assembly to the extension tube such that operation of the vacuum source causes air to be drawn through the main chamber, through the main outlet, through the extension tube, and into the handle; and causing the battery assembly to supply power to the motor such that operation of the motor assembly causes the rotating portion of the motor assembly to rotate the brush through the transmission system to rotate the brush relative to the brush housing.

15. A vacuum method as recited in claim 14, in which step of arranging the transmission system comprises the steps of: supporting a first transmission portion relative to the rotating portion of the motor, supporting a second transmission portion relative to the brush; arranging a plurality of planetary gears to engage the first and second transmission portions through the plurality of planetary gears such that rotation of the rotating portion of the motor causes rotation of the first transmission portion, rotation of the first transmission portion causes rotation of the second transmission portion, and rotation of the second transmission portion causes rotation of the brush.

16. A vacuum method as recited in claim 15, in which: the first transmission portion comprises a drive gear member; the second transmission portion comprises at least one driven gear member; and arranging a plurality of planetary gears to engage the drive gear member and the at least one driven gear member such that rotation of the at least one drive gear member causes rotation of the at least one driven gear member through the plurality of planetary gears.

17. A vacuum method as recited in claim 14, in which step of providing the main housing assembly comprises the steps of: providing a main housing that is adapted to be attached to the extension tube; and providing a brush housing that is adapted to be attached to the main housing, where the brush housing defines a brush chamber; arranging a portion of the brush within the brush chamber; and supporting the fixed portion of the motor assembly relative to the brush housing.

18. A vacuum method as recited in claim 14, further comprising the step of supporting the battery assembly by the power head.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a first example power head of the present invention;

(2) FIG. 2 illustrates the first example power head attached to an example vacuum assembly using a handle adapter system;

(3) FIG. 2A illustrates an example electrical system of the first example power head in use mode;

(4) FIG. 2B illustrates the example electrical system of the first example power head in a charge mode;

(5) FIG. 3 is a top plan view of the first example power head in a first configuration;

(6) FIG. 4 is a top plan view of the first example power head in a second configuration;

(7) FIG. 5 is a side elevation view of the first example power head in the first configuration, the opposite side elevation view being reversed;

(8) FIG. 6 is a rear elevation view of the first example power head in the first configuration;

(9) FIG. 7 is a front elevation view taken along lines 7-7 in FIG. 4 depicting the first example power head in the second configuration;

(10) FIG. 8 is a bottom plan view of the first example power head in the first configuration;

(11) FIG. 9 is a side elevation, cutaway view taken along lines 9-9 in FIG. 3 depicting the first example power head in the first configuration;

(12) FIG. 10 is a detail view of a portion of the first example power head as depicted in FIG. 9 illustrating a first example motor gear assembly;

(13) FIG. 11 is a side elevation, cutaway view taken along lines 11-11 in FIG. 3 depicting the first example power head in the first configuration;

(14) FIG. 12 is a front elevation, cutaway view taken along lines 12-12 in FIG. 3 depicting a brush motor assembly of the first example power head;

(15) FIG. 13 is a front elevation, cutaway view taken along lines 13-13 in FIG. 3 depicting side air chambers and a battery storage compartment of the first example power head;

(16) FIGS. 14 and 15 are side elevation, partial cutaway views depicting a wheel lift assembly of the first example power head in lowered and raised configuration, respectively;

(17) FIG. 16 is a side elevation view depicting a handle adapter system that may be used with the first example power head;

(18) FIG. 17 is a detail, side elevation, cutaway view similar to FIG. 10 depicting a portion of a second example power head comprising a second example motor gear assembly; and

(19) FIG. 18 is a is a detail, side elevation, cutaway view similar to FIG. 10 depicting a portion of a third example power head comprising a third example motor gear assembly.

DETAILED DESCRIPTION

(20) Referring initially to FIG. 1 of the invention, depicted at 20 therein is a first example power head system constructed in accordance with, and embodying, the principles of the present invention. The example power head system 20 comprises a power head 22 (FIG. 2), a power head remote 24 (FIG. 2), and a power head adapter system 26 (FIG. 2). FIG. 2A illustrates an electrical system 28 forming part of the power head system 20.

(21) The first example power head system 20 is adapted to be used as part of a vacuum system 30. The vacuum system 30 comprises a hose 32 connected between a vacuum source 34 and a handle 36. An extension tube 38 is connected between the handle 36 and the power head system 20. As is conventional, when connected together as shown in FIG. 2, the hose 32, handle 36, and extension tube 38 define a vacuum passage that extends between vacuum source 34 and the power head system 20.

(22) The first example power head 22 comprises a main body assembly 40, a brush assembly 42, and a latch system 44 for detachably attaching the brush assembly 42 to the main body assembly 40.

(23) The main body assembly 40 comprises a main housing 50 defining a main chamber 52 and a battery chamber 54. The main chamber 52 defines a main inlet 56 and a main outlet 58. The example battery chamber 54 is isolated from the main chamber 52 and is adapted to contain a battery assembly 60. As shown in FIGS. 2A and 2B, first and second main contacts 62 and 64 are electrically connected to the battery assembly 60. The first and second main contacts 62 and 64 may be embodied in any number of physical forms, but one common form is as an electrical socket mounted on the main housing 50 as depicted in FIG. 7. The example main body assembly 40 further comprises a wheel assembly 70 comprising wheels 72, a wheel carriage 74, and a wheel shaft 76.

(24) The brush assembly 42 comprises a brush housing 80 defining a brush chamber 82. The brush chamber 82 defines a brush inlet 84 and a brush outlet 86. The brush assembly 42 further comprises a brush 90 arranged within the brush chamber 82 and a brush drive system 92. The brush drive system 92 comprises a brush motor 94. The example brush drive motor 94 is electrically connected to first and second brush contacts 96 and 98 as shown in FIG. 2A. The first and second brush contacts 96 and 98 may also take many different physical forms and are depicted in FIG. 4 as an electrical plug. The electrical plug formed by the brush contacts 96 and 98 is configured to engage the electrical socket formed by the main contacts 62 and 64 such that the battery assembly 60 provides power to the brush motor 94.

(25) The example latch system 44 comprises a first latch assembly 120 and a second latch assembly 122. The example latch assemblies 120 and 122 are identical, and, as depicted in FIG. 4, the example latch assembly 120 comprises a latch anchor 124 rigidly secured to the brush housing 80 and a latch arm assembly 126 rotatably attached to the main housing 50. The example latch arm assembly 126 rotates between locked and unlocked position to detachably secure the brush housing 80 to the main housing 50. The latch assemblies 120 and 122 may take other forms. For example, the example latch assemblies 120 and/or 122 may be embodied as a detent member integrally formed with one of the main housing 50 and the brush housing 80 and a latch opening integrally formed in the other of the main housing 50 and the brush housing 80. In this form, the detent member defining a cam surface displaces the detent member to allow a detent projection on the detent member to enter the latch opening.

(26) The latch assemblies 120 and 122 are configured to detachably attach the brush housing 80 to the main housing 50. When the brush housing 80 is attached to the main housing 50, the brush outlet 86 is in fluid communication with the main inlet 56, and a power head flow path is defined. The power head flow path extends from the brush inlet 84, through the brush chamber 82, through the brush outlet 86, through the main inlet 56, through the main chamber 52, and out of the main outlet 58.

(27) The example power head remote 24 comprises a remote housing 130 and one or more remote buttons 132. A wireless communication system (not shown) formed by the electrical system 28 and the remote 24 allows the brush motor 94 to be turned on and off using the remote button(s) 132. The wireless communications system is or may be conventional and will not be described herein in detail.

(28) The example adapter system 26 comprises a fixed member 140, a movable member 142, a first adapter member 144, and a second adapter member 146. The example fixed member 140 is sized and dimensioned to engage the main housing 50. The movable member 142 is rotatably supported by the fixed member 140 and is sized and dimensioned to receive the extension tube 38. The extension tubes 38 may come in different sizes and/or styles, and the first and second adapter members 144 and 146 are sized and dimensioned to engage the movable member 142 on one end and a selected size and/or style of the extension tube 38. The example adapter 26 may take a number of different configurations, but in each configuration the adapter system forms a substantially air-tight connection between one size and/or style of the extension tubes 38 and the main housing 50. When the adapter system 26 is formed between the extension tube 38 and the main housing 50, the vacuum source 34 causes air to flow through the main inlet 56, through the main chamber 52, and out of the main outlet 58.

(29) Referring now more specifically to the main chamber 52, FIGS. 9, 11, and 13 illustrate that the main chamber 52 comprises a rear portion 150, a central portion 152, a first side portion 154, a second side portion 156, and an outlet portion 158. The central portion 152 in turn defines a central inlet portion 160, a central intermediate portion 162, and a central main portion 164. Each of the first and second side portions 154 and 156 define a side inlet portion 170, a side intermediate portion 172, and a side outlet portion 174. The central inlet portion 160 and the side inlet portions 170 are each in fluid communication with the main inlet 56, and the central main portion 164 and the side main portions 174 are each in fluid communication with the outlet portion 158. The outlet portion 158 is in turn in fluid communication with the main outlet 58.

(30) In the example main housing 50, the battery chamber 54 is arranged above the central main portion 164 and between the central side portions 172 defined by the first and second side portions 154 and 156. This arrangement of the battery chamber 54 provides space for the battery assembly 60 while minimizing a height of the main housing 50 and maintaining adequate air flow through the main chamber 52.

(31) Referring now to FIGS. 9 and 13-15, the example wheel assembly 70 will be described in further detail. The wheel carriage 74 defines first and second wheel hubs 180 and 182 each supporting one of the wheels 72. A carriage cam surface 184 is formed on the wheel carriage 74, and a shaft cam surface 186 is formed on the wheel shaft 76. The cam surfaces 184 and 186 are sized, dimensioned, and arranged such that axial rotation of the wheel shaft 76 displaces the wheel carriage 74 between a fully retracted position (FIG. 14) and a fully extended position (FIG. 15). A knob 188 on the wheel shaft 76 facilitates axial rotation of the wheel shaft 76. When the brush housing 80 is attached to the main housing 50, axial rotation of the wheel shaft 76 thus allows the height of the brush inlet 84 and brush 90 relative to the floor surface supporting the wheels 72. The wheel assembly 70 thus allows the power head system 20 to be reconfigured to be adapted to accommodate different floor materials.

(32) Referring now in more detail to the brush drive assembly 92, FIGS. 10 and 12 illustrate that the brush 90 defines a brush axle 210 and bristles 212 outwardly extending from the brush axle 210. Conventionally, the bristles 212 are arranged in one or more spiral patterns centered about a longitudinal axis of the brush axle 210. FIGS. 10 and 12 further illustrate that the brush axle 210 defines an axle chamber 214.

(33) FIGS. 10 and 12 further illustrate that the brush drive assembly 92 further comprises a first bearing 220, a second bearing 222, and a motor mount 224. The example first and second bearings 220 and 222 support the brush 90 within the brush chamber 82 for axial rotation relative to the brush housing 80, and the example motor mount 224 supports the brush motor 94 within axle chamber 214 defined by the brush axle 210 of the brush 90 such that a motor shaft 226 is substantially aligned with a longitudinal axis of the brush 90. The example brush drive assembly 90 further comprises a transmission 228 comprising a ring gear 230, a drive gear 232, and first, second, and third planetary gears 234, 236, and 238. The ring gear 230 is rigidly secured to an interior surface of the brush 90, and the drive gear 232 is rigidly secured to the motor shaft 226. The first, second, and third planetary gears 234, 236, and 238 are arranged between the drive gear 232 and the ring gear 230 such that rotation of the drive gear 232 causes axial rotation of the brush 90.

(34) FIG. 2B illustrates that the example power head system 20 further comprises a charger 240 that is electrically connected to first and second charger contacts 242 and 244. The example first and second charger contacts 242 and 244 are configured to engage the first and second main contacts 62 and 64 to allow the battery forming a part of the battery assembly 60 to be charged. In particular, the example first and second contacts 242 and 244 take the form of an electrical plug like the example electrical plug formed by the first and second brush contacts 96 and 98.

(35) FIG. 17 illustrates a second example power head 320 in which the brush motor 94 is not mounted within the brush 90. In this example, a drive gear 322 is mounted on the motor shaft 226. The brush motor 94 is mounted relative to the brush housing 80 such that the drive gear 322 is arranged within the brush chamber 82 and substantially above the brush 90. A ring gear 324 is rigidly connected to the brush 90 and arranged to engage the drive gear 322. Rotation of the brush motor 94 causes rotation of the drive gear 322, which in turn rotates the ring gear 324 to cause axial rotation of the brush 90.

(36) FIG. 18 illustrates a third example power head 330 in which the brush motor 94 is not supported by the brush housing 80. In this example, the brush motor 94 is supported by the main housing 50. A drive gear 332 is mounted on the motor shaft 226, and the brush motor 94 is mounted relative to the brush housing 80 such that the drive gear 332 is arranged partly within the main chamber 52 and partly such that a portion of the drive gear 332 extends out of the main chamber 52 through the main inlet 56. A ring gear 334 is rigidly connected to the brush 90 and arranged to engage the drive gear 332 when the brush housing 80 is attached to the main housing 50. Rotation of the brush motor 94 causes rotation of the drive gear 332, which in turn rotates the ring gear 334 to cause axial rotation of the brush 90.