Abstract
A vacuum cleaner includes a housing defining a longitudinal axis, an inlet defining an opening through which debris is provided into the housing, a cyclone chamber configured to receive the debris from the inlet, the cyclone chamber being annular, defining a central opening and a debris opening positioned radially outward of the central opening. The vacuum cleaner includes a dust collection chamber configured to receive the debris from the cyclone chamber via the debris opening, a suction motor assembly positioned within the housing and configured to generate an airflow through the inlet and the cyclone chamber, and an airflow passage extending from the central opening of the cyclone chamber to the suction motor assembly. The suction motor assembly draws the airflow from the cyclone chamber through the airflow passage. The airflow passage extends downward from the cyclone chamber and into an interior of the dust collection chamber.
Claims
1. A vacuum cleaner comprising: a housing defining a longitudinal axis; an inlet defining an opening through which debris is provided into the housing; a cyclone chamber configured to receive the debris from the inlet, the cyclone chamber being annular, defining a central opening and a debris opening positioned radially outward of the central opening; a dust collection chamber configured to receive the debris from the cyclone chamber via the debris opening; a suction motor assembly positioned within the housing and configured to generate an airflow through the inlet and the cyclone chamber; and an airflow passage extending from the central opening of the cyclone chamber to the suction motor assembly, wherein the suction motor assembly is configured to draw the airflow from the cyclone chamber through the airflow passage, and wherein the airflow passage extends downward from the cyclone chamber and into an interior of the dust collection chamber.
2. The vacuum cleaner of claim 1, further comprising a separator plate positioned within the housing to separate the cyclone chamber from the dust collection chamber, wherein the debris opening is formed within the separator plate, and wherein the airflow passage passes through the separator plate.
3. The vacuum cleaner of claim 2, wherein the separator plate is movable relative to the housing to provide access to an interior of the cyclone chamber.
4. The vacuum cleaner of claim 3, wherein the inlet is located external to a remainder of the housing, the vacuum cleaner further comprising an internal inlet channel located within the housing and extending between the inlet and the cyclone chamber, wherein the separator plate is movable relative to the housing to provide access to an interior of the internal inlet channel.
5. The vacuum cleaner of claim 1, wherein the airflow passage extends downward and then rearward from the central opening to the suction motor assembly.
6. The vacuum cleaner of claim 1, further comprising a pre-motor filter positioned within the airflow passage and arranged substantially perpendicular to the longitudinal axis of the housing such that the airflow through the pre-motor filter, perpendicular to a plane of the pre-motor filter, is substantially parallel to the longitudinal axis of the housing.
7. The vacuum cleaner of claim 1, wherein the airflow passage is located centrally within the dust collection chamber such that the dust collection chamber extends to either widthwise side of the airflow passage.
8. The vacuum cleaner of claim 1, wherein at least a portion of the airflow passage is integrally formed as a single component with the dust collection chamber.
9. The vacuum cleaner of claim 1, wherein the dust collection chamber is movable relative to the housing from a closed position to an open position to permit emptying of the dust collection chamber, wherein at least a portion of the airflow passage is movable with the dust collection chamber between the open position and the closed position.
10. The vacuum cleaner of claim 1, further comprising a grate positioned at the central opening and configured to prevent large debris within the cyclone chamber from entering the airflow passage.
11. A vacuum cleaner comprising: a housing defining a longitudinal axis; an inlet located external to a remainder of the housing, the inlet defining an opening through which debris is provided into the housing, the inlet extending substantially parallel to the longitudinal axis; a cyclone chamber configured to receive the debris from the inlet, the cyclone chamber being annular, defining a central opening and a debris opening positioned radially outward of the central opening; an internal inlet channel located wholly within the housing and extending between the inlet and the cyclone chamber, a dust collection chamber configured to receive the debris from the cyclone chamber via the debris opening; a suction motor assembly positioned within the housing and configured to generate an airflow through the inlet, the internal inlet channel, and the cyclone chamber; an airflow passage extending from the central opening of the cyclone chamber to the suction motor assembly, wherein the suction motor assembly is configured to draw airflow from the cyclone chamber through the airflow passage, and a separator plate positioned within the housing to separate the cyclone chamber from the dust collection chamber, wherein the debris opening is formed within the separator plate, and wherein the separator plate is movable relative to the housing to provide access to an interior of the cyclone chamber and an interior of the internal inlet channel.
12. The vacuum cleaner of claim 11, wherein the separator plate defines a lower surface of at least a portion of the cyclone chamber and at least a portion of the internal inlet channel.
13. The vacuum cleaner of claim 11, wherein the separator plate is rotatable about a hinge.
14. The vacuum cleaner of claim 11, wherein the dust collection chamber is movable relative to the housing between a closed position and an open position, and wherein the separator plate is accessible for movement relative to the housing when the dust collection chamber is in the open position.
15. The vacuum cleaner of claim 11, further comprising at least one adjustment mechanism that selectively holds the separator plate in a use position and is rotatable away from the separator plate to allow the separator plate to be opened.
16. The vacuum cleaner of claim 11, wherein the internal inlet channel is non-linear and deviates from the longitudinal axis of the housing such that the airflow is introduced tangentially to the cyclone chamber.
17. A vacuum cleaner comprising: a housing defining a longitudinal axis; an inlet located external to a remainder of the housing, the inlet defining an opening through which debris is provided into the housing; a cyclone chamber configured to receive the debris from the inlet, the cyclone chamber being annular, defining a central opening and a debris opening positioned radially outward of the central opening; a dust collection chamber configured to receive the debris from the cyclone chamber via the debris opening; a suction motor assembly positioned within the housing and configured to generate an airflow through the inlet and the cyclone chamber; and an airflow passage extending from the central opening of the cyclone chamber to the suction motor assembly, wherein the suction motor assembly is configured to draw the airflow from the cyclone chamber through the airflow passage, wherein the housing defines a hinge pin extending substantially perpendicular to the longitudinal axis, wherein the dust collection chamber defines an L-shaped bracket that extends over and around the hinge pin such that the dust collection chamber is rotatable about an axis of the hinge pin between a closed position and an open position, and wherein the L-shaped bracket is removable from the hinge pin when the dust collection chamber is in the open position such that the dust collection chamber is removable from the housing.
18. The vacuum cleaner of claim 17, wherein the L-shaped bracket of the dust collection chamber is not removable from the hinge pin in the closed position.
19. The vacuum cleaner of claim 17, wherein a majority of the hinge pin is visible and external to a remainder of the housing.
20. The vacuum cleaner of claim 17, further comprising a latch assembly configured to secure the dust collection chamber in the closed position, the latch assembly including a handle, a latch arm, and a catch plate, wherein the handle is a user engagement member that is coupled to the dust collection chamber and is rotatable relative to the dust collection chamber, wherein the latch arm is a bar shaped as an inverted-U engaged with the handle, and wherein the catch plate defines a hook supported by the housing that is engageable by the latch arm when the latch assembly secures the dust collection chamber to the housing in the closed position.
21. The vacuum cleaner of claim 1, further comprising a light configured to illuminate a surface to be cleaned by the vacuum cleaner, wherein the light includes a plurality of light emitting diodes or a plurality of fiber optic cables.
22. The vacuum cleaner of claim 1, wherein the suction motor assembly includes a motor, an impeller blade, and a foam sleeve positioned around the motor to decrease blade pass frequency peaks generated by a speed and a blade count of the impeller blade.
23. The vacuum cleaner of claim 1, wherein the inlet is adjustable relative to the housing such that the orientation of a distal end of the inlet is rotatable relative to the housing.
24. The vacuum cleaner of claim 1, wherein a lower surface of the housing includes an attachment structure for attaching to components having a mating attachment structure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view of a vacuum cleaner.
[0029] FIG. 2 is a side view of the vacuum cleaner of FIG. 1.
[0030] FIG. 3 is a cross-sectional side view of the vacuum cleaner of FIG. 1
[0031] FIG. 4 is a cross-sectional view of an inlet channel and cyclone chamber of the vacuum cleaner of FIG. 1, as viewed from below.
[0032] FIG. 5 is a cross-sectional view of a separator plate of the vacuum cleaner of FIG. 1, as viewed from below.
[0033] FIG. 6A is a side view of a portion of a vacuum cleaner having a bristle assembly in a retracted position.
[0034] FIG. 6B is a partial side view of a portion of the vacuum cleaner of FIG. 6A, with the bristle assembly in an extended position.
[0035] FIG. 7 is a forward perspective view of a vacuum cleaner having a light assembly.
[0036] FIG. 8 is a perspective view of a hinge assembly of a dust collection chamber of the vacuum cleaner of FIG. 1.
[0037] FIG. 9 is a cross-sectional side view through a latch assembly of the dust collection chamber of the vacuum cleaner of FIG. 1.
[0038] FIG. 10 is a perspective view of an inlet that is movable between various positions according to one embodiment.
[0039] FIG. 11 is a schematic illustration of an inlet that is movable between various positions, according to another embodiment.
[0040] FIG. 12 is a side view of an inlet that is movable between various positions and shown in an engaged position, according to yet another embodiment.
[0041] FIG. 13 is a side view of the inlet of FIG. 12 shown in a disengaged position.
[0042] FIG. 14 is a top view of an inlet that is movable between various positions according to yet another embodiment.
[0043] FIG. 15 a cross-sectional view of an inlet channel and cyclone chamber of a vacuum cleaner having a variable-width inlet channel.
[0044] FIG. 16 is a rear perspective view of a vacuum cleaner having an attachment structure.
[0045] FIG. 17 is an upper perspective view of a floor attachment tool for use with a vacuum cleaner, such as the vacuum cleaner of FIG. 1.
[0046] FIG. 18 is a lower perspective view of the floor attachment tool of FIG. 17
[0047] FIG. 19 is an upper perspective view of a further floor attachment tool having a lighting assembly.
[0048] FIG. 20 is a perspective view of a vacuum cleaner according to a further embodiment.
[0049] FIG. 21 is a cross-sectional side view of the vacuum cleaner of FIG. 20.
[0050] FIG. 22 is a cutaway perspective view of a separator plate of the vacuum cleaner of FIG. 20.
[0051] FIG. 23 is a rear perspective view of the vacuum cleaner of FIG. 20.
[0052] FIG. 24 is a front perspective view of the vacuum cleaner of FIG. 20.
[0053] FIG. 25 is a lower cutaway view of the vacuum cleaner of FIG. 20 taken at the separator plate.
[0054] FIG. 26 is a left-side cross-sectional view of a vacuum cleaner, according to another embodiment.
[0055] FIG. 27 is a rear perspective view of the vacuum cleaner of FIG. 26.
[0056] FIG. 28 is a right-side cross-sectional view of the vacuum cleaner of FIG. 26.
[0057] FIG. 29 is a cross-sectional side view of a vacuum cleaner, according to another embodiment.
[0058] FIG. 30 is a perspective view of a vacuum cleaner having multiple, distinct light emitting diode (LED) portions.
[0059] FIG. 31 is a perspective view of an alternative separator plate for a vacuum cleaner.
[0060] FIG. 32 is a cross-sectional side view of the alternative separator plate of FIG. 31.
[0061] FIG. 33 is a lower perspective view of a crevice tool positioned relative to the vacuum cleaner of FIG. 1.
[0062] FIG. 34 is a perspective view of a cyclone chamber according to an embodiment.
DETAILED DESCRIPTION
[0063] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
[0064] FIGS. 1-5 and 8-9 illustrate a vacuum cleaner 1100 including an inlet 1104, a cyclone chamber 1108, a separator plate 1112, a dust collection chamber 1116, a pre-motor filter 1120, a suction motor assembly 1124, and an airflow passage 1128 between the pre-motor filter 1120 and the suction motor assembly 1124. The suction motor assembly 1124 draws air and debris (e.g., dust and larger particles and pieces) into the vacuum cleaner 1100 from the environment (around the vacuum cleaner) through the inlet 1104. The air and debris are drawn through the inlet 1104 and into the cyclone chamber 1108. Within the cyclone chamber 1108, the heavier debris falls past the separator plate 1112 and into the dust collection chamber 1116. The air within the cyclone chamber 1108 is drawn through the central opening 1156 and downwards to into the airflow passage 1128 to pre-motor filter 1120. The airflow is drawn from the airflow passage 1128, through the pre-motor filter 1120 and substantially to the suction motor assembly 1124 and then through outlet openings 1132 in the housing 1136 of the vacuum cleaner, where the air is vented from inside the vacuum cleaner 1100 back to the environment. In some embodiments, a filter 1195 is positioned within the housing 1136 of the vacuum cleaner 1100 adjacent the outlet openings 1132 to prevent an ingress of materials (e.g., dust, debris) into the housing 1136 through the outlet openings 1132. In some embodiments, the filter 1195 is a foam material that attenuates sound, accounting for frequency peaks in the sound generated by the vacuum cleaner 1100. In some embodiments, the filter 1195 is formed as an open cell foam sheet having a thickness of 5 mm. In some embodiments, an additional foam sleeve 1197 is positioned around the motor to further minimize blade pass frequency peaks generated by the speed and blade count of the impeller blade. In some embodiments, the foam sleeve 1197 has a thickness of 15 mm.
[0065] The housing 1136 of the vacuum cleaner 1100 surrounds and encloses the cyclone chamber 1108, the separator plate 1112, the pre-motor filter 1120, the suction motor assembly 1124, and the airflow passage 1128. The housing 1136 may also surround a portion of the inlet 1104. The dust collection chamber 1116 is separable from and coupled to the housing 1136. The housing 1136 has a length (longer than its width and height) extending from a front end of the housing 1136 to a rear end of the housing 1136. The inlet 1104 is located at the front end of the housing 1136. A longitudinal axis A11 extends in the lengthwise direction of the vacuum cleaner 1100. The longitudinal axis A11 is substantially parallel to a horizontal ground surface on which the vacuum cleaner 1100 rests. In the illustrated embodiment, the longitudinal axis A1 is also parallel to the longitudinal axis of the inlet 1104.
[0066] The housing 1136 includes a lower surface 1192 that rests upon the horizontal ground surface. An upper surface 1196 is opposite the lower surface 1192 and includes a handle 1182. The handle 1182 includes a gripping portion and a forward post coupling the gripping portion to the remainder of the housing 1136. The gripping portion extends longitudinally and is located above the remainder of the housing 1136. The forward post of the handle 1182 extends at an angle upward from the upper surface 1196 along a central axis A13. The gripping portion of the handle 1182 is angled downward (relative to the longitudinal axis A11) along a central axis A14, as it extends rearward. While the handle 1182 is described as having a forward post and a rearward gripping portion extending along axes A13, A14, the handle 1182 is also relatively rounded such that these axes A13, A14 are a linear fit of the respective portions. In the illustrated embodiment, the angle between the two axes A13, A14 is an obtuse angle (e.g., greater than 90 degrees, between 90 and 120 degrees. The housing 1136 includes a battery receptacle 1186 configured to receive a rechargeable battery (not shown) adjacent a rear end and a lower end of the housing 1136. The battery is configured to provide power to the suction motor assembly 1124. The battery receptacle is angled (see insertion axis A16 of the battery receptacle 1186) relative to the longitudinal axis A11 by approximately 10 degrees (e.g., 5-15 degrees). As shown in FIG. 1, a power switch 1118 is located on the handle 1182 (e.g., at a forward end of the gripping portion) and is movable between an off-position and an on-position for actuating the vacuum cleaner 1100 between an off-state (in which the motor assembly 1124 is not activated) and an on-state (in which the motor assembly 1124 is activated).
[0067] The inlet 1104 is a substantially cylindrical passage that extends from a first (distal) end 1140 to a second (proximal) end 144. The distal end 1140 is the end through which debris is drawn into the vacuum cleaner 1100. The second end 1144 is at (e.g., within) the housing 1136 of the vacuum cleaner and provides the debris from the inlet 1104 to the cyclone chamber 1108. As shown, an axis of the inlet 1104 is substantially parallel (or colinear) with the longitudinal axis A11 of the vacuum cleaner 1100. In the embodiment shown, the inlet 1104 includes a tapered opening at the first end 1140 such that the opening is not perpendicular to the axis of the inlet. In other embodiments, the opening may be otherwise angled. The inlet 1104 broadens in diameter nearer to the second end 1144. In some embodiments, attachments are attachable to the end 1140 of the inlet 1104 to provide additional attachment heads suitable for different surfaces (e.g., a brushed attachment head, a crevice tool, etc.). In other embodiments, the inlet 1104 may be replaceable by alternative inlets having different attachment heads.
[0068] As shown in FIG. 4, an internal inlet channel 1150 is located wholly within the housing 1136 and is positioned between the inlet 1104 (which is predominantly external to the housing 1136) and the cyclone chamber 1108. A first end 1154 of the internal inlet channel 1150 is positioned at the second end 1144 of the inlet 1104 to receive airflow and debris therefrom. A second end 1158 of the internal inlet channel 1150 is coupled directly to (e.g., is integrally formed with) the inlet of the cyclone chamber 1108 and provides the airflow and debris from the internal inlet channel 1150 to the cyclone chamber 1108. The internal inlet channel 1150 is non-linear and deviates from the longitudinal axis A11 of the inlet 1104 such that the dirty air is introduced tangentially to the cyclone chamber 1108 thus creating a cyclone airflow within the cyclone chamber 1108. In the embodiment shown, the internal inlet channel 1150 defines a first curved portion extending from the first end 1154 towards the second end 1158 and a second curved portion extending from the second end 1158 towards the first end 1154 such that the passage deviates from the axis A11 without harsh corners or angles that would otherwise significantly impede airspeed or flow of debris.
[0069] The cyclone chamber 1108 is positioned rearward of the inlet 1104 within the housing 1136 and provides diverging paths for the debris and airflow drawn through the inlet 1104. The cyclone chamber 1108 includes an outer cylindrical sidewall 1148 through which the cyclone chamber 1108 receives the airflow and debris from the inlet 1104. A top wall 1152 covers one end of the cyclone chamber and an annular lower wall 1164 covers the opposite, lower end, with the exception of a central opening 1156 and a debris opening 1168 extending therethrough. As shown, the central opening 1156 is defined by an inner cylindrical sidewall 1160 nested within the outer cylindrical sidewall 1148 that extends upward from the lower wall 1164 to extend upward and into the interior of the cyclone chamber 1108 such that at least a portion of the cyclone chamber 1108 has an annular cross-section. In the illustrated embodiment, the inner cylindrical sidewall 1160 extends nearly the full height (e.g., at least two-thirds of the full height) of the cyclone chamber 1108. The lower wall 1164 is formed at least in part by the separator plate 1112 that forms a barrier between the cyclone chamber 1108 and the dust collection chamber 1116. In some embodiments, the separator plate 1112 also forms a barrier between the cyclone chamber 1108 and the airflow passage 1128. The debris diverges from the airflow generated by the suction motor assembly 1124 as the airflow is drawn upward and then down through the central opening 1156 and the debris, too heavy to move upward to the central opening 1156, moves downward through the separator plate 1112. In the embodiment shown, a grate 1146 is positioned over the opening 1156 to prevent debris from passing through the central opening 1156. As shown, the grate 1146 has a geometric (e.g., hexagonal) pattern, though other designs may be used.
[0070] The separator plate 1112 is shown in greater detail in FIG. 5 and is defined as a plate (as shown, a substantially circular plate having an arm) having a debris opening 1168 through which debris is configured to pass from the cyclone chamber 1108 to the dust collection chamber 1116. The debris opening 1168 is positioned radially outward of the central opening 1156. As shown, the opening 1168 is formed adjacent a radial extent of the circular portion of the separator plate 1112. The opening 1168 has a first width at a first end 1172 and a second width, less than the first width at a second end 1176, opposite the first end 1172. The width of the opening 1168 tapers gradually between the two ends 1172, 1176 in the direction of the cyclone airflow. The first end 1172 is offset from the second end 1176 by approximately 120 degrees (e.g., 110-130 degrees, 90-150 degrees, more than 90 degrees) such that the opening 1168 does not extend around a majority of the separator plate 1112. As shown, the opening 1168 covers less than 50 percent of the separator. In the embodiment shown, the opening 1168 is generally C-shaped. The opening 1168 is large enough to permit a reasonably large item of debris (that can fit through the inlet 1104) to pass therethrough but is otherwise limited in size to limit the influence of circulating airflow within the cyclone chamber 1108 from stirring up the debris within the dust collection chamber 1116. As described in greater detail below, the airflow passage 1128 also passes through the separator plate 1112, though is distinct from the opening 1168 and does not provide access to the dust collection chamber 1116.
[0071] A vortex finder gap height is defined between the top of the inner cylindrical sidewall 1160 and the underside of the top wall 1152 and corresponds to the non-annular portion of the cyclone chamber 1108 above the inner cylindrical sidewall 1160. A separator height is a height of the cyclone chamber 1108 and is defined between the separator plate 1112 and the top wall 1152. A separator diameter is a diameter of the cyclone chamber 1108 and is defined by the interior surface of the outer cylindrical sidewall 1148. A vortex finder diameter is defined as a diameter of the central opening 1156. An inlet width is defined as a width of the internal inlet channel 1150 measured perpendicular to the airflow direction through the internal inlet channel 1150 at a location between the two ends 1154, 1158. In some embodiments, the inlet width may be an average inlet width. In the illustrated embodiment, the inlet width is measured perpendicular to the airflow direction at the earliest intersection of the internal inlet channel 1150 and the cyclone chamber 1108. For a separator diameter of 115 mm and an airflow of 40 CFM, the ratio between the separator diameter and the vortex finder diameter is 3.3 (e.g., 3.0-3.5, 3.3). Additionally, the ratio between the separator diameter and the separator height is 2.3 (e.g. 2.0-2.5, 2.3). Further, a ratio between the separator diameter and the inlet width is 4.6 (e.g., 4.4-4.8, 4.6). Further still a ratio between the separator height and the vortex finder height is 3.3 (e.g., 3.0-3.5, 3.3). The abovementioned ratios maximize separation efficiency while reducing the resistance of the separator.
[0072] The separator plate 1112 includes two adjustment mechanisms 1180 that permit a user to rotate the separator plate 1112 relative to the lower wall 1164 to remove the separator plate 1112 and provide access to the inside of the cyclone chamber 1108. As shown, each adjustment mechanism is a tab 1180 coupled to a post 1170 for rotation relative to the separator plate. When each tab 1180 is rotated below the separator plate 1112, the tabs 1180 hold the separator plate 1112 in a use position (i.e., locked position) to separate the interior of the cyclone chamber 1108 from the interior of the dust collection chamber 1116. When each tab 1180 is rotated away from the separator plate 1112, the separator plate 1112 is openable (e.g., removable, rotatable about hinge 1166) to provide access to the interior of the cyclone chamber 1108. The tabs 1180 are located within the dust collection chamber 1116 such that the separator plate 1112 is openable when the dust collection chamber 1116 is opened and/or removed from the remainder of the housing 1136. A user can rotate the tabs 1180 without a tool (i.e., using only fingers) to open or remove the separator plate 1112. In some embodiments, the adjustment mechanism 1180 permits the separator plate 1112 to pivot downward to provide access to the cyclone chamber 1108, while other embodiments permit removal of the separator plate 1112. In the illustrated embodiment, the separator plate 1112 extends under not only the cyclone chamber 1108, but also the internal inlet channel 1150. As such, when the separator plate 1112 is opened, the interior of the internal inlet channel 1150 is similarly opened up (i.e., the underside of the channel 1150 is removed) such that a majority (e.g., at least half) of the internal inlet channel 1150 between the two ends 1154, 1158 is opened to simplify removal of debris from within the internal inlet channel 1150. The separator plate 1112 is accessible for movement relative to the housing 1136 when the dust collection chamber 1116 is opened.
[0073] The dust collection chamber 1116 is positioned below the cyclone chamber 1108 and separator plate 1112 and receives the debris drawn in through the inlet 1104 through the opening 1168 in the separator plate 1112. In some embodiments, the dust collection chamber 1116 is formed of a transparent or translucent material such that a user can identify a state (empty, partially full, nearly full, entirely full, etc.) of the dust collection chamber 1116. The dust collection chamber 1116 is located below the cyclone chamber 1108 and rearward of the inlet 1104 and defines an internal storage volume for the gathered debris. The dust collection chamber 1116 is removable from the housing 1136 (and the inlet 1104 and cyclone chamber 1108) to empty the dust collection chamber 1116. In some embodiments, the dust collection chamber 1116 is pressed inward (i.e., squeezed on opposing sides) to release clips that couple the dust collection chamber 1116 to the housing 1136. In other embodiments, the dust collection chamber 1116 may otherwise flip downward (e.g., on a hinge) and/or have clips or buttons that are displaced to separate the dust collection chamber 1116 from the housing 1136.
[0074] FIGS. 3 and 8 illustrates a hinge 1130 for supporting the dust collection chamber 1116 on the housing 1136. As shown, the hinge 1130 is located at the underside 1192 of the housing 1136 and at the rearward edge of the dust collection chamber 1116 such that rotation of the dust collection chamber 1116 relative to the housing 1136 includes a downward rotation of the front side of the dust collection chamber 1116. The housing 1136 includes a hinge pin 1122 defining an axis A17 that is substantially perpendicular to the longitudinal axis A11. The hinge pin 1122 is supported at each end by apertures 1126 formed in the housing 1136. In other embodiments, the hinge pin 1122 may be integrally formed with the remainder of the housing 1136. In the illustrated embodiment, a majority of the hinge pin 1122 is visible and external to the remainder of the housing 1136. The dust collection chamber 1116 includes the hinge 1130 formed as an L-shaped bracket 1130 that extends over and around the hinge pin 1122. In particular, the dust collection chamber 1116 rotates about the axis A17 of the hinge pin 1122 between open and closed positions and the hinge pin 1122 rests within the internal corner of the L-shaped bracket in each of the open and closed positions. In some embodiments, when the dust collection chamber 1116 is in the open position (i.e., for emptying), the dust collection chamber 1116 is slidable forward to separate the dust collection chamber 1116 from the hinge pin 1122 and therefore the housing 1136. In the closed position, the geometry of the L-shaped bracket and the housing 1136 prohibit separation of the dust collection chamber 1116 from the housing 1136. In some embodiments, the pre-motor filter 1120 is accessible for cleaning and/or replacement when the dust collection chamber 1116 is separated from the housing 1136.
[0075] As shown in FIG. 9, the dust collection chamber 1116 is secured to the housing in the closed position via a latch assembly 1162. The latch assembly 1162 includes a handle 1138, a latch arm 1142, and a catch plate 1163. The handle 1138 is a user engagement member that is coupled to the dust collection chamber 1116 and is rotatable by the user relative to the dust collection chamber 1116 about axis A18. The latch arm 1142 is a bar (e.g., round bar) shaped as an inverted-U, with the distal ends of the latch arm 1142 engaged with the handle 1138 and collectively rotatable about the axis A19. The catch plate 1163 defines a hook supported by the housing 1136. The catch plate 1163 is engageable by the latch arm 1142 (i.e., the central portion of the latch arm 1142 extends over the hook of the catch plate 1163) when the latch 1162 secures the dust collection chamber 1116 to the housing 1136 in the closed position. The latch arm 1142 is moved out of engagement with the catch plate 1163 to open the dust collection chamber 1116 by a user moving the handle 1138 upward (i.e., rotating the handle about axis A18), providing clearance between the latch arm 1142 and catch plate 1163, which allows for subsequent rotation of the latch arm 1142 away from the catch plate 1163 (about axis A19).
[0076] The airflow passage 1128 extends downward and then rearward from the central opening 1156 to the suction motor assembly 1124 and is a hollow conduit for providing suction airflow between the suction motor assembly 1124 and the cyclone chamber 1108 and extends between a first end 1184 at the cyclone chamber 1108 and a second end at the pre-motor filter 1120 and suction motor assembly 1124. The airflow passage 1128 is positioned centrally within the dust collection chamber 1116, with the dust collection chamber 1116 extending forward of the airflow passage 1128 and to either widthwise side of the airflow passage 1128. In some embodiments, the airflow passage is integrally formed as a single component with the dust collection chamber 1116. As such, when the dust collection chamber 1116 is opened, the airflow passage 1128 is similarly opened. As such, the first end 1184 may be accessible for cleaning upon opening the dust collection chamber 1116.
[0077] The pre-motor filter 1120 is positioned within a rearward portion of the airflow passage 1128 directly upstream of the suction motor assembly 1124. In particular, the pre-motor filter is provided in the airflow path between the cyclone chamber 1108 and the suction motor assembly 1124 to prevent dirt, dust, and debris in the cyclone chamber 1108 from reaching the suction motor assembly 1124. As described above with respect to the hinge 1130, the dust collection chamber 1116 is openable to provide access to the pre-motor filter 1120 for removal and cleaning or replacement of the pre-motor filter 1120, when necessary. In other embodiments, a portion of the housing 1136 or the cyclone chamber 1108 is removable to provide access to the pre-motor filter 1120. In some embodiments, the pre-motor filter is a pleated filter. In other embodiments, the pre-motor filter is an open-cell foam filter. As shown in FIG. 2, the pre-motor filter 1120 is angled substantially perpendicular (as shown by axis A15) to the longitudinal axis A11 of the vacuum cleaner 1100 such that an airflow direction through the filter 1120 is substantially parallel to the longitudinal axis A11 as it passes rearward through the housing 1136.
[0078] The suction motor assembly 1124 includes a suction motor (e.g., an electric motor) and an impeller coupled to an output shaft of the motor. The suction motor assembly 1124 is operable to generate a working airflow along the working airflow path from the inlet 1104 to the cyclone chamber 1108, through the pre-motor filter 1120, through the airflow passage 1128, and to the outlet openings 1132. In some embodiments, an outlet filter is positioned within the housing 1136 adjacent the outlet openings 1132 to prevent debris from passing into the housing through the outlet openings 1132. The suction motor rotates the impeller to draw dirty air (air with debris) through the inlet 1104 to move the debris into the dust collection chamber 1116. The suction motor assembly 1124 is located rearward of the second end 1188 of the airflow passage 1128, the cyclone chamber 1108, the dust collection chamber 1116 and the inlet 1104. The motor (i.e., the rotational axis A12 of the motor output shaft of the motor) is angled upward at approximately 5 degrees (e.g., at least 5 degrees, 3-10 degrees, 5-15 degrees) rearward and upward relative to the longitudinal axis A11.
[0079] As shown in FIG. 8, the underside 1192 of the vacuum cleaner 1100 includes a keyhole aperture 1134 for mounting the vacuum cleaner 1100 on a screw, hook, or other protrusion. In the illustrated embodiment, the keyhole aperture 1134 is rearward of the dust collection chamber 1116 and is forward of the battery receptacle 1186. The keyhole aperture is located in the rearmost portion of the ground engaging lower surface 1192 such that when the vacuum cleaner 1100 is hung with the handle 1182 at the top and the inlet 1104 at the bottom, the majority of the weight of the vacuum cleaner 1100 is below the keyhole aperture 1134.
[0080] FIGS. 6A-6B illustrate a vacuum cleaner 1200 similar to the vacuum cleaner 1100 illustrated in FIGS. 1-5 and 8-9, except as otherwise described. Reference numerals correspond to similar elements, incremented by 100. The inlet 1204 of the vacuum cleaner 1200 is dissimilar from the inlet 1104 with the inclusion of an integrated bristle assembly 1202. The integrated bristle assembly 1202 includes a slidable input member 1206 positioned on an exterior of the inlet 1204 and movable (e.g., linearly slidable) by a user (e.g., a finger of a user) between a first, stowed position (FIG. 6A) and a second, extended position (FIG. 6B). A plurality of bristles 1210 are coupled to the slidable input member 1206 and movable with the slidable input member 1206 between the first and second positions. As shown, in the first position, the plurality of bristles 1210 are substantially positioned within the inlet 1204, with a majority (e.g., at least 50%, at least 75%, at least 90%) of the length of the bristles 1210 within the inlet 1204 and rearward of the first end 1240 of the inlet 1204. In the second position, the plurality of bristles 1210 extend substantially out of and forward of the end 1240 of the inlet 1204 such that the bristles are configured to engage a surface to be cleaned to assist with the collection of debris by the inlet 1204.
[0081] FIG. 7 illustrates a vacuum cleaner 1300 similar to the vacuum cleaner 1100 illustrated in FIGS. 1-5 and 8-9, except as otherwise described. Reference numerals correspond to similar elements, incremented by 200. A light ring 1314 is provided around the inlet 1304 and in particular is formed adjacent the second end 1344 of the inlet 1304 on a forward-facing surface of the housing 1336. The light ring 1314 provides illumination in the area being cleaned as it provides illumination on all sides of the inlet 1304. In some embodiments, the light ring 1314 is actuated on when the motor is actuated. In some embodiments, the light ring 1314 is formed of a plurality (e.g., eight) of individual light emitting diodes (LEDs). In other embodiments, the light ring 1314 is formed of a plurality of fiber optic cables. In some embodiments, a diffuser is positioned in front of the light ring to provide a more consistent light output.
[0082] FIG. 10 illustrates a vacuum cleaner 1400 similar to the vacuum cleaner 1100 illustrated in FIGS. 1-5 and 8-9, except as otherwise described. Reference numerals correspond to similar elements, incremented by 300. The vacuum cleaner 1400 has an inlet 1404 that is dissimilar from the inlet 1104. The inlet 1404 is capable of rotation relative to the housing 1436 of the vacuum cleaner 1400. As shown, the inlet 1404 includes a forward component 1401, which defines the first distal end 1440 through which debris enters the vacuum cleaner 1400. A rearward component 1403, formed separate from the forward component 1401, defines the second end 1440 of the inlet 1404 through which the debris passes into the housing 1436. Each of the first and second components 1401, 1403 are substantially tubular, defining a passage through which the debris passes into the housing 1436, with a bendable, corrugated tube 1407 extending between the first and second components 1401, 1403. The first component 1401 includes a pair of rearwardly extending arms 1405A on diametrically opposed sides. The second component 1403 includes similar arms 1405B, extending forward to engage the arms 1405A of the first component. The first and second sets of arms 1405A, 1405B define a rotational axis A20 about which the first component 1401 is rotatable relative to the second component 1403 to modify the inlet angle of the first end 1440 relative to the housing 1436. As shown, one or both of the first arms 1405A include a toothed wheel for selectively engaging with a tooth 1411 of a slider 1409 coupled to the second component 1403. In a forward position, as shown, the tooth 1411 engages teeth 1405C of the wheel to hold the angle of the first component 1401 relative to the second component 1403. In some embodiments, the slider 1409 is locked into the forward position until it is moved rearward by a user to a rearward, unlocked position, in which the tooth 1411 disengages the toothed wheel 1405C, allowing for relative rotation of the components 1401, 1403. In other embodiments, the slider 1409 is biased into the forward position (e.g., by a biasing member such as a spring). The bias may be overcome be manually sliding the slider 1409 rearward or by otherwise rotating the first component 1401 until the biasing force is overcome.
[0083] FIG. 11 illustrates an inlet 1504 for a vacuum cleaner similar to the vacuum cleaner 1100 illustrated in FIGS. 1-5 and 8-9, except as otherwise described. Reference numerals correspond to similar elements, incremented by 400. The inlet 1504 is formed of three separate, yet connection components, a first component 1513 located at a first end 1540 of the inlet 1504, a second component 1515 located rearward of the first component 1513, and a third component 1517 located rearward of the first and second components 1513, 1515 and defining the second end 1544 of the inlet 1504. The first component 1513 is coupled to and rotatable relative to the second component 1515, the second component 1515 is coupled to and rotatable relative to the third component 1517, and the third component 1517 is coupled to the housing of a vacuum cleaner. Each of the three components 1513, 1515 are generally cylindrical to define the inlet 1504, though the first and second components 1513, 1515 are trapezoidal (when viewed from the side) such that rotation of the first and/or second components 1513, 1515 modify an angle of the first end 1540 relative to the second end 1544. In a first orientation, the three components 1513, 1515, 1517 are aligned with one another such that the inlet 1504 is linear. In a second orientation, the second component 1515 is rotated relative to the third component 1517 such that the first end 1540 is angled approximately 45 degrees relative to the second end 1544. In a third orientation, the first component 1513 is further rotated relative to the second component 1515 such that the first end 1540 is angled perpendicular to the second end 1544.
[0084] FIGS. 12-13 illustrate an inlet 1604 for a vacuum cleaner similar to the vacuum cleaner 1100 illustrated in FIGS. 1-5 and 8-9, except as otherwise described. Reference numerals correspond to similar elements, incremented by 500. The inlet 1604 is capable of rotation relative to a housing of a vacuum cleaner. As shown, the inlet 1604 includes a forward component 1619, which defines the first distal end 1640 through which debris enters the vacuum cleaner. A rearward component 1621, formed separate from the forward component 1619, defines the second end 1644 of the inlet 1604 through which the debris passes out of the inlet 1604. Each of the first and second components 1619, 1621 are substantially tubular, defining a passage through which the debris passes. The first component 1619 is coupled to the second component 1621 for rotation relative to the second component in a similar manner as the first and second components 1401, 1403 of the inlet 1404 shown in FIG. 10. A toothed wheel 1627 is mounted to the inlet 1604 at the point of relative rotation. A prong 1625 extends from a base 1623 that is coupled to (e.g., extends around) the first component 1619. The prong 1625 is moveable into (FIG. 12) and out of (FIG. 13) engagement with the teeth of the toothed wheel 1627 to selectively inhibit or allow rotation of the first component 1619 relative to the second component 1621.
[0085] FIG. 14 illustrates an inlet 1704 for a vacuum cleaner similar to the vacuum cleaner 1100 illustrated in FIGS. 1-5 and 8-9, except as otherwise described. Reference numerals correspond to similar elements, incremented by 600. At least a portion of the inlet 1704 (and, as shown, the distal end) is capable of rotation relative to a housing of a vacuum cleaner. As shown, the inlet 1404 includes a forward component 1729, which defines the first distal end 1740 through which debris enters the vacuum cleaner. A rearward component 1731, formed separate from the forward component 1701, defines the second end 1740 of the inlet 1704 through which the debris passes into the housing. Each of the first and second components 1729, 1731 are substantially tubular, defining a passage through which the debris passes into the housing, with a bendable, corrugated tube 1733 extending between the first and second components 1729, 1731. The first component 1729 includes a pair of rearwardly extending arms 1739 on diametrically opposed sides. The second component 1731 includes similar arms, extending forward to engage the arms 1739 of the first component. The interaction between the two components 1729, 1731 defines a rotational axis about which the first component 1729 is rotatable relative to the second component 1731 to modify the inlet angle of the first end 1740 relative to the second end 1744. Arms 1735 are coupled to the first component 1729 and are biased into engagement with the second component 1731 to maintain a desired angle between the two components 1729, 1731. The arms 1735 include heads 1737 that extend radially inward from the remainder of the arms 1735 to engage the second component 1731. The arms 1735 are pressable radially inward (against the bias) to unseat the heads 1737 from engagement with the second component 1731 of the inlet 1704 to permit rotation of the first component 1729 relative to the second component 1731. In releasing the arms 1735, the arms are biased again into engagement with the second component 1731 to hold the relative angle between the two components 1729, 1731.
[0086] FIG. 15 illustrates a vacuum cleaner 1800 similar to the vacuum cleaner 1100 illustrated in FIGS. 1-5 and 8-9, except as otherwise described. Reference numerals correspond to similar elements, incremented by 700. The vacuum cleaner 1800 is substantially similar to the vacuum cleaner 1100 shown in FIG. 4, though the internal inlet channel 1850 is modified. In particular, one longitudinal wall 1841 of the internal inlet channel 1850, which extends substantially the entire length of the internal inlet channel 1850 is movable to adjust a width of the internal inlet channel. FIG. 15 illustrates three distinct positions (a minimum position, an intermediate position, and a maximum position) in which the longitudinal wall 1841 is adjustable and lockable. In some embodiments, the longitudinal wall 1841 may be locked into specific discrete positions. In other embodiments, the longitudinal wall 1841 may be lockable into any position between (and including) a minimum position and a maximum position. In a maximum position, the width of the internal inlet channel 1850 is maximized to allow for debris of larger size to pass therethrough. In the minimum position, the width of the internal inlet channel 1850 is minimized to increase the velocity of airflow therethrough. In some embodiments, the wall 1841 is manually adjustable (i.e., by moving a separator plate, similar to the separator plate 1112, as described with respect to FIG. 5). In other embodiments, a switch (not shown) on an exterior of the housing 1836 may be actuated to modify the airflow velocity.
[0087] FIG. 16 illustrates a vacuum cleaner 1900 similar to the vacuum cleaner 1100 illustrated in FIGS. 1-5 and 8-9, except as otherwise described. Reference numerals correspond to similar elements, incremented by 800. FIG. 16 illustrates the underside 1992 of the housing 1936 adjacent to the battery receptacle 1186. Rather than incorporating a keyhole aperture (or, in other embodiments, in addition to incorporating a keyhole aperture), the lower surface 1992 of the housing 1936 includes an attachment structure 1943 (such as a PACKOUT attachment structure) for attaching to storage organizers, toolboxes, and other components having a mating attachment structure. The attachment structure 1943 includes a protrusion that clips into slots of the mating structure. In some embodiments, the attachment structure 1943 is integrally formed into the lower surface 1992 of the housing 1936. In other embodiments, the attachment structure 1943 is attachable to the lower surface 1992 of the housing 1936. As shown, a fastener 1947 extends through a slot 1945 to engage an opening (such as the keyhole aperture 1134 shown in FIG. 8 or a threaded aperture) of the housing 1936 to affix the attachment structure 1943 to the housing 1936.
[0088] FIGS. 17-18 illustrate a floor tool 2100 for use with a vacuum cleaner, such as the vacuum cleaner 1100. The floor tool 2100 includes a housing 2104 that defines a suction inlet 2150 (FIG. 18) through which dust and debris are drawn into an interior 2146 (i.e., suction chamber) of the housing 2104. The housing 2104 is coupled to an outlet assembly 2108 defining an outlet 2112 through which debris is drawn from the interior 2146 of the housing 2104 into an inlet (such as inlet 1104 shown in FIG. 1) of a vacuum cleaner. In some embodiments, the outlet assembly 2108 may be coupled directly to the inlet of a vacuum cleaner. In other embodiments, the outlet assembly 2108 may be coupled indirectly with a rigid, flexible, or combination flexible/rigid assembly positioned therebetween to increase the distance between the handheld vacuum cleaner (e.g., vacuum cleaner 1100) and the floor tool 2100.
[0089] The floor tool 2100 is supported on a floor surface (e.g., a horizontal surface) with a plurality of wheels 2116 located adjacent a rear side 2126 of the housing 2104 and a pair of rollers 2162 (FIG. 18) adjacent a front side 2124 of the housing 2104. Each of the wheels 2116 and rollers 2162 are coupled to the housing 2104, though the wheels 2116 are larger and visible from above, while the rollers 2162 are located within the housing 2104 and only visible from below. The housing 2104 has a width extending between a first side edge 2130 and a second side edge 2134, a depth extending between the front side 2124 and the rear side 2126, and a height extending between a top side 2138 and an under side 2142. The width is greater in size than the depth, and the depth is greater in size than the height. The shape of the housing is substantially that of a rectangular prism. As shown in FIG. 18, the suction inlet 2150 is formed wholly within the under side 2142 (i.e., bottom surface) of the housing 2104, the under side being substantially parallel to and adjacent to the ground surface when all of the wheels 2116 and rollers 2162 are in engagement with the ground surface. The width of the suction inlet 2150 is substantially identical to the width of the housing 2104, only less by the width of the two side edges 2130, 2134. The height of the suction chamber 2146 within the housing 2104 is variable, increasing nearer to the center of the housing 2104. In the illustrated embodiment, a height of the suction chamber 2146 linearly increases from a nearly negligible height (i.e., less than 10% of the maximum height of the suction chamber) from each side edge 2130, 2134 to a central opening 2154 of maximum internal height. The central opening 2154 is open to an inlet 2158 of the outlet assembly 2108 such that debris within the suction chamber 2146 is directed in a widthwise direction towards the central opening 2154 and into the outlet assembly 2108 via the inlet 2158.
[0090] The outlet assembly 2108 extends between the inlet 2158 and the outlet 2112 and includes a flexible tube 2120 (e.g., corrugated hose) housed within the otherwise rigid outlet assembly 2108. The outlet assembly is rotatable about axis A21 with the flexibility of the flexible tube. The inlet 2158 is defined by a rigid body and is rigidly fixed to the housing 2104. The outlet 2112 is defined by a rigid body and is rigidly fixed to a vacuum cleaner (such as vacuum cleaner 1100). The flexible tube 2120 extends therebetween and provides a continuous flow path between the inlet 2158 and the outlet 2112 regardless of the relative rotation of the rigid bodies defining the inlet 2158 and outlet 2112.
[0091] FIG. 19 illustrates a floor tool 2200 similar to the floor tool 2100 illustrated in FIGS. 17-18, except as otherwise described. Reference numerals correspond to similar elements incremented by 100. The floor tool 2200 includes additional lighting arrangements for illuminating the floor area surrounding the floor tool 2200. In some embodiments, a plurality of lights 2280 (e.g., LEDs) are positioned on the front side 2224 of the housing 2204 to illuminate the area directly in front of the floor tool 2200. In the illustrated embodiment, nine individual lights are evenly spaced along the full width of the floor tool directly above the suction inlet (similar to suction inlet 2150 shown in FIG. 18). In other embodiments, more or fewer lights 2280 may be utilized. Additionally or alternatively, an array of lights 2274 is provided atop the upper surface of the housing 2204. As shown, a light housing 2270 is mounted to (or otherwise integrally formed with) the housing 2204 having a plurality of passages formed therein. Each one of the passages receives a fiber optic cable 2274 and directs the light from the fiber optic cable 2274 in various forward facing angles. A bracket 2278 mounted to the outlet assembly 2208 organizes and supports the fiber optic cables 2274. In some embodiments, such as is described with respect to FIG. 7, a vacuum cleaner may incorporate a light source. In such embodiments, the light source may be extended downward (e.g., via fiber optic cables) to the floor tool 2200 and may be organized and supported via the bracket 2278.
[0092] FIGS. 20-25 illustrate a vacuum cleaner 100 including an inlet 104, a cyclone chamber 108, a separator plate 112, a dust collection chamber 116, a pre-motor filter 120, a suction motor assembly 124, and an airflow passage 128 between the pre-motor filter 120 and the suction motor assembly 124. The suction motor assembly 124 draws air and debris (e.g., dust and larger particles and pieces) into the vacuum cleaner 100 from the environment (around the vacuum cleaner) through the inlet 104. The air and debris are drawn through the inlet 104 and into the cyclone chamber 108. Within the cyclone chamber 108, the heavier debris falls past the separator plate 112 and into the dust collection chamber 116. The air within the cyclone chamber 108 is drawn upwards through the pre-motor filter 120 and into the airflow passage 128. The airflow is drawn from the airflow passage 128 substantially to the suction motor assembly 124 and then through outlet openings 132 in the housing 136 of the vacuum cleaner, where the air is vented from inside the vacuum cleaner 100 back to the environment.
[0093] The housing 136 of the vacuum cleaner 100 surrounds and encloses the cyclone chamber 108, the separator plate 112, the dust collection chamber 116, the pre-motor filter 120, the suction motor assembly 124, and the airflow passage 128. The housing 136 may also surround a portion of the inlet 104. The housing 136 has a length (longer than its width and height) extending from a front end of the housing 136 to a rear end of the housing 136. The inlet 104 is located at the front end of the housing 136. A longitudinal axis A1 extends in the lengthwise direction of the vacuum cleaner 100. The longitudinal axis A1 is substantially parallel to a horizontal ground surface on which the vacuum cleaner 100 rests. The housing 136 includes a lower surface 192 that rests upon the horizontal ground surface. An upper surface 196 is opposite the lower surface 192 and includes a handle 182. The handle 182 includes a gripping portion and two posts coupling the gripping portion to the remainder of the housing 136. The gripping portion extends longitudinally and is located above the remainder of the housing 136. The gripping portion of the handle 182 is angled downward at approximately 15 degrees (e.g., 10-20 degrees) rearward relative to the longitudinal axis A1 (see central axis A3 of the handle 182). The rearward post is substantially vertical and the forward post extends upward and rearward. The housing 136 includes a battery receptacle 186 configured to receive a rechargeable battery (not shown) adjacent a rear end and a lower end of the housing 136. The battery is configured to provide power to the suction motor assembly 124. The battery receptacle is angled (see insertion axis A4 of the battery receptacle 186) relative to the longitudinal axis A1 by approximately 10 degrees (e.g., 5-15 degrees).
[0094] The inlet 104 is a substantially cylindrical passage that extends from a first (distal) end 140 to a second (proximal) end 144. The distal end 140 is the end through which debris is drawn into the vacuum cleaner 100. The second end 144 is at (e.g., within) the housing 136 of the vacuum cleaner and provides the debris from the inlet 104 to the cyclone chamber 108. As shown, an axis of the inlet 104 is substantially parallel (or colinear) with the longitudinal axis A1 of the vacuum cleaner 100. In the embodiment shown, the inlet 104 includes a tapered opening at the first end 140 such that the opening is not perpendicular to the axis of the inlet. In other embodiments, the opening may be otherwise angled. The inlet 104 broadens in diameter nearer to the second end 144 to correspond to the height of the cyclone chamber 108. The inlet 104 turns at the second end 144 such that the dirty air is introduced tangentially to the cyclone chamber 108 thus creating a cyclone airflow within the cyclone chamber 108. In some embodiments, attachments are attachable to the end 140 of the inlet 104 to provide additional attachment heads suitable for different surfaces (e.g., a brushed attachment head, a crevice tool, etc.). In other embodiments, the inlet 104 may be replaceable by alternative inlets having different attachment heads.
[0095] The cyclone chamber 108 is positioned rearward of the inlet 104 within the housing 136 and provides diverging paths for the debris and airflow drawn through the inlet 104. The cyclone chamber 108 includes an outer cylindrical sidewall 148 through which the cyclone chamber 108 receives the airflow and debris from the inlet 104. An annular top wall 152 covers a portion of one end of the cyclone chamber, with the exception of a central opening 156 extending therethrough. As shown, the central opening 156 is defined by an inner cylindrical sidewall 160 nested within the outer cylindrical sidewall 148. The inner cylindrical sidewall 160 extends downward into the interior volume of the cyclone chamber 108 such that at least a portion of the cyclone chamber 108 has an annular cross-section. A lower wall 164 is formed at least in part by the separator plate 112 that forms a barrier between the cyclone chamber 108 and the dust collection chamber 116. The debris diverges from the airflow generated by the suction motor assembly 124 as the airflow is drawn upward through the central opening 156 and the debris moves downward through the separator plate 112.
[0096] The separator plate 112 is shown in greater detail in FIG. 22 and is defined as a plate (as shown, a circular plate) having an opening 168 through which debris is configured to pass from the cyclone chamber 108 to the dust collection chamber 116. As shown, the opening 168 is formed adjacent a radial extent of the separator plate 112. The opening 168 has a first width at a first end 172 and a second width, greater than the first width at a second end 176, opposite the first end 172. The width of the opening 168 tapers gradually between the two ends 172, 176 in the direction of the cyclone airflow. The first end 172 is offset from the second end 176 by approximately 120 degrees (e.g., 110-130 degrees, 90-150 degrees, more than 90 degrees) such that the opening 168 does not extend around a majority of the separator plate 112. As shown, the opening 168 covers less than 50 percent of the separator. In the embodiment shown, the opening 168 is generally C-shaped. The opening 168 is large enough to permit a reasonably large item of debris (that can fit through the inlet 104) to pass therethrough but is otherwise limited in size to limit the influence of circulating airflow within the cyclone chamber 108 from stirring up the debris within the dust collection chamber 116. The separator plate 112 includes two adjustment mechanisms 180 that permit a user to rotate the separator plate 112 relative to the lower wall 164 to remove the separator plate 112 and provide access to the inside of the cyclone chamber 108. The separator plate 112 is rotatable between a locked position in which the separator plate 112 is installed and an unlocked position in which the separator plate 112 is removable from the lower wall 164. As shown, the adjustment mechanisms 180 include tabs extending perpendicular to the plate of the separator plate 112 and into the dust collection chamber 116. A user can provide an index finger on one tab 180 and a thumb on the other tab to generate a rotational force to remove (and reinstall) the separator plate 112. In other embodiments, the adjustment mechanism 180 may permit the separator plate 112 to pivot downward to provide access to the cyclone chamber 108.
[0097] The dust collection chamber 116 is positioned below the cyclone chamber 108 and separator plate 112 and receives the debris drawn in through the inlet 104 through the opening 168 in the separator plate 112. In some embodiments, the dust collection chamber 116 is formed of a transparent or translucent material such that a user can identify a state (empty, partially full, nearly full, entirely full, etc.) of the dust collection chamber 116. The dust collection chamber 116 is located below the cyclone chamber 108 and rearward of the inlet 104 and defines an internal storage volume for the gathered debris. The dust collection chamber 116 is removable from the housing 136 (and the inlet 104 and cyclone chamber 108) to empty the dust collection chamber 116. In some embodiments, the dust collection chamber 116 is pressed inward (i.e., squeezed on opposing sides) to release clips that couple the dust collection chamber 116 to the housing 136. In other embodiments, the dust collection chamber 116 may otherwise flip downward (e.g., on a hinge) and/or have clips or buttons that are displaced to separate the dust collection chamber 116 from the housing 136.
[0098] The pre-motor filter 120 is positioned above the cyclone chamber 108. In particular, the pre-motor filter is provided in the airflow path between the cyclone chamber 108 and the suction motor assembly 124 to prevent dirt, dust, and debris in the cyclone chamber 108 from reaching the suction motor assembly 124. In some embodiments, the housing 136 (i.e., the upper surface 196 of the housing 136) is openable to provide access to the pre-motor filter 120 for removal and cleaning or replacement of the pre-motor filter 120, when necessary. In other embodiments the cyclone chamber 108 is removable downwardly from the housing 136 to provide access to the pre-motor filter 120 from the bottom of the vacuum cleaner 100. In some embodiments, the pre-motor filter is a pleated filter. In other embodiments, the pre-motor filter is an open-cell foam filter. As shown in FIG. 3, the pre-motor filter 120 is angled relative to the longitudinal axis A1 of the vacuum cleaner 100. The pre-motor filter 120 is generally planar (identified by reference numeral A5) such that airflow through the filter 120 is transverse to the plane. The plane of the pre-motor filter 120 is angled at approximately 10 degrees (e.g., 5-15 degrees) rearward relative to the longitudinal axis A1 such that airflow passing through the filter 120 perpendicular to the plane is heading upward and rearward through the housing 136.
[0099] The airflow passage 128 extends rearward from the pre-motor filter 120 to the suction motor assembly 124 and is a hollow conduit for providing suction airflow between the suction motor assembly 124 and the cyclone chamber 108. A first end 184 of the airflow passage 128 is positioned at the pre-motor filter 120. A second end 188, opposite of the first end 184 is positioned at the suction motor assembly 124. The airflow passage 128 is generally S-shaped between the two ends 184, 188. The airflow passage 128 extends substantially horizontally rearward from the first end 184 (i.e., generally parallel to the longitudinal axis A1 of the vacuum cleaner 100), extends vertically downward from there, and then rearward to the second end 188. Adjacent the second end 188, the airflow passage 128 is angled at approximately 10 degrees (e.g., 5-15 degrees) rearward and upward relative to the longitudinal axis A1.
[0100] The suction motor assembly 124 includes a suction motor (e.g., an electric motor) and an impeller coupled to an output shaft of the motor. The suction motor assembly 124 is operable to generate a working airflow along the working airflow path from the inlet 104 to the cyclone chamber 108, through the pre-motor filter 120, through the airflow passage 128, and to the outlet openings 132. The suction motor rotates the impeller to draw dirty air (air with debris) through the inlet 104 to move the debris into the dust collection chamber 116. The suction motor assembly 124 is located rearward of the second end 188 of the airflow passage 128, the cyclone chamber 108, the dust collection chamber 116 and the inlet 104. The motor (i.e., the rotational axis A2 of the motor output shaft of the motor) is angled upward at approximately 5 degrees (e.g., at least 5 degrees, 3-10 degrees, 5-15 degrees) rearward and upward relative to the longitudinal axis A1.
[0101] FIGS. 26-28 illustrate a vacuum cleaner 200 similar to the vacuum cleaner 100 illustrated in FIGS. 20-25, except as otherwise described. Reference numerals correspond to similar elements, incremented by 100. Rather than having a vertical rearward post, the gripping portion of the handle 282 extends downward to the remainder of the housing 236. A battery 290 coupled to the battery receptacle 286 is illustrated in FIG. 28. As shown, the battery receptacle 286 (and therefore the battery 290 coupled thereto) is coupled at an angle relative to the longitudinal axis A1 such that a bottom surface of the battery 290 is not parallel or coplanar with the lower surface 292 of the housing. As such, only a portion (e.g., an edge) of the battery 290 rests upon a horizontal surface with the housing 236 of the vacuum cleaner 200 in some embodiments. In other embodiments, the battery 290 is suspended above the horizontal ground surface such that none of the battery 290 contacts the horizontal surface. A further distinction of the vacuum cleaner 200 relative to the vacuum cleaner 100 is the shape of the top wall 252 and inner sidewall 260 of the cyclone chamber 208. Rather than a vertical inner sidewall, the inner sidewall tapers inward from the top wall 252 to the opening 256. In some embodiments, as shown in FIG. 26, the airflow passage 228 may be dissimilar (e.g., extending vertically downward through the dust collection chamber 116 and then rearward to the suction motor assembly 224). In the embodiment of FIG. 26, the pre-motor filter is a planar filter oriented vertically and positioned in front of the suction motor assembly 124.
[0102] FIG. 29 illustrates a vacuum cleaner 300 similar to the vacuum cleaner 100 illustrated in FIGS. 20-25, except as otherwise described. Reference numerals correspond to similar elements, incremented by 200. The shape of the airflow passage 328 is dissimilar from the airflow passage 128 illustrated in FIGS. 20-25. Rather than having a substantially S-shaped profile, the airflow passage 328 includes a horizontal portion (i.e., in the direction of the longitudinal axis A1) extending rearward from a first end 384 at the pre-motor filter 320. The horizontal portion terminates at a downward portion angled (e.g., at approximately 45 degrees, at 30 to 60 degrees) downward and rearward to the suction motor assembly 324 at the second end 388. The angle of the suction motor assembly 324 (i.e., the angle of the rotational axis of the motor of the suction motor assembly) is similar to the angle of the downward portion of the airflow passage 328.
[0103] FIG. 30 illustrates a vacuum cleaner 400 similar to the vacuum cleaner 100 illustrated in FIGS. 20-25, except as otherwise described. Reference numerals correspond to similar elements, incremented by 300. As shown in FIG. 30, in some embodiments, the housing 436 of the vacuum cleaner 400 includes a plurality of light emitting diodes (LEDs) 410, 414, 418 spaced apart from one another about the inlet 404. The first LED 410 is located above the inlet 404, the second LED 414 is located to a first side (e.g., a right side) of the inlet 404, and the third LED 418 is located to a second side (e.g., a left side) of the inlet 404, opposite the first side. Each LED 410, 414, 418 is separate and distinct from each other LED 410, 414, 418. Collectively, the LEDs 410, 414, 418 illuminate an area around the distal end 440 of the inlet 404 and the area surrounding the distal end 440 of the inlet 404 such that a user can identify debris in an area adjacent the distal end 440 of the inlet 404. By utilizing multiple LEDs 410, 414, 418 on multiple sides of the inlet 404, the intensity of shadows cast by the inlet 404 is diminished.
[0104] FIGS. 31-32 illustrate a vacuum cleaner 500 similar to the vacuum cleaner 100 illustrated in FIGS. 20-25, except as otherwise described. Reference numerals correspond to similar elements, incremented by 400. The separator plate 512 illustrated in FIGS. 31-32 differs from the separator plate 112. The separator plate 512 is a conical separator plate extending downward into the interior volume of the dust collection chamber 516 such that the opening 568 of the separator plate 512 is located lower relative to the inlet 504. The tapered separator plate 512 also increases the interior volume of the cyclone chamber 508. The opening 568 is circular and centered on the conical separator plate 512. The adjustment mechanism 580 includes a clip that selectively holds the conical separator plate 512 in position. When the clip 580 is moved to release the conical separator plate 512 (to provide access to the interior of the cyclone chamber 508), the conical separator plate rotates about a hinge 522.
[0105] FIG. 33 illustrate a vacuum cleaner 600 similar to the vacuum cleaner 100 illustrated in FIGS. 20-25, except as otherwise described. Reference numerals correspond to similar elements, incremented by 500. One or both of the housing 636 and the dust collection chamber 616 include a recess 650 formed therein. The recess 650 is configured to receive an attachment 654 for the vacuum cleaner 600, such as a crevice tool. In some embodiments, the recess includes retention members 658 (e.g., deformable protrusions) configured to releasably secure the attachment 654 within the recess 650. The recess 650 has sufficient depth such that when the attachment 654 is positioned within the recess 650, a lower surface 692 of the housing 636 rests upon a horizontal ground surface.
[0106] FIG. 34 illustrates a cyclone chamber 708 similar to the cyclone chamber 108 except as otherwise described. FIG. 34 illustrates the off-center introduction of air into the cyclone chamber 708 to create the cyclone airflow therein. A vertical outlet 762 extends upward from the top wall 752 of the cyclone chamber 708 to the pre-motor filter 720 and the suction motor arrangement 728. In some embodiments, the diameter of the vertical outlet 762 tapers down as the outlet 762 extends further away from the top wall 752.
