Abstract:
A multi-use vacuum cleaner capable of use as an upright vacuum or as a detachable vacuum module further comprising a cyclonic dirt separator has a detachable vacuum module selectively mounted to the base and support member of an upright vacuum cleaner. The vacuum module includes the vacuum motor, motor driven fan, cyclonic dirt separator and hose. The vacuum cleaner may be operated as an upright vacuum, or alternatively, the module can be separated from the base assembly and may be used independently of and at a great distance from the base assembly for a wide variety of cleaning purposes.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional application Ser. No. 60/319,849, filed Jan. 10, 2003, which is incorporated herein in its entirety, and is a continuation in part of U.S. patent application Ser. No. 10/249,113, filed Mar. 17, 2003 now abandoned, a continuation in part of Ser. No. 09/849,143, filed May 4, 2001 now abandoned, which claims the benefit of U.S. Provisional Application 60/201,933, filed May 5, 2000 and U.S. Provisional Application 60/269,044, filed Feb. 15, 2001, all of which are incorporated herein in their entirety. 
    
    
     BACKGROUND OF INVENTION 
     1. Field of the Invention 
     This invention relates to a multi-use vacuum cleaner, and, more particularly, to a vacuum cleaner having a vacuum module comprising a cyclonic dirt separator which is detachably mounted to a power foot and upright support member. 
     2. Description of the Related Art 
     A multi-use vacuum cleaner capable for use as an upright vacuum or as a detachable vacuum module is disclosed in U.S. Pat. No. 5,524,321 to Weaver et al., issued Jun. 11, 1996 and U.S. Pat. No. 5,309,600 to Weaver et al. issued May 10, 1994. A detachable vacuum module is selectively mounted to the foot and support member of an upright vacuum cleaner. The vacuum module includes the vacuum motor, motor driven fan, vacuum bag and hose. The vacuum cleaner may be operated as an upright vacuum, or alternatively, the module can be separated from the foot and upright support member to be used independently of and at a great distance from the foot and upright support member for a wide variety of cleaning purposes. 
     The U.S. Patent Application Publication No. US2002/0011050 to Hansen et al., published Jan. 31, 2002, discloses a suction cleaner with a cyclonic dirt separator comprising a dirt collection assembly including a cyclonic separator having an inlet aperture and an outlet aperture, and a suction source fluidly connected with the cyclonic separator. In one embodiment, the cyclonic dirt separator includes a separator plate cooperating with the housing to separate the cyclonic separator from a dirt collecting cup. The separator plate has an outer diameter smaller than the inner diameter of the dirt tank, creating a gap between the outer edge of the separator plate and the inner wall of the cyclonic separator. 
     SUMMARY OF INVENTION 
     According to the invention, a multi-use upright vacuum cleaner combines the ease of use and compact configuration of an upright vacuum cleaner with the portability and multiple applications of a canister vacuum wherein the main filtration is accomplished with a cyclonic dirt separator. The vacuum cleaner has a foot assembly having a suction nozzle and adapted to move along a surface to be cleaned, an upright handle assembly pivotally mounted to the foot assembly for manipulation of the foot assembly along the surface to be cleaned. 
     The handle assembly includes a module platform pivotally mounted to the foot assembly, an elongated structural support, and a portable cleaning module. The elongated structural support is rigidly mounted at a lower portion to the module platform and forms a handle grip at an upper portion. The portable cleaning module is detachably mounted as a unit to the module platform and includes a module housing, a dirt separator mounted in the module housing for separating dust and dirt from dirt laden air, a suction conduit having a first end connected to the module housing in fluid communication with the dirt separator and a second with a removable coupling. A motor-driven fan is supported in the module housing for creating suction within the suction conduit and for moving the dirt laden air through the dirt separator. 
     A working air conduit is connected at a first end to the suction nozzle in the foot assembly and is removably connected at another end to the suction conduit removable coupling. When the portable cleaning module is mounted on the module platform, the vacuum cleaner functions as an upright vacuum cleaner and the motor-driven fan draws dirt laden air from the suction nozzle in the foot assembly to the suction conduit and moves the dirt laden air to the dirt separator for separation of dirt from air. When the portable cleaning module is removed from the module platform, the portable vacuum module can function by itself as a portable vacuum cleaner and the motor-driven fan draws dirt laden air from the second end of the suction conduit and moves the dirt laden air to the dirt separator for separation of dirt from air. 
     According to the invention, the dirt separator includes a cyclone separation chamber into which the dirt laden air is tangentially introduced through an inlet thereto. 
     In a preferred embodiment of the invention, the elongated structural support comprises a pair of spaced elongated frames that are joined at upper portions thereof and the portable cleaning module is positioned between the spaced elongated frames when it is mounted on the module platform. Preferably, the spaced elongated frames form a handle grip at an upper portion thereof. In addition, the spaced elongated frames are tubes. 
     Typically, the suction conduit is at least in part flexible for movement of the second end thereof with respect to the module housing during use of the portable cleaning module when it is detached from the module platform. Cleaning tools, carried by the elongated structural support can be mounted on the second end of the suction conduit when the portable cleaning module is detached from the module platform. In one embodiment, the other end of the working air conduit is integrated into the module platform and is formed by an opening in the module platform. The suction conduit removable coupling is removably mounted to the opening in the module platform. 
     In one embodiment, the cyclone separation chamber has an outlet and the motor driven fan has an inlet connected to the cyclone separator chamber outlet. In another embodiment, the motor driven fan has an inlet connected to the first end of the suction conduit and an outlet connected to the cyclone separator chamber inlet. 
     Typically, the dirt separator further includes a dirt cup removably mounted in the module housing beneath the cyclone separator to collect dirt separated from air therein. Further, the module housing further includes a handle integrally formed at an upper portion thereof for carrying the portable cleaning module when it is detached from the module platform. 
     In one embodiment, the portable cleaning module has a handle, preferably at an upper portion thereof, for hand carrying the cleaning module. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       In the drawings: 
         FIG. 1  is a perspective view of the multi-use vacuum cleaner having a detachable vacuum module with cyclonic dirt separation. 
         FIG. 2  is a rear quarter perspective view of the vacuum module separated from the upright vacuum cleaner foot assembly. 
         FIG. 3  is a partial sectional view of the vacuum module and foot assembly taken along lines  3 — 3  of  FIG. 1 . 
         FIG. 4  is a front cross sectional view of the cyclonic separator for a vacuum module as shown in  FIG. 1 . 
         FIG. 5  is a perspective view of the multi-use vacuum cleaner of  FIG. 1  with the dirt cup removed. 
         FIG. 6  is a schematic view of an alternative embodiment of the module illustrated in  FIGS. 1–5  according to the invention. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to  FIGS. 1 and 2 , an upright vacuum cleaner  10  comprises an upright handle assembly  12  and a foot assembly  14 . The upright handle assemble  12  comprises a module platform  24 , an elongated structural support  19  and a detachable cyclonic vacuum module  16 . The elongated structural support  19  is formed by a pair of spaced apart elongated frames in the form of support tubes  20  that are joined to form a grip  18  at an upper portion thereof. The support tubes  20  merge in an arc-like configuration at an upper end of the support tubes  20  and merge into the grip  18 . A mechanical stop  22  is positioned approximately midway between a lower end of each support tube  20  and the arc-like configuration. The stop  22  is a block-like structure to provide lateral support for the detachable cyclonic vacuum module  16 . The module platform  24  is rigidly attached to the lower ends of the support tubes  20  in a generally perpendicular fashion. Wheel axle bearings (not shown) extend through the first end of the support tube  20  in a horizontal direction. The upright handle assembly  12  including the module platform  24  rotates about the wheel axle bearings. An upholstery tool  26  is removably attached to a recessed upholstery tool caddy  28  located on an upper rearward surface of the upright handle assembly  12 . 
     Referring to  FIGS. 1 ,  2  and  3 , the foot assembly  14  further comprises a foot housing  30 , a wheel  32 , a brush chamber  34 , and a working air path described in more detail below. The brush chamber  34  comprises a cavity formed horizontally at a forward section of the foot housing  30 . Brush chamber  34  further comprises a brush  36 . Brush  36  is a generally well known horizontal brush roll that is driven by a separate brush motor (not shown) located within the foot housing  30 . An electric switch (not shown) on the detachable cyclonic vacuum module  16  selectively supplies power to the brush motor. A wheel axle  38  passes through the wheel axle bearings in the support tubes  20  and is rigidly fixed to either side of the foot housing  30 . Wheel  32  is rotatably mounted to axle  38 . 
     Referring to  FIG. 3 , the working air path comprises a suction nozzle aperture  40 , a flexible working air conduit  42 , and an air conduit interface  44 . Suction nozzle aperture  40  is formed on a lower surface of brush chamber  34 . Space between the brush  36  and the brush chamber  34  allow air to pass through brush chamber  34 . Flexible working air conduit  42  is fluidly connected to suction nozzle  40  on one end, is routed through a lower portion of the foot housing  30  and terminates at the air conduit interface  44  on an upper rearward surface of the foot housing  30 . Thus, an uninterrupted air path is created through the foot housing from the suction nozzle  40  to the air conduit interface  44 . A more complete description of a suitable foot assembly  14  and of a suitable mounting between the module platform  24  and the detachable module  16  is disclosed in U.S. Pat. Nos. 5,524,321 and 5,309,600 to Weaver et al., which are incorporated herein by reference in their entirety. 
     Referring to  FIGS. 1 ,  2  and  3 , the detachable cyclonic vacuum module  16  further comprises a module housing  46 , a cyclonic separator  48 , a removable dirt cup  50 , a dirt cup latch  52 , a filter tray assembly  54 , fan chamber  56 , an external hose  58  and an outlet air conduit  60 . The module housing  46  provides structure for the detachable cyclonic vacuum module  16 . Cavities are formed within the module housing  46  to support the cyclonic separator  48 , the removable dirt cup  50 , and the fan chamber  56 . A handle  62  is integrally formed in at an upper surface of the module housing  46 . Handle  62  provides a convenient location for a user to grasp and lift the detachable cyclonic vacuum module  16 . The external hose  58  has at one end a hose fitting  94  that is removably received in air conduit interface  44  and the other end is connected to cyclone air inlet aperature  78 . 
     Referring to  FIG. 3 , a fan motor assembly  64  further comprises a fan  66  and a motor  68 . Fan motor assembly  64  is located vertically within the fan chamber  56 . Fan  66  further comprises a fan air inlet  70  and a plurality of working air exhaust apertures  71 . Optionally, a post motor filter can be placed in the working air exhaust between the fan motor assembly  64  and the exhaust apertures  71 . Filter tray  54  is a generally box like structure with solid side-walls supported by a framework structure to create a permeable floor. Filter tray  54  is removably inserted into a corresponding cavity in the module housing  46  between the fan chamber  56  and the dirt cup latch  52 . A permeable foam filter  72  fits within the perimeter of the filter tray  54  and is supported by the filter tray floor. Foam filter  72  is air permeable so that the air passes through the topside of the foam filter, through the foam filter, and exits the bottom side of the foam filter adjacent to the fan inlet  70 . Foam filter  72  removes fine particles from the airstream prior to the airstream entering the fan inlet  70 . 
     Referring to  FIG. 5 , dirt cup latch  52  comprises a lever that rotates about a center axis inline with the fan motor assembly  64 . A pair of mating ramps raise and lower an upper surface of the dirt cup latch  52  as the dirt cup latch is moved from side to side. Removable dirt cup  50  is supported by an upper surface of the dirt cup latch  52  in a cavity  96  in the module  16 . As dirt cup latch  52  is moved to the lower setting, the removable dirt cup  50  moves down separating from the cyclonic separator  48  and allows the dirt cup  50  to be removed from the detachable cyclonic vacuum module  16 . One commercially available embodiment of the dirt cup latch is found in the Clean-View Model 3591 bagless upright vacuum cleaner sold by BISSELL Homecare, Inc. 
     Referring to  FIGS. 3 and 4 , cyclonic separator  48  comprises a cylindrical sidewall  74 , a circular upper wall  76  and a cyclone air inlet aperture  78 . Circular upper wall  76  further comprises an exhaust outlet  80  comprising a centrally located aperture therethrough. A collar  82  depends from a lower surface of upper wall  76 . A separator plate  84  in the form of a solid disk having an upstanding annular collar  86  is located in spaced relation below the upper wall  76 . In the preferred embodiment, the upstanding annular collar  86  is aligned with the depending collar  82  of the upper wall  76 . A cylindrical screen  88  is retained at the ends thereof by each of the collars  82 ,  80 . In this manner, separator plate  84  is suspended from upper wall  76 , forming a toroidal chamber  90  between the cylindrical screen  88  and the side wall  74 , and between the upper wall  76  and the separator plate  84 , respectively. In the preferred embodiment, air inlet aperture  78  is vertically aligned between upper wall  76  and separator plate  84  such that tangential airflow generated from air inlet aperture  78  is directed into the toroidal chamber  90 . 
     With further reference to  FIGS. 3 and 4 , the tangential air-flow containing particulate matter passes through the inlet air aperture  78  and into toroidal chamber  90  and travels around the cylindrical screen  88 . As the air travels about the toroidal chamber  90 , heavier dirt particles are forced toward sidewall  74 . These particles fall under the force of gravity through a gap  92  defined between an edge of separator plate  84  and the sidewall  74 . Referring particularly to  FIG. 4 , dirt particles falling through the gap  92  drop through and are collected in the dirt cup  50 . The upper end of the dirt cup  50  is received in a nesting relationship to the side wall  74  to seal the dirt cup  50  with the cyclone separator  48 . As the working inlet air traverses through toroidal chamber  90 , casting dirt particles towards sidewall  74 , the inlet working air is drawn through cylindrical screen  88 , through exhaust outlet  80 , and into an outlet air conduit  60 . Outlet air conduit  60  is integrally molded in a rear wall of module housing  46 . Air moves through outlet air conduit  60  to the pre-motor filter  72 . Pre-motor filter  72  removes additional particulate matter from the exhaust airstreams prior to the airstreams being drawn through the fan motor assembly  64 . A post-motor filter  71  can also be provided downstream of the fan motor assembly  64  to remove additional fine particulate matter from the exhaust airstream before it is released to the atmosphere. An example of a suction cleaner with cyclonic dirt separation may be found in U.S. Patent Application Publication No. US2002/0011050 to Hansen et al. and is incorporated herein by reference in its entirety. 
     All of the elements that create suction are contained within the cyclonic vacuum module  48 . When the detachable cyclonic vacuum module  16  is attached to the upright handle assembly  12  the device may be operated as an ordinary upright vacuum cleaner. When power is applied to the fan motor assembly  64 , fan  66  turns creating an airflow. Suction is created at suction nozzle  40  thus drawing debris into the working air path. Dirt laden air continues to flow through the working air conduit  40  into hose  58  through inlet air aperture  78  whereby the dirt laden air is forced to rotate within the cyclonic separator  48 , thus separating the dirt from the air. Clean air then passes through cylindrical screen  88  through exhaust outlet  80 , through outlet air conduit  60  and into fan chamber  56  as previously described. With the detachable cyclonic vacuum module  16  detached from the upright handle assembly  12 , the flexible hose  58  hose fitting  94  can be removed from the air coupling interface  44 . Thus the user can attach the upholstery tool  26  to the hose fitting  94 , and utilize the detachable cyclonic vacuum module  16  as an effective portable upholstery cleaning device. 
     Referring now to  FIG. 6  where like numerals have been used to describe like parts, a detachable cyclone cleaning module  100  includes a module housing  102 , a cyclone separation chamber  104  formed within the module housing  102 , a flexible suction conduit  110  and a motor driven fan  66 . The cyclone separation chamber has an inlet opening  106  and an outlet opening  108 . The flexible suction conduit  110  has a first end  112  connected to the housing and a second end  114  with hose coupling  94  that is adapted to mount into the module platform suction opening when the cleaning module is mounted to the module platform  24  ( FIGS. 1–3 ) and is freely movable when the cleaning module is removed from the module platform  24 . The motor driven fan  66  has an inlet opening  118  that is connected to the suction conduit first end  112  and an outlet opening  116  that is connected to the inlet  106  to the cyclone separation chamber  104 . The outlet to the cyclone separation chamber  104  is connected to a filter to remove remaining dirt and dust fines that are not separated from the air in the cyclone separation chamber  104 . A dirt cup  124  is mounted in the module housing beneath the cyclone separation chamber to collect dirt and dust separated from the air in the cyclone separation chamber. 
     While the invention has been specifically described in connection with certain embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing description and drawings without departing from the spirit of the invention, which is described in the appended claims.