Vacuum filter

A debris canister and filter assembly, which may be used in a vehicular vacuum cleaner, includes a debris canister having an inlet, an outlet, and a peripheral side wall. The peripheral side wall at least partially defines an interior space of the debris canister. A filter is disposed in the interior space of the debris canister, and includes filter media having a non-pleated portion and a pleated portion. The peripheral side wall forms a corner of the debris canister, and the filter media has a rounded-corner shaped to fit adjacent to the corner of the peripheral side wall.

FIELD OF DISCLOSURE

The present disclosure relates generally to a vacuum filter, and in particular, a compact vacuum filter for a vacuum cleaner.

BACKGROUND

In order to clean a vehicle, such as a car or truck, a vacuum cleaner is often used to vacuum dirt and debris. However, it can be awkward and/or inconvenient to use a typical in-home vacuum cleaner to clean out the interior of a vehicle. To address this inconvenience, attempts have been made to permanently install on-board vehicle vacuum. Such on-board vehicle vacuum cleaners have a compact design to fit within small compartments of the vehicle.

On-board vehicle vacuum cleaners typically include a filter disposed within a collection module to filter air that travels through the vacuum cleaner as air travels through to the motor housing. Conventional filters include either a flat screen covering the inlet to the motor housing, or a bulkier cylindrical filter made of pleated filter media. While the flat screen coverings do not occupy as much space as the pleated cylindrical filters, the flat screen coverings typically have shorter life spans than that of pleated cylindrical filters.

SUMMARY

According to aspects of the present disclosure, a compact filter cartridge for a vacuum cleaner maximizes filtration capacity and minimizes occupied space within a debris canister. The filter cartridge may be positioned against an interior wall of the debris canister, providing more available storage space in the debris canister for debris collection. The filter cartridge is shaped to fit snugly against the interior wall of the debris canister, and in one exemplary embodiment, the filter cartridge is shaped to fit within a corner of the debris canister.

In accordance with a first exemplary aspect, a canister and filter assembly for a vacuum cleaner may include a debris canister having an inlet, an outlet, and a peripheral side wall. The peripheral side wall may at least partially define an interior space of the debris canister. A filter may be disposed in the interior space of the debris canister. The filter may include a filter media having a non-pleated portion and a pleated portion. The peripheral side wall may form a corner, and the filter media may have a corresponding corner shape that may fit adjacent to the corner of the peripheral side wall.

In accordance with a second exemplary aspect, a canister and filter assembly for a vacuum cleaner may include a canister having an inlet, an outlet, and a side wall at least partially defining an interior space. A filter may be disposed in the interior space of the canister. The filter may include a filter media with a first portion that is pleated. An interior layer of material may be disposed adjacent to a second portion of the filter media. The second portion of the filter media may be stretched over the interior layer of material to form a non-pleated portion of filter media.

In accordance with a third exemplary aspect, a filter cartridge for a vacuum cleaner may include a sheet of filter media including a non-pleated portion and a pleated portion. A cavity may be at least partially defined by the filter media. The non-pleated portion may have a first side and a second side that meet to form a corner, the corner having an angle in a range of approximately 45 degrees to approximately 180 degrees between the first side and the second side of the non-pleated portion.

In accordance with a fourth exemplary aspect, a vacuum cleaner may include a vacuum module configured to draw a vacuum. The vacuum module may include a motor disposed in a motor housing. A collector module may be configured to collect debris from air drawn by the vacuum module. The collector module may include a collector housing and a debris canister removably disposed in the collector housing. The debris canister may include an inlet, an outlet, and a peripheral side wall having an interior surface. The interior surface may at least partially define an interior space of the debris canister. A filter cartridge may be disposed in the debris canister, and may include a filter media having a pleated portion and a non-pleated portion. The collector module and the vacuum module may be operatively connected by an interconnecting duct.

In accordance with a fifth exemplary aspect, a filter cartridge for a vacuum cleaner may include a filter forming a closed loop, the closed loop including an outer edge and first end. A cap may be coupled to the first end of the filter and may include an outer perimeter comprising a first corner having a first radius of curvature, a second corner having a second radius of curvature, and a third corner having a third radius of curvature. The second radius of curvature may be substantially equal to the third radius of curvature, and the first radius of curvature may be greater than the second radius of curvature and the third radius of curvature.

In further accordance with any one or more of the foregoing first, second, third, fourth, and fifth aspects, the canister and filter assembly, vacuum cleaner including the canister and filter assembly, and filter cartridge may include any one or more of the following forms.

In some forms, the pleated portion of the filter media may have a first surface area and the non-pleated portion of the filter media may have a second surface area. The first surface area may be greater than the second surface area.

In some forms, an interior layer of material may be disposed adjacent the non-pleated portion of the filter media.

In some forms, the outlet of the debris canister may be disposed adjacent the corner of the peripheral side wall.

In some forms, the non-pleated portion of the filter media may be disposed adjacent to an interior surface of the corner of the peripheral side wall.

In some forms, the filter may be disposed adjacent to the corner of the debris canister. The filter may at least partially surround the outlet.

In some forms, the filter may include a cap coupled to a first end of the filter media and a fitting coupled to a second end of the filter media.

In some forms, the fitting may at least partially surround the outlet when the fitting is coupled to the debris canister.

In some forms, the filter media may include an outer perimeter, and the pleated portion may provide a curve in the outer perimeter.

In some forms, the non-pleated portion of the filter media may be disposed adjacent to an interior surface of the side wall of the canister.

In some forms, the pleated portion of the filter media may have a first thickness and the non-pleated portion of the filter media may have a second thickness. The first thickness may be greater than the second thickness.

In some forms, the side wall of the canister may form a corner and the outlet of the canister may be proximally located to the corner of the canister.

In some forms, the non-pleated portion of the filter media may be adjacent the corner of the canister.

In some forms, the filter media may include a first end and a second end, wherein the second end of the filter media is adjacent to the outlet of the canister.

In some forms, the filter media may include an exterior surface and an interior surface. The non-pleated portion of the exterior surface may face the side wall, and the pleated portion of the exterior surface may face the interior space of the debris canister.

In some forms, the filter may include a cap coupled to the first end of the filter media and a fitting coupled to the second end of the filter media. The fitting may include an aperture.

In some forms, the interior layer may be disposed on an interior side of the non-pleated portion of the filter media. The interior layer may be metal.

In some forms, the interior layer may be plastic.

In some forms, the pleated portion may have a round shape and is connected to the non-pleated portion to form a closed loop.

In some forms, the fitting may include an aperture positioned adjacent to the cavity defined by the filter media.

In some forms, the filter media may include a first end and a second end. The filter cartridge may include a cavity partially defined by the first end and the second end. The cavity of the filter cartridge may be in fluid communication with the interconnecting duct.

In some forms, the filter cartridge may be disposed adjacent to the corner formed by the side wall. The filter cartridge may at least partially surround the outlet of the debris canister.

In some forms, the fitting may be removably coupled to the debris canister. The fitting may at least partially surround the outlet when the fitting is coupled to the debris canister.

In some forms, the cap may extend radially outward from the outer edge of the filter.

In some forms, a second cap may be coupled to a second end of the filter, wherein the second cap includes an outer perimeter substantially aligned with the outer perimeter of the cap.

In some forms, the outer perimeter of the cap may include a fourth corner having a fourth radius of curvature, wherein the fourth radius of curvature is greater than the first radius of curvature.

In some forms, a ratio between the fourth radius of curvature and the first radius of curvature may be approximately 2 to 1.

In some forms, the filter may include a pleated portion extending along the outer edge of the filter between the second corner and the fourth corner of the cap and between the fourth corner and the third corner of the cap.

In some forms, filter may include a non-pleated portion extending along the outer edge of the filter between the first corner and the second corner of the cap.

Any one or more of these aspects may be considered separately and/or combined with each other in any functionally appropriate manner. In addition, any one or more of these aspects may further include and/or be implemented in any one or more of the optional exemplary arrangements and/or features described hereinafter. These and other aspects, arrangements, features, and/or technical effects will become apparent upon detailed inspection of the figures and the following description.

DETAILED DESCRIPTION

FIGS. 1-3illustrate an example vacuum cleaner10and a filter cartridge12constructed in accordance with the teachings of the present disclosure. The example vacuum cleaner10may be installed and operated within a vehicle (e.g., a car, truck, van, SUV, or other type of vehicle). For example, the vacuum cleaner10may be installed within a passenger compartment of the vehicle to provide easy access to clean the interior of the vehicle.

The exemplary vacuum cleaner10has a modular configuration and includes a vacuum module14and a collector module18connected in a side-by-side arrangement. The vacuum module14includes a motor/impeller unit20configured to draw a vacuum disposed in a motor housing22. The collector module18includes a collector housing24and a debris canister26removably disposed within an interior compartment27of the collector housing24. The collector module18is operatively connected to the vacuum module14via an interconnecting duct28to transport debris to the collector module18from air drawn by the vacuum module14. In particular, the duct28fluidly connects an interior space30of the debris canister26to an interior compartment32of the motor housing22. As shown inFIG. 1, a vacuum hose or wand may be connected to the collector housing24via a hose connector34, which extends outwardly from an intake port36of the collector housing24. InFIGS. 2 and 3, the interconnecting duct28extends between the vacuum module14and the debris canister26of the collector module18. The debris canister26includes a hinged lid38that encloses the interior space30to facilitate disposal and containment of the debris collected in the canister26. As illustrated, the collector module18is operatively connected to the vacuum module14in a side-by-side configuration. However, in other examples the vacuum module14and the collector module18may connect to each other in a number of different assembly arrangements (e.g., as an integrated unit). For example, multiple configurations of a modular vehicle vacuum cleaner are disclosed in PCT/US2017/042616, the disclosure of which is incorporated by reference herein.

The debris canister26couples to the collector housing24when the debris canister26is pushed into place within the interior compartment27. As shown inFIGS. 2 and 3, the debris canister26is arranged to align an exhaust port40of the collector housing24with an outlet port42of the debris canister26when the debris canister26is coupled to the collector housing24. The intake port36of the collector housing24is also aligned with an inlet port44of the debris canister26when the debris canister26and the collector housing24are coupled. It will be appreciated that one or more sealing components may be arranged between the debris canister26and the collector housing24such that the exhaust port40of the collector housing24is sealably connected with the outlet port42of the debris canister26, and the intake port36of the collector housing24is sealably connected with the inlet port44of the debris canister26. As such, when the debris canister26is aligned with and coupled to the collector housing24, the interconnecting duct28extends between the outlet port42of the debris canister26and an inlet port46of the motor housing22. In this arrangement, the filter cartridge12is disposed over the outlet port42and the interconnecting duct28.

In operation, the vacuum module14provides a suction force so that a vacuum hose may collect debris from a target cleaning surface when operatively coupled to the collector module18. The suction force pulls debris into the intake port36of the collector housing24and through the inlet port44of the debris canister26to deposit debris into the interior space30of the debris canister26of the collector module18. The suction force pulls air through the filter cartridge12disposed in the interior space30and through the duct28connecting the outlet port42of the debris canister26and the inlet port46of the motor housing22. In this way, any air that is pulled into the interior compartment32of the motor housing22is first filtered through the filter cartridge12.

InFIGS. 4-6, the debris canister26of the vacuum cleaner10is shown isolated from the collector housing24. The debris canister26includes the inlet port44defining the inlet, the outlet port42defining the outlet, and a peripheral side wall48at least partially defining the interior space30of the debris canister26. As shown inFIG. 4, the inlet port44and the outlet port42of the debris canister26are formed in opposite first and second corner portions50and52, respectively, of the peripheral side wall48. In particular, the outlet port42is formed in a seat54protruding from a floor56of the peripheral side wall48. The seat54is disposed in the corner portion52of the debris canister26, and is shaped to accommodate the interconnecting duct28of the vacuum cleaner10. The seat54provides a stable support surface that is sized to receive the filter cartridge12. As shown inFIG. 4, the filter cartridge12is aligned with the outlet port42formed in the seat54. The peripheral side wall48extends upwardly from an outer peripheral edge of the floor56to form a boxed enclosure with multiple sides58,60,62, and64. The peripheral sidewall48has an interior surface66that at least partially surrounds the interior space30of the debris canister26. An upper edge68of the peripheral sidewall48defines an opening into the interior space30, and the lid38seals with the upper edge68to cover the opening of the interior space30when the debris canister26is closed. As shown inFIGS. 4-6, an inlet fitting70is formed in the first side58of the peripheral wall48, and is removably coupled to a filter bag71, as shown inFIG. 7. In the illustrated example ofFIG. 4, the seat54is integrally formed with the peripheral side wall48of the debris canister26. However, in other examples, the seat54may be manufactured separately, and may be subsequently attached to the floor56of the debris canister26during assembly. In another example, the seat54may have a surface that is adapted to mate with a surface of the filter cartridge12to ensure alignment of the filter cartridge12with the outlet port42disposed in the seat54.

As shown inFIG. 7, the filter bag71is coupled to the inlet port44of the debris canister26, and is disposed within the interior space30to filter out debris from the air drawn into the debris canister26from the hose connector34. The filter bag71is removably coupled to an inlet fitting70, which surrounds the inlet port44. The filter bag71provides a generally fluid tight seal with the fitting70at the inlet corner portion50of the debris canister26. The lid38of the debris canister26can be selectively opened to provide access to the filter bag71within the interior space30. The filter bag71may be disposable or reusable, and is made of a porous material that permits air to flow through the bag71, while containing large debris and dirt particles within the volume of the bag71. The filter bag71may be removed, discarded or emptied, and replaced by accessing the interior space30of the debris canister26when the lid38is open. In operation, when the motor/impeller unit20is turned on, air and debris is pulled through the hose connector34and inlet port44and into the filter bag71of the debris canister26. The vacuum force continues to draw air through the filter bag71, interior space30of the debris canister26, and the filter cartridge12before passing through the outlet port42. Any debris that passes through the filter bag71may be filtered by the filter cartridge12before the air exits the debris canister26and enters the vacuum module14, thus providing an extra layer of filtering of the air. In this way, the air that is pulled into the motor/impeller unit20through the interconnecting duct28will be substantially free of dirt and debris, which could otherwise damage the impellers or other portions of the motor/impeller unit.

The debris canister26is preferably made of a durable plastic, such as polyethylene, that may be formed by injection molding, thermoforming, or compression molding, but may instead be formed of any other suitable and durable material including metal, fiberglass, or other similar materials, or any combination of these materials. The debris canister26can be injected molded such that the inlet port44and outlet port42are integrally formed with the peripheral side wall48of the canister26. In other examples, the inlet port44and the outlet port42may be manufactured separately from the debris canister26, and then subsequently attached to the peripheral wall48during assembly of the debris canister26. Alternatively, the inlet port44and the outlet port42may be created after the debris canister26is formed.

The filter cartridge12includes a filter media74, a top cap78, and a fitting or bottom cap82. When the filter cartridge12is coupled to the seat54of the debris canister26, as shown inFIGS. 5-7, the filter cartridge12is adjacent to the peripheral side wall48of the debris canister26and the fitting82rests against the seat portion54. The filter media74is shaped so that the filter cartridge12may fit closely to the interior surface66of the second and third sides60,62of the peripheral wall48. The filter cartridge12has a curved front side72that faces away from the corner portion52of the peripheral wall48and faces the interior space30. The front side72is curved to maximize exposed surface area of the filter cartridge12, and extends between perpendicular second and third sides60and62of the peripheral wall48, which meet to form the corner portion52. As will be described in more detail below, the filter cartridge12has a back side shaped to match the rounded corner portion52of the debris canister26for a tight fit within in the debris canister26.

The cap78and the fitting82of the filter cartridge12are shaped to ensure that when an operator couples the filter cartridge12to the debris canister26, the pleated portion84is disposed within a primary flow path F of the canister26(FIG. 5), and the non-pleated portion88is disposed adjacent to the interior surface66of the debris canister26. This particular arrangement and placement of the filter media74maximizes the exposed surface area of the filter media74and minimizes the occupied space of the filter cartridge12within the debris canister26. The larger surface area of the pleated portion84is disposed within a vacuum air flow path F, which is defined between the inlet port44and the outlet port42of the debris canister26. The non-pleated portion88is not directly disposed in the primary air flow path F, and is instead positioned adjacent the interior surface66of the corner portion52of the peripheral side wall48of the debris canister26where there is less airflow. To minimize occupied space, the non-pleated portion88has a reduced thickness and therefore smaller surface area so that the back side90of the filter cartridge12can be closer to the peripheral side wall48.

Turning toFIGS. 8 and 9, the filter media74is an enclosed filter loop and includes a pleated portion84and a non-pleated portion88. In the illustrated example, the pleated portion84is disposed on the front side72of the filter cartridge12, as shown inFIG. 8, and the non-pleated portion84is disposed on a back side90of the filter cartridge12. The back side90is shaped to face the interior surface66of the peripheral wall48when the filter cartridge12is coupled to the debris canister26(FIGS. 4-7). The back side90may be shaped to fit within a particular angle of the corner portion52of the peripheral side wall48. In the illustrated example, the perpendicular sides60and62of the side wall48meet at substantially a 90 degree angle. Thus, the back side90of the filter cartridge12has a first side81and a second side83(seeFIG. 9) that meet to form a corner with an angle of substantially 90 degrees or less. However, in other examples, the debris canister26may have a smaller or larger angled corner52, and the back side90of the filter cartridge12may correspond to fit against the corner52of the debris canister26. In one example, the back side90may be constructed accordingly to form an angle in a range of approximately 45 degrees to approximately 180 degrees.

The filter media74defines the middle or central portion of the filter cartridge12, and may be one material that forms both the pleated portion84and the non-pleated portion88. The filter media74may be made of a first material and a second material that is different than the first material. In this example, the pleated portion84may be formed from the first material and the non-pleated portion88may be formed from the second material. The second material forming the non-pleated portion88may have the same or better filtration capabilities as the first material forming the pleated portion84. The different materials may be attached (e.g., welded, glued, connected, interwoven, etc.) to form the enclosed filter loop.

InFIGS. 10-12, the filter media74includes a first end92, a second end94, and cavity96is at least partially defined (i.e., surrounds) by the filter media74. The cavity96is configured to fluidly couple to an opening of the outlet port42when the filter cartridge12is attached to the debris canister26. The cavity96defined by the filter media74is closed at a first end92by the cap78and partially closed at the second end94by the fitting82. The cap78and the fitting82may be coupled to the filter media74in such a way that would facilitate replacing the filter media74at the end of its useful life. As such, the cap78is coupled to the first end92of the filter media74and the fitting82is coupled to the second end94of the filter media74. When the filter cartridge12is placed over the outlet port42of the debris canister26, the second end94of the filter media74and the fitting82are adjacent to the outlet port42.

The cap78and the fitting82match the outer peripheral shape of the filter media74. The cap78is coupled to the first end92of the filter media74opposite the fitting82. The cap78has an interior side104directly adjacent to the first end92of the filter media74, and an exterior side106facing away from the filter media74. The cap78includes an upper lip108that hangs slightly beyond an outer perimeter of the filter media74. An outer edge110of the cap78may help contain the filter media74within the filter cartridge12, and may be configured to directly engage the interior surface66of the peripheral side wall48. The outer edge110of the cap78is shaped to match the irregular shape of the filter media74, and fits within the corner portion52of the debris canister26. The outer edge110includes a rounded corner portion114and a curved portion116that substantially match the general outer perimeter of the non-pleated portion88and pleated portion84of the filter media74, respectively.

The fitting82is similarly shaped with a curved portion118aligned with the front side72of the filter cartridge12, and a rounded corner portion120aligned with the back side90of the filter cartridge12. The fitting82is coupled to the second end94of the filter media74. The fitting82has an interior side124adjacent to the second end94of the filter media74, and an exterior side126arranged to abut the seat54of the debris canister26. The fitting82has a bottom lip130that slightly extends beyond the outer perimeter of the filter media74. An outer edge134of the fitting82may help contain the filter media74within the filter cartridge12, and may be configured to directly engage the interior surface66of the peripheral side wall48.

InFIGS. 10-12, the fitting82defines a central aperture100that is sized to align with and receive the outlet port42of the debris canister26. The aperture100of the fitting82traverses through the interior side124and the exterior side126of the fitting82, and is sized to receive and at least partially surround the outlet port42of the debris canister26. The outlet port42is disposed within the aperture100of the fitting82so that the filter cartridge12surrounds the outlet port42when the filter cartridge12is coupled to the debris canister26(FIG. 2). When the filter cartridge12is installed within the debris canister26, the fitting82of the filter cartridge12forms a fluid-tight seal with the outlet port42via one or more seals. The fluid tight seal may be formed between the outlet port42and the fitting82, the fitting82and the seat54, or a seal may be formed at both locations. The filter cartridge12may be secured to the debris canister26by a threaded connection, by snap-fitting, by interference fitting, or by friction-fitting. In this case, the aperture100of the fitting82is sized according to an outer perimeter of the outlet port42so that the fitting82and the outlet port42may be attached by interference fit. The filter cartridge12may be uncoupled from the outlet port42by pulling the filter cartridge12away from the debris canister26. The fitting82and the cap78may be configured to match the contoured interior surface66of the peripheral wall48when the filter cartridge12is secured to the seat54to ensure both proper alignment of the outlet port42and arrangement of the filter media74relative to the interior space30of the debris canister26. Other arrangements for securing the filter cartridge12to the debris canister26while providing a fluid-tight seal are possible, and in some examples, the filter cartridge12may be permanently secured over the outlet port42.

As shown inFIGS. 11 and 13, the outer edge134of the fitting82defines the outer perimeter and includes a first corner (defined by the rounded corner portion120), a second corner140, a third corner142, and a fourth corner (defined in part by the curved portion118). The outer edge134is shaped so that the corner portion120is different than the curved portion118. Similarly, the pleated portion84of the filter media74, which follows the shape of the curved portion118of the fitting82has a different geometry than the non-pleated portion88of the filter media74. For example, the outer edge134defines the first corner120with a first radius of curvature R1, the second corner140with a second radius of curvature R2, and the third corner142with a third radius of curvature R3. The second and third radii of curvature R2and R3of the illustrated example are substantially equal, however in other examples the second and third radii R2and R3of curvature may be different. The first radius of curvature R1is greater than the second and third radii of curvature R2and R3, thus forming the rounded corner shape120to fit within the corner portion52of the debris canister26. The fourth corner118has a fourth radius of curvature R4that is greater than the first radius of curvature R1. In this example, the first radius of curvature R1is different than each of the second, third, and fourth radii of curvature R2, R3, and R4, and the first radius of curvature R1is less than the fourth radius of curvature R4. For example, a ratio R1:R2of the first radius of curvature R1to the second radius of curvature R2may be approximately 1:2 or 1:2.5. However, in other examples, the outer edge134may define each corner differently depending upon the particular arrangement desired for the filter cartridge12. For example, the fourth radius of curvature R4may be less than or substantially equal to the first radius of curvature R1. In yet another example, the fourth radius of curvature R4may be substantially equal to the second and third radii of curvature R2and R3. In the illustrated example, the pleated portion84of the filter media74extends along an outer edge of the filter media74between the second corner140and the fourth corner118, and between the fourth corner118and the third corner142. The non-pleated portion88extends along the outer edge of the filter media74between the second corner140and the first corner120and between the first corner120and the third corner142. However, in another example, the outer edge134of the fitting82may not define a fourth corner, and as such, the pleated portion84may extend from the second corner140to the third corner142. It will be appreciated that the outer edge110of the cap78is parallel to the outer edge134of the fitting82such that the radii of curvature of the cap78may be identical to the radii of curvature of the fitting82.

As discussed previously, the filter media74is composed of non-pleated88and pleated84portions. The pleated portion84of the filter media74may have uniform folds (i.e., the folds are the same size) extending around the curve of the front side72of the filter cartridge12. As illustrated inFIGS. 9-11, the filter media74is folded into multiple pleats and formed into a partially-cylindrical shape where the pleated portion84has a round and “rippled” or “pleated” appearance, and the non-pleated portion88has a rounded corner shape formed by the first side and the second side. The non-pleated portion88is adjacent the peripheral wall48because the non-pleated portion88has less surface area than the surface area of the pleated portion84, and therefore the non-pleated portion88advantageously occupies less space within the interior space30of the debris canister26. In the example shown inFIG. 12, the non-pleated portion88has a thickness T1which is substantially the same measurement as the thickness of the filter media material. As such, the non-pleated portion88occupies less space within the debris canister26than the pleated portion84, and the non-pleated portion88permits the cartridge12to sit closer to the peripheral side wall48. A thickness T2of the pleated portion84is measured from an innermost point148of one fold150or pleat of the multiple pleats to an outermost point152of the same fold150, as shown inFIG. 12. The pleated portion84is adjacent the interior space30such that the pleats of the filter media74are in contact with, or exposed to, the airstream F during vacuum operation (FIG. 5). In other embodiments, the pleated portion84may have non-uniform folds such that the pleats change in size around the curve of the front side72of the filter media74. For example, the pleated portion84may include very small folds at either end of the curved front side72until the filter media74gradually flattens into the non-pleated portion88of the back side90.

The filter cartridge12may include an interior layer154for additional structural support for the filter media74. For example, as shown inFIGS. 10 and 12, the interior layer154is illustrated adjacent to the non-pleated portion88within the cavity96of the filter cartridge12. The interior layer154is preferable a rigid and porous material, such as a metal mesh, and may extend partially around or completely around the entire length of the back side90of the filter media74. The interior layer154may be porous to allow air flow through the non-pleated portion88of the filter media74, and may be metal, woven fiber, plastic, or other suitable material. Alternatively, the interior layer154may be a non-porous material. The interior layer154is constructed to bear the weight of the cap78when the filter cartridge12is assembled.

Further, the interior layer154may be used to help shape the non-pleated portion88during manufacturing of the filter cartridge12. For example, the interior layer154may be sufficiently rigid to help form and shape initially pleated filter media material into the non-pleated portion88. In one example method, a portion of a continuous piece of pleated filter media74is stretched over the interior layer154until the pleats or folds of the filter media74are flattened. After the non-pleated portion88is formed, the filter media74may then be secured to the interior layer154to hold the shape of the filter media74and keep the non-pleated portion88flat against the interior layer154. The interior layer154may be shaped to hold the non-pleated portion88to match the corner portion52. In other words, the filter media74(initially pleated) may be wrapped around the interior layer154, which acts as a frame for the filter media74, to form the non-pleated portion88and mold the non-pleated portion88into the shape of the back side90. The remainder of the filter media74may be molded or shaped so that the pleated portion84forms the curved shape of the front side72of the filter media74. In another example method, filter media74is formed by combining two different materials. The non-pleated portion88may be a different material than the pleated portion84and is attached to the pleated portion84by suitable means. The different material of the non-pleated portion88may have a porosity that is equal to or greater than a porosity of the material of the pleated portion84. In other words, the different material may have the same filtration capability or better filtration capability as the pleated filter media74. In another example, the different material may be non-porous.

Once the filter media74is shaped, the cap78and the fitting82are attached to the first and second ends92,94of the filter media74, respectively, to create an assembled filter cartridge unit12. The second end94of the filter media74may be fixed (e.g., glued, welded, or clamped) to the interior side124of the fitting82after the filter media74is arranged in the desired shape. The cap78may be fixed (e.g., glued, welded, or clamped) to the top end92of the filter media74to enclose the filter media74. In another embodiment, the filter cartridge12may be assembled by first attaching the cap78to the first end92of the filter media74before the fitting82is attached to the second end94. In yet another embodiment, the porous inner layer154may be removed once the filter media74is secured to either the fitting82or the cap78. In another example, the filter cartridge12may be constructed without the porous inner layer154, and may incorporate a different support structure.

In other embodiments, the filter cartridge12may not include the inner interior layer154. Instead, the non-pleated portion88may be shaped by flattening, heat treating, stretching, or shaping the filter media74by other suitable methods so that the non-pleated portion88deforms and holds its shape. In yet another example, the filter media74may not be arranged from a continuous piece of pleated filter media, and may instead be composed of two separate pieces of filter media74arranged to form the closed filter loop. The filter media74may be made of a stiff, porous material such that the filter media74may be malleable and maintain its shape easily without requiring the inner interior layer154. The non-pleated portion88may be non-porous.

The filter media may be made of any number of suitable filtration materials, such as, for example, cloth, glass-fiber materials, split-fiber materials, solution-spun fibers and materials made from such fibers, felt materials, natural fiber filter material, expanded polytetrafluoroethylene (PTFE) membranes, expanded ultra-high molecular weight polyethylene (PE) membranes and materials, melt-blown media, such as melt-blown polypropylene (PP) or melt-blown polyethylene (PE), microporous open cell polymers, such as polyurethane foam, poly(ethylene terephthalate), (PET) or polyphenylene sulfide (PPS) based materials, as well as copolymer-based materials thereof, high-efficiency particulate air (HEPA), triboelectrified media and materials.

The filter cartridge12of the present disclosure advantageously provides a compact design and irregular shape to fit against the peripheral wall48of the debris canister26while also maximizing filter capacity. In this particular example, the filter cartridge12is shaped to fit within the corner portion52of the debris canister26and sit closely to the interior surface66of the peripheral wall48. The configuration of the filter cartridge12facilitates removing and replacing the filter cartridge12from the debris canister26so that an operator may easily align the filter cartridge12to cover the outlet port42formed in the peripheral wall48. The vacuum cleaner10ofFIGS. 1-3is one example of a vacuum cleaner that may incorporate a debris canister26and the compact filter cartridge12as illustrated inFIGS. 4-7. However, other configurations of vacuum cleaners, including vacuum cleaners that are not specifically for installation within a vehicle, may incorporate the debris canister26and/or the filter cartridge12, which is shown inFIGS. 8-12. This particular arrangement and placement of the filter media74maximizes the exposed surface area of the filter media74and minimizes the occupied space of the filter cartridge12within the debris canister26. The cap78and the fitting82may be coupled to the filter media74in such a way that would facilitate replacing the filter media74at the end of its useful life.

The figures and description provided herein depict and describe preferred embodiments of a compact filter cartridge and a vacuum cleaner including such a filter cartridge for purposes of illustration only. One skilled in the art will readily recognize from the foregoing discussion that alternative embodiments of the components illustrated herein may be employed without departing from the principles described herein. Thus, upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs for filter cartridges for a vehicular vacuum cleaner. Thus, while particular embodiments and applications have been illustrated and described, it is to be understood that the disclosed embodiments are not limited to the precise construction and components disclosed herein. Various modifications, changes and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation and details of the methods and components disclosed herein without departing from the spirit and scope defined in the appended claims.