Filter system for a vacuum cleaner

A vacuum cleaner system includes at least one air flow control valve coupled to a vacuum motor, a pressure chamber and a filter. The at least one valve is operable to couple the at least one filter to the vacuum source to provide suction therethrough when the at least one valve is in a first position, and alternately to couple the at least one filter to the pressure chamber when the at least one valve is in a second position to supply pressurized air from the pressure chamber to the at least one filter to clean the at least one filter.

BACKGROUND AND SUMMARY

The present disclosure relates to a filter system for a vacuum cleaner. More particularly the present disclosure relates to a vacuum filter system which uses pressurized air generated by a vacuum motor to clean the filters.

Industrial vacuum cleaners are used in many applications. One illustrative application is a vacuum cleaner for use with a floor grinder. Such floor grinders grind concrete and typically need an adequate vacuum to operate properly. The present disclosure provides a robust vacuum option designed to provide continuous suction without having to stop and clear vacuum filters. The present disclosure also provides a more robust and rugged system designed to withstand the heavy use and abuse that is typical in the concrete grinding industry. The filter system of the present disclosure may also be used with other types of vacuum cleaners such as residential central vacuums, car wash vacuums or other industrial applications.

The system and method of the present disclosure provides an efficient system and method for cleaning the vacuum filters by allowing the pressure from the blower or exhaust of a vacuum motor to be selectively forced through the filters in reverse, thereby cleaning the filters. Therefore, the filters are thoroughly cleaned. The filters do not have to be cleaned as often, therefore increasing the life of filter system components. An illustrated embodiment uses a single motor to provide both suction for the vacuum and pressure for cleaning of the filters. A rotary valve arrangement of the filter system is simple to operate, while providing longevity. Main components of the filter system are located outside of the airstream, thereby providing easy replacement of the filter components.

The filter system of the present disclosure uses an exhaust from the same vacuum motor that provides the suction to selectively force air through the filters in reverse. Therefore, the illustrated filter system uses pressure to clean the filter. Conventional filter cleaning systems either use ambient air or a separate blower to clean the filters. Using pressure to clean the filters provides a more thorough cleaning and therefore allows increased cycle time. Increasing the cycle time decreases the number of times each component must operate in a given time frame and, as a result, increases the duration of all electrical components. For example, conventional vacuum filter systems clean filters every few seconds (such as every seven seconds, for example) to reduce the likelihood of clogging.

The rotary valve arrangement of the present disclosure allows the main filter components to be located outside of the air stream. This increases the duration of all mechanical components. Other vacuum filter systems have key filter components located in the air stream and are therefore more prone to premature failure.

According to an illustrated embodiment of the present disclosure, a vacuum cleaner system includes a housing having an interior region, an inlet opening, and at least one outlet opening. The system also includes a vacuum motor having an exhaust, a pressure chamber coupled to the exhaust of the vacuum motor, and at least one filter located in the interior region of the housing in communication with the at least one outlet opening of the housing. The system further includes at least one air flow control valve. Each valve is coupled to the vacuum motor, the pressure chamber and a filter. The at least one valve is operable to couple the at least one filter to the vacuum source to provide suction therethrough when the at least one valve is in a first position, and alternately to couple the at least one filter to the pressure chamber when the at least one valve is in a second position to supply pressurized air from the pressure chamber to the at least one filter to clean the at least one filter.

Additional features of the present system and method will become apparent to those skilled in the art upon consideration of the following detailed description of illustrative embodiments exemplifying the best mode of carrying out the present system and method as presently perceived.

DETAILED DESCRIPTION OF THE DRAWINGS

For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, which are described below. The embodiments disclosed below are not intended to be exhaustive or limit the invention to the precise form disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. Therefore, no limitation of the scope of the claimed invention is thereby intended. The present disclosure includes any alterations and further modifications of the illustrated devices and described methods and further applications of the principles of the disclosure which would normally occur to one skilled in the art to which the invention relates. Corresponding reference characters indicate corresponding parts throughout the several views.

The present disclosure relates to a vacuum cleaner10diagrammatically shown inFIG. 1. Illustratively, the vacuum cleaner10includes a lower housing portion11having an interior region12and an inlet14. An upper housing portion16includes a vacuum motor18and a pressure chamber20. An outlet22of the vacuum motor18is illustratively coupled to the pressure chamber20. Exhaust from the vacuum motor18creates pressure in the pressure chamber20as discussed below. Therefore, a separate blower is not required for the pressure chamber20. A cover24is located over the vacuum motor18and pressure chamber20. Control valves26are coupled to the vacuum source18and pressure chamber20and to filters28located within the interior region12of lower housing portion11.

In normal operation, vacuum source18creates suction within the interior region12of lower housing portion11to draw air and other materials through inlet opening14in the direction of arrow30. The flow control valves26normally permit flow of air and material through filters28in the direction of arrows32. Filters28remove particulate matter from the air in a conventional manner.

The filters28may become clogged with dust or other particles entrained in the air flowing through the lower housing portion11. In order to clear the filters28, the flow control valves26are selectively actuated to cause pressurized air from pressure chamber20to pass through filters28in the direction of arrow34, thereby removing the dust and particulate matter from the filter28. In one embodiment, timing of the valve26to supply pressure from the pressure source20to the filter28is controlled electronically by a controller. Timing is based upon the type of material being vacuumed by the vacuum cleaner10.

In another embodiment, a manually operated valve is used for the filter cleaning process. Use of manually operated valves reduces the cost of the filter system by eliminating the electronics involved in automatically powering the valves26. In another embodiment, the flow control valves26are operated with a wireless remote. This embodiment is particularly useful for a single filter operation. The remote control provides more automation than a manual actuator, but still eliminates the added cost of an electronic timer.

FIGS. 2-4illustrate additional details of upper housing portion16containing the filter system of one embodiment of the present disclosure. Upper housing portion16includes a body portion40, an inner cover plate42and an outer cover24. As shown inFIG. 4, body portion40includes an outer wall44and a spaced apart inner wall46which define the pressure chamber20therebetween. Body portion40also includes a bottom plate48having apertures50in communication with filters28.

Inner wall46of body portion40includes an aperture52coupled to the outlet22of the vacuum motor18. Inner wall46of body portion40also includes apertures54in communication with pressure chamber20. Outer wall44of the body portion40also includes openings55to allow exhaust from the vacuum motor18to exit the pressure chamber20in a controlled manner. Openings55are sized to optimize operation of the vacuum motor18while maintaining adequate pressure within the pressure chamber20for cleaning the filters28. Therefore, the size and quantity of exhaust apertures55varies depending on the specifications of the vacuum motor18used.

Filters28are coupled to the bottom surface48of body portion40by connecting rods56as best shown inFIG. 10. A mounting bracket58is coupled to the bottom surface48by fasteners60. The rods56include a wing nut62coupled to a first threaded end portion62and a second threaded end portion64configured to engage mating threads of mounting bracket58. Rods56extend through an opening66of filters28. Wing nut62engages a portion of the filter28to hold the filter28in place on the bottom surface48of body portion40when the threaded end64of rod56is coupled to the threaded mounting bracket58as shown inFIG. 10.

ReferringFIGS. 3-6, a central vacuum chamber70is coupled to bottom surface48of body portion40. Chamber70includes openings72which cooperate with the flow control valves26as discussed below to provide air flow to the vacuum chamber70. Chamber70is coupled to bottom surface48with suitable fasteners so that the vacuum chamber70is sealed to the bottom surface48. Vacuum motor18is mounted to the top surface74of chamber70by suitable fasteners so that suction is applied to the central aperture76of top surface74by vacuum motor18.

As shown inFIGS. 4 and 5, three flow control valves26are provided in an illustrated embodiment of the present disclosure. The arrangement of the flow control valves26relative to the vacuum motor18is best shown inFIG. 5. It is understood that one or more control valves26may be used in different embodiments, depending on the application. For example, one, two or three filters28and flow control valves26may be used. In each case, the vacuum motor18maintains the same efficiency relative to the air flow. The process works well with one filter due to the inflow of the pressurized air from the pressure chamber20caused by the exhaust of vacuum motor18as described herein. The single filter embodiment provides a very compact unit and significant cost savings which allows for entry into markets such as, for example, residential central vacuums, car wash vacuums and various other industrial applications.

Details of the flow control valves26are illustrated inFIGS. 7-9. Each flow control valve26includes a housing80having a central cylindrical portion82and first and second passageways84and86coupled to the central cylindrical portion82. A plurality of mounting portions88are located near bottom edge89to secure and seal the housing80to the bottom surface48of body portion40in the orientation shown inFIGS. 5 and 6. First passageways84of the valves26are in communication with openings72of inner vacuum chamber70. Second passageways86of valves26are in communication with openings54of pressure chamber20.

As best shown inFIGS. 8 and 9, each of the valves26includes a valve actuator paddle90having a top surface92, first and second arms91and93extending away from a central hub99, and first and second sealing surfaces94and96coupled to ends of arms91and93, respectively, on opposite sides of the paddle90. A rotary solenoid98is illustratively coupled to top surface92of actuator paddle90. Solenoid98is also coupled to a cover100by mounting posts102which extend through apertures104of cover100and are secured thereto by suitable fasteners. The actuator paddle90is rotatable by the solenoid98to selectively position one of the sealing members94or96against the passageway openings84and86, respectively, to control air flow through the valve26. Bottom edge portions95and97of sealing members94and96, respectively, extend below the bottom edge89of housing80and below the bottom plate48. A bearing area is incorporated into the valve actuator paddle90and integrated with the bottom plate48to maintain concentricity. This arrangement compensates for vertical movement of the solenoid98during opening and closing of the valve and maintains proper sealing despite the vertical movement.

The valve actuator paddle90and cylindrical portion82of housing have internal draft angles that permit the solenoid98to clear itself as it rotates during operation and moves vertically relative to the housing80. The angles taper from larger to smaller on the actuator paddle90toward the filter end and smaller toward the bottom on the filter end of the cylindrical portion82of valve housing80to prevent the valve actuator paddle90from contacting the side wall of the cylindrical portion82upon the vertical movement caused by the solenoid98.

Details of operation of the flow control valves26are best shown inFIG. 6. Two of the flow control valves26are shown positioning the actuator paddles90so that sealing surface94is offset from passageway84while sealing surface96blocks passageway86as illustrated at locations110inFIG. 6. Therefore, the control valves26at locations110ofFIG. 6permit air flow from the interior region12of the lower housing portion11of vacuum cleaner10through filters28, cylindrical housings82and passageways84into the vacuum chamber70. InFIG. 6, the control valve26at location112has been actuated so that sealing surface94of actuator paddle90blocks the passageway84to the vacuum chamber70while sealing surface96is spaced apart from passageway86coupled to aperture54of the pressure chamber20. Therefore, the valve26at location112permits air flow from pressure chamber20through passageway86and into cylindrical body portion82of valve26. Since the passageway84is blocked by sealing surface94, air from the pressure chamber20passes downwardly through filter28as illustrated by arrow34inFIG. 1to clean the filter28. After a predetermined period of time, the valve26at location112moves the actuator paddle90back to a normal operating position as shown at locations110inFIG. 6to seal passageway86and open passageway84so that normal suction is also applied through the cleaned filter28at location112.

In the illustrated embodiment, arms91and93of actuator paddle are aligned at an angle of about 155° relative to each other. Therefore, 25° rotation of actuator paddle90by the solenoid98moves the actuator paddle90from a first position shown at locations110to a second position shown at location112.

Another embodiment of the present disclosure is shown inFIGS. 11-13. The filter system shown inFIG. 11includes two or more filters28. One filter28or divided compartment continues to provide suction while the other filter(s)28is (are) being cleaned. Illustratively, three filters28are shown in theFIG. 11embodiment. Each filter28includes its own cleaning mechanism or valve226as shown inFIG. 11. Each valve226may be mechanically controlled by a rotary solenoid actuator298as shown inFIG. 12, manually controlled with a spring return, or controlled by a remote control. A cover300secures the rotary solenoid actuator298to the inner cylinder230.

Each valve226illustratively includes an inner cylinder230having three separate openings. A first opening232is provided for connection of filter28to a vacuum source such as vacuum motor18. A second opening234is provided for connection to a pressure cleaning chamber20. A third opening236is provided for connection directly to the filter28. The opening236connected directly to the filter28is perpendicular to the opening234connected to the vacuum source18and to the opening232connected to pressure cleaning chamber20. The opening232connected to the pressure cleaning chamber20is illustratively located approximately 205 degrees CCW from the opening234connected to the vacuum source18.

Each valve226also illustratively includes an outer cylinder240. The outer cylinder240also includes three openings including one vertical opening242connected to the vacuum chamber270, one vertical opening244connected to the pressure chamber20via passageway246and one horizontal opening connected to the filter28. Openings234and232of inner cylinder230are selectively opened and closed by valve226rotating the inner cylinder230relative to the outer cylinder240. Opening236is always open.

FIG. 13is a top view of a valve assembly226, with portions shown in dotted lines to illustrate movement of the inner valve cylinder230relative to the outer valve cylinder240. The inner cylinder230rotates approximately 20-25 degrees in the direction of the arrow inFIG. 13and connects the pressure port20to the filter28by aligning the vertical opening or pressure port232of the inner cylinder230with the outer pressure port connection or opening244in the outer cylinder240as best shown in the position232′ ofFIG. 13. The vacuum source is “disconnected” simultaneously by moving the opening or vacuum port234of the inner cylinder230out of alignment with vacuum port formed in outer cylinder240as best shown by the position234′.

Vacuum270is connected to the outer valve cylinders240and the plurality of filters28by passageways272aligned with a vacuum port234formed in the outer cylinder240. The vacuum motor18is either service mounted on top of the chamber270or connected via hosing in order to provide suction to the chamber270. The motor18is illustratively a tangential bypass motor with an exhaust horn when service mounted.

A pressure chamber20surrounds the entire mechanism and receives the exhaust air from the blower or exhaust of vacuum motor18. This exhaust air is available to rush through each valve226when the valve226is activated and the pressure port232of inner cylinder230aligns with the pressure port of outer cylinder240. This pressure chamber20provides a burst of air in reverse through the activated valve226and cleans the filter28. The mechanism and plurality of filter valves226may be controlled automatically with a timed electronic system or manually controlled at will.

The reverse pressure action is very quick so to not allow too much pressured air into the vacuum chamber270. The valve226then springs back to return to its neutral position with the opening234of inner cylinder230aligned with the vacuum port of outer cylinder240so that a vacuum is again pulled through the filter28. In the “vacuum” position, pressure opening232of inner cylinder230is not aligned with the pressure port of the outer cylinder240as shown by positions234and232inFIG. 13.

As discussed above, one of the valves226can be activated to clean an associated filter28while suction is maintained through the other filters28. This permits continuous operation of the vacuum.

While this disclosure has been described as having exemplary designs and embodiments, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains.