Battery powered vacuum cleaner

Abstract: A vacuum cleaner is provided having a handle assembly (200) and a floor engaging unit (100) pivotally mounted thereto, which includes a vacuum pump formed by a motor mounted to a base. One or more lamps are provided within the floor en­ gaging unit (100) for directly light forardly of the vacuum cleaner through a horizontally elongated lens. The handle as­ sembly (200) includes a housing (201) pivoted to the floor engaging unit (100), and a handle (202) extending from the opposite end thereof. A rigid or semirigid dirt tube extends longitudinally in one side of a recess in one side of the housing (201), and has a lower end coupled via a flexible tube to the outlet of the floor engaging unit. The dirt tube has a forwardly extending port in its other end to receive a disposable dust bag adapted to be removably assembled in the front recess. A further recess is provided in the rear of the housing for releasably receiving a rechargeable sealed lead acid battery assembly box, which includes the battery, a recharging circuit including a recharging light, and a cir­ cuit breaker that is accessible at the rear of the vacuum cleaner for being manually reset. A control board is provided at the upper end of the housing (201), including a switch en­ abling operation of the machine either with or without use of the lights. An indicator, such as a row of LEDs is also pro­ vided on the control board, to indicate the charge condition of the battery to the user.

Description: This invention relates to improvements in vacuum cleaners, and is more in particular directed to the provision of a battery powered upright vacuum cleaner. For example GB 2 181 638 describes a typical upright-type electric vacuum cleaner. The disclosed vacuum cleaner is provided with a recess in the housing which holds an electrical cord. In the past it has been common to provide portable vacuum cleaners with batteries. This technique has not been successfully employed in upright cleaner of the type having a handle assembly pivotted to a floor engaging unit, however, such vacuum cleaners hence conventionally requiring the interconnection of the cleaner with the power mains during use. While upright vacuum cleaners have many advantages, such as greater cleaning power, this interconnection creates problems in the use of the cleaner since it limits the distance that the cleaner may be used from an outlet, and the interconnecting cord tends to become tangled with furniture or the like during use. The present invention is therefor directed to the provision of an upright vacuum cleaner that overcomes the above disadvantages. Briefly stated, in accordance with the invention, a vacuum cleaner is provided having a floor engaging unit and a handle assembly pivotally mounted thereto. The floor engaging unit includes a vacuum pump formed by a motor mounted to a base, the base having airflow ducts formed therein, for directing air from an inlet nozzle to an outlet tube. One or more lamps are provided within the floor engaging unit for directly light forwardly of the vacuum cleaner through a horizontally elongated lens. The lens has a front surface with horizontal grooves formed therein shaped to direct the light downwardly to a determined location in front of the vacuum cleaner. The handle assembly includes a housing pivoted to the floor engaging unit, and a handle extending from the opposite end thereof. A rigid or semirigid dirt tube extends longitudinally in one side of a recess in one side of the housing, and has a lower end coupled via a flexible tube to the outlet of the floor engaging unit. The flexible tube may be a separate tube or it may be formed integrally with the dirt tube, having thinner walls than the dirt tube to retain its flexibility. The dirt tube has a forwardly extending port in its other end to receive a disposable dust bag adapted to be removably assembled in the front recess. A removable cover covers the front recess to permit access to the dust bag. A further recess is provided in the rear of the housing for releasably receiving a rechargeable sealed lead acid battery assembly box, the battery being adapted to being recharged either attached to the vacuum cleaner or removed therefrom. The battery assembly box includes the battery, a recharging circuit including a recharging light, and a circuit breaker that is accessible at the rear of the vacuum cleaner for being manually reset. A control board is provided at the upper end of the housing, including a switch enabling operation of the machine either with or without use of the lights. An indicator, such as a row of LEDs is also provided on the control board, to indicate the charge condition of the batter to the user. Further preferred embodiments of the invention are defined in dependent Claims 2 to 13. In order that the invention may be more clearly understood, it will now be disclosed in greater detail with reference to the accompanying drawing, wherein: Fig. 1 is a perspective view of a vacuum cleaner in accordance with the invention; Fig. 2 is a rear view of the vacuum cleaner of Fig. 1; Fig. 3 is a front plan view of the vacuum cleaner of Fig. 1, with the front cover removed; Fig. 4 is a rear plan view of the vacuum cleaner Fig. 4A is a rear plan view in accordance with Fig. 5, with the bottom cover and battery assembly removed; Fig. 5 is an enlarged perspective view of a portion of the handle assembly with the front cover partially opened; Fig. 6 is an edge view of the latch of Fig. 12; Fig. 7 is a front view of the battery assembly; Fig. 8 is a side view of the battery assembly; Fig. 9 is an enlarged cross sectional view of a portion of the handle assembly and illustrating the procedure for installing the battery assembly; Fig. 10 is a view according to Fig. 21 illustrating the battery assembly in its installed position; Fig. 11 is a partially sectional front view of the battery assembly illustrating the battery and internal circuit board therein; Fig. 12 is a side view of the battery assembly latch; Fig. 13 is a cross sectional view of the latch of Fig. 12; Fig. 14 is a front view of a battery contact finger; Fig. 15 is a side view of the battery contact finger of Fig. 14 Fig. 16 is a circuit diagram of the circuit within the battery assembly; Fig. 17 is a circuit diagram of the control circuit board of the vacuum cleaner; As illustrated in Fig. 1, the preferred embodiment of a vacuum cleaner in accordance with the invention is comprised of a floor engaging unit 100 which encloses the vacuum cleaner motor as will be discussed. The unit 100 is provided with a pair of rear wheels 101, a lever 102 for enabling the latching of the handle assembly in desired positions, and a hood 103. The vacuum cleaner further includes a handle assembly 200 pivotally mounted to the rear of the floor engaging unit 100, the handle assembly including a housing 201 whose lower end is pivoted to the floor engaging unit, a handle 202 extending from the opposite end of the canister, and a hand grip 203 preferable shaped to enable a user to comfortably grip this element. The housing 201 has a body portion 204 at the rear side thereof, the front of the housing including a bottom front cover 205 and a removable upper front cover 206. The lip 211 preferably projects rearwardly of the body a sufficient distance that, when the vacuum cleaner is on a floor and the handle assembly is positioned horizontally, the lip 211 will engage the surface of the floor to prevent the handle 202 and grip 203 pressing against the floor. This feature minimizes danger of damage to the handle assembly by stressing the handle. As illustrated in Fig. 2, showing a rear view of the vacuum in Fig. 1, the rear of the body 204 includes a recess 208 for receiving a battery assembly 300, vents 209 for venting air from the housing and a recess 210 at the upper portion thereof, having an upper lip 211, to facilitate carrying of the vacuum cleaner. Fig. 2 also shows the latch 212 permitting release of the battery assembly. As shown in Fig. 3, a battery receptacle 230 is provided laterally of the dirt tube in the lower region of the body portion, the battery receptacle 230 being formed in the body portion 204 and being opened rearwardly of the body portion, as will be discussed. Spring fingers 231 of a latch for holding the battery assembly are visible in this view of the housing. A pair of spring contact fingers 232 are mounted adjacent the bottom of the receptacle 230, at fixed positions 233, to interconnect the terminals of the battery assebmly with the internal components of the vacuum cleaner. Thus, the contact fingers 232 are connected by way of leads 235 to a control board 236 mounted at the upper end of the body portion 204, and the contact fingers 232 are connected by leads extending through a flexible conduit 237 to the motor 106 and lamps 238 in the floor engaging unit 100. The conduit 237 may be held to the base 105 by a clamp molded on the base 105. As illustrated in Fig. 5, the battery assembly 300 has a charging socket 301 on its rear side for receiving an electric plug for charging the batteries within the battery assembly. The battery assembly may also have a circuit breaker button 302, and an LED 303 for indicating that the battery is being charged. Fig. 4A shows the recess 208 with the battery assembly removed. In this view the contact fingers 232, which extend into the recess 208, are visible at the bottom of the recess. In addition, a pair of projections 250 are molded to extend laterally into the recess 208, near the lower end thereof, to enable installing the battery assembly in the recess. As illustrated in Fig. 5, the control circuit board 203 includes a switch 258 for controlling the operation of the vacuum cleaner, as well as a plurality of indicators such as LEDs 259 for indicating the operating condition of the cleaner. The battery assembly in accordance with the invention is more clearly illustrated in Figs. 7-11, and is comprised of a box having a rear receptacle 310 joined to a front receptacle 311, for enclosing a battery 312. The battery is preferably a sealed rechargeable lead acid battery, for example a 12 volt 5.0 AH battery 8805 manufactured by Gates Energy Products, Inc. The sides of the rear receptacle 310, at one end thereof, are provided with recesses 313 extending from the rear surface, for receiving the projects 250 in the sides of the battery recess 208 of the housing 201. An extension 314 at the other end of the rear receptacle 310 defines a handle as well as a latch retainer for holding the battery assembly 300 within the recess or the housing 201. The front receptacle is provided with a step 320 at the lower end thereof, and a pair of battery contacts 321 extend through corresponding apertures in the forwardly facing surface of the step 320 to contact the contacts 232 when the battery assembly is installed. The step 320 serves to inhibit accidental shorting of the battery contacts 321, and thereby discharge of the battery, upon laying of the battery assembly down on a surface. The contacts 321 are connected to a circuit board 322 mounted within the rear and front receptacles 310, 311. The front and rear receptacles may be held together by any conventional technique. The installation of the battery assembly within the recess is illustrated in Fig. 9, wherein it is seen that the battery is initially held in a slanted position in order to engage the projections in the recesses 313. Using the projects as a pivot, the battery assembly is then pivoted until it is fully received in the recess 208 of the housing 201. The battery assembly is held in place by the latch 212 which is resiliently urged downwardly behind the end of the handle extension 314, as seen in Fig. 10. As illustrated in Fig. 2, the rear receptacle has a pair of apertures for exposing a charge light 330 and the manual reset button of a circuit breaker 331, as well as a socket 332 for receiving a recharging plug. The latch 212, as illustrated in Figs. 12 and 13, has a body portion 270 with a lateral guide projection 271 adapted to be received in suitable guide slots (not shown) in the housing 201 for guiding the latch toward and away from the battery assembly. A pair of spring fingers 231 depend from opposite sides of the top of the body portion 270 to extend through a recess in the housing 201. The sides of the spring fingers 231 resiliently engage the sides of the recess through which they extend, to bias the latch 212 toward the battery assembly. The latch may be held to the housing 201 for limited by a projection 274 on the housing received in a recess 272 in the front of the latch, i.e. the side toward the housing. The rear of the latch may be provided with a recess 273 to enable the user to retract the latch for removal of the battery assembly. Figs. 14 and 15 illustrate the contacts 232 for engaging the battery assembly contacts 321. These contacts 232, which may be of a berylium copper alloy, are provided with a button 280 adapted to extend through a recess in the wall of the housing 201, to project resiliently into the recess 208. The contacts have a mounting hole 281 for mounting to the interior of the housing 201, the contacts being shaped between the hole 281 and button 280 to linearize the deflection of the button upon being contacted by the corresponding battery contact. The other end of the contact 232 is shaped as a spade connector 282 to facilitate the interconnection of the connector 232 and the circuitry within the vacuum cleaner. The circuit provided within the battery assembly 300 is illustrated in Fig. 16, wherein it is seen that the terminals 320 of the battery 312 are connected to the contacts 321 via the circuit breaker 331. The socket 332 is connected to the battery 312 via a charging rectifier 340, for charging the battery. The charging voltage is applied to the charge indicator LED 330 via a diode 341 and resistor 342. It is to be noted that the battery may be charged either while it is positioned within the recess 208 of the vacuum cleaner, or it may be removed for such charging. The circuit breaker 331 protects the battery 312 from short circuits. In order to enable charging of the battery, a step down transformer 350 may be provided having a secondary winding connected to a suitable plug 351 for being received by the socket 332, and a primary winding connected to a mains plug 352. Fig. 17 illustrates the circuit provided on the control board 236. As illustrated, the input terminals 285, connected to the connectors 232, are connected to the center contact of the two sections of the control switch 258. This switch has an OFF position, a position in which just the motor in the ground engaging unit is on, and a position in which both the motor and the lamps are on. The central position is thus useful to save current from the battery, so that the vacuum cleaner may operate for a longer time between recharging. The two ON contact positions of the lower switch section are connected to the coil of a relay 286, as well as to the center terminal of one relay contact 287. One ON contact of the upper switch section is connected to the circuit of the lamps. The relay is selected to release when the voltage applied to its coil falls below about 8.5 to 9.0 volts, in order to disconnect the battery from the motor and lamps in sufficient time to avoid a deep discharge of the battery that would affect the reliability of the battery. The contacts 287 apply the battery voltage to the vacuum cleaner motor as well as to an LED driver circuit 289 for energizing the LEDs 259. The driver circuit 289 comprises a voltmeter circuit, for selectively energizing the LEDs 259 in dependence upon the battery voltage. Since the terminal voltage of the battery is a function of the charge state, the parameters of the driver circuit 289 may be set in conventional manner to indicate determined discharge states of the battery, such as, for example, 4/5 capacity remaining, 3/5 capacity remaining, etc. In a preferred embodiment of the invention, five LEDs 259 are provided to indicate five different charge conditions. Alternatively the energizing of the lamps may be an indication of operating time remaining.

Claims: A vacuum cleaner having a floor engaging part (100) pivotally connected to a handle part (200), a vacuum pump for directing dust-laden air from a nozzle to a porous dust bag (215) removably mounted therein, said vacuum pump including a motor (106), said handle part including a housing (201, 204) having a removable cover (205, 206), a dirt tube (220), a port for removably receiving the porous dust bag (215), and a flexible tube arrangement (108) coupling the dirt tube to the vacuum pump, characterized in an externally accessible recess (208) in said housing for removably receiving a battery assembly (300), a pair of contact fingers (232) mounted to said housing and having first ends extending into said recess for contacting battery assembly contacts (232) and means for connecting the other ends of said fingers to said motor (106). The vacuum cleaner of claim 1 further comprising a battery assembly (300) in said recess (208) and having battery assembly contacts (232) releasably contacting said contact fingers, and means for releasably holding said battery assembly in said recess. The vacuum cleaner of claim 2 wherein said contact fingers (232) comprise spring contact fingers adapted to engage said battery contacts only when said battery assembly (300) is positioned within said recess (208). The vacuum cleaner of claim 2 further comprising means for pivotally assembling said battery assembly (300) in said recess (208). The vacuum cleaner of claim 4 wherein said means for pivotally assembling comprises projections (250) within said recess (208) and adjacent one end of said recess (208) and guide means on said battery assembly for releasably receiving said projections, said releasable holding means comprising a catch mounted on said housing at the end of said recess opposite said one end thereof and positioned to engage said battery assembly (300). The vacuum cleaner of claim 2 wherein said battery assembly (300) comprises a battery housing, a rechargeable battery within said housing, and a circuit connecting said battery to said battery contacts, said circuit comprising a charging circuit and a manually operable switch. The vacuum cleaner of claim 1 comprising a handle recess in the rear of said housing (201), said handle recess having a lip extending rearwardly of said housing and defining a -projection for inhibiting engagement of said handle with a floor surface upon which said vacuum cleaner is positioned. The vacuum cleaner of claim 1 comprising indicating means on said housing, said indicating means comprising means coupled to said battery (312) for indicating the charge condition of said battery. The vacuum cleaner of claim 8 wherein said indicating means comprises a plurality of LEDs (259) connected to be energized at different charge conditions of said battery. The vacuum cleaner of claim 6 wherein the switch comprises a manually resettable, automatic circuit breaker (331) connected to said battery (312) and accessible from the exterior of said handle assembly. The vacuum cleaner of claim 1 further comprising control means on said housing, electrical leads extending longitudinally within said housing, said housing having a channel formed therein for receiving said leads, and a dirt tube extending between the pump and bag and having a flange positioned to define a cover for said channel. The vacuum cleaner of claim 1 further comprising a battery assembly mounted in said recess, said housing having pivot projections (250) extending into the sides of said recess (200) at one end thereof, said battery assembly (300) including a battery box having the battery contacts (21) thereon, said battery box having pivot recesses in the sides at one end thereof for receiving said pivot projections to permit said battery box to be releasably pivotally positioned in said recess, whereby said terminals slidingly engage said fingers during pivoting of said box into said recess, mand latch means for releasably holding said battery box in said recess. The vacuum cleaner of claim 12 wherein said battery box has a step, said battery contacts (321) being positioned in said step, wherein said battery contacts cannot contact any planar surface upon which said battery box may rest.

Inventors: SCHIAZZA ALFRED, SEPKE ARNOLD L, SCHIAZZA, ALFRED, SEPKE, ARNOLD L.
Applicants: WHITE CONSOLIDATED IND INC, WHITE CONSOLIDATED INDUSTRIES, INC.
Application year: 1990
Main classification: A47L5
IPC codes: A47L9, A47L5