Abstract:
A battery-powered vacuum cleaner that may be converted from a conventional on-the-floor cleaner to a portable canister cleaner for off-the-floor or on-the-floor cleaning operations. The vacuum cleaner has a filter chamber comprising a removable dirt cup having a substantially flat filter oriented in the direction of air flow. A fan and motor assembly is angularly related to the longitudinal axis of the vacuum cleaner to provide a lower profile of the cleaner housing while cleaning under low clearance objects. A handle is adjustable relative to the housing, or it may be removed to convert the cleaner to a portable canister.

Description:
A claim for priority is hereby made under the provisions of 35 U.S.C. 119(e) for the above-identified U.S. patent application based on U.S. Provisional Application Ser. No. 60/108,912, filed Nov. 18, 1998. 
    
    
     This invention relates to vacuum cleaners and, more particularly, to battery powered vacuum cleaners which may be converted from an upright cleaner to a canister cleaner and, further, to a canister cleaner which may be carried by a shoulder strap for on the floor or off the floor cleaning operations. 
     BACKGROUND OF THE INVENTION 
     Battery powered upright cleaners are typically designed to perform specific cleaning functions such as bare floor cleaning and small area cleaning on carpets and rugs. These vacuum cleaners are useful as an accessory to a full size carpet cleaner for small jobs. It is desirable, however, to have a cleaner which is versatile enough to perform the functions of a full size vacuum but possess the advantages of a portable stick vac and a portable canister vac which may be carried by a shoulder strap. 
     BRIEF DESCRIPTION OF THE INVENTION 
     This invention provides a powerful upright style battery powered vacuum cleaner, but which may be converted into a portable canister cleaner for both on the floor and off the floor cleaning operations. The vacuum cleaner includes an upper body containing a battery, a suction motor, a multi-position extension handle, and a removable dust cup. The upper body is pivotally connected to a floor engaging nozzle assembly ahead of a brush roll air intake orifice. Toward the rear of the nozzle assembly are two rearwardly extending projections which are spaced apart and to which rear wheels are mounted. The mounting projections are spaced apart to allow the upper body assembly to pivot 90 degrees from the vertical storage position to a ground-hugging overall height that aids in gaining cleaning access under low objects such as beds, chairs, couches, etc. 
     Consistent with the objective to provide a low profile for the cleaning operations described above, the motor and fan unit in the upper body is mounted so that the axis of fan rotation is angularly related to the longitudinal axis of the upper body, and so that the fan presents an elliptical envelope of rotation when viewed in the direction of the longitudinal axis of the upper body. This arrangement permits the height of the upper body housing to be reduced for the previously described cleaning operations. 
     According to a further aspect of this invention, the upper body provides a containment chamber. The containment chamber is provided with a substantially planar filter which extends from a distal end to a proximal end of the containment chamber to separate the chamber into an airflow chamber and a dirt chamber. The direction of flow of dirt-laden air is substantially parallel to the filter so that dirt is not built up on the filter but tends to be swept away by the incoming air stream. The containment chamber is easily removed and emptied without removing the filter during each disposal operation. Periodically, the filter may be cleaned by removing it from the containment chamber. According to a further aspect of this invention, the fan comprises an impeller having a pair of circular faces one of which has a circular central opening therethrough. A plurality of spaced curved vanes are provided between the plates extending outwardly from the central opening to an outer periphery of each plate. A windguard supports the motor and fan unit. 
     The windguard comprises spaced mounting plates, the first one of which supports the motor and a second one of which has an air cone conduit. The fan is located between the plates and a plurality of exhaust vanes connect the plates just outward of the path of travel of the fan to extend a short distance from the end of the plates. The vanes extending from the plates are received in lateral slots in the housing to aid in supporting the entire assembly. An air guard cylinder extends axially from the central opening of the fan and is received in the circular opening of the air cone conduit in closely spaced relationship. The other end of the air guard cylinder forms a laterally elongated opening which communicates with an elongated aperture in an end wall of the containment chamber. Air is thus drawn in from the containment chamber into the eye of the fan and then radially outwardly through the vanes between the plates to the outside environment. 
     The motor housing is connected to a lower accessory receiving assembly by a longitudinal spine. The containment chamber is removably mounted on the spine between the motor housing and the accessory receiving assembly. A tubular opening is defined by the accessory receiving assembly and is in fluid communication with an intake opening in the containment chamber. The floor and rug cleaning housing wall nozzle is attached to the accessory receiving assembly by an outlet tube which is pivotally connected to the floor and rug cleaning nozzle. The tube may be removed from the accessory receiving assembly and a hose may be connected to the assembly to convert the unit into a canister cleaner. 
     A handle is telescoped into the spine of the vacuum cleaner and may be adjusted to project at different extensions from the cleaner to accommodate persons of different height. For canister cleaning operations the handle may be entirely removed from the unit, a carrying strap may be attached to the cleaner and the cleaner may be carried about as a portable on or off the floor cleaning unit. 
     Molded into the housing is a compartment for the battery providing accessibility from the exterior of the housing. A disconnect connection is provided on the housing to electrically engage the battery and to provide terminals for leads which run along the spine of the vacuum to the motor housing and to a switch provided at the upper portion of the housing. Leads may also extend to the accessory mounting assembly to be associated with quick disconnect connectors on the rug nozzle to a brush roll motor so that a powered brush roll accessory may be provided. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a vacuum cleaner according to this invention; 
     FIGS. 2A,  2 B, and  2 C, together comprise an exploded view of the vacuum cleaner; 
     FIG. 3 is a sectional view, the plane of the section being indicated by the line  3 — 3  in FIG. 1; 
     FIG. 4 is a cross sectional view, the plane of the section being indicated by the line  4 — 4  in FIG. 3; 
     FIG. 5 is a fragmentary sectional view, the plane of the section being indicated by the line  5 — 5  in FIG. 4; 
     FIG. 6 is a cross sectional view, the plane of the section being indicated by the line  6 — 6  in FIG. 3; 
     FIG. 7 is a cross sectional view, the plane of the section being indicated by the line  7 — 7  in FIG. 6; 
     FIG. 8 is a perspective view of the dirt containment chamber illustrating the filter removed therefrom; 
     FIG. 9 is a perspective view of the filter; 
     FIG. 10 is a sectional view of the rug nozzle according to one aspect of this invention; 
     FIG. 11 is a sectional view of the rug nozzle according to another aspect of this invention; 
     FIG. 12 is a bottom view of the rug nozzle illustrated in FIG. 11; 
     FIG. 13 is a bottom view of the rug nozzle illustrated in FIG. 12; and 
     FIG. 14 is a perspective view of a rug nozzle according to another aspect of this invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring particularly to FIGS. 1,  2 A,  2 B, and  2 C of the drawings there is illustrated a battery operated upright vacuum cleaner  10 . The vacuum cleaner  10  includes an elongated casing or upper body member  12  which is pivotally connected at its distal end to a floor and rug cleaning housing  14  and has a handle  16  projecting from its distal end. The elongated casing  12  includes a motor housing  18  at one end and an accessory receiving assembly  20  at its other end. The motor housing  18  and the assembly  20  are joined by a spine  22 . 
     Mounted within the motor housing  18  is a motor and fan assembly  24  (FIGS. 2A,  2 B,  2 C, and  3 ). The assembly  24  includes a motor  26  and a fan  28 . The motor  26  is mounted on a fan cover plate  30  within a central socket  32 . The fan  28  is mounted for rotation on the other side of the plate  30  and as may be seen in FIG. 4 comprises a plurality of curved vanes  32  extending between first and second mounting disks  34  and  36 . The disk  36  has a central air intake opening  38  defined by a cylindrical air guard  40 . A plurality of laterally extending air guide vanes  42  are provided along the lateral edges of the plate  30  and each vane  42  has an extending tab  44  (FIG.  5 ). A reducer  48  having a base plate  50  (FIG. 6) is assembled on the motor fan assembly by a plurality of recesses  52  provided in the plate  50 . The plate  50  and the plate  30  are spaced apart a distance so that both plates are spaced closely adjacent the fan  28 . 
     The fins  46  project beyond the edges of the plates  50  and  30  and are received in a slot  54  in the housing  18 . The slot  54  and spaced parallel ribs  56  and  58  serve to retain the motor fan assembly and the housing  18 . A gasket  60  is provided between the plate  50  and the rib  58  to seal the motor fan unit. 
     As may be seen most clearly in FIG. 3 the ribs  56  and  58  and the slots  54  mount the motor fan assembly at an angle with respect to a longitudinal axis of the upper body  12 . This angular mounting arrangement reduces the profile of the outer fan unit as viewed along the axis so that the width of the housing  12  measured normal to the axis may be reduced. As will become apparent reduction of this width enables the user to clean under low clearance items of furniture such as beds or the like. 
     As may be seen in FIG. 7 the angular rim  38  projects into an opening  70  in the plate  50  and is closely spaced thereto. The opening  70  communicates with a reducer tube  72  which projects from the plate  50  as a cylinder and then flows laterally outwardly to form an elongated opening  74 . The opening  74  is covered by a grate  76  and is sealed to an end wall  78 . 
     The end wall  78  and an opposite wall  80  define a cavity which receives a dust cup  82 . The cup  82  is generally rectangular but has a front face  84  molded to conform to the configuration of the body  12 . As may be seen in FIGS. 3 and 8, one end of the cup  82  has an open mouth defined by an edge  88  which is sealed against the end wall  78 . The front face  84  extends around a recess  90  in the housing  18  and is sealed by a gasket  92 . Thus the cup  82  is in fluid communication with the intake of the fan  28 . The other end of the cup is closed but has an opening  94  which communicates with an intake tube  96 . The intake tube  96  is provided with a flapper valve  98  at its upper end to minimize the gravitational discharge of debris. 
     A substantially flat filter element  100  is removably mounted in the dirt cup  82 . The filter  100  is preferably made from plastic and has a framework which comprises longitudinal sides  102  and  104  and a central frame member  106 . A rectangular frame  108  is provided at one end of the filter. A filter fabric  110  extends between the sides  102  and  104  and extends across the frame  108 . The filter  100  is mounted in the dirt cup by sliding the filter edges  102  and  104  between parallel ribs  112  and  114  which are provided on opposite sides of the dirt cup  82 . It may be noted in FIG. 8 that one side  116  of the tube  96  is flattened to closely face the filter fabric  110 . The flattened portion flows at its lower end to a full cylinder to provide a circular opening at the inlet  94 . The cylindrical portion of the tube  96  is accommodated by a complimentary cylindrical impression  118  at one end of the filter. 
     As may be seen in FIG. 3 the filter  100  separates the interior of the dirt cup  82  into a dirty air chamber  120  and a clean air chamber  122 . Since the face of the filter screen  110  is substantially in the direction of dirty air flow the screen tends not to be deeply embedded with dirt and the dirt tends to collect in the cup rather than on the filter screen. Thus the cup may be emptied without removing and cleaning the screen after each use. However, when the screen is completely coated with dirt the filter is easily removed from the dirt cup and thoroughly cleaned. To aid in this operation, it may be noted in FIG. 8 that one edge  124  of the dirt cup  82  is provided with a series of comb-like projections  126  which may be used as an aid in scraping the surface of the filter screen  110 . 
     The dirt cup  82  is retained in an operating position by an upper loop  130  which is placed over a hook  132  on the housing  18 . A lower spring hinge  134  snaps over and is retained by a detent  136 . A handle grip  140  is provided at the front face of the dirt cup  82 . 
     The inlet tube  96  and its opening  94  are seated on a gasket  150  which is provided on a T-joint and accessory holder  152  and the accessory mounting assembly  20 . The holder  152  has a cylindrical socket  154  which receives a T-joint  156 . The T-joint  156  is provided with a spring biased locking button  158  which projects through an aperture  160  in the socket  156 . The button locks the T-joint in the socket and permits removal of the T-joint  156 . The T-joint  156  has a hollow interior and is received between a cylindrical surface  162  in a lower nozzle member  164  and a complimentary cylindrical surface  166  in an upper nozzle member  168  (FIG.  2 A). With the upper and lower nozzle members  168  and  164  assembled, the T-joint  156  is permitted to swivel between vertical and horizontal positions. 
     A suction inlet opening  170  is provided in a portion of the cylindrical side wall of the T-joint  156 . When the handle and, therefore, the T-joint  156  is in an inclined operating position, the inlet opening  170  is in communication with an air inlet passage  172  formed by a wall  174  in the lower nozzle assembly  164  and a wall  176  in the upper nozzle assembly  168 . The inlet opening  170  is otherwise sealed by a lower gasket nozzle  178  provided on the cylindrical surface  162 . The passage  172  in turn communicates with an elongated chamber  178  in the lower nozzle member  164  which, in turn, is open to the floor or carpet being vacuumed. 
     A powered brush roll  180  having a multiplicity of bristles  182  is mounted for rotation in the chamber  178  and is covered by an inner shroud  184 . The brush roll  180  is driven by a drive motor  186  through a driving belt  188  and a drive wheel  190  which is connected to one end of the brush roll  180 . The drive motor  186  is mounted in the lower nozzle on motor mounting cradles  192 . 
     Referring to FIG.  12  and to the lower nozzle member  164 , a pair of small front wheels  200  are provided ahead of brush roll air intake  202  and are spaced inwardly from front corners  204 . The front corners  204  define recessed channels  206  in air communication with the brush roll air intake  202  to enhance edge and corner cleaning effectiveness. Toward the rear of the lower nozzle assembly  164 , two rearwardly extending projections  208  and  210  rotatable mount a pair of relatively large rear wheels  212  and  214 . The extensions  208  and  210  provide a space therebetween which allows the upper body assembly to pivot  90  degrees from a vertical storage position to a “ground-hugging” overall height that acids in gaining cleaning access under low objects, such as beds, chairs, couches, etc. 
     A two position height adjustment mechanism  216  comprises a carriage formed by a pair of parallel links  218  and  220 , which are fixed at one end to an axle  222 . A roller  224  is rotatably mounted between the links  218  and  220 . The axle  222  is provided with centrally located flattened portions  226  and  228  and is mounted for rotation between channel plates  230  and  232 . A leaf spring  234  is mounted on a post  236  and retains the axle  222  and, therefore, the roller  224  in the position illustrated in solid outline in FIGS. 11 and 12. In that illustrated position the roller  224  tends to minimize penetration of the section inlet opening into plush or deep pile carpeting. For bare floors or short pile carpeting, the roller may be pivoted about 180 degrees to the position illustrated in phantom outline in FIG. 12 to permit the intake opening of the nozzle to be spaced a short distance from the floor. In its pivoted position the flattened portion  226  of the axle  228  engages the spring  234 . To aid in moving the roller from its on the floor to its retracted position projecting finger grips  240  may be provided on the links  218  and  220 . Further, a flexible scraper blade  242  is mounted just rear of the intake  202  of the nozzle to scrape any debris into a position to be picked up by the intake nozzle. 
     Referring now to FIG. 13 there is illustrated a height adjustment mechanism according to a further aspect of this invention. The mechanism includes an axle  250  which is mounted for pivotable movement between a pair of bearing plates  252  and  254 . A retaining plate  256  covers and retains the axle  250  between the plates  252  and  254 . A pair of links  258  and  260  are fixed to the axle  250  and rotatably mount a roller  262 . Stabilizer ribs  264 , which project from the cover, prevent movement of the roller  262  and the axle  250  in their axial directions. Pressure pads  266  and  268  are located on opposite sides of the axle  250  and frictionally engage cam projections  270  at the ends of the axle  250  when the roller  262  is in its operative illustrated position and its phantom outline position, respectively. 
     Refer now to FIG. 14 there is illustrated a mechanism for providing a permanent elevation of the nozzle opening with respect to plush or deep pile carpeting. That mechanism includes an axle  270  which is transversely supported by end posts  272  and  274 . A plurality of rotatable rollers  276  are mounted on the axle  270  which are provided with mutually interlocking ends  278  which join the rollers  276  as a rotational unit. The interlocking end configuration of the rollers  276  prevents hair and string buildup on the axle  270  during use. The rollers  276  provide spaces therebetween which ensure adequate vacuum suction to the nozzle intake  202 . 
     Referring again to FIGS. 2A,  2 B and  2 C the brush roll motor  186  and the suction motor  26  are powered by a battery pack  280 . The battery pack  280  includes a plurality of rechargeable batteries  282  which are electrically connected in series by a plurality of busbars  284 . Additional busbars  286  and  288  provide contact points  290  and  292  in openings  294  and  296  in an upper battery case  298 . The upper battery case  298  cooperates with a lower battery case  300  to provide the battery pack  280 . A circuit board  302  is provided within the upper and lower battery cases to provide components which are required for recharging the battery. The recharging pin connector (not shown) may be inserted into an opening  304  formed by the upper and lower battery cases to recharge the batteries  282  when the battery pack  280  is removed from the vacuum cleaner or when the battery pack  280  is mounted in an operating position in the vacuum cleaner. 
     A battery compartment  306  is provided in the vacuum cleaner and has an inner configuration which conforms to the shape of the battery pack  280 . It may be noted that the battery pack  280  is asymmetrical in that one corner  308  is provided with a slight radius. This prohibits the battery pack from being mounted in an inverted position within the compartment  306 . The battery pack  280  is retained in the compartment  306  by a flexible detent  310  which engages a complimentary detent (not shown) within the compartment  306 . 
     When the battery pack  280  is installed in the compartment  306 , the contacts  294  and  296  are in electrical contact with contacts  312  and  314  which in turn supply d current from the battery pack  282  a pair of contacts  316  and  318  which are located in alignment with pin openings  320  in the housing adjacently opening  94  in the housing. When the T-joint  156  is inserted into the opening  94 , socket pins  322  mounted on the T-joint  156  electrically engage the contacts  312  and  314 . A wiring harness  324  electrically connects the pins  322  to the brush roll motor  186 . A wiring harness  326  connects the contacts  312  and  314  to a multi-position switch  328  and connects the switch to a pair of pins  322 . The switch  328  controls the supply of power to the motor  26 . A first position of the switch  328  is an off position which prevents supply of power to the motor  186  and the motor  26 . The switch has a second position which supplies power to both motors  186  and  26  and has a third position which supplies power only to the motor  26 . The last mentioned position of the switch is utilized when bare floors are vacuumed without rotation of the brush roll. 
     The handle  16  includes a shaft  340  which is slidably received in the spine  22 . A spring biased latch  342  engages an upper notch  344  to retain the handle in a retracted position, and engages a lower notch  346  to retain the handle in an extended position. the handle may also be removed from the spine  22 , if the vacuum cleaner is used as a portable canister cleaner. 
     To use the vacuum cleaner as a portable canister cleaner, the T-joint  156  is removed from the holder  152  and a connector end  348  of an accessory hose  350  (FIG. 2C) is inserted into the holder  152 . the connector end  348  is provided with electrical connector contact pins which are received in the pin openings  320  to provide power for a brush roll motor (not shown) in a cleaning accessory (also not shown) at the distal end of the hose  350 . 
     The upper body member  12  may be provided with a carrying strap  352  which is attached to the member  12  by links  354  and  356  as is indicated in FIG.  2 C. 
     While the invention has been shown and described with respect to particular embodiments thereof, those embodiments are for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiments herein described will be apparent to those skilled in the art, all within the intended spirit and scope of the invention. Accordingly, the invention is not to be limited in scope and effect to the specific embodiments herein described, nor in any other way that is inconsistent with the extend to which the progress in the art has been advanced by the invention.