Abstract:
A vacuum cleaner comprises a rigid dirt receptacle  14  having an outlet at one end, through which the collected dirt and dust can be emptied, a flap  16  for closing the outlet, and an actuator  58  for moving the flap  16  between a closed position and an open position, the actuator  58  being operable to control the position of the flap  16  between the open and closed positions.  
     A location is provided at a partially opened position of the flap  16 , at which position fine dirt and dust can be emptied through the restricted outlet in a controlled manner. The restricted size of the outlet retains any coarse and fibrous dirt inside the receptacle  14 . Once the fine dirt has been emptied, the flap  16  can be moved to its fully open position to allow the coarse dirt and fibrous matter to be emptied from the receptacle  14  separately from the fine dust.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     This invention relates to a vacuum cleaner.  
         [0003]     2. Related Background Art  
         [0004]     Vacuum cleaners conventionally comprise a permeable dust bag, which filters and retains the dirt and dust drawn into the vacuum cleaner by the induced air flow. Nowadays, it has become popular to provide vacuum cleaners, in which the separated dirt and dust is collected in a rigid dirt receptacle that can be emptied and re-used. Such so-called bagless cleaners alleviate the need to purchase and replace the dust bags. However, a disadvantage of re-usable dirt receptacles is that the receptacles are often dirty to handle and clouds of dirt and dust can be emitted into the atmosphere when the receptacles are emptied, with the obvious health risks and resultant contamination of the vacuum cleaner and the user&#39;s environment with a layer of dust.  
         [0005]     Many bagless vacuum cleaners nowadays comprise a cyclonic separator, which deposits the separated dirt and dust in a rigid dirt receptacle. Cyclonic vacuum cleaners offer the advantage over bag-type cleaners of maintaining a more constant level of suction performance regardless of the quantity of dirt present in their dirt receptacle.  
         [0006]     One of the main disadvantages of known cyclonic vacuum cleaners is that the procedure for emptying their dirt receptacles is a potentially dirty and unhygienic process. Instead of simply removing a closed paper bag full of dirt from the vacuum cleaner, and dropping it into a dustbin, emptying a cyclonic cleaner usually involves tipping a mass of loose dust and dirt out of its dirt receptacle, following removal of the receptacle from the cleaner. This emptying process can involve knocking and/or shaking the dirt receptacle to dislodge agglomerated dust and any masses of fibrous material, such as fluff and hairs that may be present.  
         [0007]     This problem is exacerbated because fine dirt typically collects at the base of the dirt receptacle, with coarse and fibrous dirt lodging in the upper region of the receptacle. When the dirt receptacle is inverted for emptying, the entire mass of dirt falls in an uncontrolled manner into the vessel used for its final disposal, typically a dustbin or refuse bag. This uncontrolled discharge usually results in the lighter dirt fractions being disturbed by the movement of the heavier fractions, whereupon the clothing and anatomy of the vacuum cleaner user may become contaminated with dust. The attendant escape of dust into the user&#39;s home environment is equally undesirable.  
         [0008]     Many popular cyclonic vacuum cleaners have a simple cylindrical dirt receptacle, usually of transparent plastic material, which is removed from the cleaner and inverted over the dustbin for emptying. More recent cleaners have had a pivoted flap at the bottom of their dirt receptacle, this being released by some form of manually-operated latch to swing open for emptying under gravity or, in some cases, being spring-loaded to aid opening. In either case, dust and fibres suddenly fall out of the dirt receptacle when the flap opens. This flap-type emptying system exacerbates the problem of contamination, since the fine dust falls out of the bottom of the receptacle closely followed by the coarse and fibrous dirt, which falls through and/or lands on top of the fine dust causing clouds of fine dust to become airborne and contaminate the environment during the emptying process.  
         [0009]     Thus, there is the need to provide a dirt receptacle for a cyclonic vacuum cleaner which is clean to use and does not generate clouds of dirt and dust when emptied.  
         [0010]     EP 1 199 023 attempts to solve the above-mentioned problems by providing a cyclonic separator for a vacuum cleaner in which the lower region of the cylindrical dirt receptacle is separated from the upper region by a perforated disc-shaped partition. In use, the fine dust and dirt particles fall through the perforations in the disc and are retained in the region below the disc. The coarser particulate and fibrous material are retained above the disc. During emptying, the lower region of the dirt receptacle can be opened and carefully emptied into a suitable waste receptacle for disposal. Having emptied the fine dust, the entire dirt receptacle containing the coarse and fibrous material, may then be inverted over the waste receptacle to complete the emptying process.  
         [0011]     Although the dirt receptacle emptying arrangement disclosed in EP 1 199 023 constitutes a considerable improvement over the emptying arrangements of most commercially available cyclonic cleaners, the receptacle is complicated and expensive in construction and is difficult to use.  
         [0012]     We have now devised a vacuum cleaner which alleviates the above-mentioned problems.  
       SUMMARY OF THE INVENTION  
       [0013]     In accordance with this invention, there is provided a dirt receptacle for a vacuum cleaner, the receptacle comprising a rigid container having an outlet for the emptying of collected dirt, a closure for closing the outlet, and an actuator for moving the closure between a closed position and an open position, said actuator being operable to control the position of the closure between said open and closed positions.  
         [0014]     In use, the receptacle is emptied by initially moving the closure to a partially opened position, in which fine dirt and dust can be emptied through the restricted outlet in a controlled manner. The restricted size of the outlet retains any coarser and fibrous dirt inside the receptacle. Once the fine dirt has been emptied, the closure can be moved to its fully open position to allow the coarse dirt and fibrous matter to be emptied from the receptacle.  
         [0015]     The present invention thus provides a clean and hygienic way of empting the receptacle by allowing the fine and coarse dirt to be emptied in two distinct operating stages, thereby avoiding the problem of dust contamination when all of the dirt is released in an uncontrolled single stage.  
         [0016]     The restricted size of the opening also allows a more controlled release of the fine dirt and avoids the problem of dust contamination caused by a sudden release of the dirt.  
         [0017]     The receptacle is simple and inexpensive in construction and is straightforward to use.  
         [0018]     Preferably, the closure locates at said partially opened position, in order to provide a tactile indication to the user that the closure is in the correct position for the emptying of fine dust.  
         [0019]     Preferably, the outlet is provided at a position on the container which is located at the bottom thereof when the container is in use, such that the outlet is positioned directly adjacent the fine dirt which collects at the bottom of the container.  
         [0020]     Preferably means are provided for retaining the closure in said open and/or closed positions.  
         [0021]     Preferably the closure is biassed into said fully open position.  
         [0022]     Preferably, the container comprises an open bottom forming the outlet.  
         [0023]     Preferably, the closure comprises a flap pivoted to the container.  
         [0024]     Preferably the actuator comprises a handle mounted directly to said flap, preferably adjacent the point where the flap is pivoted to the container.  
         [0025]     Preferably the flap is also mounted to the container for translatory movement towards and away from said outlet thereof.  
         [0026]     Preferably means are provided to guide the translatory movement of said flap towards and away from said outlet.  
         [0027]     Preferably said guide means is arranged to only permit pivotal movement of the flap, when the latter is in a partially opened position between said open and closed positions.  
         [0028]     Preferably, the guide means is arranged to hold said flap in its fully opened position.  
         [0029]     Also, in accordance with this invention, there is provided a vacuum cleaner comprising a dirt receptacle as hereinbefore described.  
         [0030]     Preferably the vacuum cleaner comprises a cyclonic separator having a cylindrical-walled separation chamber.  
         [0031]     Also, in accordance with this invention, there is provided a method of emptying a dirt receptacle of a vacuum cleaner, the receptacle comprising a rigid container having an outlet for the emptying of collected dirt, a closure for closing the outlet, the closure being moveable between a normally closed position and an open position, the method comprising removing the dirt receptacle from the vacuum cleaner, partially opening the closure and empting fine dirt from the receptacle through the restricted outlet prior to fully opening the closure and empting the remaining dirt from the receptacle. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0032]     Embodiments of this invention will now be described by way of examples only and with reference to the accompanying drawings, in which:  
         [0033]      FIG. 1  is a schematic view of a vacuum cleaner in accordance with this invention;  
         [0034]      FIG. 2  is a perspective view of a dirt collection bin of the cleaner of  FIG. 1 , showing the discharge flap thereof in its closed state;  
         [0035]      FIG. 3  is a side view of the dirt collection bin of the cleaner of  FIG. 1 , showing the discharge flap thereof in its closed state;  
         [0036]      FIG. 4  is a perspective view of a dirt collection bin of the cleaner of  FIG. 1 , showing the discharge flap thereof in its partially opened state;  
         [0037]      FIG. 5  is a side view of the dirt collection bin of the cleaner of  FIG. 1 , showing the discharge flap thereof in its partially opened state;  
         [0038]      FIG. 6  is a perspective view of a dirt collection bin of the cleaner of  FIG. 1 , showing the discharge flap thereof in its fully opened state;  
         [0039]      FIG. 7  is a side view of the dirt collection bin of the cleaner of  FIG. 1 , showing the discharge flap thereof in its fully opened state;  
         [0040]      FIG. 8  is a perspective view of a dirt collection bin of an alternative embodiment of vacuum cleaner in accordance with this invention, showing the discharge flap thereof in its closed state;  
         [0041]      FIG. 9  is a perspective view of the dirt collection bin of  FIG. 8 , showing the discharge flap thereof in its fully opened state;  
         [0042]      FIG. 10  is a perspective view of a portion of a dirt collection bin of a preferred embodiment of vacuum cleaner in accordance with this invention, showing the discharge flap thereof in its closed state;  
         [0043]      FIG. 11  is a perspective view of a portion of the dirt collection bin of  FIG. 10 , showing the discharge flap thereof in its partially opened state;  
         [0044]      FIG. 12  is a perspective view of a portion of the dirt collection bin of  FIG. 10 , showing the discharge flap thereof in its fully opened state; and  
         [0045]      FIG. 13  is a longitudinal sectional view through a portion of the dirt collection bin of  FIG. 10 .  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0046]     Referring to  FIG. 1  of the drawings, there is shown an upright vacuum cleaner comprising a wheeled suction head  10 , to which a body portion  11  is pivoted for movement between an upright position and an inclined operative position. A motor and fan are mounted in a bottom portion  12  of the body  11  of the cleaner.  
         [0047]     A separation unit  13  mounted in the body  11  of the cleaner comprises a cyclone separator and a filter. In use, the fan induces an airflow through the cleaner from the suction head  10  through the separation unit  13 , where dirt and dust separated from the airflow by the cyclone is collected in a removable dirt collection bin  14  mounted directly below the separation unit  13 . The cyclone separator comprises a cylindrical wall and for practical purposes, the side wall of the collection bin  14  is a downward extension of the wall of the cyclone.  
         [0048]     The cyclonic separation action causes the finer dirt particles F to collect at the bottom of the collection bin  14  below the coarser dirt particles and fibrous matter C.  
         [0049]     Referring to  FIGS. 2 and 3  of the drawings, the collection bin  14  comprises a cylindrical side wall  15  having an open top which communicates with the cyclone separator. The bottom of the bin  14  is closed by a flap  16  which is pivoted by a shaft to the side wall  15  of the bin  14  for rotation about an axis which extends perpendicular to the longitudinal axis of the bin. A torsion spring  17  biases the flap  16  downwardly into a position where the bottom of the bin  14  is fully open.  
         [0050]     The flap  16  comprises a pair of spaced-apart formations  18 , between which the above-mentioned shaft extends. Each formation  18  comprises an outwardly facing abutment surface which lies in a plane that extends parallel to both the longitudinal axis of the bin and rotational axis of the flap  16 , when the later is in its fully closed position.  
         [0051]     An actuator  19  is slidably mounted to the outer surface of the side wall  15  of the bin  14  for movement in a direction which extends parallel to the longitudinal axis of the bin. The actuator  19  comprises a pair of arms having lower ends which abut the respective flap formations  18 .  
         [0052]     A foldable handle  20  is attached to the arms of the actuator  19  for sliding the actuator  19  in the upward and downward directions shown in the drawings. In its fully downward position, the bottom ends of the arms of the actuator  19  bear against the abutment surface of the flap formations  18 , thereby holding the flap in its closed position and preventing the collected dirt and dust from falling out of the bottom of the bin  14  whilst the cleaner is in use and whilst the bin  14  is being carried to a waste receptacle for emptying. The handle  20  also serves as a handle for supporting the bin  14  whilst it is being carried.  
         [0053]     Referring to  FIGS. 4 and 5  of the drawings, in order to empty the bin  14 , the user slides the actuator  19  upwardly using the handle  20 , thereby allowing the flap  16  to open under the spring bias, until the bottom ends of the arms of the actuator  19  engage in respective detents  21  formed in the abutment surfaces of the flap formations  18 . In this position, the flap  16  is retained in the partially open position and the fine dirt and dust F at the bottom of the bin  14  can be emptied through the small opening at the bottom of the bin  14 . Any coarse dirt and fibrous matter C cannot pass through the opening and is retained inside the bin  14 .  
         [0054]     Referring to  FIGS. 6 and 7  of the drawings, in order to fully empty the bin  14 , the user has to slide the actuator  19  more upwardly using handle  20 , thereby allowing the flap  16  to fully open under the applied spring bias. In this position, all of the remaining dirt and dust inside the bin  14  is free to fall through the open bottom of the bin  14 .  
         [0055]     Following emptying of the bin  14 , the actuator  19  is returned to its lower position using the handle  20 , thereby closing the flap  16  against the spring bias. The body  11  of the cleaner is preferably adapted such that the bin  14  cannot be mounted to the cleaner until the actuator  19  has been returned to the lower position, thereby avoiding the risk of the flap  16  opening whilst the bin  14  is removed from the cleaner.  
         [0056]     The upper surface of the flap  16  is contaminated with dirt and dust. However, it will be appreciated that actuator  19  enables the user to open and close the flap  16  without having to touch the flap itself.  
         [0057]     Referring to  FIGS. 8 and 9  of the drawings, there is shown an alternative embodiment of a bin  14 , which is similar to the above-mentioned bin and like parts are given like reference numerals. In this embodiment, a pair of pinions  42  are mounted to the flap  16  for rotation about the rotational axis of the flap  16 . A handle  40  is pivotally mounted to the external surface of the wall  15  of the bin  14  for rotation about an axis which extends parallel to the axis of flap rotation. A second pair of pinions  41  are mounted to the handle  40  and are engaged with respective ones of the flap pinions  42 .  
         [0058]     In order to open the flap  16 , the handle  40  is rotated about its rotational axis, causing the pinions  41  to correspondingly turn the flap pinions  42 . A detent (not shown) is provided to retain the flap  16  in its partially opened position and to provide a tactile indication to the user that the flap  16  is in the correct position for the emptying of fine dirt.  
         [0059]     Referring to FIGS.  10  to  13  of the drawings, there is shown a preferred embodiment of a bin  14 , which is similar to the above-mentioned bins and like parts are given like reference numerals. The flap  16  is pivotally mounted between a pair of parallel spaced apart flanges  52  provided on the lower end of the rear of the side wall  15  of the bin  14 . The flanges  52  extend parallel to each other and axially of the bin. Each flange  52  comprises an upper slot  53  which extends axially of the bin and a lower unshaped slot  54  having long and short arms  54   a ,  54   b  extending axially of the bin.  
         [0060]     The flap  16  comprises a portion  56  which extends between the flanges  52 . A pair of upper projections  55  extend outwardly from opposite sides of the flap extension  56  into the respective upper slots  53  of the flanges  52 . A pair of lower projections  57  also extend outwardly from opposite sides of the flap extension  56  into the respective lower slots  54  of the flanges  52 .  
         [0061]     A handle  58  extends over the outer surface of the flap extension  56 . The lower edge of the handle  58  is spaced away from the outer surface of the flap extension  56 , so that a user can grasp the handle  58  in the palm of their hand, with their fingers extending around the lower edge of the handle. A concealed spring  59 , connected between the flap extension  56  and the exterior of the wall  15  of the bin  14 , biasses the flap  16  upwardly. A seal  59  extends around the flap  16  to seal against the bottom edge of the wall  15  of the bin  14 .  
         [0062]     In use, when the bin  14  is stowed on the body  11  of the vacuum cleaner, the flap  16  is in the closed position of  FIG. 10 . The spring  59  serves to retain the flap  16  in the closed position, so that no dirt and dust can escape. The handle  58  is preferably concealed behind the bin  14  when the latter is stowed on the body  11  of the vacuum cleaner.  
         [0063]     In order to empty the bin  14 , the user removes the bin  14  from the body  11  of the cleaner. The user then pushes the handle  58  downwardly, thereby allowing the flap  16  to open under the spring bias, until the projections  55 ,  57  on the flap extension  56  reach the lowermost point of their respective slots  53 ,  54 . It will be appreciated that the attitude of the flap  16  remains constant as the handle is pushed downwardly as hereinbefore described.  
         [0064]     In this position, as shown in  FIG. 11 , the flap  16  can be retained in the partially open position by maintaining a downward bias on the handle  58 . Fine dirt and dust at the bottom of the bin  14  can be emptied through the small opening at the bottom of the bin  14 . Any coarse dirt and fibrous matter cannot pass through the opening and is retained inside the bin  14 .  
         [0065]     In order to fully empty the bin  14 , the user has to pull the lower edge of the handle  58  away from the bin  14 , causing the lower projections  57  to slide along the bottom of their respective unshaped slots  54 , allowing the flap  16  to pivot further open about an axis extending through the upper projections  55 . The downwards force on the handle  58  is then released, thereby causing the lower projections  57  to move a short distance up the short arms  54   b  of the lower slots  54 . The spring  59  serves to retain the flap  16  in this fully open position, as shown in  FIG. 11 , in which all of the remaining dirt and dust inside the bin  14  is free to fall through the open bottom of the bin  14 .  
         [0066]     Following emptying of the bin  14 , the handle  58  is pushed downwardly and then inwardly, thereby allowing the flap to close under the applied spring bias. The body  11  of the cleaner is preferably adapted such that the bin  14  cannot be mounted to the cleaner until the flap  16  has been closed, thereby avoiding the risk of dirt and dust escaping from the bin when in use.  
         [0067]     A bin in accordance with the present invention is simple and inexpensive in construction, yet allows a staged discharge of fine and coarse dirt, thereby minimising the risks of dust contamination during emptying.  
         [0068]     Whilst an upright vacuum cleaner has been shown and described in the drawings, it will be appreciated that the present invention is equally applicable to a canister or other type of vacuum cleaner.  
         [0069]     Reference is made to our co-pending US applications claiming priority from United Kingdom Patent Application Nos. 0307929.0 and 0307930.8 of 5 Apr. 2003, the disclosures of which are incorporated herein by reference.  
         [0070]     While the preferred embodiments of the invention have been shown and described, it will be understood by those skilled in the art that changes or modifications may be made thereto without departing from the true spirit and scope of the invention.