Abstract:
A vacuum cleaner including a dirt cup assembly including a first stage cyclonic separator operable to at least partially separate debris from an airflow, a second stage cyclonic separator downstream from the first stage cyclonic separator and operable to at least partially separate the debris from the airflow, a container having a sidewall that at least partially defines the first stage cyclonic separator, and a shroud having a lower perforated portion located within the container, and an upper portion that surrounds and receives the second stage cyclonic separator. The upper portion is located outside of the first container such that the upper portion forms an outside wall of the dirt cup above the sidewall of the container. The shroud further includes an intermediate portion between the lower portion and the upper portion, and the intermediate portion is coupled to the sidewall of the first container.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application No. 61/444,312, filed Feb. 18, 2011, the entire contents of which are hereby incorporated by reference herein. 
    
    
     BACKGROUND 
     The present invention relates to vacuum cleaners, and more particularly to dirt cups for use in vacuum cleaners. 
     A dirt cup is used to collect the dirt, dust, and other debris drawn in or vacuumed by a vacuum cleaner. When the dirt cup fills up with dirt, the user detaches the dirt cup from the vacuum cleaner and empties the collected dirt from the dirt cup. The dirt cup is then reattached to the vacuum cleaner. A vacuum cleaner that uses a dirt cup to collect dirt instead of a replaceable vacuum bag eliminates the need to purchase and replace vacuum bags as each bag fills up with dirt. 
     SUMMARY 
     In one embodiment, the invention provides a vacuum cleaner including a suction source operable to generate an airflow, a suction nozzle in fluid communication with the suction source and configured to remove debris from a surface using the airflow, and a dirt cup assembly including a first stage cyclonic separator operable to at least partially separate the debris from the airflow, a second stage cyclonic separator downstream from the first stage cyclonic separator and operable to at least partially separate the debris from the airflow, a container having a sidewall that at least partially defines the first stage cyclonic separator, and a shroud having a lower perforated portion located within the container, and an upper portion that surrounds and receives the second stage cyclonic separator. The upper portion is located outside of the first container such that the upper portion forms an outside wall of the dirt cup above the sidewall of the container. The shroud further includes an intermediate portion between the lower portion and the upper portion, and the intermediate portion is coupled to the sidewall of the first container. 
     In another embodiment, the invention provides a vacuum cleaner including a suction source operable to generate an airflow, a suction nozzle in fluid communication with the suction source and configured to remove debris from a surface using the airflow, and a dirt cup assembly including a first stage cyclonic separator operable to at least partially separate the debris from the airflow, a second stage cyclonic separator downstream from the first stage cyclonic separator and operable to at least partially separate the debris from the airflow, and a container having an upper end, a lower end, and a sidewall that extends between the upper end and the lower end to at least partially define the first stage cyclonic separator. The dirt cup assembly further includes a shroud having a lower perforated portion located within the container and an upper portion that surrounds and receives the second stage cyclonic separator. The upper portion is located outside of the first container. The shroud further includes an intermediate portion between the lower portion and the upper portion. The dirt cup assembly further includes a top lid attached to the upper portion of the shroud such that the top lid is spaced from the upper end of the container. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a vacuum cleaner according to an embodiment of the invention. 
         FIG. 2  is an exploded view of a dirt cup for use with the vacuum cleaner of  FIG. 1 . 
         FIG. 3  is a cross-sectional view of the dirt cup of  FIG. 2 . 
         FIG. 4  is another cross-sectional view of the dirt cup of  FIG. 2 . 
         FIG. 5  is a perspective view of a portion of a container of the dirt cup of  FIG. 2 . 
         FIG. 6  is a perspective view of a portion of a shroud of the dirt cup of  FIG. 2 . 
         FIG. 7  is a perspective view of a central support, a skirt, and the shroud of the dirt cup of  FIG. 2 . 
         FIG. 8  is a perspective view of the skirt of the dirt cup of  FIG. 2 . 
         FIG. 9  is a perspective view of the central support and the shroud of the dirt cup of  FIG. 2 . 
     
    
    
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a vacuum cleaner  100  that includes a dirt cup assembly  105  detachably secured to a body  110 . The vacuum cleaner further includes a foot  115  including a suction nozzle  120 , a handle  125 , and a suction source  130 . The foot  115  is pivotally connected to the body  110 . The suction source  130  can be a motor and fan assembly or other suitable structure for creating a vacuum. The vacuum cleaner  100  as described above is an upright vacuum cleaner. Alternatively, the vacuum cleaner  100  can be of other types, including a canister vacuum cleaner, a central vacuum cleaner, a back-pack style canister vacuum cleaner, and the like. 
     As shown in  FIGS. 2-3 , the dirt cup assembly  105  includes a container  135 , a shroud  140 , a skirt  145 , a central support  150 , a cyclone assembly  155 , a top cover or lid  160 , and a bottom cover or lid  165 . The container  135  is a hollow cylinder and includes a sidewall  170 , a central passageway  175 , a top end  180 , a bottom end  185 , and a tangential air inlet  190 . The sidewall  170  partially defines the central passageway  175 , which extends from the top end  180  to the bottom end  185 . Three locking cutouts  195 ,  200 , and  205  are formed in sidewall  170  at the top end  180 . Each cutout  195 ,  200 , and  205  includes an opening  210  ( FIG. 5 ) that extends longitudinally into the sidewall  170  and a slot  215  that extends into the sidewall  170  and along the curve of the sidewall  170 . Each slot  215  defines a locking ledge  217  positioned adjacent to the opening  210 . Each slot  215  communicates with the associated opening  210  and both the slot  215  and the opening  210  communicate with the central passageway  175 . A locking detent  220  is positioned within the slot  215 . The first cutout  195  is located on the front of the container  135  and the opening  210  of the first cutout  195  is smaller than the openings  210  of the second cutout  200  and the third cutout  205 . In one embodiment, the container  135  is made of substantially transparent plastic. Alternatively, the container  135  can be shapes other than a cylinder. Alternatively, more or fewer cutouts  195 ,  200 , and  205  can be formed in the container  135 . 
     Referring to  FIGS. 3 ,  7 , and  9 , the shroud  140  is a conduit that includes an upper portion  225 , an intermediate portion  230 , and a lower portion  235 . A central passageway  240  passes through the shroud  140 . The upper portion  225  includes a sidewall  245 , a mounting flange  250 , a mounting ring  255 , and an upper opening  260 . The mounting flange  250  extends radially outward from the sidewall  245  and the mounting ring  255  extends upwardly from the mounting flange  250 . The upper opening  260  and central passageway  240  are sized and shaped so that the central support  150  and the cyclone assembly  155  can be inserted through the upper opening  260  into the central passageway  240 , leaving a gap  265  between the sidewall  245  and the cyclone assembly  155 . 
     As shown in  FIG. 6 , the intermediate portion  230  of the shroud  140  is positioned between the upper portion  225  and the lower portion  235 . The intermediate portion  230  includes a sidewall  270 , an upper flange  275 , an intermediate flange  280 , and a lower flange  290 . Each of the flanges  275 ,  280 , and  290  extends radially outward from the sidewall  270 . The intermediate flange  280  is positioned between the upper flange  275  and the lower flange  290 . The intermediate flange  280  includes three locking tabs  295 ,  300 , and  305 . The first locking tab  295  is located on the front of the shroud  140  and is smaller than the second locking tab  300  and the third locking tab  305 . A seal or gasket  310  is positioned in the space between the intermediate flange  280  and the lower flange  290 . Alternatively, more or fewer locking tabs  295 ,  300 , and  305  can be included on the intermediate flange  280 . 
     As shown in  FIGS. 2 ,  3 , and  9  the lower portion  235  of the shroud  140  extends downwardly from the intermediate portion  230 . The lower portion  235  includes a sidewall  315 , a lower wall  320 , and a lower opening  325 . The sidewall  315  is substantially frusto-conical in shape and includes multiple holes, openings, or perforations  330  therethrough. The lower opening  325  is sized and shaped to receive the central support  150 . At least one positioning cutout  335  is formed in the lower wall  320 . Multiple circular positioning protrusions  340  extend from the bottom surface of the lower wall  320 . The lower opening  325  and the central passageway  240  are sized and shaped so that the central support  150  can be inserted through the lower opening  325  into the central passageway  240 , leaving a gap  345  between the sidewall  315  and the central support  150 . In one embodiment, the shroud  140  is made of substantially transparent plastic. 
     As shown in  FIG. 8 , the skirt  145  is ring-shaped and includes a central wall  350 , a side wall  355 , and a central passageway  360 . Four locking cutouts  365  are formed in the central wall  350 . Each cutout  365  includes an opening  370  that extends longitudinally into the central wall  350  and a slot  375  that extends into the central wall  350  and along the curve of the central wall  350 . Each slot  375  defines a locking ledge  377  positioned adjacent to the opening  370 . Each slot  375  communicates with the associated opening  370  and both the slot  375  and the opening  370  communicate with the central passageway  360 . Four positioning springs  380  are formed in the central wall  350 . The side wall  355  extends radially outward from the central wall  350  and is angled downwards from the top surface of the central wall  350  in the illustrated embodiment. A pair of gripping tabs  385  is provided on the bottom of the skirt  145  to allow a user to grip and twist the skirt  145 . In one embodiment, the skirt  145  is made of substantially transparent plastic. Alternatively, more or fewer cutouts  365  can be formed in the skirt  145 . 
     As shown in  FIGS. 2 ,  3 ,  7 , and  9 , the central support  150  is a hollow tube that includes a sidewall  390 , a central passageway  395 , a flange  400 , four locking tabs  405 , and at least one positioning protrusion  410 . The side wall  390  defines the central passageway  395 , which extends the length of the central support  150 . The flange  400  extends radially outward from the sidewall  390 . The four locking tabs  405  extend outwardly from the sidewall  390  and are positioned below the flange  400 . The positioning protrusion  410  also extends from the sidewall  390  and is positioned below the flange  400 . In one embodiment, the central support  150  is made of substantially transparent plastic. Alternatively, more or fewer locking tabs  405  can be formed on the central support  150 . 
     As shown in  FIGS. 2 and 3 , the cyclone assembly  155  includes a plurality of secondary cyclones  415  and is secured to the bottom of the top lid  160  and to the top of central support  150  to form a single component such that the cyclone assembly  155  is removable from the container  135  with the lid  160 . Screws or other appropriate fasteners are used to secure the cyclone assembly  155  to the top lid  160  and the central support  150 . Alternatively, the cyclone assembly  155  is not included and the vacuum cleaner  100  is a single stage cyclonic vacuum cleaner. Alternatively, the cyclone assembly includes a single cyclone  415 . 
     As shown in  FIGS. 2 and 3 , the top lid  160  includes a body  420 , a handle  425 , and a bottom wall  430 . A mounting slot  435  is formed in the bottom wall  430 . The mounting slot  435  is ring-shaped. An air passage  440  extends from the bottom wall  430  to an air outlet  445 . A filter  450  is positioned within the air passage  440 . The filter  450  can be a foam filter, an electrostatic filter, a HEPA filter, or other appropriate type of filter. 
     As shown in  FIG. 3 , the bottom lid  165  is pivotally coupled to the container  135  by a hinge  455  located at or near the bottom end  185  of the container  135 . The bottom lid  165  pivots about the hinge  455  between a closed position where the bottom lid  165  closes the bottom end  185  and a number of open positions. A lock or latch  460  secures the bottom lid  465  in the closed position. 
     To assemble the dirt cup assembly  105 , the central support  150  and the cyclone assembly  155  are first inserted into the shroud  140  through the upper opening  260  and into the central passageway  240 . The positioning cutout  335  in the lower wall  320  of the shroud  140  receives positioning protrusion  410  of the central support  150  to correctly orient the shroud  140  relative to the central support  150 . The central support  150  passes through lower opening  325  of the shroud  140  so that the lower wall  320  of the shroud  140  contacts the flange  400  of the central support  150 . The shroud  140  is attached to the top lid  160  so that the mounting slot  435  of the top lid  160  receives the mounting ring  255  of the shroud  140  and bottom wall  430  of the top lid  160  rests on the mounting flange  250  of the shroud  140 . Aligning or guiding features on the top lid  160  and on the upper portion  225  of the shroud  140  can be included to help guide the mounting ring  255  into the mounting slot  435 . 
     The shroud  140  is secured to the combination of the top lid  160 , the central support  150 , and the cyclone assembly  155  by the skirt  145 . The central support  150  is inserted through the central opening  360  of the skirt  145 . The opening  370  of each locking cutout  365  of the skirt  145  receives a corresponding locking tab  405  of the central support  150 . The user then rotates or twists the skirt  145  in a first direction so that each of the locking tabs  405  is moved into the slot  375  of the locking cutout  365  in a twist-locking arrangement where the ledge  377  of each locking cutout  365  is positioned above the corresponding locking tab  405 . The twist-lock between the skirt  145  and the central support  150  secures the shroud  140  between the skirt  145  and the top lid  160 . Also, the positioning springs  380  of the skirt  145  is depressed by a corresponding positioning protrusion  340  of the shroud  140 . The gripping tabs  385  provide locations for the user to grip while twisting the skirt  145  into the locked position. The shroud  140  can be unsecured from the combination of the top lid  160 , the central support  150 , and the cyclone assembly  155  by twisting the skirt  145  opposite the first direction so that the locking tabs  405  of the central support  150  pass through the openings  370  of the skirt  145 . 
     The combination of the shroud  140 , the central support  150 , the cyclone assembly  155 , and the top lid  160  is secured to the container  135  by a twist-lock between the shroud  140  and the container  135 . The locking tabs  295 ,  300 , and  305  of the shroud  140  are each inserted through the corresponding opening  210  of the locking cutouts  195 ,  200 , and  205  of the container  135 . The first locking tab  295  and the opening  210  of the first locking cutout  195  are sized differently than the other locking tabs  300  and  305  and the other openings  210  of the locking cutouts  200  and  205  to ensure that the shroud  140  is oriented properly with respect to the container  135 . The user then rotates or twists either the shroud  140  or the container  135  in a first direction so that each of the locking tabs  295 ,  300 , and  305  is moved into the slot  215  of the corresponding locking cutout  195 ,  200 , and  205  in a twist-locking arrangement where the ledge  217  of each locking cutout  195 ,  200 , and  205  is positioned above the corresponding locking tab  295 ,  300 , and  305 . Each locking tab  295 ,  300 , and  305  is positioned in the detent  220  of the corresponding slot  215  in the locked position. The twist-lock between the shroud  140  and the container  135  secures the combination of the shroud  140 , the central support  150 , the cyclone assembly  155 , and the top lid  160  to the container  135 . In the locked position, the upper flange  275  of the shroud  140  is positioned on the top end  180  of the container  135 . The gasket  310  provides a substantially air-tight seal between the shroud  140  and the container  135 . The shroud  140  can be unsecured from the container  135  by twisting either the shroud  140  or the container  135  opposite the first direction so that the locking tabs  295 ,  300 , and  305  of the shroud  140  pass through the openings  210  of the container  135 . 
     As shown in  FIG. 3 , when assembled, the outermost wall or exterior surface of the dirt cup assembly  105  is formed in part by the shroud  140  and in part by the container  135 . Therefore, only a single wall, the wall of the shroud  140 , is between the exterior surface and the secondary cyclones  415  in a radial direction of the container  135 . This single wall design saves material over double wall designs where the shroud is positioned entirely within the container. The transparent container  135 , shroud  140 , skirt  145  and central support  150  allow the user to see clogs or obstructions that may form within the dirt cup assembly  105 . This allows the user to better service or troubleshoot problems related to clogs or obstructions. 
     During use of the vacuum cleaner  100 , the suction source  130  generate an airflow that draws dirty air through the suction nozzle  120  to the tangential air inlet  190  in the container  135 . The dirty air enters the dirt cup assembly  105  through the tangential air inlet  190  and is swirled in a cyclonic manner between the interior surface of the container  135  and the combination of the shroud  140 , the skirt  145 , and the central support  150 , which defines a first cyclonic separator. This cyclonic action separates relatively large dirt particles from the dirty air. The partially cleaned air flows through the perforations  330  in the shroud  140 , which can further filter the air, through the gaps  345  and  265  to the cyclone assembly  155 . The partially cleaned air is swirled in a cyclonic manner within the cyclones  415 , which form a second cyclonic stage downstream from the first cyclonic stage. This cyclonic action separates relatively small dirt particles from the partially cleaned air. The cleaned air passes from the cyclones  415  to the air passage  440  in the top lid  160 . The cleaned air passes through the filter  450  and exits the top lid  160  through the air outlet  445 , then to the suction source  130  where the air is exhausted from the vacuum cleaner  100 . 
     To empty the dirt cup assembly  105 , the dirt cup assembly  105  is released from the body  110 . The dirt cup assembly  105  is then positioned above a trash can or other waste container and the bottom lid  165  is opened to empty the dirt collected in container  135  into the trash can. After the dirt cup assembly  105  is emptied, the bottom lid  165  is returned to the closed position and the dirt cup assembly  105  is secured to the body  110 . 
     Various features of the invention are set forth in the following claims.