Patent Publication Number: US-7219389-B2

Title: Nozzle assembly housing for vacuum cleaner

Description:
This application claims the benefit of U.S. Patent Application Ser. No. 60/490,634 filed on Jul. 28, 2003. 

   TECHNICAL FIELD 
   The present invention relates generally to the floor care equipment field and, more particularly, to a nozzle assembly housing for a vacuum cleaner or the like incorporating a hinged removable panel and to a related method of securing a removable panel to a housing of a vacuum cleaner. 
   BACKGROUND OF THE INVENTION 
   Upright, canister and hand-held vacuum cleaners have long been known in the art. Many such vacuum cleaners incorporate one or more rotary agitators. These rotary agitators are equipped with cleaning structures including but not limited to beater bars, wipers, brushes and bristle tufts. As the agitators are rotated relative to the floor being cleaned, these cleaning structures function to beat dirt and debris from the nap of an underlying carpet. 
   Whether driven by the motor of the suction fan generator or an independent agitator drive motor, the linkage between the motor and the agitators in many vacuum cleaners is made by means of a belt. While advances in belt technology have made significant gains in service life, belts still become worn over time and require replacement. Further, in the event of an agitator jam, a vacuum cleaner is typically designed to sacrifice a relatively inexpensive belt in order to save the agitator drive motor. Thus, most vacuum cleaner operators will be faced with a belt change at least once during the operating life of a vacuum cleaner. 
   In many vacuum cleaners, it is difficult and time consuming to service the agitator drive belt. Often, one must remove the top or bottom of the agitator housing in order to access the belt. This can be difficult, time consuming and also very inconvenient. Further, many individuals are not mechanically inclined and the prospect of such a task leads them to take their vacuum cleaner to professional vacuum cleaner service personnel. This is often a time consuming and frustrating situation that creates an unfavorable impression upon the consumer. 
   In an effort to address this problem, efforts have been made in the past to simplify agitator drive belt service. For example, U.S. Pat. No. 3,916,476 to Johnson et al. discloses a vacuum cleaner incorporating an access door that is pivotally attached to the main housing by means of a hinge. When opened, the door allows access to the agitator drive belt for servicing thereof. 
   While very useful and effective for its intended purpose, some individuals find the open access door to be an annoyance or hindrance to belt changing. The present invention addresses this problem by providing a pivoting access door or panel that is separate and free from the main housing of the nozzle assembly. Thus, after pivotally opening the access door, it may be set to the side thereby eliminating any potential for the access panel to get in the way of the belt changing process. 
   SUMMARY OF THE INVENTION 
   In accordance with the purposes of the present invention as described herein, a nozzle assembly housing is provided. That nozzle assembly housing includes a first wall, a second wall and an access opening in the first and second walls. A locking tab receiver is provided on the first wall adjacent the access opening. A notch is provided on the second wall adjacent the access opening. Additionally, a removable panel is provided for closing the access opening. The panel includes a locking tab on a first edge mating with the locking tab receiver and a hinge lug on a second edge received in the notch so as to allow pivotal movement of the panel relative to the second wall of the housing. 
   More specifically describing the invention, a first shoulder is provided on the second wall adjacent a first end of the notch. Additionally, a second shoulder is provided on the second wall adjacent a second end of the notch. Together, the shoulders engage a rear face of the removable panel. Still further, a third and fourth shoulder may be provided on the first and second walls for engaging a rear face of the removable panel. These shoulders function to hold the panel flush with the first and second walls when the panel is properly seated to close the opening. 
   The removable panel includes a first guide and a second guide. Both the first and second guides may be substantially L-shaped. When the removable panel is seated to close the access opening, the first guide engages the second wall and the third shoulder. The second guide engages the second wall and the fourth shoulder. Each of the first and second guides also includes a projecting tip engaging the second wall. The projecting tips are rounded. 
   Still further, the removable panel also carries a belt guard. In addition, the removable panel includes a finger grip adjacent the locking tab. This finger grip allows the operator to conveniently engage and disengage the locking tab from the locking tab receiver. 
   In accordance with still another aspect of the present invention, a vacuum cleaner is provided incorporating the nozzle assembly housing of the present invention. Further, a method is provided of securing a removable panel to a housing of a vacuum cleaner. The method includes inserting a hinge lug on a first portion of the removable panel into a cooperating notch on the housing, pivoting the panel in an arc about the hinge lug until a locking tab on a second portion of the panel is adjacent a locking tab receiver on the housing and engaging the locking tab with the locking tab receiver. The engaging step includes depressing the panel adjacent the second portion and pivoting the panel in an arc after depressing. 
   A method of removing a separate, removable panel from the walls of a vacuum cleaner housing is also disclosed. That method includes the steps of (a) depressing a portion of the panel to release a locking tab on the panel from a locking tab receiver on one of the walls; (b) pivoting the panel on a hinge formed between the panel and another of the walls; and (c) removing the panel from the walls. The present invention provides the operator of the vacuum cleaner with the convenience and operating simplicity of a hinged panel for providing access to an agitator drive belt in the housing of the nozzle assembly. Advantageously, this is done while also avoiding any potential inconvenience that might be related to such a panel attached to the nozzle assembly. Specifically, the separate, fully removable hinged panel of the present invention may be positioned at a location remote from the nozzle assembly where it cannot possibly interfere with the belt changing operation. 
   In the following description there is shown and described a preferred embodiment of this invention, simply by way of illustration of one of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive. 

   
     BRIEF DESCRIPTION OF THE DRAWING 
     The accompanying drawing incorporated in and forming a part of the specification, illustrates several aspects of the present invention, and together with the description serves to explain certain principles of the invention. In the drawing: 
       FIG. 1  is a perspective view of a vacuum cleaner incorporating the nozzle assembly housing of the present invention; 
       FIG. 2  is a detailed fragmentary and perspective view showing the separate, removable panel hinged into a slightly open position to allow access to the agitator drive belt on the underlying pulley held in the nozzle assembly housing; 
       FIG. 3  is a detailed, fragmentary perspective view showing the shoulders on the walls of the housing around the access opening; 
       FIG. 4  is a detailed inside perspective view of the separate, removable panel; 
       FIG. 5  is a top plan view of the housing of the nozzle assembly with the panel covering the access opening and engaging the main body of the housing; 
       FIG. 6  is a cross-sectional view through line  6 — 6  of  FIG. 5 ; and 
       FIG. 7  is an inside elevational and fragmentary view showing how the locking tab, hinge lug and guides on the removable panel engage the nozzle assembly housing. 
   

   Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawing. 
   DETAILED DESCRIPTION OF THE INVENTION 
   Reference is now made to  FIG. 1  illustrating an upright vacuum cleaner  10  incorporating the nozzle assembly housing  12  of the present invention. 
   As illustrated, the vacuum cleaner  10  incorporates a canister assembly housing  14  that is pivotally connected to the nozzle assembly housing  12 . The canister assembly housing  14  carries a control handle  13 , a hand grip  15  and an on/off actuator switch  17 . The canister assembly housing  14  also includes a cavity for holding a dirt cup  16  for collecting dirt and debris. The dirt cup  16  may or may not include structures to produce cyclonic airflow in order to assist in separation of dirt from the airstream as it passes through the vacuum cleaner  10 . In the alternative, the cavity may simply house a state-of-the-art bag filter behind an access door or cover instead of a dirt cup. 
   The vacuum cleaner  10  also includes a suction generator (not shown) that is mounted in an internal chamber in the canister assembly housing  14 . Of course, in an alternative embodiment, that suction generator could be housed in the nozzle assembly housing  12  if desired. In the illustrated embodiment, a drive belt  20  connects the drive shaft (not shown) of the suction generator motor with a step down pulley  22  that is connected by a second belt to one or more rotary agitators provided on the nozzle assembly housing. 
   As best illustrated in  FIGS. 2 ,  5  and  6 , the nozzle assembly housing  12  includes a first wall  28  and a second wall  30 . An access opening  32  is provided in the first and second walls  28 ,  30 . Additionally, a locking tab receiver  34  is provided on the inner surface  36  of the first wall adjacent the access opening  32 . Similarly, a notch or slot  38  is provided on the second wall  30  adjacent the access opening  32 . 
   As best illustrated in  FIGS. 2–7 , a separate, removable panel  40  closes the access opening  32  in the nozzle assembly housing  12 . The panel  40  includes a projecting locking tab  42  on the first edge  44  of a first portion and a projecting hinge lug  46  on a second edge  48  of a second portion. When the panel  40  is properly seated on the first and second walls  28 ,  30  of the nozzle assembly housing  12 , the locking tab  42  engages the locking tab receiver  34  and the hinge lug  46  engages the notch  38 . 
   As best illustrated in  FIGS. 2 and 3 , the first and second walls  28 ,  30  of the nozzle assembly housing  12  include a series of shoulders that engage and back the panel  40  so that the panel is held flush in those walls. More specifically, a first shoulder  50  is provided on the second wall  30  adjacent a first end of the notch  38 . A second shoulder  52  is provided on the second wall  30  adjacent a second end of the notch  38 . Third and fourth shoulders  54 ,  56  are provided on the first and second walls  28 ,  30 . 
   As best illustrated in  FIG. 4 , the panel  40  includes a first guide  58  and a second guide  60 . Each of the guides  58 ,  60  is substantially L-shaped. As the panel  40  is properly seated in the first and second walls  28 ,  30  to close the access opening  32 , the first guide  58  is adjacent to and engages the second wall  30  and the third shoulder  54 . Simultaneously, the second guide  60  is adjacent to and engages the second wall  30  and the fourth shoulder  56 . 
   As illustrated, each of the first and second guides  58 ,  60  includes a projecting tip  62  that is rounded. The separate, removable panel  40  also carries a belt guard, generally designated by reference numeral  64 . As illustrated, the belt guard  64  comprises a substantially U-shaped metal rod having a first end that is received in an aperture  66  in the end of the reinforcing rib  68  and a second end abutting a ledge or channel  70  provided on a second reinforcing rib  72 . The belt guard  64  ensures that a damaged drive belt  20  does not contact and accidentally damage the panel  40  which is typically constructed from relatively lightweight plastic material. 
   As best illustrated in  FIGS. 2 and 5 , the panel  40  also includes a finger grip  74  adjacent the locking tab  42 . As illustrated, the finger grip  74  comprises a raised ridge  76  defining a substantially D-shaped recess or cavity  78 . This finger grip  74  is useful when securing and removing the panel  40  as described in greater detail below. 
   During the life of the vacuum cleaner  10 , it may become necessary to service the drive belt  20  that transmits rotary motion to the agitator or agitators of the vacuum cleaner  10 . This may be done by removing the panel  40 . Toward this end, one engages a thumb or finger in the D-shaped cavity  78  of the finger grip  74  and depresses the panel  40 . This action functions to release the locking tab  42  from the locking tab receiver or lip  34 . The operator continues to depress the panel  40  as the panel is pivoted in an arc about the longitudinal axis of the hinge lug  46  that at this time is received in the notch  38  in the second wall  30  (see action arrow A in  FIG. 2 ). The guides  58  and  60  and the rounded tips  62  thereof help to ensure smooth pivoting motion of the panel  40  relative to the wall  30 . 
   Once the locking tab  42  clears the first wall  28 , it is no longer necessary to depress the panel  40 . Consequently, the panel  40  may then simply be lifted so as to withdraw the hinge lug  46  from the notch  38 . The panel  40  is then completely free of the walls  28 ,  30  of the housing  12  and it may then be positioned at any remote location so as to not possibly interfere in any way with the servicing of the drive belt  20 . 
   After servicing the drive belt  20 , the panel  40  may again be seated on the walls  28 ,  30  in order to close the access opening  32  in the housing  12 . This is done by first inserting the hinge lug  46  in the notch  38 . Next, the panel  40  is pivoted in an arc about the hinge lug  46  as the operator depresses a portion of the panel  40  by engaging the D-shaped cavity  78  of the finger grip  74 . This combined action allows the locking tab  42  to clear the edge of the first wall  28  and engage the locking tab receiver  34 . The pivoting movement of the panel  40  is halted when the locking tab  42  is fully engaged with the locking tab receiver or lip  34  and the first edge  44  of the panel is received against the first wall  28 . At this point the operator releases the pressure provided at the finger grip  74  and the panel  40  is fully and properly seated on the walls  28 ,  30  to close the access opening  32 . Advantageously, the locking tab  42  and the projecting hinge lug  46  function with the projecting tips  62  of the guides  58  and  60  to secure the panel  40  in the seated position. Simultaneously, the shoulders  50 ,  52 ,  54  and  56  function together to form a recessed shelf for receiving the panel  40  and holding the panel flush with the walls  28 ,  30  so as to provide an aesthetically pleasing appearance. 
   The foregoing description of the preferred embodiment of this invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. For example, the nozzle assembly housing  12  of the present invention is illustrated as being part of an upright vacuum cleaner  10 . It should be appreciated, however, that the nozzle assembly housing  12  could just as easily be part of a power nozzle of a canister vacuum cleaner and/or the rotary agitator equipped nozzle portion of a hand-held vacuum cleaner. Further, while the locking tab  42  is provided on the panel  40  and the locking tab receiver  34  is provided on the first wall  28  in the illustrated embodiment, the positions of the tab and receiver could just as easily be reversed. The present invention and claims are considered to be sufficiently broad to cover such an alternative arrangement. In addition, while the access opening and panel are described with regard to the servicing of an agitator drive belt, the housing structure could just as easily be associated with the servicing of a different belt or other structural feature of a vacuum cleaner that might require periodic servicing. 
   The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiment do not and are not intended to limit the ordinary meaning of the claims and their fair and broad interpretation in any way.