Patent Publication Number: US-2006000053-A1

Title: Suction port assembly and a vacuum cleaner having the same

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      This application claims the benefit of Korean Patent Application No. 2004-50990, filed Jul. 1, 2004, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.  
     FIELD OF THE INVENTION  
      The present invention relates generally to a vacuum cleaner and more particularly, to a suction port assembly of a vacuum cleaner for drawing in dirt on a surface being cleaned.  
     BACKGROUND OF THE INVENTION  
      Vacuum cleaners draw in dirt on a surface being cleaned using a suction force generated by a vacuum source mounted in a main body thereof. As is known, vacuum cleaners comprise a cleaner body having therein a motor that generates a vacuum force, a suction port assembly facing a surface being cleaned to draw in dirt on the surface, and an extension path for guiding the dirt drawn in into the suction port to the cleaner body. The extension path often comprises an extension tube connector movably connected to the suction port assembly, an extension tube connected to the extension tube connector, and a suction hose between the cleaner body and the extension tube.  
       FIGS. 1A and 1B  are perspective views schematically showing bottom and top sides, respectively, of a suction port assembly. Referring to  FIGS. 1A and 1B , the suction port assembly comprises an upper housing  10  and a lower housing  11 . A suction port  14 , for drawing in dirt from a surface being cleaned, is formed in the lower housing  11 . The lower housing  11  also has a dust moving channel  12  formed at opposite sides thereof, through which dusts positioned adjacent to the opposite sides S are drawn into a vacuum source through the suction port  14 .  
      The suction port assembly shown in  FIGS. 1A and 1B  is provided with a single suction path for transmitting the vacuum force by which dust can be drawn in. As a result the vacuum is most intense at the center C of the suction port  14  but decreases away from the center C. Therefore, cleaning efficiency is good at the center C of the suction port  14  but degrades towards the sides S of the suction port assembly. Accordingly, the suction port assembly is not efficient in cleaning large surface areas. In addition, since the top of the suction port assembly is usually made from an opaque material, it is impossible to determine if dirt is caught in the suction port assembly. It is therefore necessary to check the entire suction path of a vacuum cleaner in order to find the position at which the suction path is obstructed. A suction port assembly that provides a more uniform vacuum and which allows for a see-through inspection of suction paths would be an improvement over the prior art.  
     SUMMARY OF THE INVENTION  
      An aspect of the present invention is to solve at least the above problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present invention is to provide an improved suction port assembly allowing efficient cleaning of a surface of large area and a vacuum cleaner having the same.  
      Another aspect of the present invention is to provide an improved suction port assembly allowing visual check of a path from the outside of the suction port assembly and a vacuum cleaner having the same.  
      In order to achieve the above-mentioned aspect, there is provided a suction port assembly comprising upper and lower housings; a plurality of suction ports formed in the lower housing; and a plurality of paths formed in the upper and lower housings to guide air drawn in into the suction ports. With this arrangement, even wide areas can be cleaned more effectively.  
      The upper housing defines first and second suction paths and a suction path cover defining a top of the first and second suction paths. The upper housing is connected to the lower housing with a top cover. A first joint part is formed along the edge of the path cover and a second joint part formed on the lower housing. The upper and lower housings are tightly engaged with each other to minimize suction force losses caused by air leaks between the housings.  
      A fluid guide rib is formed on the first and second paths so as to guide the drawn-in air toward a vacuum source while preventing the swirling phenomena of the drawn-in air, whereby the loss of suction force can be further prevented.  
      In one embodiment the top cover is formed with a cutout section in a shape corresponding to that of the suction path cover, and the suction path cover is exposed to the outside through the cutout section. The suction path cover is preferably made of a transparent plastic material, so that the first and second suction paths can be inspected for obstructions from the outside. Consequently, it is not needed to check the entire suction path of a vacuum cleaner when dirt might be caught in the suction port assembly. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The above and other objects, features and advantages of the present invention will be more apparent from the following detailed description taken with reference to the accompanying drawings, in which:  
       FIGS. 1A and 1B  are perspective views schematically showing the top and bottom sides of a conventional suction port assembly;  
       FIG. 2  is a perspective view schematically showing a vacuum cleaner according to an embodiment of the present invention;  
       FIG. 3  is an exploded perspective view of a suction port assembly according to an embodiment of the present invention;  
       FIG. 4  is a perspective view schematically showing the bottom side of a lower housing according to an embodiment of the present invention;  
       FIG. 5  is a perspective view schematically showing a top cover according to an embodiment of the present invention;  
       FIG. 6  is a cross-sectional view of a path cover taken along the line VI-VI of  FIG. 3 ;  
       FIG. 7  is a cross-sectional view of a main part taken along the line VII-VII of  FIG. 2 ;  
       FIG. 8  is a perspective view schematically showing the bottom side of a path according to an embodiment of the present invention;  
       FIG. 9  is a partially broken-away and perspective view schematically showing a swirling phenomena of an air stream drawn into the suction port assembly, from which a flow guide rib is omitted;  
       FIG. 10  is a partially broken-away and perspective view schematically showing air streams drawn into the suction port assembly provided with a flow guide rib according to an embodiment of the present invention; and  
       FIG. 11  is a cross-sectional view showing the connected relationship between a path cover, a top cover, and a lower housing according to another embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODMIMENTS  
      Hereinbelow, certain embodiments of the present invention will be described in detail with reference to the accompanying drawings.  
       FIG. 2  is a perspective view of a vacuum cleaner according to one embodiment of the present invention. The vacuum cleaner comprises a cleaner body  100  mounting therein a vacuum source, a suction port assembly  200  for drawing in dirt from a surface being cleaned using a vacuum force generated by the vacuum source, and an extension path  110  connected to the suction port assembly  200  and to the cleaner body  100 . Dirt is drawn in through the suction port assembly  200  to the cleaner body  100  through the extension path  110 .  
      The extension path  110  comprises an extension tube connector  116 , one end of which has a rotatable articulation joint or knuckle  118  that rotatably connects to the suction port assembly  200 . A first end of an extension tube  114  is connected to the second or opposite end of the extension tube connector  116 . One end of suction hose  112  is connected to the extension tube  114 , the other end of which is connected to the cleaner body  100 . With this arrangement, air-entraining dirt is drawn in through the suction port assembly  200  and moves to the cleaner body  100  via the extension tube connector  116 , the extension tube  114 , and the suction hose  112 .  
       FIG. 3  is an exploded perspective view schematically showing the suction port assembly  200  shown in  FIG. 2 . Referring to  FIG. 3 , the suction port assembly  200  comprises a molded upper housing  210  defining an upper part of the suction port assembly  200 . A molded lower housing  222  defines the lower part of the suction port assembly  200 .  
      The upper housing  210  has a suction path cover  250 , which when assembled, is seated on a first joint part  234  formed into the lower housing  222 . The upper housing also has a top cover  212  positioned over the suction path cover  250  and is connected to the lower housing  222 .  
      The suction path cover  250  has a generally arch-shaped cross-section, when viewed in the direction perpendicular to the flowing direction of the drawn-in air, and is made of a transparent plastic material so that the flow of drawn-in dirt can be viewed from the outside to check whether the dirt is caught. Polycarbonate or ABS (acrylonitrile-butadiene-styrene terpolymer) resin may be used.  
      The top cover  212  is connected to the lower housing  222  by means of a plurality of coupling holes  238  and a plurality of fasteners  236 . The fasteners  236  can be embodied as threaded screws or threaded bolts, both of which are know to those of ordinary skill in the art. The suction path cover  250  extends through the top cover  212  and through a cutout section  214  formed in the top cover  212 . In addition, the rear end of the lower housing  222  and the rear end of the top cover  212  are provided with lower and upper extension tube connector mounts  224  and  264  in such a manner that the rotatable articulation joint  118  of the extension tube connector  116  can be rotatably seated.  
      The lower housing  222  is formed with first and second suction ports  226  and  228  laterally spaced from each other. Each of the first and second suction ports  226  and  228  are located between the central part C and the opposite sides S of the lower housing  222 . The first and second suction ports  226  and  228  are preferably located substantially mid-way between the central part C and the opposite sides S. With such an arrangement of the suction ports  226  and  228 , the suction force generated from the vacuum source can be more evenly applied over the width of the suction post assembly  200 , so that wide surfaces can be more effectively cleaned.  
      The lower housing  222  includes first and second suction paths  230  and  232  fluidly communicating with the first and second suction ports  226  and  228 , respectively. The first and second suction paths  230  and  232  are air conduits and spaces, formed in such a manner that the lower housing  222  defines the bottom surface  231  of the suction paths and the path cover  250  defines the top of the suction paths  230  and  232  when the path cover  250  is connected to the first joint part  234  formed in the lower housing  222 . The flange  258  formed along the edge of the path cover  250  is described in detail hereinbelow.  
       FIG. 4  is a perspective view schematically showing the bottom side of the lower housing  222 . The bottom side of the lower housing  222  comprises a lateral dust moving channels  240  formed at the two opposite sides S of the lower housing  222  and connected to the aforementioned suction ports  226  and  228  so as to allow dusts located adjacent to the opposite sides S of the suction port assembly  200  to be drawn in and moved to the suction ports  226  and  228 . A front dust moving channel  244  is also formed in the lower housing  222  to allow dusts in front of the suction port assembly  200  to be drawn in and moved to the suction ports  226  and  228  through one or more central dust moving channels  242  formed between the first suction port  226  and the second suction port  228 .  
      The central dust moving channels  242  are recessed from the bottom surface of the lower housing  222  and located between the first and second suction ports  226  and  228 . As shown, the central dust moving channels  242  are separated from each other by a separation rib  246 . The separate central dust moving channels  242  on the left and right sides of the rib  246  are connected to the first suction port  226  and the second suction port  228 , respectively. With this arrangement, the dust drawn in from the central part C of the suction port assembly  200  is drawn into the suction ports  226  and  228  through the central dust moving channels  242 .  
       FIG. 5  is a perspective view schematically showing the bottom side of the top cover according to an embodiment of the present invention. Referring to  FIG. 5 , the top cover  212  has a cutout section  214  formed therethrough, through which the fluid cover  250  extends so that it is externally exposed. A compression rib  216  is formed around the cutout section  214  in such a manner that the compression rib  216  projects downwardly. The compression rib  216  is formed in a shape similar to that of the cutout section  214  and seated on the guide rib  254  (see  FIG. 6 ) formed on the top surface of the path cover  250 .  
       FIG. 6  is a cross-sectional view of the path cover taken along the line VI-VI of  FIG. 3 . Referring to  FIG. 6 , the cross-section of the path cover  250  is taken in the direction perpendicular to the drawn-in air flowing direction, in which the guide rib  254  is formed to upwardly project along the edge of the path cover  250 . The guide rib  254  is formed in a shape corresponding to the compression rib  216  (see  FIG. 5 ) and the compression rib  216  is seated on the guide rib  254  when coupling the top cover  212  and the lower housing  222 . A second joint part  262  is formed at the end of the bottom surface of the path cover  250 . In this embodiment, the second joint part  262  is formed in a stepped shape and engaged with the first joint part  234  in an airtight manner. The first joint part  234  will be described hereinbelow.  
       FIG. 7  is a cross-sectional view showing the main part taken along the line VII-VII of  FIG. 2 . Referring to  FIG. 7 , the first joint part  234  is formed in a stepped shape in the lower housing  222 , and the second joint part  262  is also formed in a stepped shape along the edge of the bottom surface of the path cover  250  to correspond to that of the first joint part  234 . As the first joint part  234  and the second joint part  262  are engaged with each other, the path cover  250  (see  FIG. 3 ) and the lower housing  222  can be connected with each other while keeping the airtight state between them. Accordingly, the airtight state of the path can be maintained and thus the loss of suction force can be prevented beforehand.  
      On the top surface of the path cover  250 , the guide rib  254  is formed along the edge of thereof and upwardly projects, and the compression rib  216  is formed on the bottom surface of the top cover  212  in a shape corresponding to that of the guide rib  254 . With this arrangement, the compression rib  216  formed on the bottom surface of the top cover  212  compresses the flange  258  formed on the path cover  250  (see  FIG. 3 ). Therefore, the first joint part  234  and the second joint part  262  are compressed against each other by the compression rib  216  and thus more securely engaged with each other. With this engagement, airtightness can be more securely maintained. Meanwhile, the compression rib  216  is seated on the guide rib  254  while compressing the flange  258 . Therefore, the top cover  213  can be prevented from moving on the path cover  250 .  
       FIG. 8  is a perspective showing the bottom side of the path cover  250  according to an embodiment of the present invention. Referring to  FIG. 8 , a flow guide rib  270  is formed at the central part of the front end of the inner wall of the path cover  250 . The guide rib  270  comprises a first flow guide rib part  274  extending from the central front end of the path cover  250  toward the first suction port  226  (see  FIG. 3 ) and a second flow guide rib part  278  extending toward the second suction port  228  (see  FIG. 3 ). The front sides of the flow guide rib parts  274  and  278  are provided with guide surfaces  280  with a predetermined curvature by which air drawn in along the guide surfaces  280  changes its direction so that the drawn-in air is rotated or conducted to the vacuum source. The guide surfaces  280  have an optimum curvature, by which the swirling flow generated at the junction of the first and second paths  230  and  232  is reduced as much as possible. The optimum curvature of the guide surfaces will depend on the air flow rate and other parameters and is best obtained through by experimentation. By experimentally optimizing the flow guide rib parts  274  and  278  suction force loss caused by air flow direction change can be minimized. In the embodiment shown, the flow guide rib  270  is formed on the path cover  250 . Since the flow guide rib  270  serves as means for changing the flow direction of drawn-in air, the flow guide rib  270  may be alternatively provided in the lower housing  222  (see  FIG. 3 ). Alternatively, both the lower housing  222  and the path cover  250  may be provided a flow guide rib  270 .  
       FIG. 9  is a partially broken-away and perspective view schematically showing the swirling phenomena of the air drawn in into the suction port assembly, from which a flow guide rib  270  is omitted.  FIG. 10  is a partially broken-away and perspective view of the suction port assembly schematically showing the drawn-in air streams within the suction port assembly provided with a flow guide rib  270 .  
      Referring to  FIG. 9 , the air drawn in into the first suction port  226  and the second suction port  228  moves along the first path  230  and the second path  232 . The air streams moving along the first path  230  and the second path  232  come into collision with each other at the junction of the first path  230  and the second path  232  because the flow directions thereof are not smoothly changed. Due to such collision, a swirling turbulent flow is generated at the junction. The swirling turbulent flow not only reduces the flow rate of the drawn-in air but also results in loss of suction force.  
      Referring to  FIG. 10 , in the suction port assembly  200  provided with a flow guide rib  270 , the air streams drawn in through the first suction port  226  and the second suction port  228  move along the first path  230  and the second path  232 , and their flow directions are smoothly changed at the junction of the first path  230  and the second path  232  by the flow guide rib  270 , respectively. Consequently, the swirling flow generated at the junction can be significantly reduced, thereby reducing suction loss.  
       FIG. 11  is a cross-sectional view showing the first and second joint parts according to another embodiment of the present invention. Referring to  FIG. 11 , the first and second joint parts  234  and  262  consist of a rib and a groove in order to further enhance the airtightness of the path. Beyond the above-mentioned embodiments, it is also possible to additionally provide a means for maintaining airtightness, such as rubber.  
      Hereinbelow, description is made as to a method of assembling a suction port assembly  200  according to an embodiment of the present invention with reference to  FIG. 3 .  
      First, the rotatable articulation joint  118  of the extension tube connector  116  is connected to the lower side extension tube connector mount  224  formed at the rear end of the lower housing  222 , and then the path cover  250  is seated on the lower housing  222 . The seating is performed by coupling the first joint part  234  formed in the lower housing  222  and the second joint part  262  (see  FIG. 7 ) formed on the path cover  250 .  
      Next, the top cover  212  is put over the lower housing  222  and the path cover  250 . At this time, the articulation  118  of the extension tube connector  116  is connected to the upper side extension tube connector mount  264  formed on the top cover  212 , so that the extension tube connector  116  is pivotally connected to the upper housing  210 .  
      Then, the a plurality of coupling elements such as screws are fitted into the a plurality of coupling holes  238  formed in the top cover  212  and the lower housing  222 . At this time, the compression rib  216  (see  FIG. 5 ) formed on the bottom surface of the cutout section  214  of the top cover is engaged with the guide rib  254  (see  FIG. 6 ) formed at the end of the flange  258  simultaneously compressing the flange  258  formed in the path cover  250 . Therefore, the path cover  250  is safely connected while maintaining the airtightness.  
      In such an embodiment, the path cover  250  is installed in the suction port assembly  200  and positioned between the top cover  212  and the lower housing  222 . However, it is also possible to form the path cover  250  integral to the top cover  212 .  
      Because two suction paths are formed in the suction port assembly  200 , the efficiency for cleaning the lateral sides of a suction port assembly  200  can be enhanced. Wide surfaces can therefore be efficiently cleaned.  
      In addition, by forming a path cover  200  with a transparent material, dirt drawn into and flowed through the suction port assembly  200  can be visually checked from the outside of the suction port assembly. Therefore, it is not needed to check the entire suction path of a vacuum cleaner to solve a problem caused by dirt caught in the suction port assembly.  
      According to the present invention, a flow guide rib  270  formed in a suction path can reduce the swirling phenomena of drawn-in air, thereby reducing the loss of suction force.  
      As a first joint part  234  formed on the path cover and a second joint part  262  formed on the lower housing are engaged with each other, the path cover is seated on the lower housing and a top cover compresses the first and second joint parts. As a result, assemblability can be enhanced and airtightness can be securely maintained. Due to such airtightness, the loss of suction force can be prevented.  
      While certain embodiments of the present invention have been shown and described with reference to the representative embodiments thereof in order to exemplify the principle of the present invention, the present invention is not limited to the embodiments. It will be understood that various modifications and changes can be made by those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims. Therefore, it shall be considered that such modifications, changes and equivalents thereof are all included within the scope of the present invention.