Patent Publication Number: US-8978199-B2

Title: Vacuum cleaner with debris collector

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/759,697, filed Feb. 1, 2013, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     Upright vacuum cleaners employ collection systems for separating and collecting contaminants from a working airstream for later disposal. Some collection systems can include a cyclone separator for separating contaminants from a working airstream and a removable dirt cup for receiving and collecting the separated contaminants from the cyclone separator. The cyclone separator can have a single cyclonic separation stage, or multiple stages. In another arrangement, the collection system can include an integrally-formed cyclone separator and dirt cup, with the dirt cup being provided with a bottom-opening dirt door for contaminant disposal. Other types of collection systems such as centrifugal separators or bulk separators use high-speed rotational motion of the air/debris to separate the dirt by centrifugal force. 
     Typically, working air enters and exits at an upper portion of the collection system, as the lower portion of the collection system is used to collect debris. Before exiting the collection system or passing to a downstream separation stage, the working air may flow through an exhaust grill. The exhaust grill can have openings through which air may pass. The openings may be defined by perforations or holes, or may be defined between spaced vanes or louvers. During operation, the openings of the exhaust grill may become blocked or clogged with debris, requiring periodic cleaning of the exhaust grill. 
     BRIEF SUMMARY 
     According to one embodiment of the invention, a vacuum cleaner includes a housing comprising a suction nozzle, a suction source fluidly connected to the suction nozzle creating a working airstream through the housing, a separation module separating contaminants from the working airstream, and an exhaust grill assembly. The separation module includes at least one separation chamber having an air inlet in fluid communication with the suction nozzle, an air outlet, and at least one collection chamber which receives contaminants separated by the at least one separation chamber. The exhaust grill assembly has an exhaust grill having openings through which the working airstream may pass and mounted within the at least one separation chamber fluidly upstream from the air outlet such that the working airstream passes through the openings of the exhaust grill before reaching the air outlet, and a plurality of debris catching tines extending below the exhaust grill within the at least one collection chamber which prevent elongated debris from wrapping around and blocking the openings of the exhaust grill. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a perspective view of a vacuum cleaner having a separation module according to the invention. 
         FIG. 2  is a front sectional view through a separation module according to a first embodiment of the invention. 
         FIG. 3  is a perspective sectional view through a separation module according to a first embodiment of the invention. 
         FIG. 4  is a view similar to  FIG. 3 , illustrating the collection of debris in the separation module during operation. 
         FIG. 5  is a sectional view through a separation module according to a second embodiment of the invention. 
         FIG. 6  is a perspective sectional view through a separation module according to a third embodiment of the invention. 
         FIG. 7  is a view similar to  FIG. 6 , illustrating the collection of debris in the separation module during operation. 
         FIG. 8  is a perspective sectional view through a separation module according to a fourth embodiment of the invention. 
         FIG. 9  is a view similar to  FIG. 8 , illustrating the collection of debris in the separation module during operation. 
         FIG. 10  is a sectional view through a separation module according to a fifth embodiment of the invention. 
         FIG. 11  is a view similar to  FIG. 10 , illustrating the collection of debris in the separation module during operation. 
         FIG. 12  is a perspective view of a separation module according to a sixth embodiment of the invention. 
         FIG. 13  is a view similar to  FIG. 12 , illustrating the collection of debris in the separation module during operation. 
         FIG. 14  is a view similar to  FIG. 13 , illustrating the emptying of debris in the separation module during operation. 
         FIG. 15  is a front perspective view of a separation module according to a seventh embodiment of the invention, with a portion of the separation module cut away to show some interior components. 
         FIG. 16  is a rear perspective view of the separation module from  FIG. 15 . 
         FIG. 17  is a sectional view of the separation module taken through line XVII-XVII of  FIG. 15 . 
         FIG. 18  is a front view of the separation module, illustrating the appearance of a transparent portion of the separation module. 
         FIG. 19  is a close-up, sectional view through a lower portion of the separation module from  FIG. 15  to illustrate configuration of debris catching tines. 
         FIG. 20  is a perspective view of the separation module from  FIG. 15  illustrating the collection of debris in the separation module during operation. 
         FIG. 21  is a view similar to  FIG. 20 , illustrating the emptying of debris in the separation module during operation. 
     
    
    
     DETAILED DESCRIPTION 
     The invention relates to vacuum cleaners and in particular to vacuum cleaners having cyclonic dirt separation. In one of its aspects, the invention relates to an improved exhaust grill for a cyclone module assembly. For purposes of description related to the figures, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in  FIG. 1  from the perspective of a user behind the vacuum cleaner, which defines the rear of the vacuum cleaner. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. 
     Referring to the drawings, and in particular to  FIG. 1 , an upright vacuum cleaner  10  comprises an upright handle assembly  12  pivotally mounted to a foot assembly  14 . The handle assembly  12  further comprises a primary support section  16  with a grip  18  on one end to facilitate movement by a user. A motor cavity  20  is formed at an opposite end of the handle assembly  12  to contain a conventional suction source such as a vacuum fan/motor assembly (not shown) oriented transversely therein. A post-motor filter housing  22  is formed above the motor cavity  20  and is in fluid communication with the vacuum fan/motor assembly. The handle assembly  12  pivots relative to the foot assembly  14  through a pivot axis that is coaxial with a motor shaft (not shown) associated with the vacuum fan/motor assembly. Alternatively, the handle assembly  12  can be coupled to the foot assembly  14  by a multi-axis joint. A mounting section  24  on the primary support section  16  of the handle assembly  12  receives a collection system  26  according to a first embodiment of the invention for separating and collecting contaminants from a working airstream for later disposal. In one conventional arrangement illustrated herein, the collection system  26  is shown as a cyclone separation module  26 . However, it is understood that other types of separation modules can be used, such as centrifugal separators or bulk separators. The vacuum cleaner  10  can also be provided with one or more additional filters upstream or downstream of the collection system  18 . 
     The foot assembly  14  comprises a housing  28  with a suction nozzle  30  formed at a lower surface thereof and that is in fluid communication with the vacuum fan/motor assembly. While not shown, an agitator can be positioned within the housing  28  adjacent the suction nozzle  30  and operably connected to a dedicated agitator motor, or to the vacuum fan/motor assembly within the motor cavity  20  via a stretch belt as is common in the vacuum cleaner art. Rear wheels  32  are secured to a rearward portion of the foot assembly  14  and a pair of support wheels (not shown) is secured to a forward portion of the foot assembly  14  for moving the foot assembly  14  over a surface to be cleaned. 
       FIGS. 2-3  are a front and perspective, respectively, sectional view through the separation module  26  of  FIG. 1 . The separation module  26  illustrated herein comprises a single-stage cyclone separator  34  for separating contaminants from a dirt-containing working airstream and a dirt cup  36  which receives contaminants separated by the cyclone separator  34 . The cyclone separator  34  defines a separation chamber  38  and comprises a side wall  40 , a top wall  42 , and an open bottom defined by an edge  44 . An air inlet  46  to the separation chamber  38  is formed in the side wall  40  and can be defined by an inlet conduit extending outwardly from the side wall  40 . While not illustrated, the inlet  46  is in fluid communication with the suction nozzle  30  ( FIG. 1 ). 
     The dirt cup  36  defines a collection chamber  48 , and comprises a side wall  50 , a bottom wall  52 , and an open top defined by an edge  54  that is selectively joined to the bottom edge  44  of the cyclone separator  34 . A gasket  56  can be provided between the edges  44 ,  54 . While the separation chamber  38  and collection chamber  48  are shown herein as being defined by separate housings, it is also contemplated that the separation chamber  38  and collection chamber  48  can be defined by a common or integral housing. In this case, the bottom wall  52  defining the collection chamber  48  can be provided with a dirt door for selectively releasing debris collected therein from the separation module  26 , which can be referred to as a “bottom-empty” separation module. 
     An air outlet  58  from the separation module  26  can be provided in the top wall  42  of the cyclone separator  34 . While not illustrated, the outlet  58  is in fluid communication with the suction source in the motor cavity  20  ( FIG. 1 ). 
     The separation module  26  further comprises a grill assembly  60  positioned within the separation chamber  38 , upstream of the outlet  58 . The grill assembly  60  can include a grill having a plurality of grill openings  62  through which air may pass. The openings  62  may be defined between spaced vanes or louvers  64 , as shown herein, or may be defined by perforations or holes in the side wall of the grill assembly  60 . A separator plate  66  can be provided on the grill assembly  60 , and can project radially outwardly from a lower end of the grill assembly  60 . The separator plate  66  serves to separate the separator chamber  38  from the collection chamber  48 , and can define, along with the side wall  40  of the cyclone separator  34 , a debris outlet  68  from the separation chamber  38 . 
     The separation module  26  further includes a plurality of debris catching tines  70  which depend downwardly from the separator plate  66 . The debris catching tines  70  are configured to prevent debris, such as hair, from wrapping around and blocking or clogging the grill assembly  60 . More specifically, the tines  70  can be located on the bottom of the separator plate  66  and extend downwardly into the collection chamber  48  and comprising free terminal ends  72 . The tines  70  are oriented vertically, i.e. parallel to a central axis X of the separation module  26 , and can comprise thin, stiff rods having a circular cross-section. The tines  70  can be spaced from each other around the periphery of the separation plate  66 , and can form a ring-shaped pattern such that each tine  70  is equidistant from the central axis X. The tines  70  can be made from metal or plastic. 
     The performance of the tines  70  can be dependent on several factors, including the diameter of the tines  70 , the spacing between adjacent tines  70 , the diameter of the ring-shaped pattern formed by the tines  70  in comparison with the inner diameter of the dirt cup  36 , and the length of the tines in comparison to the length of the dirt cup. These dimensions can vary, based on the dimensions of the separation module  26 , including the diameter of the separator plate  66 , separation chamber  38 , and the collection chamber  48 , and the length or height of the collection chamber  48 . In one example, the diameter of each tine  70  is about 3 mm, with the spacing between adjacent tines being about 12 mm. With these dimensions, the total number of tines  70  can be about 30. For a given tine spacing, the total number of tines can be expressed as a function of the diameter A of the separator plate  66 . For example, when the center to center spacing between adjacent tines is around 12 mm, the total number of tines  70  can be expressed as a function of the diameter A of the separator plate  66  in millimeters. More specifically the total number of tines  70  can be approximated by the formula: 0.26(A). However, the diameter and spacing between tines  70 , and thus, the total number of tines  70  can vary. For example, the spacing between the tines  70  can vary from approximately 5-100 mm, and the total number of tines  70  can vary from approximately 3-100. The diameter of the ring-shaped pattern formed by the tines  70  can be expressed as a function of the inner diameter B of the dirt cup  36  measured at the top edge  54 . More specifically, the diameter of the ring-shaped pattern formed by the tines  70  can be approximated by the formula: 0.70(B), but can range from about 0.5(B) to 0.9(B). 
     The terminal ends  72  of the tines  70  are spaced from the bottom wall  52  of the collection chamber  48  a distance S. As shown herein, the tines  70  can extend a length of greater than half the distance D between the separator plate  66  and the bottom wall  52  of the collection chamber  48 . More specifically, the tines  70  can extend at least ¾ of the distance D between the separator plate  66  and the bottom wall  52  of the collection chamber  48  to maximize the collection of debris, such as hair, on the tines  70 . 
     Other configurations are contemplated, such as tines  70  that can extend about ½ of the distance D between the separator plate  66  and the bottom wall  52  of the collection chamber  48 , for example. Ultimately, the length of the tines  70  can vary, depending on the configuration of the separation module  26  and airflow patterns therein or other design constraints, for example. However, if the tines  70  are too short, they will not collect a desirable amount of debris. 
       FIG. 4  is a view similar to  FIG. 3 , illustrating the collection of dirt, hair, and other debris in the separation module  26  during operation. During operation, string-like or elongated debris  74 , such as pieces of hair, fabric fibers, and fuzz, that are entrained within the swirling airflow are caught and retained on the tines  70  for later disposal, while particle-like debris  76 , such as dirt, are collected at the bottom of the dirt cup  36  in the collection chamber  48 . The elongated debris can be shaken or wiped off the tines  70  when the dirt cup  36  is emptied. The tines  70  effectively prevent elongated debris  74  from wrapping around the grill assembly  60 , which can hinder performance by blocking or clogging the grill openings  62  and can further present a nuisance clean-up issue for users. 
     The tines  70  of the first embodiment can also be used on other types of separation modules  26 , including multi-stage or multi-cyclone modules, bottom-empty modules having releasable dirt doors, modules with the air outlet formed in the bottom of the dirt cup, etc. Some non-limiting examples of further embodiments of separation modules with debris catching tines are shown in  FIGS. 5-21 , and can be used with the vacuum cleaner  10  of  FIG. 1 . 
       FIG. 5  is a sectional view through a separation module  80  according to a second embodiment of the invention. The separation module  80  can be provided on the vacuum cleaner shown in  FIG. 1 . The separation module  80  comprises an upper casing  82  and a lower casing  84 , with a carry handle  86  located on the upper casing  82 . The carry handle  86  has an actuator  88  that operates a rotatably mounted and biased upper latch  90  that releasably secures the separation module  80  to the vacuum cleaner  10  ( FIG. 1 ). The separation module  80  further has a pivotally mounted bottom door  92  that is attached to the lower casing  84  by a hinge  94 . When the separation module  80  is removed from the vacuum cleaner, the debris collected therein can be emptied by releasing the bottom door  92 . A pivoting lever  96  that releasably engages the bottom door  92  for selectively opening the bottom door  92  and emptying the lower casing  84  is provided opposite the hinge  94 . 
     The separation module  80  further comprises a first separation stage comprising a primary separation chamber  98  and a second separation stage comprising multiple parallel secondary separation chambers  100  located downstream of and positioned above the primary separation chamber  98 . A tangential working air inlet  102  to the primary separation chamber  98  is formed in the upper side wall of the lower casing  84 . The debris separated by the primary separation chamber  98  collects in the bottom of the lower casing  84  in a first collection chamber  104  and the debris separated by the secondary separation chambers  100  collects in the bottom of the lower casing  84  in a second collection chamber  106 . The debris from the secondary separation chambers  100  passes from the bottom of the secondary separation chambers  100  to the second collection chamber  106  through chutes  108 . 
     A perforated grill assembly  110  is positioned between the primary separation chamber  98  and the secondary cyclones  100 , and is removably mounted to a plate  112  positioned between the upper and lower casings  82 ,  84 . A conduit  114  leads from the interior of the perforated grill assembly  110  to the inlets of the secondary separation chambers  100  and is mounted to the top of the plate  112 . An inner cover  116  is mounted on top of the secondary separation chambers  100  and forms an exhaust pathway for each secondary cyclone  100  formed integrally therein. An outer cover  120  is mounted over and spaced from the inner cover  116  to form an exhaust plenum in which air discharged from each secondary cyclone  100  mixes before it exits the separation module  80  through an air outlet  122  integrally formed in the outer cover  120 . Optionally, an exhaust filter (not shown) can be placed upstream from the air outlet  122 , such as in the exhaust plenum for example, or downstream from the air outlet  122 . 
     The separation module  80  further includes a plurality of debris catching tines  70  which depend downwardly from the grill assembly  110 . The tines  70  can be substantially similar to the tines  70  described above for the first embodiment, including having free terminal ends  72 . The terminal ends  72  of the tines  70  are spaced from the bottom door  92  of the lower casing  84  a distance S. As shown herein, the tines  70  can extend a length of greater than half the distance D between the lowermost end of the grill assembly  110  and the bottom door  92  closing the collection chambers  104 ,  106 . More specifically, the tines  70  can extend at least ¾ of the distance D between the lowermost end of the grill assembly  110  and the bottom door  92 . 
       FIG. 6  is a perspective sectional view through a separation module  26  according to a third embodiment of the invention. The separation module  26  can be provided on the vacuum cleaner shown in  FIG. 1 . The third embodiment of the separation module  26  is substantially similar to the first embodiment, but differs from the first embodiment by having a tine cleaner which cleans at least some of the elongated or string-like debris  74  from the tines  70 . One embodiment of a tine cleaner is a tine stripper mechanism  124  for stripping the elongated or string-like debris  74  from the tines  70 . The tine stripper mechanism  124  comprises a movable tine plate  126  which is provided above the stationary separator plate  66 , and a handle  128  attached to the tine plate  126  for selectively raising the tine plate  126  away from the separation plate  66 . The tines  70  project from a lower surface of the tine plate  126 , and the separate plate  66  has a plurality of slots  130  configured to slidingly receive the tines  70 . The tine plate  126  further includes an inner opening  132  providing clearance for the tine plate  126  to move vertically with respect to the grill assembly  60 . 
     The handle  128  includes at least one connecting rod  134  coupled to the upper surface of the tine plate  126 , and a hand grip  136  provided on the exterior of the separation module  26  and coupled to the at least one connecting rod  134 . As shown herein, two connecting rods  134  are coupled to the tine plate  126  and are spaced from each other on opposite sides of the grill assembly  60 . The connecting rods  134  extend upwardly through the separation chamber  38  and pass through openings  138  provided in the top wall  42  of the cyclone separator  34 . Optionally, seals (not shown) can be provided around the openings  138  to prevent air leaks through gaps between the openings  138  and connecting rods  134 . The hand grip  136  is coupled to both of the connecting rods  134  exterior of the cyclone separator  34 . 
       FIG. 7  is a view similar to  FIG. 6 , illustrating the collection of dirt, hair, and other debris in the separation module during operation. After a cleaning operation, elongated or string-like debris  74  are collected on the tines  70 , while particle-like debris  76  are collected at the bottom of the dirt cup  36  in the collection chamber  48 . The tine stripper mechanism  124  is operated in order to release the elongated or string-like debris  74  from the tines  70  into the dirt cup  36 . A user grips the hand grip  136  and pulls upwardly on the handle  128  to raise the tine plate  126  and the tines  70  away from the separator plate  66 . There is a tight clearance between each tine  70  and its associated slot  130 , so that the tine  70  can slide through the slot  130 , but that any elongated or string-like debris  74  on the tine  70  cannot pass through the slot  130 . The elongated or string-like debris  74  are stripped off tines  70 , and fall into the collection chamber  48  of the dirt cup  36 . In this way, all collected debris (elongated or string-like debris  74  and particle-like debris  76 ) can be emptied simultaneously when the dirt cup  34  is removed from the vacuum cleaner  10  and inverted over a waste receptacle. 
     The entire separation module  26  can be removed from the vacuum cleaner  10  prior to operating the tine stripper mechanism  124 . Alternatively, the vacuum cleaner  10  can be configured to allow sufficient clearance for raising the handle  128 , such that the user can operate the tine stripper mechanism  124  with the separation module  26  still installed on the vacuum cleaner  10 , and then remove just the dirt cup  36  for emptying. 
       FIG. 8  is a perspective sectional view through a separation module  26  according to a fourth embodiment of the invention. The separation module  26  can be provided on the vacuum cleaner shown in  FIG. 1 . The fourth embodiment of the separation module  26  differs from the third embodiment by having a modified version of a tine stripper mechanism  140  for stripping the elongated or string-like debris  74  from the tines  70 . The tine stripper mechanism  140  comprises a movable stripper plate  142  which is provided below the stationary separator plate  66 , and a handle  144  attached to the stripper plate  142  for selectively lowering the stripper plate  142  away from the separation plate  66 . The tines  70  project from a lower surface of the separation plate  66 , and the stripper plate  142  has a plurality of slots  146  configured to slidingly receive the tines  70 . 
     The handle  144  includes at least one connecting rod  148  coupled to the stripper plate  142 , and a hand grip  150  provided on the exterior of the separation module  26  and coupled to the at least one connecting rod  148 . As shown herein, two connecting rods  148  are coupled to the stripper plate  142  and are spaced from each other on opposite sides of the grill assembly  60 . The connecting rods  148  extend upwardly through the separation chamber  38  and pass through openings  151  provided in the separator plate  66  and openings  152  provided in the top wall  42  of the cyclone separator  34 . Optionally, seals (not shown) can be provided around the openings  152  to prevent air leaks through gaps between the openings  152  and connecting rods  148 . The hand grip  150  is coupled to both of the connecting rods  148  exterior of the cyclone separator  34 . 
       FIG. 9  is a view similar to  FIG. 8 , illustrating the collection of dirt, hair, and other debris in the separation module during operation. After a cleaning operation, elongated or string-like debris  74  are collected on the tines  70 , while particle-like debris  76  are collected at the bottom of the dirt cup  36  in the collection chamber  48 . The tine stripper mechanism  140  is operated in order to release the elongated or string-like debris  74  from the tines  70  into the dirt cup  36 . A user grips the hand grip  150  and pushes downwardly on the handle  144  to lower the stripper plate  142  over the tines  70 , away from the separator plate  66 . There is a tight clearance between each tine  70  and its associated slot  146 , so that the slot  146  can slide over the tine  70 , but that any elongated or string-like debris  74  on the tine  70  cannot pass through the slot  146 . The elongated or string-like debris  74  are stripped off tines  70 , and fall into the collection chamber  48  of the dirt cup  36 . In this way, all collected debris (elongated or string-like debris  74  and particle-like debris  76 ) can be emptied simultaneously when the dirt cup  34  is removed from the vacuum cleaner  10  and inverted over a waste receptacle. 
     The entire separation module  26  can be removed from the vacuum cleaner  10  prior to operating the tine stripper mechanism  140 . Alternatively, the vacuum cleaner  10  can be configured to allow sufficient clearance for the raised handle  144 , such that the user can operate the tine stripper mechanism  140  with the separation module  26  still installed on the vacuum cleaner  10 , and then remove just the dirt cup  36  for emptying. 
       FIG. 10  is a sectional view through a separation module  26  according to a fifth embodiment of the invention. The separation module  26  can be provided on the vacuum cleaner shown in  FIG. 1 . The fifth embodiment of the separation module  26  is substantially similar to the first embodiment, but differs from the first embodiment by having horizontally-oriented tines  70 , and a tine stripper mechanism  154  for stripping the elongated or string-like debris  74  from the tines  70 . The separation module  26  of the fifth embodiment also has the air outlet  58  provided in the bottom wall  52  of the dirt cup  36 . An outlet conduit  156  extends through the separation module  26 , from the grill assembly  60  to the air outlet  58 . 
     The tine stripper mechanism  154  comprises a movable plate in the shape of a ring  158  which is provided below the stationary separator plate  66 , and a handle  160  attached to the ring  158  for selectively rotating the ring  158  relative to the separation plate  66 . One or more tine plates  162  project(s) from a lower surface of the ring  158 , and the tines  70  extend from the tine plate  162  to terminal ends  72 . The tines  70  extend in a generally horizontal plane from the plate  162 , i.e. perpendicular to the central axis X of the separation module  26 , and can be curved such that the tines  70  bend around the central axis X of the separation module  26 . The tines  70  can be curved such that it there is a constant distance between the tine  70  and the central axis X. On each tine plate  162 , a plurality of tines  70  are provided, and can be spaced vertically from each other. A corresponding slotted plate  164  projects from the lower surface of the separate plate  66  and has a plurality of tine slots  166  configured to slidingly receive the tines  70  on the associated tine plate  162 . While only one tine plate  162  and slotted plate  164  are shown in the figures, the ring  158  and separator plate  66  can be provided with multiple sets of tine plates  162  and slotted plates  164 , respectively. 
     The handle  160  includes at least one connecting shaft  168  coupled to the ring  158 , and a knob  170  provided on the exterior of the separation module  26  and coupled to the at least one connecting shaft  168 . The connecting shaft  168  extends upwardly through the separation chamber  38  and passes through an opening  172  provided in the top wall  42  of the cyclone separator  34 . Optionally a seal (not shown) can be provided around the opening  172  to prevent air leaks through gaps between the opening  172  and connecting shaft  168 . The knob  170  is coupled to the connecting shaft  168  exteriorly of the cyclone separator  34 . 
       FIG. 11  is a view similar to  FIG. 10 , illustrating the collection of dirt, hair, and other debris in the separation module during operation. After a cleaning operation, elongated or string-like debris  74  are collected on the tines  70 , while particle-like debris  76  are collected at the bottom of the dirt cup  36  in the collection chamber  48 . The tine stripper mechanism  154  is operated in order to release the elongated or string-like debris  74  from the tines  70  into the dirt cup  36 . A user grips the knob  170  and rotates the shaft  168  to rotate the ring  158  relative to the separator plate  66 . This moves the tines  70  away from the slotted plate  164 . There is a tight clearance between each tine  70  and its associated slot  166 , so that the tine  70  can slide through the slot  166 , but that any elongated or string-like debris  74  on the tine  70  cannot pass through the slot  166 . The elongated or string-like debris  74  are stripped off tines  70 , and fall into the collection chamber  48  of the dirt cup  36 . In this way, all collected debris (elongated or string-like debris  74  and particle-like debris  76 ) can be emptied simultaneously when the dirt cup  34  is removed from the vacuum cleaner  10  and inverted over a waste receptacle. During stripping, the slotted plate  164  remains stationary, and can include a ring slot  174  for allowing the ring  158  to pass through the slotted plate  164 . In another embodiment, the tine plate  162  can remain stationary while the slotted plate  164  is moved over the tines  70 . 
     The entire separation module  26  can be removed from the vacuum cleaner  10  prior to operating the tine stripper mechanism  154 . Alternatively, the vacuum cleaner  10  can be configured to allow sufficient clearance for rotating the knob  170 , such that the user can operate the tine stripper mechanism  154  with the separation module  26  still installed on the vacuum cleaner  10 , and then remove just the dirt cup  36  for emptying. 
       FIG. 12  is a perspective view of a separation module  176  according to a sixth embodiment of the invention. The separation module  176  can be provided on the vacuum cleaner shown in  FIG. 1 . The separation module  176  comprises a housing  178  defining a single-stage separation chamber  180  for separating contaminants from a dirt-containing working airstream. The housing  178  includes a side wall  182 , a top wall  184 , and an open bottom defined by an edge  186 . An air inlet  188  to the separation chamber  180  is formed in the side wall  182  and can be defined by an inlet conduit extending outwardly from the side wall  182 . While not illustrated, the air inlet  188  is in fluid communication with the suction nozzle  30  ( FIG. 1 ). An air outlet  190  from the separation module  176  can be provided in the top wall  184  of the housing  178 . While not illustrated, the air outlet  190  is in fluid communication with the suction source in the motor cavity  20  ( FIG. 1 ). The debris separated in the separation chamber  180  collects in the bottom of the housing  178  in a collection chamber  192  defined therein. 
     The housing  178  further has a pivotally mounted bottom door  194  that is attached to the open bottom edge  186  of the housing  178  by a hinge  196 , the door  194  defining the bottom of the collection chamber  192 . When the separation module  176  is removed from the vacuum cleaner, the debris collected in the collection chamber  192  can be emptied by releasing the bottom door  194 . A pivoting lever  198  that releasably engages the door  194  for selectively opening the door  194  and emptying the housing  178  is provided opposite the hinge  196 . 
     The separation module  176  further comprises a grill assembly  200  positioned within the separation chamber  180 , upstream of the air outlet  190 . The grill assembly  200  can include a grill having a plurality of grill openings  202  through which air may pass. The openings  202  may be defined between spaced vanes or louvers  204 , as shown herein, or may be defined by perforations or holes in the side wall of the grill assembly  200 . A separator plate  206  can be provided on the grill assembly  200 , and can project radially outwardly from a lower end of the grill assembly  200 . The separator plate  206  serves to separate the separator chamber  180  from the collection chamber  192 , and can define, along with the side wall  182  of the housing  178 , a debris outlet  208  from the separation chamber  180 . 
     The separation module  176  further includes a plurality of debris catching tines  70  which depend downwardly from the grill assembly  200  and extend downwardly into the collection chamber  192 . The tines  70  can be substantially similar to the tines  70  described above for the first embodiment, including having free terminal ends  72 . The terminal ends  72  of the tines  70  are spaced from the bottom door  194  of the housing  178 . The tines  70  are oriented vertically, i.e. parallel to a central axis X of the separation module  176 . 
     In addition to the vertical tines  70 , the separation module  176  further includes a second set of debris catching tines  210  that are provided on the bottom door  194  of the housing  178 . The debris catching tines  210  are configured to collect elongated debris  74 , such as hair, in the collection chamber  192 . More specifically, the tines  210  can be located on the bottom door  194  and extend upwardly into the collection chamber  192  to free terminal ends  212 , which are below the separation chamber  180 . The tines  210  can be oriented at an acute angle to the door  194 , i.e. non-parallel to the inner surface of the door  194 , and can comprise thin rods having a circular cross-section. In one example, the diameter of the tines  210  is about 3 mm. The tines  210  can be spaced from each other on the inner surface of the door  194 . The tines  210  can be made from metal or plastic. 
     In addition to collecting debris, the angled tines  210  can have a second function of acting as a tine stripper mechanism for stripping the elongated or string-like debris  74  from the tines  70 . The angle and length of the tines  210  can be configured such that the terminal ends  212  of the tines  210  intersect elongated debris  74  collected on the vertical tines  70 . When the door  194  is opened to empty debris, the accompanying movement of the angled tines  210  helps to pull or strip off the debris  74  on the vertical tines  70 . 
     The tines  70 ,  212  themselves do not have to intersect in order for the angled tines  212  to act as a tine stripper mechanism, as shown in the illustrated embodiment. In another configuration, the angled tines  210  can at least partially intersect the vertical tines  70 . It is also noted that the arrangement of tines  70 ,  212  of the sixth embodiment can also be used on other types of separation modules, including multi-stage or multi-cyclone modules. 
       FIGS. 13-14  are views similar to  FIG. 12 , illustrating the collection of debris in the separation module  176  during operation and the subsequent emptying of the collected debris. During operation, string-like or elongated debris  74 , such as pieces of hair, fabric fibers, and fuzz, that are entrained within the swirling airflow are caught and retained on the tines  70 ,  210  for later disposal, while particle-like debris  76 , such as dirt, are collected at the bottom of the collection chamber  192 . Elongated debris  74  may initially collect on the angled tines  210 , and then on the vertical tines  70 , after which there may be some intertwining of the collected debris  74  between the tines  70 ,  212 . To empty the collection chamber  192 , the door  194  is opened, as shown in  FIG. 14 , and particle-like debris  76  falls out of the open bottom of the housing  178 . At least some of the elongated debris  74  may also fall out of the open bottom of the housing  178 . As the door  194  opens, the angled tines  210  intersecting the elongated debris  74  collected on the vertical tines  70  can pull or strip off the debris  74  on the vertical tines  70 . The intertwining of the collected debris  74  between the tines  70 ,  212  may also help pull or strip off the debris  74  on the vertical tines  70 , even without a direct intersection between the angled tines  210  and the debris  74  on the vertical tines  70 . When the door is fully open, gravity and the orientation of the angled tines  210  helps the debris  74  on the angled tines  210  fall off. If needed, the elongated debris  76  also can be shaken or manually wiped off the tines  70 ,  210  when the door  194  is open. 
       FIGS. 15-21  illustrate a multi-cyclone separation module  214  according to a seventh embodiment of the invention, which can be provided on the vacuum cleaner of  FIG. 1  and configured for removable mounting therewith. The separation module  214  can be substantially similar to separation module  176  shown in  FIGS. 12-14 , except that separation module  214  incorporates a secondary separation stage for separating debris from the working airstream after it passes through a primary separation stage. Additionally, the multi-cyclone separation module  214  incorporates both vertical tines  70  and angled tines  210  for collecting elongated or string-like debris. Because certain aspects of the tine configuration differ slightly from the previous embodiments, the forthcoming description will focus only on salient differences to the extent the tine configuration of the seventh embodiment differs from the configuration disclosed in previous embodiments. 
     Referring to  FIGS. 15-16 , the multi-cyclone separation module  214  comprises a housing  216  with an outer cover  218  having a carry handle  220  located on an upper portion of the housing  216 . While not shown, the carry handle  220  can carry a latch that releasably secures the separation module  214  to the vacuum cleaner  10  ( FIG. 1 ), similar to the latch disclosed in  FIG. 5 . The separation module  214  further has a pivotally mounted bottom door  222  that is attached to the lower end of the housing  216  by a hinge  224 . When the separation module  214  is removed from the vacuum cleaner, the debris collected therein can be emptied by releasing the bottom door  222 . A pivoting lever  226  that releasably engages the bottom door  222  for selectively opening the bottom door  222  and emptying the housing  216  is provided opposite the hinge  224 . 
     The housing  216  defines a primary separation stage with a primary separation chamber  228 , and a secondary separation stage with a plurality of secondary cyclone separators  230 . The primary separation chamber  228  is defined by a generally cylindrical primary separator sidewall  232  of the housing  216  which extends generally along a central axis X of the module  214 . A working air inlet  234  to the primary separation chamber  228  is formed in an upper portion of the sidewall  232  and communicates with a helical air inlet passage leading to the primary separation chamber  228 . The air inlet  234  is in fluid communication with the suction nozzle  30  ( FIG. 1 ) when the separation module  214  is mounted to the vacuum cleaner  10 . 
       FIG. 17  is a cross-sectional view through line XVII-XVII of  FIG. 15 . An inner cover  236  is mounted on top of the secondary cyclones  230  and forms at least a portion of an exhaust pathway for each secondary cyclone  230 . The outer cover  218  is mounted over and spaced from the inner cover  236  to form an exhaust plenum in which air discharged from each secondary cyclone  230  mixes before it exits the separation module  214  through an air outlet  238  integrally formed in the outer cover  218 . Optionally, an exhaust filter (not shown) can be placed upstream from the air outlet  238 , such as in the exhaust plenum for example, or downstream from the air outlet  238 . 
     Referring to  FIGS. 16-17 , debris that is separated by the primary separation chamber  228  collects at the bottom of the sidewall  232  in a first collection chamber  240 . Debris separated by the secondary cyclone separators  230  collects in one or more second collection chambers  242  defined by one or more bumped out walls  244  on the perimeter of the sidewall  232 . As shown, two collection chambers  242  are provided (visible in  FIG. 16 ), and each collection chamber  242  receives debris from two secondary cyclone separators  230  which are provided on the exterior of the sidewall  232 , although other configurations of collection chambers and separators are possible. In the illustrated embodiment, the two collection chambers  242  are spaced around the perimeter of the sidewall  232  and define a gap  246  therebetween on the rear of the sidewall  232  that can nest a portion of the upright handle assembly  12  ( FIG. 1 ). Both collection chambers  242  are enclosed around their perimeter by the bumped out walls  244 , which are radially spaced from the primary separator sidewall  232 . Each collection chamber  240 ,  242  is open at their bottom edge, which are collectively closed by the door  222 , which, when closed, forms the bottom of the collection chambers  240 ,  242 . 
     The bumped out walls  244  can house at least a portion of the secondary cyclones  230 . As illustrated, each bumped out wall  244  houses the lowermost ends of two adjacent frusto-conical secondary cyclones  230 . However, it is contemplated that the bumped out walls  244  can be configured to house the entirety of the cyclones  230  instead of merely housing the lower ends thereof. 
       FIG. 18  is a front view of the separation module  214 . The housing  216  can be at least partially formed by transparent material such that the interior and/or rear components of the separation module  214  can be viewed by a user. In one configuration, the sidewall  232  and the bumped out walls  244  can be formed from transparent material (as indicated by the phantom lines used in  FIG. 18 ) such that the secondary cyclones  230  are at least partially visible when the separation module  214  is viewed from the front. Moreover, the secondary cyclones  230  and the bumped out walls  244  can extend laterally beyond the perimeter of the sidewall  232  when viewed from the front of the module  214  so that the secondary cyclones  230  and second collection chambers  242  are more visible when viewed from the front of the vacuum cleaner  10 . With a transparent sidewall  232 , the tines  70 ,  210  and the contents of the collection chambers  240 ,  242  will also be visible. 
     Referring to  FIGS. 17-18 , the multi-cyclone separation module  214  further comprises an exhaust grill assembly  248  within the housing  216 , which is fluidly positioned downstream of the primary separation chamber  228  and upstream of the secondary cyclone separators  230 . The grill assembly  248  can comprise a downwardly tapered or conical shaped frame  252  and can further comprise mesh screen  254  wrapped around the support frame  252 . The screen  254  comprises a plurality of openings through which air may pass. A separator plate  258  can extend radially outwardly from a lower end of the grill frame  252 . The separator plate  258  includes an outwardly flared skirt  260  with an open top mounted to a lower end of grill frame  252  and an open bottom defined by a downwardly-depending lip  262  on the skirt  260 . The skirt  260  flares outwardly in a downward direction such that the lip  262  defines the outer perimeter of the separator plate  258 . 
     A primary debris outlet  264  from the primary separation chamber  228  can be defined between the lip  262  of the separator plate  258  and the sidewall  232 . A secondary debris outlet  266  from each cyclone separator  230  is defined by the open bottom of the secondary cyclone  230 . A conduit  268  inside the frame  252  defines at least a portion of a fluid conduit leading from the primary separation chamber  228  to the inlets of the secondary separation chambers  230 . 
       FIG. 19  is a close-up, sectional view through a lower portion of the separation module from  FIG. 15  to illustrate configuration of debris catching tines  70 ,  210 . Debris catching tines  70  depend downwardly from the grill assembly  248  and are oriented vertically or generally parallel to central axis X. In one example, eight tines  70  are arranged in a circular pattern near the outer edge of the separator plate  258 . The linear spacing between adjacent tines  70  can about 28 mm and the diameter formed by the ring of tines  70  is about 73 mm, although other dimensions for the lines  70  are contemplated. 
     Each tine  70  can comprise a conical-shaped member that tapers inwardly from an upper portion  270  to a lower portion  272  having a free terminal end  274 . The upper portion  270  can be cored out or hollow, whereas the lower portion  272  can comprise a solid, thin stiff rod. The tines  70  can further comprise external, tapered ribs  276  for stiffening and improving durability of the tines  70 . The ribs  276  can project radially from the outer surface of each tine  70 , but gradually taper down and blend into the surface of the lower end  272 . In the embodiment shown, each tine  70  comprises four orthogonal ribs  276 . The tines  70  are preferably molded out of a thermoplastic material such as acrylonitrile butadiene styrene (ABS) or polypropylene (PP), for example. 
     The lower portion  272  of each tine  70  can further comprise at least one inward step  278  that reduces the diameter of the tine  70  at the terminal end  274 . The terminal end  274  can also include a rounded tip  280 . The step  278  and rounded tip  280  are configured to enhance release of debris and hair from the tines  70 . As shown, the lower portion  272  includes two inward steps  278  that successively reduce the diameter of the tine  70  at the terminal end  274 . In one example, each inward step  278  can reduce the diameter of the tine  70  by about 0.5 mm to 2.5 mm and preferably within a range between about 0.75 mm to 1.5 mm, although using larger or smaller steps  278 , as well as omitting one or all steps, is also contemplated. In another embodiment, the lower portion  272  of the tine  70  can be smoothly tapered in order to gradually reduce the diameter of tine  70  toward the terminal end  274  without the use of one or more discrete steps  278 . 
     The conical configuration of the vertical tines  70  of the seventh embodiment can also tend to enhance shedding and release of debris collected by the tines  70 . In one example the diameter of the upper portion  270  at the top of a tine  70  is about 16 mm and the diameter of the terminal end  274  is about 4 mm. Thus, the conical tine configuration can be approximated by a ratio of tine diameters along the length of the tine  70  such that the diameter of the upper portion  270  at the top of a tine  70  is about four times the diameter of the terminal end  274 , or a ratio of about 4:1. However, a range of tine diameter ratios is contemplated, such as from about 2:1 to about 7:1. 
     Similarly, the conical configuration of the tines  70  can be expressed as a ratio of tine length to the diameter of the upper portion  270  at the top of a tine  70 . In one example, the length of the tine  70  is about 67 mm and the diameter of the upper portion  270  at the top of a tine  70  is about 16 mm. Thus, the conical tine configuration can be approximated by a ratio such that tine length is about four times the diameter of the tine diameter taken at the upper portion  270  at the top of a tine  70 , or a length-to-diameter ratio of about 4:1. However, a range of length-to-diameter ratios are contemplated, such as ratios from about 2:1 to 10:1. 
     In the illustrated embodiment, the tines  70  about half the distance D between the bottom of the separator plate  258  and the bottom door  222 . In one example, the distance D can be 128 mm and the distance S from the terminal ends  274  of the tines  70  to the bottom door  222  is 64 mm. Thus, in this example the tines  70  extend into the first collection chamber  240  about 50% of the distance D. However, it is contemplated that in alternate embodiments, the tines  70  can extend a length greater than or less than half the distance D between the separator plate  258  and the bottom door  222  to achieve desired performance and depending on the configuration of the module  214 . 
     A debris guard  282  can be mounted beneath the grill assembly  248 , within the circular grouping of tines  70  to prevent debris from becoming lodged and stuck between the tines  70  and the grill assembly  248 . In one example, the debris guard  282  comprises a convex or dome-shaped member in the center of the grouping of tines  70 . However, the debris guard  282  can comprise other shapes, such as flat, concave or a combination thereof, for example. 
     The separation module  214  further includes angled tines  210  provided on the bottom door  222  of the housing  216 , similar to the previous embodiment. The angled tines  210  can be formed out of a semi-resilient material that is resistant to abrasion and less prone to breakage than a more brittle material. In one example, the angled tines  210  can be molded out of a thermoplastic polyurethane (TPU) having a durometer of about 70 or 80 shore A, although other materials are contemplated, including those having higher or lower hardness levels. 
     One or more angled tines  210  can extend upwardly from a bottom door  222  into the first collection chamber  240 . The angled tines  210  can be fastened to the bottom door  222  by mechanical fasteners (not shown) or other manufacturing methods such as heat staking, adhesive, or welding, for example. In the illustrated embodiment, a pair of angle tines  210  is attached to the bottom door  222  via a common mount  284  provided on the upper surface of the bottom door  222 . 
     Each tine  210  can comprise a conical-shaped member that tapers inwardly from a lower portion  286  at the mount  284  to an upper portion  288  having a free terminal end  290 . The entire tine  210  can comprise a solid, thin stiff rod, or may be at least partially hollow. While not shown, the tines  210  can further comprise external ribs, similar to the ribs  276  described above for the vertical tines  70 . 
     The angled tines  210  can also be tapered along their length such that the terminal ends  290  are a smaller diameter compared to the diameter of the angled tine  210  near the mount  284 . The upper portion  288  can further comprise one or more inward steps  292  and a rounded tip  294 , which further reduce the diameter of the tines  210  at the terminal ends  290  and enhance shedding and release of debris. In one example, the diameter of the angled tine  210  at the lower portion  286  near the mount  284  is about 12.5 mm and the diameter of the tine  210  at the terminal end  290  is about 4 mm. In this example, the ratio of tine diameters along the length of the tine  210  is about 3:1. Additionally, the length of the angled tine  210  is about 89 mm and the largest diameter taken near the mount  284  is about 12.5 mm. Thus, the length-to-diameter ratio of the angled tine  210  is about 7:1. However, similar to the vertical tines  70 , a range of length-to-diameter ratios is contemplated for the angled tines  210 , such as ratios from about 2:1 to about 10:1. 
     A vertical gap G can be provided between the terminal ends  274  of the vertical tines  70  and the terminal ends  290  of the angled tines  210 , and is measured along a plane parallel to the central axis X of the module  214 . In one example, the gap G is about 15 mm, which test results have shown to provide desirable performance. However, other configurations are contemplated, including a zero or negative gap—meaning that the terminal ends  274 ,  290  of the vertical and angled tines  70 ,  210  can be co-planar or can intersect/overlap each other. 
       FIG. 20-21  are perspective views of the separation module  214 , illustrating the collection and emptying of debris in the separation module  214  during operation. In operation, string-like or elongated debris  74  entrained within the swirling airflow are caught and retained on the tines  70 ,  210  for later disposal, while particle like debris  76 , such as dirt, are collected at the bottom of the first collection chamber  240  and second collection chambers  242 . Because the secondary cyclones  230  and second collection chambers  242  are positioned outside of the first collection chamber  240 , the center of the first collection chamber  240  is unobstructed so that elongated debris  74  may initially collect on the angled tines  210 . The elongated debris  74  continues to build up on the angled tines  210  and eventually collects on the vertical tines  70 , after which there may be some intertwining of the collected debris  74  between the tines  70 ,  210 . 
     When the multi-cyclone separation module  214  is emptied, the door  222  is opened and particle-like debris  76  falls out of the open bottoms of collection chambers  240 ,  242 . In addition to collecting debris, the angled tines  210  can have a second function of acting as a tine stripper mechanism for stripping the elongated or string-like debris  74  from the tines  70 . As the door  22  opens, the angled tines  210  intersecting the elongated debris  74  collected on the vertical tines  70  can pull or strip off the debris  74  on the vertical tines. The intertwining of the collected debris  74  between the tines  70 ,  210  may also help to pull or strip off the debris  74  on the vertical tines  70 . When the door  222  is fully open, the debris  74  sheds or falls off the tines  70 ,  210 . The conical shape, the steps  278 ,  292 , and the rounded tips  280 ,  284  on the terminal ends  274 ,  290  of the tines  70 ,  210  enhance release of debris  74  from the tines  70 ,  210  by gravity, although a user can shake or manually wipe off the tines  70 ,  210  if necessary. 
     The above described embodiments provide for a variety of benefits, including improved debris collection in vacuum cleaner separation modules. These features, alone or in combination, create a superior separation module for vacuum cleaners. One advantage that may be realized in the practice of some embodiments of the described separation module is that debris catching tines are provided with the grill assembly, which prevents elongated or string-like debris from wrapping around and blocking or clogging the openings of the exhaust grill. Previous separation modules have included features directed toward discouraging or preventing re-entrainment of collected dirt particles into the working air flow, but these do not address particular issue of elongated or string-like debris wrapping around the exhaust grill. 
     Another advantage that may be realized in the practice of some embodiments of the described separation module is that a tine stripper mechanism can be provided for stripping elongated or string-like debris from the debris catching tines without requiring a user to manually pull the debris from the tines. The tine stripper mechanism can even be integrated with an existing emptying mechanism, such as a bottom dirt door. 
     Another advantage that may be realized in the practice of some embodiments of the described separation module is that the tines have a rod-like or conical shape, which tends to improve shedding and release of debris. 
     Yet another advantage that may be realized in the practice of some embodiments of the described separation module is that, in the case of a multi-stage module, positioning the secondary separation stage outside the primary separator separation stage provides more space within the primary separation stage and primary for separating and collecting string-like or elongated debris  74 , which can be somewhat voluminous as it collects and becomes intertwined on the tines in the primary collection chamber. Prior art multi-cyclonic separators commonly position one or more secondary separators and a secondary collection chamber concentrically within the primary separator, which occupies volume at the center of the separation module. Thus, less volume is available in the primary separator and collection module for separating and collecting string-like or elongated debris  74 . Also, because elongated debris  74  typically tends to collect at the center of the collection chamber, occupying that volume with secondary separators and collection chamber is not ideal, because the elongated debris  74  is prevented from agglomerating, collecting and intertwining at the center of the chamber and could be prone to re-entrainment. Additionally, less volume is available in the primary collection chamber, which causes the primary collection chamber to fill more quickly and requires a user to empty the tank frequently. The separation module design disclosed herein ameliorates problems with prior art designs by moving the secondary separators and collection chambers outside the primary separator and collection chamber. Because the secondary separator does not occupy the central portion of the primary, the elongated debris  74  is free to agglomerate, collect and intertwine on the tines for later disposal. 
     While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. For example, while the cyclone module assemblies illustrated herein are shown having a single stage separator or two concentric stages of separation, it is understood that the tines could be applied to a separator with multiple parallel first and/or second stage, or additional downstream separators, or other types of cyclone separators. Reasonable variation and modification are possible with the scope of the foregoing disclosure and drawings without departing from the spirit of the invention which, is defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.