Patent Publication Number: US-2023135280-A1

Title: Shroud for hand vacuum cleaner

Description:
FIELD 
     The present disclosure relates to vacuum cleaners. More particularly, the present disclosure relates to impeller shrouds for wet/dry type hand vacuum cleaners. 
     BACKGROUND 
     Vacuum cleaners, such as single hand operated vacuum cleaners, are typically useable for dry cleaning or wet and dry type extraction. Some known hand vacuum cleaners include an impeller shroud positioned in the airflow path. Such shrouds may direct the air flow through and/or out of the vacuum cleaner. 
     SUMMARY 
     One example embodiment of the present invention provides a vacuum cleaner including a housing defining a dirty air inlet and an exhaust outlet and a suction motor assembly operable to create a working airflow path from the dirty air inlet to the exhaust outlet. The suction motor assembly includes a motor having a motor shaft rotatable about a motor axis defining an axial direction, an impeller, and a shroud supported within the housing. The impeller includes a base plate coupled to the motor shaft for rotation with the motor shaft, a cover plate spaced from the base plate and including an impeller inlet aligned with the motor axis, and a plurality of vanes extending between the base plate and cover plate. Rotation of the impeller draws in the working airflow in the axial direction through the impeller inlet and expels the working airflow outwardly from the plurality of vanes in a radial direction perpendicular to the axial direction. The shroud includes a forward wall covering and facing the cover plate and having a shroud inlet aligned with the impeller inlet, and an annular axial wall extending from the outer perimeter of the forward wall in the direction of the motor axis. The annular axial wall includes an opening aligned with the exhaust outlet and redirects the working airflow exiting radially from the impeller into the axial direction. The opening allows the working airflow exiting radially from the impeller to pass unimpeded by the shroud toward the exhaust outlet. 
     Another example embodiment of the present invention provides a suction motor assembly operable to create a working airflow path from a dirty air inlet to an exhaust outlet. The suction motor assembly includes a motor having a motor shaft rotatable about a motor axis defining an axial direction, an impeller, and a shroud. The impeller includes a base plate coupled to the motor shaft for rotation with the motor shaft, a cover plate spaced from the base plate and including an impeller inlet aligned with the motor axis, and a plurality of vanes extending between the base plate and cover plate. Rotation of the impeller draws in the working airflow in the axial direction through the impeller inlet and expels the working airflow outwardly from the plurality of vanes in a radial direction perpendicular to the axial direction. The shroud includes a forward wall covering and facing the cover plate and having a shroud inlet aligned with the impeller inlet, and an annular axial wall extending from an outer perimeter of the forward wall in a direction of the motor axis. The annular axial wall includes an opening configured to be aligned with the exhaust outlet and redirects the working airflow exiting radially from the impeller into the axial direction. The opening is further configured to allow the working airflow exiting radially from the impeller to pass unimpeded by the shroud toward the exhaust outlet. 
     Still another example embodiment of the present invention provides a shroud of a vacuum cleaner that includes a housing supporting an impeller configured for creating a working airflow path between a dirty air inlet and an exhaust outlet. The shroud includes a forward wall having a shroud inlet configured to be aligned with an inlet of the impeller inlet along an axial direction, an annular axial wall extending away from an outer perimeter of the forward wall along the axial direction, and an opening formed in the annular wall. The opening is configured to be arranged in line with a portion of the exhaust outlet along the radial direction. The annular axial wall and the opening define an overall circumferential perimeter of the shroud. The annular axial wall occupies more than half of the overall circumferential perimeter, and the opening occupies less than half of the overall circumferential perimeter. 
     Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view of a vacuum cleaner, according to an embodiment of the disclosure, illustrating a portion of a housing shifted to reveal an inside of the housing. 
         FIG.  2    is a partially cross-sectioned perspective view of the vacuum cleaner of  FIG.  1   , taken through line  2 - 2  of  FIG.  1   , illustrating a shroud and impeller arrangement. 
         FIG.  3    is a cross-sectional top view of the hand vacuum cleaner of  FIG.  1   , taken through line  3 - 3  of  FIG.  1   , including a magnified view of a sealing area. 
         FIG.  4    is a side view of a shroud shown in  FIG.  2   . 
         FIG.  5 A  is a side view of a shroud, according to one embodiment of the present invention, useable with the vacuum cleaner of  FIG.  1   . 
         FIG.  5 B  is a perspective view of the shroud of  FIG.  5 A . 
         FIG.  6    is a side view of a shroud, according to another embodiment of the present invention, useable with the vacuum cleaner of  FIG.  1   . 
         FIG.  7 A  is a side view of the shroud of  FIG.  5 A  positioned within the housing of the vacuum cleaner of  FIG.  1   . 
         FIG.  7 B  is an enlarged view of a portion of  FIG.  7 A , illustrating an example airflow path through the shroud and housing. 
         FIG.  7 C  is a view similar to  FIG.  2   , alternately illustrating the shroud of  FIG.  5 A  positioned within the housing and illustrating an example airflow path. 
         FIG.  8 A  is a side view of the shroud of  FIG.  6    positioned within the housing of the vacuum cleaner of  FIG.  1   . 
         FIG.  8 B  is an enlarged view of a portion of  FIG.  8 A , illustrating an example airflow path through the shroud and the housing. 
         FIG.  8 C  is a view similar to  FIG.  2   , alternately illustrating the shroud of  FIG.  6    positioned within the housing and illustrating an example airflow path. 
     
    
    
     Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION 
       FIGS.  1 - 3    illustrate a vacuum cleaner  10 , according to an embodiment of the disclosure. In the illustrated embodiment, the vacuum cleaner  10  is a hand vacuum cleaner  10  useable for dry of wet and dry type extraction, although other types of vacuums, such as upright, cannister, box, or the like are contemplated. 
     The vacuum  10  of the illustrated embodiment includes a housing  12 , a collector or tank  14  providing a dirty air tank inlet  16 , and a battery  20  removably coupled to the housing  12 , with the housing  12  extending along an axis A generally in an axial direction AD between a first end  24  and a second end  28 . The vacuum  10  further includes a suction motor assembly  30  supported in the housing  12 , and the housing  12  includes a handle  32  having a switch  36 , a battery receptacle  38 , a dirty air inlet  16 , and exhaust outlets  40 . As described in greater detail below with reference to  FIGS.  3 ,  7 A -B, and  8 A-B, the suction motor assembly  30  is operable to generate a working airflow WA and create a working airflow path WAP from the dirty air inlet  16  to the exhaust outlets  40 . 
     As shown in  FIG.  1   , the exhaust outlets  40  are defined by a plurality of exhaust vents  42  that are formed in the housing  12  and positioned along the axis A between the first end  24  and the second end  28 . In the illustrated embodiment, the plurality of exhaust vents  42  includes forward vents  43  and rearward vents  44 . As illustrated in  FIG.  3   , the plurality of exhaust vents  42 , including the forward vents  43  and the rearward vents  44 , are located symmetrically on opposing sides of the housing  12 . In the illustrated arrangement, the plurality of exhaust vents  42  are located on opposite side of the handle  32 . In some embodiments, the plurality of exhaust vents  42  may be positioned on opposing upper and lower portions of the housing  12 . The handle  32  may be positioned adjacent a top of the housing  12  and may allow a user to grasp and carry the hand vacuum  10  during, for example, a vacuuming or carrying operation. A grip  45  is positioned along the handle  32  to increase a gripping ability of a user. 
     In the illustrated embodiment, the switch  36  is an ON/OFF switch  36  that is configured to activate (e.g., turn ON) and deactivate (e.g., turn OFF) the motor assembly  30 . 
     The tank  14  is removably coupled/mounted to the housing  12 , and, as shown in  FIGS.  1  and  2   , the housing  12  supports the tank  14  and includes a tank releasing button  68  that may be used to release the tank  14  from the housing  12 . In other embodiments, the housing  12  can support multiple tanks. In the illustrated embodiment, the tank releasing button  68  is positioned adjacent a top of the vacuum  10 . When the tank  14  is coupled to the housing  12 , a body of the tank  14  is positioned between the tank inlet  16  and the housing  12  and is configured to store extracted debris and/or liquid that is separated from the working airflow. Further, when the tank  14  is coupled to the housing  12 , the suction motor assembly  30  is operable to generate the working airflow from the dirty air tank inlet  16  to the exhaust outlet  40 . 
     Positioned inside the tank  14  and removably coupled to the housing  12  is a filter assembly  48  that includes a filter housing  52  and a filter member  56  encased in the housing  52 . The filter assembly  48  is configured to separate dust and debris from the working airflow WA to then be collected in the tank  14 . In the illustrated embodiment, a periphery or outer surface  18  ( FIGS.  1  and  3   ) of the of the filter housing  52  may be compressed or sandwiched between the tank  14  and the housing  12  to form a seal. In some embodiments, the outer surface  18  extends radially around the hand vacuum  10  to form a radial seal such that the filter assembly  48  forms the seal between the tank  14  and the housing  12 . 
     With specific reference to the magnified view of  FIG.  3   , the filter assembly  48  further supports a sealing member  22 , such as a gasket, ring, and/or the like. In the illustrated embodiment, the sealing member  22  is a radial gasket  22  that provides a seal between the tank  14  and the filter assembly  48 . In some embodiments, the gasket  22  may be integrally formed on the filter assembly  48 . As further illustrated in  FIG.  3   , a portion (e.g., the outer surface  18 ) of the filter housing  52  is generally z-shaped and forms a sealing area or contact between multiple surfaces of the tank  14  and housing  12 . As illustrated in  FIG.  1   , the outer surface  18  of the filter assembly  48  may terminate at an interface between the housing  12  and the filter assembly  48  and/or tank  14 . As illustrated in  FIGS.  1  and  3   , the outer surface  18  includes a lip  21  that covers an edge  23  at an open end of the tank  14  along the axial direction AD. In some embodiments, the outer surface  18  contours with a shape of the housing  12  and is compressed against the housing  12  so as to not cover the exhaust outlets  40 . For example, the lip  21  may be compressed between the housing  12  and the edge  23  along the axial direction AD except for, in some embodiments, in a region of the exhaust outlets  40 . In the region of the exhaust outlets  40 , the filter assembly  48  may still be radially compressed between the tank  14  and the housing  12  to provide the seal. 
     As illustrated in  FIGS.  1  and  3   , the tank inlet  16  is adjacent the first end  24  of the tank  14  and is permanently defined by the tank  14 . Extracted debris enters the tank inlet  16  once the hand vacuum  10  is activated (e.g., the suction motor assembly  30  is energized). A dust flap  72  may be coupled to the tank inlet  16  and positioned inside the tank  14  to prevent debris from exiting the tank  14  through the tank inlet  16  (e.g., when the suction motor assembly  30  is not energized). After separated debris is deposited in the tank  14 , the tank  14  may be removed, for example, through actuation of the release button  68 , and a user may empty the debris from the tank  14 . 
     Referring still to  FIGS.  1  and  3   , the suction motor assembly  30  includes a motor  74 , an impeller  78 , and a shroud  82 . In the illustrated embodiment, the impeller  78  may be a fan, airfoil, and/or the like, which includes a base plate  86 , a cover plate  90 , and a plurality of vanes  94 . As shown in  FIG.  3   , the base plate  86  can be coupled to an output shaft  98  of the motor  74  such that rotation of the shaft  98  drives actuation (e.g., rotation) of the impeller  78 . The cover plate  90  may be at least partially spaced from the base plate  86  and defines an impeller inlet  102 . In the illustrated embodiment, the motor shaft  98  rotates about a motor axis MA, which is aligned with an axis of IA of the impeller  78 . Referring briefly to  FIGS.  2  and  3   , the plurality of vanes  94  extend principally in the axial direction AD between the base plate  86  and the cover plate  90  such that rotation of the impeller  78  draws the working airflow WA generally in the axial direction AD through the impeller inlet  102  and expels the working airflow WA outwardly in a radial direction RD. In the illustrated embodiment, the radial direction RD and the axial direction AD are substantially perpendicular relative one another. 
     As introduced above, the removable battery  20  is received by the battery receptacle  38  and is configured to supply power to the motor  74 , which may be energized (e.g., by selective operation of the switch  36 ) to rotate the motor shaft  98  and thus the impeller  78 . Once actuated, the impeller  78  rotates to generate the working airflow WA through the vacuum  10 . 
     As illustrated in  FIGS.  1 - 3   , the impeller  78  is positioned generally within/inside the shroud  82  and is at least partially surrounded by the shroud  82  such that the shroud  82  is configured to at least partially redirect the working airflow WA. Positionable in the housing  12  between the suction inlet  16  and the motor  74 , the shroud  82  includes a first or forward wall  112  and a second or annular axial wall  116 . As shown in  FIG.  2   , the shroud  82  further includes one or more support members  118  configured to support the shroud  82  in the housing  12 . The support members  118  may be solid or hollow beams, arms, and/or the like. 
     With continued reference to  FIGS.  1 - 3   , the forward wall  112  faces the cover plate  90  and may cover portions and/or all of the cover plate  90 . The forward wall  112  further has a shroud inlet  120  that is generally aligned with the impeller inlet  102  in the axial direction AD. 
     In some embodiments, the shroud inlet  120  is generally cone-shaped and defines a diameter D measured along the axial direction AD. Stated another way, the shroud inlet  120  may have different diameters D depending on where along the axial direction AD the diameter D is measured. In the illustrated embodiment, the shroud inlet  120  has a frustoconical shape, and the diameter D of the shroud inlet  120  decreases as the inlet  120  approaches the annular axial wall  116  in the axial direction AD. In some embodiments, the portion of the forward wall  112  that includes/forms the shroud inlet  120  may follow an hour glass-shape such that the diameter D decreases and increases as the inlet  120  approaches the annular axial wall  116  in the axial direction AD. 
     Shown particularly in  FIG.  4   , the annular axial wall  116  extends from an outer perimeter OP of the forward wall  112  along the axial direction AD (e.g., in a direction of the motor axis MA). In some embodiments of the shroud  82 , such as the embodiment of a shroud  82   a  illustrated in  FIGS.  5 A,  5 B, and  7 A -C and the embodiment of a shroud  82   b  illustrated in  FIGS.  6 , and  8 A -C, the respective annular axial wall  116  may include an opening (e.g. opening  124   a  of shroud  82   a  and opening  124   b  of shroud  82   b ) configured to be aligned with the exhaust outlet  40 , particularly with the forward exhaust vents  43 . In each embodiment of the shroud  82 ,  82   a ,  82   b , the respective annular axial wall  116  may redirect the working airflow WA that exits the impeller  78  in the radial direction RD into the axial direction AD. In alternate example embodiments of the shroud (e.g., shroud  82   a , shroud  82   b ), the opening (e.g. opening  124   a  of shroud  82   a  and opening  124   b  of shroud  82   b ) allows the working airflow WA that exits the impeller  78  in the radial direction RD to pass unimpeded toward the exhaust outlet  40  (e.g., the forward exhaust vents  43 ). 
     Referring briefly back to  FIG.  2   , the illustrated forward vents  43  are shown as partially cross-sectioned, while the shroud  82  remains non-sectioned. The illustrated annular axial wall  116  of the illustrated shroud  82  may include one or more cutouts  128 , recesses, or the like formed therein to allow a portion of the working airflow WA exiting radially from the impeller  78  to pass through a portion of the shroud  82 . Working airflow WA that does not pass unimpeded by the shroud  82  may then bypass the first exhaust vent  43  such that the annular axial wall  116  does impede the working airflow WA and directs the working airflow WA in the axial direction AD to be exhausted through rearward exhaust outlets  44  (e.g., rearward exhaust vents  44 ). In some embodiments, the shroud  82  may not include recesses that allow radial working airflow WA to pass through such that all of the working airflow WA is exhausted through the rearward exhaust vents  44 . In other words, the annular axial wall  116  may impede working airflow WA from exhausting through the forward vents  43 , while the recesses  128  define openings that may allow working airflow WA to exhaust through the forward vents  43 . 
     Referring now to  FIGS.  5 A- 8 C , some of the differences between the shroud  82  and the alternate shrouds  82   a ,  82   b  will now be described in greater detail. One example construction of the vacuum cleaner  10  includes the shroud  82 , another example construction of the vacuum cleaner  10  includes the shroud  82   a , and yet another example construction of the vacuum cleaner  10  includes the shroud  82   b . It should therefore be understood that other elements of the vacuum cleaner  10  (e.g., other than the shrouds  82 ,  82   a ,  82   b ) are generally and substantially similar across embodiments of the vacuum cleaner  10 . 
     With specific reference to  FIGS.  5 A,  5 B, and  7 A- 7 C , some differences between the shroud  82  and the shroud  82   a  are described using reference numerals followed by the letter “a”. Similarly, with specific reference to  FIGS.  6  and  8 A- 8 C , some differences between the shroud  82  and the shroud  82   b  are described using reference numerals followed by the letter “b”. 
     Referring now to  FIGS.  7 A and  8 A , similar to the shroud  82 , the impeller  78  is positioned generally within/inside the shroud  82   a ,  82   b  and is at least partially surrounded by the shroud  82   a ,  82   b  such that the shroud  82   a ,  82   b  is configured to at least partially redirect the working airflow WA. Also positionable in the housing  12  between the suction inlet  16  and the motor  74 , the shroud  82   a  includes the first or forward wall  112  and a second or annular axial wall  116   a ,  116   b . The forward wall  112  faces the cover plate  90  of the impeller  78  and may cover portions and/or all of the cover plate  90 . The forward wall  112  of the shroud  82   a ,  82   b  further has the shroud inlet  120  that is generally aligned with the impeller inlet  102  in the axial direction AD. 
     As shown in  FIGS.  5 A and  6   , the annular axial wall  116   a ,  116   b  extends from the outer perimeter OP of the forward wall  112  along the axial direction AD (e.g., in a direction of the motor axis MA). The annular axial wall  116   a ,  116   b  further includes the opening  124   a ,  124   b  (introduced above), which is configured to be aligned with the forward exhaust vents  43 . In the illustrated embodiment, the annular axial wall  116   a ,  116   b  includes a first portion  132  and second portion  136 . In some embodiments, the first portion  132  is a lower portion and the second portion  136  is an upper portion, although different relative positions/arrangements are considered. As best illustrated in  FIGS.  5 A and  6   , the opening  124   a ,  124   b  is defined by at least a portion or part of the second portion  136 . 
     As illustrated in  FIG.  5 B , the annular axial wall  116   a  of the shroud  82   a , including the opening  124   a , defines an overall circumferential perimeter CP of the shroud  82   a . In the illustrated embodiment, the opening  124   a  occupies less than half of the overall circumferential perimeter CP, while the annular axial wall  116   a , not including the opening  124   a , occupies more than half of the overall circumferential perimeter CP. In some embodiments, the opening  124   a  occupies more than half of the overall circumferential perimeter CP and the annular axial wall  116   a , not including the opening  124   a , occupies less than half of the overall circumferential perimeter CP. It should be understood that  FIG.  5 B  could also be representative of the shroud  82   b  such the opening  124   b  occupies less than half of the overall circumferential perimeter CP, while the annular axial wall  116   b , not including the opening  124   b , occupies more than half of the overall circumferential perimeter CP. For the annular axial wall  116   a  of the shroud  82   a  and the annular axial wall  116   b  of the shroud  82   b , the opening  124   a ,  124   b  may be substantially continuous along the occupied portion of the overall circumferential perimeter CP. 
     As further shown in  FIG.  5 A , the annular axial wall  116   a  of the shroud  82   a  includes a lip  140  that extends into the opening  124   a . In the illustrated embodiment, the lip  140  extends from the forward wall  112 . In other embodiments, the lip  140  extends into the opening  124   a  from the first portion  132  of the annular axial wall  116   a . The lip  140 , which may be a curved lip  140 , extends at least partially in the radial direction RD and at least partially in the axial direction AD. As shown in  FIG.  5 B , the lip  140  may be positioned on the shroud  82   a  adjacent the opening  124   a  and between two of the cutouts  128  in the forward wall  112 . It can be seen in  FIG.  6    that the annular axial wall  116   b  of the shroud  82   b  does not include the lip, the significance of which will be described in greater detail below. 
     As illustrated in  FIGS.  7 A-C  and  8 A-C, the first portion  132  of the annular axial wall  116   a ,  116   b  overlaps the impeller  78  in the radial direction RD and the second portion  136  does not overlap the annular axial wall  116   a ,  116   b  in the radial direction such that, in some embodiments, the second portion  136  is recessed relative the first portion  132  relative the axial direction AD. In the illustrated embodiment, a line LL extending along the radial direction RD intersects at least one forward vent  43  of the exhaust outlets  40 , the opening  124   a ,  124   b , and the impeller  78 . In other words, at least a portion of the forward vents  43  and at least a portion of the opening  124   a ,  124   b  are substantially planer (e.g., positioned in a common plane). 
     As best shown in  FIGS.  7 A-B  and  8 A-B, working airflow WA that enters through the shroud inlet  120  flows into the impeller  78 , principally in the axial direction AD, and exits the impeller  78  principally in the radial direction RD. The annular axial wall  116   a ,  116   b , where present (e.g., not present in the opening  124   a ,  124   b ), redirects the working airflow WA in the axial direction AD. The opening  124   a ,  124   b , however, allows the working airflow WA exiting the impeller  78  to flow unimpeded by the annular axial wall  116   a ,  116   b  toward the forward vents  43  and out of the housing  12 . The presence of the opening  124   a ,  124   b  allows for greater air exhaustion, which may lead to decreased backpressure and/or increased airflow through the vacuum cleaner  10 . In some instances, the opening  124   a ,  124   b  may provide an outlet for liquid separated from the working airflow WA such that the separated liquid does not pass through or contact components (e.g., motor  34 , circuitry, or the like) of the vacuum  10 . 
     The working airflow WA that does not pass radially outwardly past the annular axial wall  116   a ,  116   b  may then bypass the forward vents  43  and exit the housing  12  via one or more rearward vents  44 . The lip  140 , as illustrated particularly in  FIGS.  7 A- 7 C , may smooth the transition of the working airflow WA passing through the opening  124   a  and out of the housing  12 . In some embodiments, the lip  140  may include perforations. In some embodiments, such as for the shroud  82   b  of  FIGS.  6  and  8 A- 8 C , the lip  140  may be omitted. 
     Although not specifically discussed herein with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the embodiments as described. 
     Various features of the invention are set forth in the following claims.