Patent Abstract:
A bagless vacuum cleaner system dustcup assembly and method for using said system with a vacuum cleaner apparatus to separate dirt from a mixture of dirt and air inducted into said vacuum cleaner apparatus. Said bagless vacuum cleaner system generally comprises a dustcup assembly, a handle assembly and a motor intake adaptor.

Full Description:
This application is a continuation of U.S. application Ser. No. 11/617,827 filed Dec. 29, 2006, now U.S. Pat. No. 7,422,614, which is a continuation of U.S. application Ser. No. 11/035,413 filed Jan. 14, 2005, now U.S. Pat. No. 7,163,568, which is a continuation of U.S. application Ser. No. 10/429,298, filed May 5, 2003, now U.S. Pat. No. 6,863,702, which is a continuation of U.S. application Ser. No. 09/759,396, filed Jan. 12, 2001, now U.S. Pat. No. 6,558,453, which claims the benefit of U.S. Provisional Application No. 60/176,356, filed Jan. 14, 2000. 

   FIELD OF THE INVENTION 
   The present invention relates to vacuum cleaners, and more particularly, to a bagless dust cup assembly to be used in lieu of a disposable dirt collection bag with an upright vacuum cleaner apparatus. 
   BACKGROUND OF THE INVENTION 
   The present invention is directed toward an improved air/dirt separation system for an upright vacuum cleaner. The invention is further directed toward an assembly that may be retrofitted into an existing bag-style upright cleaner. The assembly according to the invention replaces a disposable bag system with an easy-empty permanent dustcup and cleanable permanent filter. Although the system successfully supplants the throwaway dustbag in this retro-fit application, the broader scope of the invention contemplates creation of an entirely new vacuum system that is dedicated to the bagless concept. Alternatively, by substitution of components, it is contemplated that the assembly of the present invention may be used to configure an upright vacuum cleaner that is adapted for either bag or bagless use. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1   a  is a front elevational view of a vacuum cleaner according to the present invention; 
       FIG. 1   b  is a cross sectional view of the cleaner as seen along line B-B of  FIG. 1   a;    
       FIG. 2   a  is a front elevational view of a dustcup of the cleaner; 
       FIG. 2   b  is a rear and bottom perspective view of the dustcup; 
       FIG. 2   c  is a top and front perspective view of the dustcup; 
       FIG. 3   a  shows a top perspective view of the filter assembly of the present invention; 
       FIG. 3   b  shows a side and bottom perspective view of the filter assembly and the cyclone module of the present invention; 
       FIG. 4   a  is a top and side perspective view of a plenum chamber member; 
       FIG. 4   b  is a top perspective view of the plenum chamber member; 
       FIG. 4   c  is a top plan view of the plenum chamber member; 
       FIG. 4   d  is a bottom plan view of the plenum chamber member; 
       FIG. 5   a  is a top and side perspective view of a cyclone module; 
       FIG. 5   b  is a side elevational view of the cyclone module; 
       FIG. 5   c  is a top plan view of the cyclone module; 
       FIG. 5   d  is a bottom view of the cyclone module; 
       FIG. 6  is an exploded perspective view of the assembly at the lower end of the handle; 
       FIG. 7   a  is a rear perspective view of a rear handle bracket; 
       FIG. 7   b  is a front perspective view of the rear handle bracket; 
       FIG. 8   a  is a top and front perspective view of the front bracket; 
       FIG. 8   b  is a bottom and rear perspective view of the front bracket; 
       FIG. 9   a  is a top perspective view of a top-hinged support; 
       FIG. 9   b  is a top perspective view of the top-hinged support; 
       FIG. 9   c  is a top perspective view of the top-hinged support; 
       FIG. 10  is a front perspective view of a cover; 
       FIG. 11  is a view of the plenum chamber member and the top-hinged support connected together, with other portions of the assembly removed; 
       FIG. 12   a  is a top perspective view of the motor intake adaptor; 
       FIG. 12   b  is a bottom perspective view of the motor intake adaptor; and 
       FIG. 13  is a perspective view of the latch. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   The dustcup assembly according to the present invention is used in all upright vacuum cleaner apparatus  100  having a vacuum cleaner base portion  101 , a vacuum cleaner body portion or rear housing  102 , and a vacuum cleaner upstanding handle  104  ( FIGS. 1   a - 1   b ). The base portion  101  includes. a horizontally extending, elongated internal compartment  105  that receives a known rotating brush element (not shown) and cooperates with the body portion  102  to receive a known motor. The motor serves as a drive for the rotating brush and for a known suction fan or impeller. Rotation of the suction fan or impeller creates suction that is selectively communicated to a conventional hose (not shown), which may be operably connected to either the elongated internal compartment  105  containing the rotating brush element or to any of a number of known off-the-floor cleaning tools (not shown). 
   The body portion  102  is pivotally connected to the base portion  101  and has a rotational axis that is coaxial with the motor axis. The body portion  102  carries a filter/cyclone module, and has an upstanding handle  104  secured thereto. 
   A dustcup  106  ( FIGS. 2   a - 2   c ) is removably secured to the cleaner body portion  102 . The dustcup  106  is a molded plastic part that is preferably at least partially transparent, but may also be translucent or opaque. By having at least a part of the dustcup  106  transparent, the amount of collected dust can be readily seen by the operator and thereby visually indicates when the cup  106  should be emptied. 
   The dustcup  106  integrally provides and defines a dustcup chamber  108  and a dustcup passageway  110 . The dustcup chamber  108  is disposed toward a front side of the dustcup  106  and is open at a top section  107  of the dustcup  106  and closed at all other sections thereof. The dustcup chamber  108  receives and retains a dirt/dust mixture inducted into the vacuum cleaner apparatus  100  either by the rotating brush element or by any of the off-floor cleaning tools, and preferably, the dustcup chamber  108  has at least a transparent front wall  109 . Additionally, the dustcup chamber is provided with a step-like barrier  111  at the base thereof. Dirt-laden air flowing spirally downward impinges against the barrier  111  and dirt particles are caused to separate from the air by striking the barrier  111 . The filter/cyclone module is received by the top section  107  of the dustcup  106  and communicates with both the dustcup chamber  108  and the dustcup passageway  110 . 
   The dustcup passageway  110  is disposed toward a rear side of the dustcup  106  and defines a path for a stream of clean air to flow from an upper end of the dustcup  106  to a lower end of the dustcup  106 . The dustcup passageway  110  serves as a conduit that connects a lower motor inlet (not shown) to an upper plenum chamber  200 . In operation, the dustcup passageway  110  communicates suction from the motor/fan to the dustcup  106 , as will be apparent from the following description. 
   A dustcup handle  112  is attached to the front wall  109  of the dustcup  106  and provides a means for an operator of the vacuum cleaner apparatus  100  to easily grasp and hold or transport the dustcup  106  when it is independent of the body portion  102 . 
   The dustcup  106  has a generally round or circular top end region  113  that assists in receiving a cyclonic module. The inventors have found that the circular configuration of the dustcup top end region  113  is superior to other contours. However, it has also been found that the dustcup  106  may deviate from the round configuration as one moves downwardly away from the top end without negatively affecting the dirt-separating performance. 
   As will be described hereinafter, the cyclonic module receives a dirt-laden stream of air and separates the dirt from the air. The dirt is retained in the dustcup chamber  108 . The dirt-free air is directed to the motor/fan via the dustcup passageway  110 . The cyclonic module includes a filter assembly  114  ( FIGS. 3   a - 3   b ), a plenum chamber member  116  ( FIGS. 4   a - 4   d ), and a cyclone module  118  ( FIGS. 5   a - 5   c ). 
   The filter assembly  114  includes a filter  124  and a cup-like filter receptacle or holder  126 . The filter receptacle  126  removably fastens to and extends downwardly from the cyclone module  118  and has a generally frustoconical form. 
   The filter receptacle  126  is provided with a circular opening  127  defined by its large end  128  and is thus adapted to receive and support the filter  124 . The filter  124  is generally cone-shaped, with an open top end  129 , and is formed from an open cell flexible foam material. The filter  124  is slidably inserted into the circular opening  127  of the filter receptacle  126 . The filter receptacle  126  and associated filter  124  are adapted to be received by the cyclone module  118 . The filter receptacle  126  is provided at its large open end  128  with a plurality of mounting hooks  121 . The mounting hooks  121  extend upwardly from and are spaced circumferentially about the open end  128 . Each of the hooks  121  has a circumferentially directed projection  121   a  that defines a slot-like void  122  between a bottom edge  121   b  of the projection  121   a  and the top edge of the open end  128 . Each of the mounting hooks  121  also has on its vertically oriented outside surface a rib-like projection  123 . The projection  123 , which is situated proximate to the slot-like void  122  defined by each of the hooks  121 , extends vertically across the outside surface of each of the mounting hooks  121  and works with the hooks  121  to removably attach the filter assembly  114  to the cyclone module  118  in a manner to be explained in subsequent discussion. In addition to the mounting hooks  121  the filter receptacle  126  is also provided at its large open end with a plurality of bump-like structures  125 . The bump-like structures  125  extend a relatively short distance upward from and are spaced circumferentially about the open end  128  and between the mounting hooks  121 . When the filter assembly  114  is attached to the cyclone module  118 , the bump-like structures  125  engage the cyclone module  118  in a manner that will also be subsequently described. 
   The filter receptacle  126  is further comprised of a plurality of elongated, rib-like appendages  191  that extend downwardly from the large open end  128  of the receptacle  126 . Each of the rib-like appendages  191  is angled inwardly relative to the open end  128  and connect at their lower end to an annular collar  192  that is integrally joined to the periphery of a flat, circular top portion  193  of a cylindrical lower portion  194  of the filter receptacle  126 . The cylindrical lower portion  194  is provided with a series ribs of  195 . The ribs  195 , which are molded into the outer surface of the cylindrical lower portion  194 , extend vertically along the outer surface and are separated from one another in the circumferential direction so as to define a series of depressions  196  between the ribs  195 . The ribs  195  and the depressions  196  cooperate to create a gripping surface that can be grasped by a user of the vacuum cleaner apparatus  100  and to impart rotational movement to the receptacle  126  for purposes to be subsequently described. 
   The filter receptacle  126  is further provided with a porous screen element  197 . The screen element  197 , which is preferably fabricated from interwoven nylon filaments, engages the periphery of the large open end  128 , the rib-like appendages  191  and the annular collar  192  so as to form a permeable barrier between the filter  124  and the air-dirt mixture that swirls about the interior of the dirtcup chamber  108 . The screen element  197  serves to prevent relatively large dirt particles from contacting and adhering to the filter  124 . 
   The cyclone module  118  ( FIGS. 5   a - 5   c ) is disposed beneath the plenum chamber member  116  and is secured to the plenum chamber member  116  via a plurality of upstanding screw-receiving bosses  140 . The plenum-chamber member  116  cooperates with the cyclone module  118  to define a peripheral labyrinth or tongue and groove sealing interlock  117  between a lower edge  119  of the plenum chamber member  116  and an upper surface edge  120  of the cyclone module  118 . This provides a means for positive positioning or registration between these elements of the assembly and air-tight sealing without the need for additional gaskets. The plenum chamber member  116  is further provided with a handle  115  that is removably fastened to the top of the plenum chamber member by known fastening means such as screws (not shown) that are received by the screw-receiving bosses  140  provided in the cyclone module  118 . 
   The cyclone module  118  includes an upper wall  142  that has a peripheral opening  141  that communicates with a peripheral volute passage  144  of a volute structure  145 , and a downwardly-flanged central opening  143  around which a plurality of relatively flat, elongated appendages  146  downwardly extend. The elongated appendages  146  angle inwardly relative to the central opening  143  and they are connected at their lower ends to a disk-like portion  139 . The appendages  146  and the disk-like portion  139  define a frustoconical, cage-like structure  150 . The cage-like structure  150  is dimensionally configured like the inside surface of the filter  124  and is thus made capable of receiving the filter  124 . The structure  150  acts both as a support for the filter  124  and as a means to prevent it from inwardly distorting or collapsing due to negative pressure when the vacuum cleaner apparatus  100  is in operation. 
   The wall  142  of the cyclone chamber  118  is provided with a first plurality of arcuate raised structures  153 . The structures  153  are arranged about the central opening  143  in a circular pattern and they define a first plurality of relatively deep inverted channels  154  that have openings  155  on the bottom surface  147  of the upper wall  142  and that further have openings  156  on the vertically extending sides  157  of the channels  154 . 
   Additionally, the upper wall  142  of the cyclone chamber  118  is provided with a second plurality of arcuate raised structures  158 . The structures  158  are arranged about the central opening  143  and located between the structures  153  so that the raised structures  158  lie on the same circle that passes through the raised structures  153 . The raised structures  158  define a second plurality of inverted channels  159  that are shallow relative to the inverted channels  154  and that have openings  160  on the bottom surface  147  of the cyclone module  118 . Also on the bottom surface  147 , a pair of rib-like projections  162  and  164  are provided. The projection  162  forms a circular arc and lies just radially outside of the inverted channels  154  and  159 . The projection  164  forms a continuous circle and is positioned radially between the central opening  143  and the inverted channels  154  and  159 . Both of the rib like projections  162  and  164  extend a short distance vertically downward from the bottom surface  147 ; however, the rib-like projection  162  extends farther downwardly than the rib-like projection  164 . 
   The first plurality of inverted channels  154  and the second plurality of channels  159  are also situated on the wall  142  of the cyclone module  118  so that the bottom openings  155  receive the mounting hooks  121  of the filter receptacle  126  and so that the openings  160  receive the bump-like structures  125  also of the filter receptacle  126 . Once the mounting hooks  121  and the bump-like structures  125  are so received by the bottom openings  155  and  160 , they are caused to rotatably move within the channels  154  and  159  so that, in the case of the mounting hooks  121 , the circumferentially directed projections  121   a  and the rib like projections  123  are received by the side openings  156  of the channels  154  to secure the filter receptacle  126  to cyclone module  118  and so that, in the case of the bump-like structures  125 , the structures  125  cause the top  129  of the filter  124 , which projects a short distance vertically above the top of the filter receptacle  126 , to become compressed against the circular rib-like projection  164  and the portions of the bottom surface  147  of the cyclone module  118 , lying radially inward and outward of the projection  164 . The hooks  121  and the bump-like structures  125  are caused to rotatably move in the above described fashion when the user of the vacuum cleaner apparatus  100  grasps the downwardly extending portion of the filter receptacle  126  and twists the receptacle  126  in a clockwise direction relative to the bottom surface  147  of the wall  142  of the cyclone module  118 . When the receptacle  126  is so twisted, the bottom edge  121   b  of the projection  121   a  engages the top surface of the upper wall  142  and the rib-like projection  123  engages an outer edge of the opening  156  of the inverted channel  154  to resist rotational movement of the receptacle  126  until such time as the operator desires to remove the receptacle  126  and the filter  125  from the module  118 . It should also be noted that, when the projections  121   a  and the ribs  123  engage the inverted channels  154  and the wall  142  in the above described manner, a portion of the outside surface of the top of the receptacle  126  rests just inside of the projection  164  an thus provides an outer seal for the filter  124 . 
   The inlet passageway or chimney  130  of the plenum chamber member  116  vertically aligns with the peripheral volute opening  141  of the cyclone module  118  and serves to introduce dirt-laden air tangentially into the top of the chamber  108  of the dustcup  106  via the cyclone module  118 . The volute structure  145  extends downwardly from the upper wall  142  and defines the passage  144  that extends spirally downward from the upper wall  142 . 
   Finally, a resilient gasket element  161  is mounted on the lower surface  143  of the flange that forms the perimeter of the cyclone module. The gasket  161  provides the seal between the cyclone module  118  and the top surface of the dustcup  106 . 
   When the plenum chamber member  116  and the cyclone module  118  are properly assembled an air space or chamber  200  is provided between the top wall  147  of the cyclone module  118  and the bottom surface of the plenum chamber member  116 . This air space  200  is required in order to allow airflow to communicate between the suction fan and the dustcup intake port. 
   To complete the adaptation of the dustcup assembly in this retro-fit application there is a need for components that will accept the dustcup  106  into the existing housing  102  with minimal impact to existing configuration and will enhance operator interface. Additionally, in order to maintain the minimum size of the shipping carton, the upstanding handle  104  is packaged detached from the vacuum body  102 . The upstanding handle  104  includes a peripheral handle rib  165  at the lower portion thereof. The handle rib  165  locates and retains the components that will ultimately interact with the dustcup  106 . 
   The lower handle assembly  170  ( FIG. 6 ) includes a rear handle bracket  171  ( FIGS. 7   a - 7   b ), a front handle bracket  172  ( FIGS. 8   a - 8   b ), a top-hinged support  174  ( FIGS. 9   a - 9   c ), and a top cover  176  ( FIG. 10 ). These components, in conjunction with a latch  178  ( FIG. 13 ) and various conventional springs and gaskets, define the assembly  170  that is permanently attached at the base of the upstanding handle  104 . When the upstanding handle  104  is mounted to the top of the rear housing  102  by the operator, the above listed parts of the assembly  170  work in concert with the dustcup  106 , as will be apparent from the following. 
   To complete the adaptation of the dustcup  106  to the existing upright rear housing  102  it is necessary to provide means for getting airflow from the suction fan into the dustcup passageway  110  that is located at the rear of the dustcup  106 . A motor intake adapter  180  ( FIGS. 12   a - 12   b ) provides a transition between the dustcup passageway  110  and the suction fan. The adaptor  180  is a molded plastic structure having a flat, generally rectangular base portion  181 , a walled structure  184  extending upwardly from the base portion  181 , a thin, vane-like structure  186  extending upwardly from the base portion  181  and outwardly from a side of the walled structure  184 , and a mounting flange  182 . The walled structure  184  defines a passageway  188  having a top opening  187  and a bottom opening  189  that is situated in the base portion  182  of the adaptor  180 . The passageway is preferably provided with an open cell foam filter  190  that serves as a final means to catch any dirt particles before the air stream enters the suction motor. The vane-like structure  186  is provided with a semi-circular aperture  185 . When installed in the vacuum cleaner apparatus  100 , the bottom side of the base portion  181  and the opening  189  of the passageway  188  are situated at the opening of the intake of the suction motor, the vane-like structure  186  engages an already existing post-like projection within the rear housing  102 , and the mounting flange  182  is captured by a preexisting rib structure inside the rear housing  102  and the motor cover. When the motor cover is attached to the rear housing  102 , the flange  182  of the adapter  180  is trapped between the suction motor intake and the preexisting rib structure of the housing  102  and a seal is created between the face of the motor intake and the motor intake adapter  180 . A molded gasket (not shown) is positioned on the top perimeter surface of a walled structure  184  and acts as the resilient seal that is compressed by the lower flange of the dustcup passageway  110  when the dustcup  106  is pivoted into its working position partially recessed inside the rear housing  102 . 
   In operation, with dustcup assembly installed, motor intake to suction fan is in fluid communication with a suction nozzle (not shown). Negative pressure is generated by the suction fan and pulls air through the system. Dirt mixed with air enters the nozzle, travels through the hose and continues through the hose connector. The hose connector is mounted to a chimney extension  175  on the tophinged support  174 . Air flows through the inlet  131  on the plenum chamber and into the top of the cyclone module intake port  143  and is caused to bend 90 degrees by the volute  145  and internal rib construction. 
   Air exits the cyclone inlet and enters the top of circular portion of the chamber  108  of the dustcup  106  in a path tangential to the inner wall. After traveling about halfway around the inside circumference of the dustcup chamber  108 , the air/dirt mixture encounters the helical downward-ramped spiral  149  of the base of the cyclone intake. As the air/dirt mixture encounters the spiral  149 , the mixture is encouraged to travel axially downward while still maintaining the centrifugal forces of high speed rotation that effectively separates the large particle matter from the air flow. Air passing the open end of the spiral acts as a siphon to help pull incoming air even more quickly into the interior of the dustcup chamber  108 . The greater that the velocity is of the air entering the dustcup chamber  108 , the greater is the efficiency of the system. 
   By introducing this ramped helical profile  149  to the interior contour, dirt is biased away from, the filter assembly  114 , providing less dwell time for the air/dust mixture to be in proximity to the filter assembly  114 . As the air/dust mixture is forced into a rapid circular motion, centrifugal forces act upon the more dense dust particles, pressing them against the inside walls of the dustcup chamber  108  and away from the filter assembly  114 . This reduces the effects of negative air-pressure that might otherwise cause dust to go directly into the filter  124  instead of precipitating to the base of the dustcup chamber  108 . The distinct advantage of locating the filter  124  in the top area of the dustcup chamber  108  is to keep it out of the accumulation of dust and debris that gather in the dustcup  106  and to maintain unimpeded air flow until the cup  106  is filled with dirt. There is less chance that dirt will collect around the filter element  124  and allows easier debris removal from the filter surface when servicing by the operator. After dirt and air enter the dustcup chamber  108  and are separated by centrifugal forces, because the air has less density than the dirt, it flows into the center area of the dustcup chamber  108  where it travels upward, attracted by the negative pressure area proximate to the filter  124 . The air travels past the screen element  197  and then through the open cell filter  124  and enters the plenum chamber  200 , while minute debris is blocked by the filter. The plenum chamber  200  is defined by the sealed space between the cyclone module  118  and the plenum chamber member  116 , and provides, a communication path for filtered air from the dustcup chamber  108  to the dustcup passageway  110 . Because the plenum chamber  200  is in fluid communication with the top of the clean passageway  110  of the dustcup  106 , filtered air proceeds to the motor intake and is ultimately routed into a HEPA filter element  199  before it is exhausted to atmosphere. 
   To empty the contents collected inside the dustcup  106  the operator must pull the spring-loaded latch  178  that is located on the front side of the top cover  176 . The latch  178  is provided with a latch projection  179  that disengages from a latch projection receptacle  173  provided in the front handle bracket  172 . Once the latch projection  179  clears the latch projection receptacle  173 , the top cover  176  and the top-hinged support  174  are free to pivot upwardly and are biased in this direction under influence of a coiled compression spring  183  nested between the front handle bracket  172  and the top-hinged support  174 . When the top cover  176  and top-hinged support  174  pivot upwardly the outer flange skirt  177  of the top-hinged support  174  raises and allows the dustcup  106  to be removed without this intended interference. The operator grasps the handle  112  of the dustcup  106  and removes the dustcup  106  by pivoting it away from the rear housing  102 . There is slight pressure required to release the dustcup  106  from the housing  102  as the projection  138  on plenum chamber member  116  is designed to create a slight interference fit with the underside of the top wall in the rear housing  102  to prevent the dustcup  106  from unintentionally falling out of the unit. To empty the dustcup  106  the operator must grasp the handle  115  attached to the top of the plenum chamber member  116  and lift upward. The plenum chamber member  116 , cyclone module  118  and filter assembly  114  will come out from the inside of the dustcup  106  allowing easy emptying of contents. If cleaning of the filter  124  is also needed at this time the operator must turn the filter receptacle  126  by grasping the cylindrical lower portion  194  thereof and rotating the receptacle  126  through the minimal arc sufficient to disengage the mounting hooks  121  from the inverted channels  154 . This action causes the filter assembly  114  to be released from the cyclone module  118 . The filter assembly  114  can then be removed for final cleaning and servicing. After the filter assembly  114  is cleaned, it can be re-installed by reversing the foregoing directions for disassembly. The plenum/cyclone assembly can then be re-positioned inside the dustcup  106  and the cup  106  can then be reinstalled into the rear housing  102 . 
   Because the hose connector is mounted into the pivoting cover assembly, the hose connector disengages the intake chimney  175  of the top-hinged support  174  when opened and re-seals to the intake chimney  175  after the cover  176  is positioned in the closed position. When the cover  176  is in the fully closed (down) position the perimeter flange  177  resides on the outside of the upper flange of the dustcup  106 , thus holding the dustcup  106  in the proper operating position without fear that the cup  106  will fall from the unit. As noted hereinbefore, the hose connector mates with the chimney extension  175  of the top cover to provide air continuity in the sealed system. 
   While the preferred embodiment of the invention has been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention.

Technology Classification (CPC): 8