Abstract:
An upright suction cleaner having a base, a body pivotally mounted on the base, a suction device, and a dirt separation system. The dirt separation system has a first and second dirt separators. the first of which may include an air-pervious shroud having a plate extending from it. An airflow path extends from the base, through the separation system, and into the suction device. A dirt collecting system is mountable to the body, and includes a first chamber to receive dirt separated by the first dirt separator, and a second chamber to receive dirt separated by the second dirt separator. The chambers are adjacent one another when mounted to the body. A tube forming part of the airflow path between the dirt separation system and the suction device is selectively mountable adjacent the dirt collecting system. An elevator assembly is provided to attach the dirt collecting system to the body.

Description:
This application is a continuation of U.S. application Ser. No. 11/281,796, filed Nov. 18, 2005, now U.S. Pat. No. 7,228,592, which is a continuation of U.S. application Ser. No. 10/430,603, filed May 6, 2003, abandoned, which is a continuation of U.S. application Ser. No. 09/759,391, filed Jan. 12, 2001, now U.S. Pat. No. 6,910,245, which claims the benefit of U.S. Provisional Application Ser. No. 60/176,374, filed Jan. 14, 2000, the entire contents of which are incorporated herein by reference in their entirety. 

   FIELD OF THE INVENTION 
   This invention relates to an improved upright vacuum cleaner having a cyclonic air path. More particularly, this invention relates to such a vacuum cleaner as provides the operator with improved performance features such as a visual indication of the condition of a removable filter to allow for more timely cleaning of such filter, an improved filter insertion and removal arrangement that allows for easy maintenance, as well as other improvements as will be described below. 
   BACKGROUND OF THE INVENTION 
   In selecting a vacuum cleaner for home use, consumers today have many choices including a choice between an upright and a canister style vacuum cleaner, a choice between a bagged or a bag less dirt collection, and, a choice between a cyclonic versus a non-cyclonic cleaning action. Typically, two very important factors in the consumer&#39;s decision regarding the purchase of a vacuum cleaner are the ease of use of the vacuum cleaner and its cleaning effectiveness. Based on these factors, the bag less style of upright vacuum cleaner has become popular recently because it no longer requires the unpleasant task of periodically changing vacuum cleaner bags. Instead, the consumer merely removes the dust cup or container and empties it over a trash receptacle. Occasionally, the consumer must also clean out a removable filter within the dust cup that traps smaller particles of dirt. One of the problems associated with the task of emptying the dust cup is that the top of the dust cup is typically open to the air thus allowing that dust previously vacuumed, can be released back into the air during the process of transporting the dust cup to the trash receptacle. 
   Another feature of today&#39;s bagless vacuum cleaners is that the dust cup or container is typically made of clear plastic so that the operator can observe the cleaning action of the vacuum cleaner. This visual effect lets the operator monitor the effectiveness of the cleaning action and determine when the container should be emptied or the filter cleaned. Examples of such bagless upright vacuum cleaners can be found in U.S. Pat. Nos. 6,146,434; 6,070,291; and, 5,558,697. The problem with relying on this visual assessment of the cleaning action is that most consumers may not realize when the cleaning effectiveness has deteriorated by simply viewing the cleaning action. In fact, the cleaning effectiveness is also dependent upon the condition of any filtering devices disposed in the airflow path and if such filter is clogged or dirty, the cleaning effectiveness of the vacuum cleaner can be compromised without the operator being able to visually detect such condition. Accordingly, it would be beneficial if a bagless upright vacuum cleaner provided some additional means for determining the cleaning effectiveness particularly with respect to any filter devices that may be included with the bagless vacuum cleaner. 
   Of further importance in the operation of such bagless vacuum cleaners is the actual task of removing and reinstalling the dirt-collecting chamber so that the dirt can be emptied into a trash receptacle. Often times the operator has to make several attempts to align the dirt-collecting chamber properly for continued operation. It would be advantageous if the bagless vacuum cleaner included a simple and easy to use arrangement for aligning and reinstalling the dirt collecting chamber following a routine exercise of emptying the chamber. 
   SUMMARY OF THE INVENTION 
   One exemplary aspect of the present invention provides an upright suction cleaner having a floor engaging base unit, a body unit pivotally mounted on the base unit, a suction generating device disposed on the body unit, and a dirt separation system disposed on the body unit above the suction generating device. The dirt separation system has a first dirt separator and a second dirt separator, and the first dirt separator includes an air-pervious shroud having a plate that extends radially from the shroud. A working airflow path extends from the base unit, through the dirt separation system and into the suction generating device. A dirt collecting system is selectively mountable to the body unit, and includes a first chamber adapted to receive a first amount of dirt separated from the working airflow path by the first dirt separator and a second chamber adapted to receive a second amount of dirt separated from the working airflow path by the second dirt separator. The first and second chambers are located adjacent one another when mounted to the body unit. A tube forms part of the airflow path between the dirt separation system and the suction generating device. The tube is selectively mountable to the body unit adjacent the dirt collecting system. An elevator assembly is located below the dirt collecting system and includes a movable lever. The elevator assembly is adapted to raise to attach the dirt collecting system to the body unit when the movable lever is placed in a first position, and to lower to release the dirt collecting system from the body unit when the movable lever is placed in a second position. The first chamber, second chamber and tube are simultaneously visible to an operator when mounted to the body unit. 
   Another exemplary aspect of the present invention provides an upright suction cleaner having a floor engaging base unit, a body unit pivotally mounted on the base unit, a suction generating device disposed on the body unit, and a dirt separation system disposed on the body unit above the suction generating device. The dirt separation system has a first dirt separator and a second dirt separator. A working airflow path extends from the base unit, through the dirt separation system, and into the suction generating device. A dirt collecting system is selectively mountable to the body unit, and includes a first chamber adapted to receive a first amount of dirt separated from the working airflow path by the first dirt separator, and a second chamber adapted to receive a second amount of dirt separated from the working airflow path by the second dirt separator. The first and second chambers are located adjacent one another when mounted to the body unit. A tube forms part of the working airflow path between the dirt separation system and the suction generating device, and is selectively mountable to the body unit. An elevator assembly is located below the dirt collecting system and adapted to raise to attach the dirt collecting system to the body unit and lower to release the dirt collecting system from the body unit. 
   Another exemplary aspect of the present invention provides an upright suction cleaner having a floor engaging base unit, a body unit pivotally mounted on the base unit, a suction generating device disposed on the base unit or the body unit, and a dirt separation system disposed on the body unit. The dirt separation system has a first dirt separator and a second dirt separator. A working airflow path extends from the base unit, through the dirt separation system. and into the suction generating device. A dirt collecting system is selectively mountable to the body unit, and includes a first chamber adapted to receive a first amount of dirt separated from the working airflow path by the first dirt separator and a second chamber adapted to receive a second amount of dirt separated from the working airflow path by the second dirt separator. The first and second chambers are located adjacent one another when mounted to the body unit. A tube forms part of the working airflow path between the dirt separation system and the suction generating device. The tube is selectively mountable to the body unit adjacent the dirt collecting system. The first chamber, second chamber and tube are simultaneously visible to an operator when mounted to the body unit. 
   Another exemplary aspect of the present invention provides an upright suction cleaner having a floor engaging base unit, a body unit pivotally mounted on the base unit, a suction generating device disposed on the base unit or the body unit, and a dirt separation system disposed on the body unit. The dirt separation system has a first dirt separator and a second dirt separator. A working airflow path extends from the base unit, through the dirt separation system, and into the suction generating device. A dirt collecting system is selectively mountable to the body unit, and includes a first chamber adapted to receive a first amount of dirt separated from the working airflow path by the first cyclonic dirt separator, and a second chamber adapted to receive a second amount of dirt separated from the working airflow path by the second dirt separator. An elevator assembly is located below the dirt collecting system and adapted to raise to attach the dirt collecting system to the body unit and lower to release the dirt collecting system from the body unit. 
   Another exemplary aspect of the present invention provides an upright suction cleaner having a floor engaging base unit, a body unit pivotally mounted on the base unit, a suction generating device disposed on the body unit, and a dirt separation system disposed on the body unit above the suction generating device. The dirt separation system has a first cyclone separator. A working airflow path extends from the base unit, through the dirt separation system, and into the suction generating device. A dirt collecting system is selectively mountable to the body unit, and includes a first chamber adapted to receive a first amount of dirt separated from the working airflow path by the first cyclonic dirt separator. An elevator assembly is located below the dirt collecting system and has a movable lever. The elevator assembly is adapted to raise to attach the dirt collecting system to the body unit when the movable lever is placed in a first position, and to lower to release the dirt collecting system from the body unit when the movable lever is placed in a second position. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will now be more fully described with reference to the accompanying drawings in which: 
       FIG. 1  is a perspective view of a front of the vacuum cleaner constructed in accordance with the present invention. 
       FIG. 2  is a perspective view of a rear of the vacuum cleaner constructed in accordance with the present invention. 
       FIG. 3  is an exploded perspective view of the vacuum cleaner according to the present invention. 
       FIG. 4  is a front elevational view of a front of a vacuum cleaner showing dirt and filter condition indicators. 
       FIG. 5  is a perspective view of the dirt collecting enclosure portion of the present invention. 
       FIG. 6  is a perspective view of the filter element portion of the present invention. 
       FIG. 7  is a perspective view of the end cap portion of the cyclone body of the present invention. 
       FIG. 8  is a perspective view of the cyclone body of the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention is directed toward an improved upright vacuum cleaner that has a plurality of cyclone filtration chambers and other mechanical filter means. The present invention uses progressive filtration wherein larger particles are removed first and then progressively smaller particles are removed from the air stream until, finally, very small particles are removed. As seen in  FIG. 1 , the vacuum cleaner of the present invention has a base  12 , a rear housing  14  and an upstanding handle (see  FIG. 3 ). The handle can be packaged separate and apart from the rear housing  14  and can be easily assembled by the user. The handle  10  includes a yoke or laterally split attachment arms that are inserted into accommodating recesses in the rear housing  14 . 
   The base  12  includes a brush roll (not shown) that is selectively rotated by a drive belt (not shown), such brush roll and drive belt being constructed according to well known techniques. The drive belt is driven by a shaft  80   a  off of motor/fan assembly  80  as shown in  FIG. 3 . The motor can be disposed in a bottom portion of the rear housing  14 , which is rotatably connected to the base  12 . Additionally, the motor/fan assembly  80  can be disposed in a plenum chamber created by the air duct and rear housing/motor cover seal  86 . The drive belt may be engaged/disengaged from the brush roll by operation of a pulley via a slide lever  16  to thereby disengage the brush roll as is desired when cleaning hard floor surfaces. As seen more clearly in  FIG. 2 , a tube  20  extends from the base  12  and communicates air and dirt upwardly from the base  12  to a hose  22 . The hose  22  extends upwardly from the tube connection around a hose hook of a top rear portion of the rear housing  14  and down to the base of the rear housing  14  and under a hose retention member  26 . The free end of the hose  22  connects to a first end of a conduit  28 . The second end of the conduit  28  is connected to a dirt sensor housing  29 . 
   The dirt sensor housing  29  extends from the conduit  28  to a rear portion of a dirt collecting enclosure  30  and acts as an input port so as to be sealingly engaged to the rear of the dirt collecting enclosure  30 . The dirt sensor housing  29  can have gaskets molded or installed therein. Additionally, the dirt sensor housing  29  is formed having a bend therein so as to extend from a downwardly facing inlet to a laterally or horizontally facing outlet that is then connected to the rear portion of the dirt collecting enclosure  30 . It would also be possible to achieve the benefits of the present invention if the inlet to the dirt sensor housing  29  were disposed in a horizontally; that is, oriented in the same manner as the horizontally facing outlet. 
   As seen in  FIG. 5 , the dirt collecting enclosure  30  has a first large chamber  32  and a smaller chamber  34 . Air and dirt are introduced into the first large chamber  32  in a tangential manner to thereby achieve a cyclonic airflow. Each of the first and second chambers  32 ,  34  has an open upper end and a closed bottom side. The dirt sensor housing  29  sealingly engages a side of the large chamber  32  at a top end thereof and surrounds an input opening  36  to the large chamber  32 . The input opening  36  is a notched opening at the top end of the first large chamber  32 . Of course, the input opening to the first large chamber  32  can be disposed in the side of the large chamber  32  thereby allowing that the upper edge of the first large chamber is continuous about its circumference. An upper edge of the dirt collecting enclosure  30  at the first large chamber  32  includes a rim or ledge. A filter element  40  is disposed in the first large chamber  32  and is laterally adjacent the input opening  36 . 
   As seen in  FIG. 6 , the filter element  40  includes an upper ring-shaped circular portion  42 , a central frustoconical portion  44 , and a lower ring-shaped portion  46 . The upper ring-shaped portion  42  rests or is seated on the ring or ledge of the large first chamber  32  so that the body of filter  40  extends into the large first chamber  32 . It should be noted that the upper ring-shaped portion  42  of filter  40  is effective for essentially closing off the large first chamber  32 . This is particularly effective during the process of emptying the dirt collecting enclosure  30  in that the seating of the filter  40  of the upper opening of the first chamber  32  substantially reduces the occurrence of dirt escaping the dirt collecting enclosure  30  when the user is emptying the dirt collecting enclosure  30  into a trash receptacle. In this manner, the filter  42  acts as both a filter and a seal. 
   The frustoconical portion  44  is perforated and serves as a filter surface. The lower ring shaped portion  46 , which includes a downwardly extending peripheral flange, serves as a baffle plate and separator for larger particles that precipitate into the bottom of the first large chamber  32 . Air from the first large chamber  32  flows through the filter member  40  and upwardly into a second cyclone  50  (see  FIG. 3 ). The second cyclone is disposed relatively above the dirt collecting enclosure  30  and is operable to deposit or direct smaller dirt particles into the second chamber  34  of the dirt collecting enclosure  30 . More specifically, relatively clean air from the first chamber  32  tangentially enters the second cyclone  50  and the cyclone chamber provided thereby via an inlet defined by the union of the cyclone body  52  and the cyclone end cap  54  (see  FIGS. 7 and 8 ). 
   The cyclone body  52  includes a circular first body portion that merges into a downwardly extending tube portion  52   a . The end of the tube portion  52   a  includes a flange and a neck, the neck extending into and sealing the second chamber  34  with the flange abutting the end face of the second chamber  34 . Air is introduced tangentially into the second cyclone  50  and spirals around the neck and downwardly into the bottom of the second chamber  34  so as to carry the smaller particles of debris therewith. The clean air from the second chamber  34  exits via the outlet tube  56  provided by the cyclone end cap  54  and flows laterally across the vacuum cleaner body and into the top end of filter tube  60 . The filter tube  60  is disposed substantially symmetrically on the opposite side of the first chamber  32  as the second chamber  34 . More specifically, the air that enters a cylindrical filter member  62  disposed within filter tube  60 , flows through the filter element  62  and exits via an outlet at the bottom of the filter tube  60 . Air is communicated from the outlet of the filter tube  60  to the motor/fan assembly  80  and then to atmosphere via a HEPA filter  82 . 
   As seen in  FIG. 3 , the vacuum cleaner includes an elevator assembly  70  that permits easy installation and sealing engagement of the dirt collecting enclosure  30  and filter tube  60  with the rear housing  14 . The elevator assembly  70  is mounted to the rear housing  14  relatively beneath the dirt collecting enclosure  30  and filter tube  60  and includes a handle  72  that is laterally shifted or pivoted. Of course, other actuation mechanisms can be utilized as well and still achieve the benefits of the present invention. For instance, a rotatable knob can achieve the same actuation effect as the lever or handle  72 . Movement of the handle  72  causes an elevator platform  74  to be moved up or down thereby either pushing the dirt collecting enclosure  30  and filter tube  60  up into sealing engagement with associated upper seals, or, permits the dirt collecting enclosure  30  and filter tube  60  to be dropped down and out of sealing engagement with the seals. Typically, the elevator assembly  70  will be moved to a lower position to permit removal of the dirt collecting enclosure  30  from the rear housing  14  for emptying, and will be moved to the upper position after the dirt collecting enclosure  30  and filter tube  60  are reinstalled to seal the assembly in position and permit further cleaning operations. A cam plate can also be provided as part of the elevator assembly  70  to achieve the raising and lowering functions. Of course, the cam operation need not be provided by a separate element but can be achieved by providing a camming surface on either the elevator platform  74  or the lever member  72 . Additionally, though the present embodiment describes a mechanical arrangement for actuating the elevator, it is contemplated herein that the elevator arrangement could also be achieved by use of an electrical or pneumatic form of actuation. 
   The cyclone body  52  and cyclone end cap  54  cooperate to filter dirt from air and to transport clean air to another location of further processing. In this regard, it is important to note that the cyclone body  52  and the cyclone end cap  54  do not require a replaceable and removable filter element. The cyclone chamber defined by the cyclone body  52  is angled with respect to vertical, and extends downwardly and laterally from the upper end to the lower end. The lower end of the cyclone chamber bends still further downwardly such that the exit of the tube is essentially vertically oriented and therefore matches the orientation of the second chamber  34  and smoothly merges therewith. 
   The cyclone body  52  has a first edge adjacent its upper end that is engaged and sealed by the cyclone end cap  54 . The cyclone end cap  54  preferably has a peripheral groove into which the first edge is inserted to form a labyrinth type seal. Naturally, additional sealing gaskets or seals may also be used. The connection between the cyclone end cap  54  and the cyclone body  52  also defines the inlet air passageway from the first chamber  32 /filter element  40  to the second cyclone as noted hereinbefore. The end cap  52  and body  54  are also attached by cooperation of tabs and mechanical fasteners (not shown) about the first edge and the peripheral groove to ensure a sealing connection. The inlet passageway is generally tangential to the inner wall surface of the cyclone body  52 , as illustrated. 
   As seen in  FIG. 4 , adjacent the on-off switch, a series of indicators  100  are provided. The indicators can be LEDs that are illuminated to indicate the occurrence of a differential pressure across one or more of the filter elements, which is indicative of a clogged or dirty filter. The filter elements being sensed are preferably the HEPA filter and/or the tube filter element  62  downstream of the cyclone filter units. A circuit board  102  (see  FIG. 3 ) with sensors extending therefrom into the airflow path, can perform the necessary detection and indication functions according to known techniques. 
   Although the hereinabove described embodiment of the invention constitutes the preferred embodiment; it should be understood that modifications could be made thereto without departing from the scope of the invention as set forth in the appended claims.