Patent Description:
Vacuum cleaners may include an inlet for bringing air into the vacuum cleaner. The air may travel through the vacuum cleaner and exhaust out of a blower port or a second outlet port. The vacuum cleaner may include sound reducing material for reducing the sound of the air within the vacuum cleaner.

<CIT> relates to a removable internal air diffuser. According to the abstract of this document, there is provided a vacuum cleaner having a housing defining first and second ports. The vacuum cleaner also includes a cap assembly. The cap assembly includes a cap head to close the first port such that airflow is directed via a flow path to the second port, a sound-influencing material, the sound-influencing material removably held to the cap head and disposed within the flow path to reduce noise effected by the airflow. The flow path is configured to cause the airflow to pass through the sound-influencing material and the flow path to the second port. The sound-influencing material is removable to allow cleaning of the sound-influencing material. The sound-influencing material may include a reticulated foam roll disposed in the frame to diffuse the discharge airflow.

The invention provides a vacuum cleaner including a suction inlet that provides entrance of a suction airflow, a diffuser, a suction source, a blower port, a duct, and a removable cap. The diffuser is in fluid communication with the suction inlet. The suction source is operable to generate the suction airflow through the suction inlet and the diffuser. The blower port is in fluid communication with the diffuser to exhaust the suction airflow. The duct is in fluid communication with the blower port and includes sound reducing baffles for disturbing the suction airflow within the duct. The sound reducing baffles include sound reducing material. The duct further includes an outlet for exhausting the suction airflow. The cap is removably coupled to the blower port such that at least a portion of the suction airflow exhausts through the blower port when the cap is removed, and when the cap is coupled to the blower port the suction airflow is travels through the duct and exhausts through the outlet.

<FIG> illustrates a vacuum cleaner <NUM> according to an embodiment of the present disclosure. The vacuum <NUM> includes a collector <NUM>, a power head <NUM>, a base <NUM>, and a housing <NUM>. The power head <NUM> includes a suction inlet <NUM>, an exhaust vent <NUM>, multiple battery bays <NUM>, a handle <NUM>, a detachable hose <NUM>, a latching assembly <NUM>, a suction source <NUM>, and a switch <NUM>. The latching assembly <NUM> may be actuated to selectively couple the collector <NUM> to the power head <NUM>. As described in greater detail below, the suction source <NUM> is powered by a battery attached to the vacuum <NUM> in the battery bays <NUM> and operates to generate a suction airflow within the vacuum <NUM>. The switch <NUM> may be actuated to energize the suction source <NUM> such that when the switch <NUM> is in an ON position, power is provided from the battery to power the suction source <NUM>. When the switch <NUM> is in an OFF position, power is not provided to the suction source <NUM>. In another embodiment, the suction source <NUM> directly receives power from a cord connected to an external power source.

With further reference to <FIG>, the base <NUM> includes caster wheels <NUM>, where one or more of the caster wheels <NUM> include a caster brake <NUM> for braking the caster wheels <NUM> and preventing movement of the base <NUM>. The base <NUM> further includes a foot pedal <NUM> to selectively detach the base <NUM> from the collector <NUM>. In another embodiment, the collector <NUM> may be formed with the base <NUM> as one piece. In yet another embodiment, the base <NUM> may include non-slip feet or other supporting members to keep the base in a stable orientation.

As illustrated in <FIG> and <FIG>, the power head <NUM> further includes a diffuser <NUM>, a blower port <NUM>, a duct <NUM>, and a cap <NUM>. The suction source <NUM> includes a filter assembly <NUM>, a fan <NUM>, and a motor <NUM>. The duct <NUM> is fluidly connected to the diffuser <NUM> and the blower port <NUM> for housing the suction airflow. The duct <NUM> includes sound reducing baffles <NUM> and an outlet <NUM> for exhausting the suction airflow. The baffles <NUM> are protrusions that may extend inwardly from walls within the duct <NUM>. The outlet <NUM> of the duct <NUM> aligns with the exhaust vent <NUM> of the power head <NUM>. In the illustrated embodiment, the sound reducing baffles include sound reducing material <NUM> for increasing the sound reduction of the airflow as it travel through the dust <NUM>, and the exhaust vent <NUM> houses sound reducing material <NUM>. In another embodiment, the duct <NUM> and vent <NUM> include other sound reducing material <NUM> such as foam, cloth, or other noise reducing materials of the like.

In the illustrated embodiment of <FIG>, the duct <NUM> has a rectangular cross-section. In some embodiments, the duct <NUM> has any shaped cross-section ideal for exhausting the suction airflow and for supporting sound reducing material <NUM> within the duct <NUM>. With continued reference to <FIG> and <FIG>, the cap <NUM> may be removably coupled to the blower port <NUM>. When the cap <NUM> is coupled to or covers the blower port <NUM>, the suction airflow bypasses the blower port <NUM> and flows through the duct <NUM> and out of the outlet <NUM>. When the cap <NUM> is removed from the blower port <NUM>, the suction airflow exhausts through the blower port <NUM> and through the outlet <NUM>. In the illustrated embodiment, the detachable hose <NUM> may be connected to the blower port <NUM> for receiving the suction airflow and exhausting the suction airflow out of the hose <NUM> such that when the hose <NUM> is attached to the blower port <NUM>, the hose <NUM> extends past the blower port <NUM> and into the diffuser <NUM> for receiving generally all of the suction airflow so that all of the suction airflow is discharged through the house <NUM> and the hose <NUM> can be used as blower.

In the illustrated embodiment, when the vacuum <NUM> is operating and the cap <NUM> is coupled to the blower port <NUM> the noise level is reduced and there is relatively little reduction in suction performance or efficiency of the vacuum cleaner <NUM>. In some embodiments, the noise level is reduced to less than <NUM> dBa when the vacuum <NUM> is operating and the cap <NUM> is coupled to the blower port <NUM>. In some embodiments, there is no more than <NUM> percent reduction in suction airflow when the vacuum <NUM> is operating and the cap <NUM> is coupled to the blower port <NUM>.

The function of the suction source <NUM> will now be described in more detail with reference to <FIG> and <FIG>. The motor <NUM> includes a shaft <NUM>, electrical connections <NUM>, and a motor housing <NUM>. The electrical connections <NUM> are disposed on the motor housing <NUM> for receiving power to power the motor <NUM>. The motor <NUM> drives the shaft <NUM> and the shaft <NUM> may be coupled to the fan <NUM> such that rotation of the shaft <NUM> corresponds to rotation of the fan <NUM> for generating the suction airflow.

With continued reference to <FIG> and <FIG>, the filter assembly <NUM> includes a filter housing <NUM> that supports a filter <NUM> on the filter housing <NUM>. In the illustrated embodiment, the vacuum cleaner <NUM> is configured such that the suction airflow generated by the suction source is received by the collector <NUM> through the suction inlet <NUM> and is sucked through the filter assembly <NUM>. In some embodiments, the vacuum cleaner <NUM> may be used to pull a debris laden suction airflow in through the inlet <NUM> and deposit debris separated from the suction airflow into the collector <NUM>. Some debris that is not separated from the airflow may be caught by the filter <NUM>.

In the illustrated embodiment, the suction source <NUM> further includes a shroud assembly <NUM>. In some embodiments, collected debris that passes through the filter <NUM> and contacts a surface over time may create abrasions on such a surface. As illustrated in <FIG>, the shroud assembly <NUM> rotates about the shaft <NUM> and operates to resist the abrasions on the motor <NUM>, the fan <NUM> and the other components included in the suction source <NUM>.

With continued reference to <FIG> and <FIG>, the diffuser <NUM> will be explained in detail. The diffuser <NUM> houses the suction airflow and is in fluid communication with the suction source <NUM>. In the illustrated embodiment, the diffuser <NUM> includes a first casting <NUM> and a second casting <NUM> coupled to each other at a plurality of connection points <NUM> such that the diffuser <NUM> has a scroll or spiral shape. In another embodiment, the diffuser <NUM> is formed of one piece.

In the illustrated embodiment, the diffuser <NUM> includes an opening <NUM>, and the opening <NUM> circumferentially surrounds the suction source <NUM> such that suction airflow entering the suction source <NUM> may pass through the diffuser <NUM> through the opening <NUM>. The diffuser <NUM> has a relatively semi-circular cross-section with a corresponding cross-sectional area. As illustrated in <FIG>, the cross-sectional area of the first casting <NUM> increases or decreases depending on where the cross-section is being taken. The suction airflow entering the diffuser <NUM> is evenly distributed within the diffuser <NUM> due to the shape of the first and second casing <NUM>,<NUM>. The suction airflow entering the diffuser <NUM> through the opening <NUM> is directed toward the blower port <NUM> through the largest cross-sectional diameter of the diffuser <NUM>.

<FIG> and <FIG> illustrate a powerhead <NUM> that can be used with the canister or collector <NUM> of <FIG> in another embodiment. The powerhead <NUM> includes a suction source <NUM> that includes a motor <NUM> and a fan <NUM>. The illustrated powerhead <NUM> further includes an inlet <NUM>. The suction source <NUM> is operable to generate a suction airflow through the inlet <NUM> to draw debris and the airflow into the canister <NUM>. The powerhead <NUM> further includes a first outlet <NUM> and a second outlet <NUM> for exhausting the suction airflow from the suction source <NUM>. The first outlet <NUM> is adjacent the fan <NUM> and upstream from the second outlet <NUM>. A duct <NUM> extends from the first outlet <NUM> to the second outlet <NUM>. The duct <NUM> may include baffles, foam, and the like that reduce the noise or the sound level of the exhaust airflow traveling through the duct <NUM> and the second outlet <NUM>. Louvers or the like may extend across the second outlet <NUM> to direct the suction airflow that exits through the second outlet <NUM>.

The powerhead <NUM> includes a cap, similar to the cap <NUM> of <FIG>. In the illustrated embodiment, the inlet <NUM> and the first outlet <NUM> are circular such that the first outlet <NUM> can receive the suction hose that attaches to the inlet <NUM>. That is, the suction hose can be disconnected from the inlet <NUM> and attached to the first outlet <NUM>. The suction hose may be attached to the first outlet <NUM> so that the vacuum cleaner can be used as a blower. The cap is circular so that the cap can cover the first outlet <NUM>. The cap may be tethered or attached to the powerhead <NUM> and the cap can also be attached to and cover the inlet <NUM>. The user may use the cap <NUM> to cover the inlet when the vacuum is not in use, particularly when the vacuum is being transported, so that debris in the canister does not undesirably exit the canister through the inlet <NUM>.

In operation, the powerhead <NUM> can be used in a first mode. In the first mode, the cap is removed and the cap does not cover the first outlet <NUM>. In the first mode, the suction airflow is exhausted from the fan <NUM> and exits the powerhead <NUM> through the first outlet <NUM>. In this first mode, the powerhead <NUM> can be used as a blower, as discussed above, and/or the powerhead <NUM> can also be used as a vacuum drawing in air and debris through the inlet <NUM>. The cap is attached to the first outlet <NUM> to cover the first outlet <NUM> to use the vacuum in a second mode or quiet mode. With the cap covering the first outlet <NUM>, the exhausted suction airflow does not exit through the first outlet <NUM> and the airflow is directed through the duct <NUM>, through the body of the powerhead <NUM>, and toward the second outlet <NUM>. The duct <NUM> dampens or reduces the noise / sound level of the exhausted suction airflow. The exhaust suction airflow then exits the powerhead <NUM> through the second outlet <NUM>. In some embodiment, the noise level is reduced to less than <NUM> dBa in the second or quiet mode. In some embodiments, there is no more than a <NUM> percent reduction is suction airflow when used in the second or quiet mode. Therefore, the powerhead <NUM> can be used by the user in a first mode when the vacuum is used as a blower and/or when noise level is not a concern. The powerhead <NUM> can be used in the second or quiet mode when noise reduction is desired but yet there is relatively little reduction is suction performance or efficiency. In other embodiments, the powerhead may include a valve or valves to direct the exhaust airflow to either the first outlet <NUM> or the second outlet <NUM>.

Claim 1:
A vacuum cleaner (<NUM>) comprising:
a suction inlet (<NUM>) providing entrance of a suction airflow;
a diffuser (<NUM>) in fluid communication with the suction inlet (<NUM>);
a suction source (<NUM>), the suction source (<NUM>) operable to generate the suction airflow through the suction inlet (<NUM>) and diffuser (<NUM>);
a blower port (<NUM>) in fluid communication with the diffuser (<NUM>) for exhausting the suction airflow;
a duct (<NUM>) in fluid communication with the blower port (<NUM>), the duct (<NUM>) including
sound reducing baffles (<NUM>) for disturbing the suction airflow within the duct (<NUM>), the sound reducing baffles (<NUM>) including sound reducing material (<NUM>), and
an outlet (<NUM>) for exhausting the suction airflow; and
a cap (<NUM>) removably coupled to the blower port (<NUM>) such that at least a portion of the suction airflow exhausts through the blower port (<NUM>) when the cap (<NUM>) is removed and when the cap (<NUM>) is coupled to the blower port (<NUM>) the suction airflow is travels downstream through the duct (<NUM>) and exhausts through the outlet (<NUM>).