Patent Description:
A housing for a handheld vacuum cleaner includes a suction opening, a cyclone chamber, and a helical passage. The suction opening is defined in the housing. The cyclone chamber is in fluid communication with the suction opening. The helical passage includes a first end, a second end, and at least one sidewall. The first end is in fluid communication with the suction opening. The second end is in fluid communication with the cyclone chamber. The at least one sidewall extends between the first end and the second end. The at least one sidewall separates the helical passage from the cyclone chamber.

A housing for a handheld vacuum cleaner includes a suction opening, a dirt cup, and a rigid arcuate passage. The suction opening is defined in the housing. The dirt cup includes a cyclone chamber defined therein. The rigid arcuate passage fluidly communicates the suction opening with the cyclone chamber. The rigid arcuate passage is discrete from the cyclone chamber along a majority of a length of the rigid arcuate passage. The rigid arcuate passage is open to the cyclone chamber at an end of the rigid arcuate passage.

A handheld vacuum cleaner includes a dirt cup, a handle, an inlet portion, and a rigid passage. The dirt cup includes a cyclone chamber defined therein. The handle is coupled to the dirt cup, with a plane bisecting the handle and the cyclone chamber. The inlet portion includes a suction opening in fluid communication with the cyclone chamber. The rigid passage fluidly communicates the suction opening with the cyclone chamber. The rigid passage includes a first end, a second end, and a sidewall. The first end of the rigid passage is in fluid communication with the suction opening. The second end is downstream from the first end. The second end is in fluid communication with the cyclone chamber. The sidewall separates the rigid passage from the cyclone chamber between the first end and the second end. A majority of the rigid passage is disposed on one side of the plane.

Features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings.

With reference to <FIG>, an embodiment of a handheld vacuum cleaner <NUM> is shown. The vacuum cleaner <NUM> includes a housing <NUM>, an inlet portion <NUM>, a dirt cup <NUM>, a passage <NUM> extending between the inlet portion <NUM> and the dirt cup <NUM>, and a handle <NUM>. In some embodiments, the housing <NUM> itself includes the inlet portion <NUM>, the dirt cup <NUM>, and the passage <NUM>. The vacuum cleaner <NUM> also includes a suction source (<FIG> and <FIG>), for example, a suction motor <NUM> that rotates a fan or impeller <NUM> to generate a suction airflow.

The inlet portion <NUM> may be integrally formed with the housing <NUM> as a single component or may be separately formed from the housing <NUM>. In the illustrated embodiment, the inlet portion <NUM> is a protrusion of the housing <NUM>. The inlet portion <NUM> includes a suction opening <NUM> defined therein for receiving liquid, dirt, and other debris drawn up from a surface being cleaned via the inlet portion <NUM> alone or via a wand or hose (not shown) attached to the inlet portion <NUM>. The inlet portion <NUM> may be a male component configured to be inserted in a female portion of a corresponding wand or hose (not shown), or the inlet portion <NUM> may be a female component configured to receive a male portion of a corresponding wand or hose (not shown).

The illustrated embodiment further includes a dirt cup <NUM> as a part of the housing <NUM>. The dirt cup <NUM> is shown as being generally cylindrical in shape, but other shapes are also contemplated herein. Some embodiments may include the dirt cup <NUM> having a bottom door <NUM> pivotably coupled to the dirt cup wall <NUM> to allow a user to quickly and easily empty the contents of the dirt cup <NUM> into, for instance, a garbage can. The pivotable bottom door <NUM> may be secured with a latch that is diametrically opposite the one or more hinge components. In some embodiments, however, the bottom of the dirt cup <NUM> may be integrally formed with the remainder of the dirt cup <NUM>, such that the lid section <NUM> must be removed to access the cyclone chamber <NUM> for emptying the dirt cup <NUM>. As shown in <FIG>, the dirt cup <NUM> includes a cyclone chamber <NUM> defined therein. The cyclone chamber <NUM> is in fluid communication with the suction opening <NUM> via the passage <NUM>, as described in more detail below. The cyclone chamber <NUM> is also in fluid communication with the suction source (<FIG> and <FIG>) of the vacuum cleaner <NUM> and receives debris that has been picked up by the vacuum cleaner <NUM>, as described below.

Turning now to <FIG>, the passage <NUM> fluidly communicates the suction opening <NUM> of the inlet portion <NUM> with the cyclone chamber <NUM> of the dirt cup <NUM>. Accordingly, the suction source (<FIG> and <FIG>) may be operable to draw dirt, liquid and other debris through the inlet portion <NUM> and into the dirt cup <NUM> via the passage <NUM>. The passage <NUM> may be integrally formed with the housing <NUM> as a single component or may be separately formed from the housing <NUM>. In the illustrated embodiment, the passage <NUM> is a rigid conduit integrally formed with and protruding or bulging from the housing <NUM>. The passage <NUM> is arcuate, following along a portion of the outer circumference of the cylindrical dirt cup <NUM>. Other embodiments, however, may include the passage <NUM> having a different route that may or may not be arcuate or positioned within the perimeter of the housing <NUM>. The passage <NUM> has a first end <NUM> and a second end <NUM>. The first end <NUM> is in fluid communication with the suction opening <NUM> of the inlet portion <NUM>. The second end <NUM> is downstream from the first end <NUM>, and the second end <NUM> is in fluid communication with the cyclone chamber <NUM> of the dirt cup <NUM>. In the illustrated embodiment, the passage <NUM> is a helical passage, in that the first end <NUM> is at a different elevation from the second end <NUM>.

As shown in <FIG>, the passage <NUM> is separated from the cyclone chamber <NUM> of the dirt cup <NUM> by a sidewall <NUM> of the passage <NUM>. The sidewall <NUM> extends along at least a portion the length of the passage <NUM> between the first end <NUM> and the second end <NUM>. More specifically, the sidewall <NUM> prevents direct communication between the suction opening <NUM> and the cyclone chamber <NUM>, instead forcing the incoming debris and air to travel a relatively circuitous route through the passage <NUM> prior to being discharged into the cyclone chamber <NUM>. As described in greater detail below, this configuration helps to prevent liquid drawn up by the vacuum cleaner <NUM> in the dirt cup <NUM> from accidentally escaping out of the dirt cup <NUM> via the suction opening <NUM> when a user tilts the vacuum cleaner <NUM> forward, for example, during a subsequent vacuuming operation. In the illustrated embodiment, the sidewall <NUM> of the passage <NUM> is a portion of the housing <NUM> and may be integrally formed as a unitary piece with the dirt cup wall <NUM>. The passage <NUM> is shown as being circular in cross-section, but other cross-sectional shapes are also contemplated herein, such as, for example, triangular, rectangular, elliptical, or the like. As such, the circular cross-section passage <NUM> is considered to have only one sidewall <NUM>, but other cross-sectional shaped passages may have more than one sidewall. In embodiments including a passage <NUM> with a triangular cross-section, for example, one of the three sidewalls may face the cyclone chamber <NUM> and the other two of the three sidewalls may project radially outwardly and may be exposed on the outside of the housing <NUM>.

Returning to <FIG>, any incoming air, debris, and/or liquid drawn up by the vacuum cleaner enters the suction opening <NUM> of the inlet portion <NUM>, travels through a straight section <NUM> of the inlet portion <NUM>, travels through a bend <NUM>, enters the first end <NUM> of the passage <NUM>, travels through the passage <NUM>, and exits the passage <NUM> via the second end <NUM> into the cyclone chamber <NUM> of the dirt cup <NUM>. In some embodiments, the cross-sectional area of the passage <NUM> at the second end <NUM> is smaller than the cross-sectional area of other portions of the passage <NUM>, such as the first end <NUM>. This arrangement may increase the speed of the operational airflow <NUM> as it enters the cyclone chamber <NUM>.

With reference to <FIG>, heavier liquid and heavier debris (compared to, for example, air) exiting the second end <NUM> of the passage <NUM> may at least partially move along a cyclonic route in the cyclone chamber <NUM> and be forced outwardly by a centrifugal force against the wall <NUM> of the dirt cup <NUM>, where the liquid and debris may then fall to the bottom of the dirt cup <NUM>, while air and lighter debris (such as fine dust) continue to move along a cyclonic route in the cyclone chamber <NUM> and then get pulled through a filter <NUM> (<FIG>) of conventional design. A suction source housing <NUM> is coupled to an upper portion of the housing <NUM> and extends centrally and downwardly into the cyclone chamber <NUM>. As the name suggests, the suction source housing <NUM> includes a cavity <NUM> for housing a motor <NUM> and impeller <NUM> (<FIG> and <FIG>) that moves the working air through the vacuum. The suction source housing <NUM> further includes a downwardly facing filter connection portion <NUM> for receiving the filter. The filter <NUM> depends from the filter connection portion <NUM> and further extends downwardly and centrally into the cyclone chamber <NUM>. In some embodiments, the filter <NUM> removably couples to the filter connection portion <NUM> with a twist-and-lock connection.

With reference to <FIG> and <FIG>, the vacuum cleaner <NUM> further includes a lid section <NUM>. In the illustrated embodiment, the lid section <NUM> is removably coupled to the housing <NUM> with a plurality of fasteners. The lid section <NUM> may be removed to replace the filter, access the motor <NUM> for cleaning or repair, or the like. The lid section <NUM> is shown as a two-part assembly of a clamshell design, but other configurations are also contemplated herein including, but not limited to, a single unitary component.

The lid section <NUM> includes one or more exhaust vents <NUM> defined therein. The exhaust vents <NUM> allow the working air to leave the vacuum cleaner <NUM> after having traveled through the suction opening <NUM>, the passage <NUM>, the cyclone chamber <NUM>, and the impeller <NUM>. The lid section <NUM> further includes a handle <NUM> that is indirectly coupled to the housing <NUM>. In some embodiments, however, the handle <NUM> is coupled directly to, for instance, the dirt cup wall <NUM>. In the illustrated embodiment, the handle <NUM> includes one or more controls <NUM> disposed thereon. The lid section <NUM> also includes a battery connection rail <NUM> coupled to an end of the handle <NUM>, although some embodiments may include the battery connection rail <NUM> coupled to, for instance, the dirt cup wall <NUM>. In the illustrated embodiment, the battery connection rail <NUM> removably receives a rechargeable battery pack (not shown). The rechargeable battery pack, in some embodiments, may also be configured to couple to and power other power tools, such as a drill.

As shown in <FIG>, the passage <NUM>, surrounded by the sidewall <NUM>, is almost completely disposed on a single side of a plane passing through and bisecting both the handle <NUM> and the cyclone chamber <NUM>. A benefit of this configuration is that the second end <NUM> of the passage <NUM> is disposed nearly centrally at the rear of the vacuum cleaner <NUM>. As such, a user would have to excessively tilt the vacuum cleaner <NUM> rearwardly relative a normal operating position in order to allow liquid that is in the bottom of the cyclone chamber <NUM> to enter the second end <NUM> of the passage <NUM>. Even if liquid enters the second end <NUM> of the passage <NUM>, the user would then have to tilt the vacuum cleaner left and subsequently forward in order for any liquid that has entered the passage <NUM> to successfully escape via the suction opening <NUM>. This pattern of orientations for the vacuum cleaner <NUM> is unconventional and would rarely occur. As such, the illustrated embodiment of a vacuum cleaner <NUM> is able to better contain liquid that has been picked up when compared to a non-circuitous pathway from the suction opening <NUM> to the cyclone chamber <NUM>. Other embodiments, however, may include the passage <NUM> extending about a majority of the perimeter of the dirt cup wall <NUM> and/or extending about the cyclone chamber <NUM> more than once. With reference to <FIG>, the passage <NUM> can also be said to extend circumferentially about a central cyclone axis of the cyclone chamber <NUM> through an angle A1. In some embodiments, this angle A1 is at least <NUM> degrees. In some embodiments, the angle A1 is between <NUM> degrees and <NUM> degrees. In some embodiments, the angle A1 is greater than <NUM> degrees, such as <NUM> degrees, <NUM> degrees, or even greater (to form a helix with multiple loops, for instance).

With reference to <FIG>, in the illustrated embodiment, the passage <NUM> is disposed such that the sidewall <NUM> is visible from the outside of the vacuum cleaner <NUM> as an outward bulge relative to the dirt cup wall <NUM> and the lid section <NUM>. Other embodiments, however, may include a passage <NUM> that is disposed in a different position such that the sidewall <NUM> is flush with the surrounding housing <NUM> and/or lid section <NUM>. Still other embodiments may include a passage <NUM> having a different cross-sectional shape to minimize or eliminate the outward bulge of the sidewall <NUM>.

As shown in <FIG>, the motor <NUM> and impeller <NUM> are disposed in the cavity <NUM> of the suction source housing <NUM>. The illustrated embodiment further includes a motor housing <NUM> disposed within the suction source housing <NUM>. The motor <NUM> is disposed entirely in the motor housing <NUM> while the impeller <NUM> is disposed outside of the motor housing <NUM> but within the suction source housing <NUM>. An end wall member <NUM> is coupled to the motor housing <NUM> between the motor <NUM> and the impeller <NUM> to separate the interior of the motor housing <NUM> from the rest of the cavity <NUM>. The motor housing <NUM> and end wall member <NUM> cooperate to act as a barrier between the motor <NUM> and any liquid that may travel through the vacuum cleaner <NUM>. As best shown in <FIG>, the motor housing <NUM> includes, for instance, a lap or tongue and groove joint where the inner wall of the motor housing <NUM> meets the lid section <NUM> and where the inner wall of the motor housing <NUM> meets the end wall member <NUM>. Some embodiments may further include a sealing material located at one or both of these joints. The arrangement shown in <FIG> allows for a fluid flow <NUM> to travel into the suction opening <NUM>, through the passage <NUM>, into the cyclone chamber <NUM>, through the filter <NUM>, through the suction source housing <NUM> past the impeller <NUM>, between inner and outer walls of the motor housing <NUM>, and out the exhaust vents <NUM> in the lid section <NUM>. This fluid flow <NUM> represents the operational airflow path through the vacuum cleaner <NUM> but also represents the flow path of any liquid that might enter and then subsequently escape the vacuum cleaner <NUM>.

In the illustrated embodiment, the lid section <NUM> further includes motor vents <NUM> defined therein. The lid section <NUM> may further include a wall and roof structure <NUM> disposed between the exhaust vents <NUM> and the motor vents <NUM>. This wall and roof structure <NUM> aids in preventing liquid from being introduced into the cavity <NUM> via the motor vents <NUM> and, more specifically, in the motor housing <NUM> even when the vacuum cleaner <NUM> is tilted and liquid escapes through the exhaust vents <NUM>. The motor vents <NUM> allow for ventilation of the motor <NUM> in order to cool the motor. This cooling airflow <NUM> may be passive in and out of the motor housing <NUM> via the motor vents <NUM>, or it may be forced airflow due to one or more fans. In the illustrated embodiment, the motor <NUM> includes a cooling fan <NUM> rotated by the driveshaft <NUM> of the motor <NUM> inside the motor housing <NUM>. The cooling fan <NUM> is located on the driveshaft <NUM> between the motor <NUM> and the impeller <NUM>.

Claim 1:
A handheld vacuum cleaner (<NUM>) comprising:
a dirt cup (<NUM>) including a cyclone chamber (<NUM>) defined therein;
a handle (<NUM>) coupled to the dirt cup (<NUM>), with a plane bisecting the handle (<NUM>) and the cyclone chamber (<NUM>);
an inlet portion (<NUM>) including a suction opening (<NUM>) in fluid communication with the cyclone chamber (<NUM>);
a rigid passage (<NUM>) fluidly communicating the suction opening (<NUM>) with the cyclone chamber (<NUM>), the rigid passage (<NUM>) including
a first end (<NUM>), the first end (<NUM>) of the rigid passage (<NUM>) being in fluid communication with the suction opening (<NUM>),
a second end (<NUM>) downstream from the first end (<NUM>), the second end (<NUM>) being in fluid communication with the cyclone chamber (<NUM>), characterized in that the rigid passage (<NUM>) includes
a sidewall (<NUM>) separating the rigid passage (<NUM>) from the cyclone chamber (<NUM>) between the first end (<NUM>) and the second end (<NUM>);
wherein a majority of the rigid passage (<NUM>) is disposed on one side of the plane.