WO2008145960A2

WO2008145960A2 - Vacuum cleaner having filter device with wiping collar

Info

Publication number: WO2008145960A2
Application number: PCT/GB2008/001697
Authority: WO
Inventors: Glyn Hauser
Original assignee: Morphy Richards Limited
Priority date: 2007-05-25
Filing date: 2008-05-15
Publication date: 2008-12-04
Also published as: WO2008145960A3; GB0710015D0; GB2449484B; GB2449484A

Abstract

A filter cleaning device for a vacuum cleaner. The vacuum cleaner comprises a filter (100) moveably mounted within the dust collection canister (101). An annular collar (200) is provided at a region of the dust collection canister (101) such that the filter (100) is capable of being moved relative to the collar (200) via a plunger-like motion to and from the canister (101). Through this motion, the external surface of the filter (100) is wiped by the annular collar (200). Hair, fluff and debris matter collected at the filter's external surface is wiped by the collar (200) and removal is facilitated by incorporating a tapered region within the filter.

Description

VACUUM CLEANER HAVING FILTER DEVICE

Field of the Invention

The present invention relates to a vacuum cleaner having a filter positioned within the suction airflow path flowing through the cleaner.

Background to the Invention

Typically, almost all vacuum cleaners have one or more filters positioned within the airflow stream. To safeguard the motor, most cleaners have a foam or HEPA filter positioned immediately upstream of the fan to separate very fine dust particles from the airflow prior to passing into the motor.

In addition to the foam or HEPA filter, most vacuum cleaners, particularly cyclonic vacuum cleaners, have a secondary filter associated with the dust collection chamber. This secondary filter is typically formed as a mesh or a perforated filter and serves to prevent larger particulate matter such as hairs and fluff from passing downstream of the dust collection canister towards the motor.

Where the vacuum cleaner is a dual or multi cyclone cleaner, involving two or more separate dust collection canisters, the mesh filter is typically positioned between the first, low efficiency chamber and the second, higher efficiency chamber so as to prevent the larger particulate matter from passing from the low to high efficiency chamber.

With use, these mesh filters associated with the dust collection canister tend to become clogged with particulate matter and require regular cleaning which would otherwise result in insufficient airflow into the vacuum motor causing overheating and damage. A number of disclosures teach of filter cleaning devices for vacuum cleaners configured to allow a user to more conveniently clean the filter. US 2004/0187253 discloses a filter cleaning device for a cyclone vacuum cleaner that includes a manipulation unit in the form of an annular collar configured to slide over the exterior surface of the filter. Brushes projecting inwardly from the collar contact the exterior surface of the filter to dislodge

5 accumulated hair, fluff and the like.

EP 1136028 similarly discloses a vacuum cleaner comprising a filter fitted with a cleaning collar which is moved in contact with the filter. Dust settled on the exterior surface is raked off as the cleaning member is moved through manual o operation, or by the suction airflow.

JP 2003-230516 discloses a cyclonic vacuum cleaner having an internal cylindrical filter fitted within the cyclone chamber. The cylindrical filter extends into the dust collection chamber through an annular aperture positioned at which5 is an annular dust removing collar. As the cylinder is inserted and drawn from the dust collection container via a plunger like motion, its exterior surface is wiped by the collar.

A problem with conventional automated or manual filter cleaning devices is o the observed inefficiency with which the debris matter is wiped from the filter's external surface. What is required is a filter cleaning device that efficiently and effectively removes matter from the filter.

Summary of the Invention 5 The inventors provide a filter cleaning device having improved cleaning capability over existing filter cleaning devices. The mesh or fine perforations forming part of the filter body, serve to snag hair and fluff matter making it difficult to dislodge and separate them from the filter. Most prior art devices attempt to address this by using brushes positioned onto the external surface to key into the 0 mesh or perforations so as to agitate the hair and fluff to encourage disassociation. However, what tends to happen with annular cleaning collars is that the fluff and hair matter is simply rolled by the collar into annular rings around the cylindrical filter body. The user is then required to manually pull these intertwined rings from the filter surface.

According to one aspect of the present invention there is provided a vacuum cleaner comprising: suction generation means configured to generate a suction airflow through a region of said cleaner; dust collection means positioned in the path of said suction airflow; a filter positioned within said dust collection means to inhibit dust matter from passing downstream of said dust collection means as said suction airflow flows through said collection means and said filter; and a collar disposed at the external surface of said filter, said collar configured to wipe a region of the external surface of said filter as said filter is displaced in a direction along its longitudinal axis; wherein a cross-sectional area of said filter along its longitudinal axis decreases from a first end to a second end, said cross- sectional area of said first end being greater than said cross-sectional area of said second end.

By providing a filter with a taper along its longitudinal axis and a collar configured to wipe and maintain contact with the tapered outer surface, hair, fluff and the like are more readily dislodged from the filter. The shape of the filter may be a cone, a truncated cone or a dome. Preferably, the filter is substantially conical shaped over approximately three quarters of its length and comprises a domed end portion. Perforations may or may not be provided at or around the domed end portion.

Preferably, the collar comprises a flexible elastic material such as rubber or a rubber based material including both natural and synthetic. As the filter and collar are moved relative to one another, the elasticised collar wipes the external surface of the filter. Preferably, the second end of the filter extends into the dust collection means and in use the collar is positioned towards the first and larger cross-sectional area end. As the collar passes over the filter surface any 'rolled' hair and fluff matter simply fall away under gravity from the filter surface due to the taper. The filer may comprise a plurality of holes, being perforations, distributed over the filter body between the external surface and the filter internal surface. Alternatively, the filter may comprises a mesh, gauze or the like.

Further, the filter may comprise means to allow a user to grip the first end and to pull and push the filter along its longitudinal axis with a plunger-like motion drawing the outer surface of the filter over the annular collar. As the annular collar is elasticised it is configured to maintain contact with the external surface over a region of the filter. In particular, the filter may be capable of being displaced in its longitudinal axis by a distance in the range 20 to 50mm.

The cleaner may comprise means to prevent the filter from being entirely removed from the dust collection canister. Alternatively, the filter may be configured to be entirely removed from the dust collection canister.

The filter may comprise guide means configured to cause the filter to rotate in a plane transverse, and in particular perpendicular, to its longitudinal axis when displaced into and out of the dust collection means. This rotation of the filter as it glides past the annular collar serves to agitate the fluff and hairs at the external surface and facilitate removal.

Preferably, the collar is configured to maintain contact with the outer surface of the filter over at least 25% of the length of the filter.

The collar may be removeably mounted at the dust collection means by way of an annular washer. Alternatively, the collar may be formed integrally with the housing of the dust collection means. Preferably, the collar is formed non- integrally with the housing for dust collection means.

Preferably, the vacuum cleaner is a cyclonic vacuum cleaner and more preferably a dual or multi cyclone vacuum cleaner. Preferably, the filter is releaseably secured in position at the dust collection means by snap-fit means provided at either or both the filter and dust collection means. Alternatively, the filter may be held in position at the dust collection canister by alternative mechanical fixing means such as screws or rivets or welding including ultrasonic and/or adhesive welding.

According to a second aspect of the present invention there is provided a cyclone vacuum cleaner comprising: suction generation means configured to generate a suction airflow through a region of said cleaner; a first dust collection canister positioned in the path of said suction airflow, said cleaner configured to create a cyclonic airflow within said dust collection canister; a second dust collection canister positioned in the path of said suction airflow downstream of said first dust collection canister, said cleaner configured to create a cyclonic airflow within said second dust collection canister; a filter positioned within said first dust collection canister configured to inhibit dust matter from passing from said first dust collection canister to said second dust collection canister; and a collar disposed at the external surface of said filter, said collar configured to wipe the external surface of said filter as said filter is displaced along its longitudinal axis relative to said collar; wherein a cross-sectional area of said filter along its longitudinal axis decreases from a first end to a second end, said cross-sectional area of said first end being greater than said cross-sectional area of said second end.

According to a third aspect of the present invention there is provided a filter assembly for a vacuum cleaner comprising: dust collection means capable of positioning within an airflow path of a vacuum cleaner; a filter positioned within said dust collection means to inhibit dust matter from passing downstream of said dust collection means as said suction airflow flows through said collection means and said filter; and a collar disposed at the external surface of said filter, said collar configured to wipe a region of the external surface of said filter as said filter is displaced in a direction along its longitudinal axis; wherein a cross-sectional area of said filter along its longitudinal axis decreases from a first end to a second end, said cross-sectional area of said first end being greater than said cross- sectional area of said second end.

Brief Description of the Drawings For a better understanding of the invention and to show how the same may be carried into effect, there will now be described by way of example only, specific embodiments, methods and processes according to the present invention with reference to the accompanying drawings in which:

Figure 1 illustrates an exploded perspective view of a dust collection canister and filter assembly according to a specific implementation of the present invention;

Figure 2a illustrates an underside view of the dust collection canister and filter of figure 1 ;

Figure 2b illustrates a cross section through A-A of figure 2a;

Figure 2c illustrates a perspective view of the filter assembly of figure 2b;

Figure 2d illustrates a particle cut-away view of region C of the filter of figure 2c;

Figure 3 illustrates a partial cut-away perspective view of the dust collection canister and filter of figure 2b;

Figure 4a illustrates a perspective view of the filter and annular cleaning collar as illustrated in figure 3;

Figure 4b illustrates the filter and annular cleaning collar of figure 4a;

Figure 5 illustrates a perspective view of the filter of figure 4b; Figure 6 illustrates a perspective view of the filter of figure 5;

Figure 7 illustrates a perspective plan view of the filter of figure 6;

Figure 8 illustrates a close-up view of region B of the filter of figure 7.

Figure 9a illustrates a side elevation view of the filter of figure 7 together with the annular cleaning collar;

Figure 9b illustrates the filter and annular cleaning collar of figure 9a with the filter displaced in an upward direction relative to the cleaning collar.

Detailed Description There will now be described by way of example a specific mode contemplated by the inventors. In the following description numerous specific details are set forth in order to provide a thorough understanding. It will be apparent however, to one skilled in the art, that the present invention may be practiced without limitation to these specific details. In other instances, well known methods and structures have not been described in detail so as not to unnecessarily obscure the description.

Referring to figure 1 , a vacuum cleaner (not shown) comprises an electrically operated fan motor (not shown) configured to generate a suction airflow through a region of the vacuum cleaner including, in particular, a dust collection container 101 and filter assembly 100. Filter 100 is removeably secured in position within dust collection canister 101 via a substantially circular aperture 108 formed within housing 110 positioned at an upper end of canister 101.

Dust collection canister 101 is divided into two chambers, a first low efficiency cyclone chamber 109 and a second high efficiency chamber 111 , both chambers 109, 111 being positioned side-by-side such that the internal volumes of each chamber do not overlap. Filter 100 is configured for removeably positioning within a portion of first chamber 109. First and second chambers 109, 111 are substantially cylindrical and comprise a slight taper such that the cross sectional area of each chamber decreases from a first end connected to housing 110 towards a second end bordered by flap 112 that is hingeably coupled to an intermediate wall portion 116 separating the lower most regions of first and second chambers 109, 111.

An air inlet projection 114 extends from a side wall of first dust collection chamber 109 immediately below housing 110. An airflow outlet 115 extends from housing 110 directly above and in fluid communication with second chamber 111.

Filter 100 comprises a substantially cylindrical portion 102 connected to the broadest end of a conical portion 103. Conical portion 103 comprises a plurality of holes 104 extending through the cone body such that substantially the entire surface area of cone 104 is perforated. A plurality of holes 105, arranged in sets, are formed within a lowermost region of the cylindrical portion 102 immediately above holes 104. The uppermost region of cylindrical portion 102 is bordered by an end cap 106 comprising a handle projection 107 of a size sufficient to be grasped between the thumb and fingers of a user.

Figure 2a illustrates an underside view of the dust collection canister of figure 1 and figure 2b illustrates a cross sectional side elevation view through A-A of figure 2a. Filter 100 is secured in position within dust collection canister 101 and in particular low efficiency chamber 109 such that cylindrical portion 102 and conical portion 103 extend fully into chamber 109 defined by chamber walls 202, moveably flap 112 and a lowermost region 203 of housing 110. A region of the cylindrical portion 102 is housed within housing 110 such that end cap 106 which is oversized relative to the cylindrical portion 102 to form a lip, sits against an upper surface 204 of housing 110. An annular collar 200 is mounted at a lowermost region of housing 1 10 via a mounting 201. Collar 200 comprises an elasticated rubber material of smaller diameter than a diameter of cylindrical portion 102. With filter 100 located in position within dust collection canister 101 as illustrated in figure 2b, annular collar 200 is stretched to increase its diameter to accommodate and abut against an outer surface of cylindrical portion 102.

Figure 2c illustrates a perspective view of the filter assembly and figure 2d illustrates a partial cut-away view of region C of the filter of figure 2c. At an uppermost region of cylindrical portion 102 are positioned a plurality of snap-fit flanges 206 configured to releaseably hold filter 100 in position within canister 101 and in particular housing 110. Each flange 206 comprises an inward projection 207 configured for seating over and about an uppermost annular lip of a retaining sleeve 208 positioned internally against the internal wall of cylindrical portion 102. Cylindrical retainer 208 is held in position with housing 110 such that as flanges 206 engage against sleeve 208 filter 100 may be releaseably secured in position within housing 110.

Cylindrical portion 102, retaining sleeve 208 and end cap 106 are a secured together by screws, adhesive welding and/or snap fit means. Alternatively, the filter components 102, 208 and 106 may be assembled together by ultrasonic welding and/or a combination of adhesive welding or any manner of mechanical fixture including screws, rivets and the like.

So as to provide an air tight seal between filter 100 and housing 110, a sealing gasket (not shown) is positioned in the region 209 between annular lip 210 extending downwardly from the internal surface 21 1 of end cap 106 and the uppermost annular rim 212 of conical portion 102. The type of gasket employed may comprise a rigid or deformable plastic or rubber based material.

Figure 3 illustrates a partial cut-away perspective view of the dust collection canister and filter assembly. Figure 4a and 4b illustrate side elevation views of filter 100 and figures 5 and 6 illustrate an upper perspective view and side elevation perspective view of filter 100, respectively. Filter 100 comprises a perforated tapered region decreasing in cross section from a first end 400 towards a relatively pointed second end 401. The plurality of holes 104 extend through the body of conical portion 103 between first and second ends 400, 401. Cylindrical portion 102 extends from the largest diameter end 400 of cone 103 such that cylindrical portion may be regarded to comprise cone end 402 and cap end 403. Holes 105 extend approximately over one third of the length of cylindrical portion 102 from cone end 402. A window 405 is formed within one half of portion 102 towards cap end 403. A pair of locating lugs 404, 405 project from cylindrical portion 102 in the upper cap end half 403 in close proximately to window 405.

Filter 100 is located in position within canister 101 such that substantially half of the cylindrical portion 102 is housed within housing 110 and half is located within chamber 109. Filter 100 is located in position within housing 110 via lugs 404, 405 being seated within locating grooves 118 formed on an internal surface of housing 110. An internal window 117 formed within housing 110 mates with window 405 formed within cylindrical portion 102.

Accordingly, an airflow passageway is created through the dust collection canister and filter assembly from air inlet 114 into low efficiency chamber 109 through filter holes 104 and holes 105 of filter 100. The airflow path then continues through the internal cavity 500 within filter 100 through the aligned filter window 405 and housing window 117 and into the second high efficiency dust collection chamber 111. The airflow passageway then continues towards the electric fan motor via canister air outlet 115 positioned downstream of filter 100 and first and second chambers 109, 111.

Figure 7 illustrates a plan perspective view of a portion of filter 100 and figure 8 illustrates a magnified view of region B of the airflow perforations illustrated in figure 7. To increase the efficiency of the electric fan motor to create a suction airflow though the vacuum cleaner, perforations 104, formed within the tapered, conical portion of filter 100 extend through the filter body in a direction parallel with the filter's longitudinal axis extending from pointed end 401 towards cap end 403 of cylindrical portion 102. Referring to figure 8, the conical filter 5 portion 103 comprises a main body wall 800 defined by an outer surface 801 and an inner surface 802 defining a region of the internal chamber 500 within filter 100. Holes 104 extend through wall 800 from outer surface 801 to inner surface 802 such that the orientation of the walls 803 of each hole 104 is substantially aligned with the longitudinal axis of filter 100. 0

Airflow inlet 114 is orientated such that as the airflow is drawn through the low efficiency chamber 109 by the electric fan motor (not shown) a cyclonic airflow is created within chamber 109. Accordingly, the airflow through filter 100 typically involves air passing through filter holes 104 from a direction from flap5 112 positioned at a lowermost region of chamber 109 towards housing 110 positioned at an uppermost region of chamber 109 as illustrated by arrows 205. As the defining walls 803 of holes 104 are aligned substantially parallel with the airflow direction 205, the airflow through the filter assembly is more efficient as the main airflow path is maintained in a substantially linear alignment. This would o not be achieved if the holes were aligned through the filter body in a direction substantially perpendicular to the main airflow path as with conventional filters.

Holes 105 are formed within cylindrical portion 102 in a direction substantially perpendicular to the hole walls 803 of the conical portion 103. In the 5 event of holes 104 becoming blocked, additional holes 105 provide a default airflow passageway through the filter to prevent overheating of the electric fan motor and damage to the vacuum cleaner. Additional holes 105 also increase the available area for airflow through the filter to increase the vacuum creation efficiency within the cleaner. 0

Figure 9a illustrates a side elevation view of the filter of figure 7 together with the annular cleaning collar and figure 9b illustrates the filter and annular cleaning collar of figure 9a with the filter displaced in an upward direction relative to the cleaning collar.

The elasticated annular cleaning collar 200 is secured in position at housing 110 so as to be held in permanent position. Filter 100 is moveably mounted within housing 110 and chamber 109 such that conical portion 103 may be extracted from and reinserted into chamber 109. This axial displacement of filter

100 is controlled by the cooperation of lugs 404, 405 slideably moveable within opposed channels 118 formed within housing 110. A user grasps filter 100 via handle 107 and via a plunger-like motion axially displaces filter 100 relative to dust collection canister assembly 101.

With the filter 100 fully inserted into chamber 109, the annular cleaning collar 200, comprising a smaller diameter than cylindrical portion 102, is stretched to accommodate filter 100 and is maintained in contact with the filter's outer surface. Figure 9a illustrates the annular cleaning collar 200 comprising annular lip 900 extending about cylindrical portion 102. The elasticated rubber collar 901 forms a substantially air-tight seal about the outer surface of cylindrical portion 102 due to the relative difference in diameters between collar 901 and portion 102.

Referring to figure 9b, following use, and to remove fluff, hair, debris matter and the like from the outer surface of conical portion 103, a user grasping handle 107 draws filter 100 in an upward direction from canister 101 and in particular housing 110. The stationary collar 200 then slides over the external surface of the cylindrical portion 102 and a region of the outer surface of conical portion 104. The elasticated collar 901 is also drawn in an upward direction by the upward movement of filter 100 serving to dissociate any hair or fluff matter entwined about filter holes 104.

The diameter of annular collar 901 is configured such that contact is maintained between collar 901 and the outer surface of conical portion 103 over at least 25% of the length of conical portion 103 between ends 400 and 401 corresponding to a distance of approximately 30mm. According to further specific implementations, the diameter of collar 901 may be selected to achieve enhanced or reduced contact over the length of cylindrical portion 104 as filter 100 is drawn from canister assembly 101.

The plunger-like axially displacement of filter 100 provides a repeated wiping of conical portion 103 by the elasticated collar 901. The entangled hair and fluff matter is then formed into annular rolls at the outer surface of cone 103. Due to the tapered side walls of cone 103, these rolled hair and fluff rings are easily dislodged and fall away under gravity, to settle at the lowermost region of chamber 109 in contact with moveable flap 112. Flap 112 is then released to empty the contents of chamber 109.

Claims

Claims:

1. A vacuum cleaner comprising:

5 suction generation means configured to generate a suction airflow through a region of said cleaner;

dust collection means positioned in the path of said suction airflow; o a filter positioned within said dust collection means to inhibit dust matter from passing downstream of said dust collection means as said suction airflow flows through said collection means and said filter; and

a collar disposed at the external surface of said filter, said collar configured5 to wipe a region of the external surface of said filter as said filter is displaced in a direction along its longitudinal axis;

wherein a cross-sectional area of said filter along its longitudinal axis decreases from a first end to a second end, said cross-sectional area of said first o end being greater than said cross-sectional area of said second end.

2. The cleaner as claimed in claim 1 wherein said filter is conical shaped.

5 3. The cleaner as claimed in claim 1 wherein said filter is dome shaped.

4. The cleaner as claimed in claim 1 wherein the shape of said filter is a truncated cone. 0

5. The cleaner as claimed in any preceding claim wherein said collar comprises a flexible elastic material.

6. The cleaner as claimed in claim 5 wherein said collar comprises rubber.

7. The cleaner as claimed in any preceding claim wherein said filter 5 comprises a plurality of holes distributed over the body of the filter, said holes extending from the external surface to an internal surface of said filter.

8. The cleaner as claimed in any one of claims 1 to 6 wherein said filter comprises a mesh. 0

9. The cleaner as claimed in any preceding claim wherein said filter comprises means to allow a user to grip one end of said filter and to pull and push said filter along said longitudinal axis. 5

10. The cleaner as claimed in any preceding claim wherein said filter is capable of being displaced in said longitudinal axis by a distance in the range 20 to 50mm.

11. The cleaner as claimed in any one of claims 1 to 9 wherein said filter is o capable of being entirely removed from said dust collection means.

12. The cleaner as claimed in any one of claims 1 to 10 comprising means to prevent said filter from being entirely removed from said dust collection means. 5

13. The cleaner as claimed in any preceding claim comprising guide means being configured to cause said filter to rotate in a plane transverse to its longitudinal axis when displaced into or out of said dust collection means.

0 14. The cleaner as claimed in any preceding claim wherein said collar is configured to maintain contact with said outer surface of said filter over at least 25% of the length of said filter as said filter is displaced into and from said dust collection means.

15. The cleaner as claimed in any preceding claim wherein said collar is removeably mounted at said dust collection means.

16. The cleaner as claimed in claim 15 further comprising an annular washer to removeably mount said collar at said dust collection means.

17. The cleaner as claimed in any one of claims 1 to 14 wherein said collar is formed integrally with a housing for said dust collection means.

18. The cleaner as claimed in any one of claims 1 to 16 wherein said collar is formed non-integrally with a housing for said dust collection means.

19. A cyclonic vacuum cleaner according to any preceding claim.

20. The cyclonic vacuum cleaner as claimed in claim 19 wherein said cleaner is a multi cyclone cleaner.

21. A cyclone vacuum cleaner comprising:

suction generation means configured to generate a suction airflow through a region of said cleaner;

a first dust collection canister positioned in the path of said suction airflow, said cleaner configured to create a cyclonic airflow within said dust collection canister;

a second dust collection canister positioned in the path of said suction airflow downstream of said first dust collection canister, said cleaner configured to create a cyclonic airflow within said second dust collection canister; a filter positioned within said first dust collection canister configured to inhibit dust matter from passing from said first dust collection canister to said second dust collection canister; and

5 a collar disposed at the external surface of said filter, said collar configured to wipe the external surface of said filter as said filter is displaced along its longitudinal axis relative to said collar; o wherein a cross-sectional area of said filter along its longitudinal axis decreases from a first end to a second end, said cross-sectional area of said first end being greater than said cross-sectional area of said second end.

22. A filter assembly for a vacuum cleaner comprising: 5 dust collection means capable of positioning within an airflow path of a vacuum cleaner;

a filter positioned within said dust collection means to inhibit dust matter o from passing downstream of said dust collection means as said suction airflow flows through said collection means and said filter; and

a collar disposed at the external surface of said filter, said collar configured to wipe a region of the external surface of said filter as said filter is displaced in a 5 direction along its longitudinal axis;

wherein a cross-sectional area of said filter along its longitudinal axis decreases from a first end to a second end, said cross-sectional area of said first end being greater than said cross-sectional area of said second end. 0

23. A vacuum cleaner substantially as herein described with reference to, and as shown in, any of the accompanying figures.

24. A cyclone vacuum cleaner substantially as herein described, with reference to, and as shown in, any of the accompanying figures.

25. A filter assembly for a vacuum cleaner substantially as herein described, with reference to, and as shown in, any of the accompanying figures.