Filter Cleaner Assembly

This application claims priority to U.S. Provisional Application No. 63/655,415, filed on Jun. 3, 2024, U.S. Provisional Application No. 63/718,217, filed Nov. 8, 2024, and U.S. Provisional Application No. 63/793,963, filed on Apr. 24, 2025. The entire contents of each is hereby incorporated by reference.

The present disclosure relates generally to air-moving units such as vacuum cleaners, and more specifically to air-moving units having filter cleaning capabilities.

Traditional air-moving unit designs, such as vacuum cleaners, typically include a filter positioned upstream of the blower assembly.

In one instance, a filter assembly for use with a power head having a blower assembly with a blower inlet contained therein and a collection container defining a collection volume, the filter assembly including a housing, where the housing includes a first connection interface configured to releasably attach to the power head, and a second connection interface configured to releasably attach to the collection container, a first filter passageway extending between and open to both first connection interface and the second connection interface, a first filter region positioned within the first passageway between the first connection interface and the second connection interface, and a master control assembly, where the master control assembly is configured to selectively reverse the flow of air through the first filter region.

Alternatively or additionally, in any combination, where the housing is configured to be stacked between the power head and the collection container.

Alternatively or additionally, in any combination, further including a second passageway extending between and open to both the first connection interface and the second connection interface, a second filter region positioned within the second passageway between the first connection interface and the second connection interface, and where the master control assembly is configured to selectively reverse the flow of air through the second filter region.

Alternatively or additionally, in any combination, where the first filter region has a first end facing the second connection interface and a second end opposite the first end, where air flows through the first filter region in a first direction when it enters via the first end and exits via the second end, and where air flows through the first filter region in a second direction when it enters via the second end and exits via the first end, the second filter region has a third end facing the second connection interface and a fourth end opposite the third end, where air flows through the first filter region in a third direction when it enters via the third end and exists via the fourth end, and where air flows through the second filter region in a fourth direction when it enters via the fourth end and exits via the third end, and where the master control assembly is operable in a first configuration, in which air passes through the first filter region in the first direction and passes through the second filter region in the third direction, a second configuration, in which air passes through the first filter region in the second direction and passes through the second filter region in the third direction, and a third configuration, in which air passes through the first filter region in the first direction and passes through the second filter region in the fourth direction.

Alternatively or additionally, in any combination, where the first connection interface is in fluid communication with the blower inlet of the blower assembly when the filter assembly is attached to the power head, and where the second connection interface is in fluid communication with the collection volume when the filter assembly is attached to the collection container.

Alternatively or additionally, in any combination, further including an ambient air port open to the exterior of the housing.

Alternatively or additionally, in any combination, further including a first valve assembly, where the first valve assembly is adjustable between a first configuration, in which the first filter region is in fluid communication with the first connection interface and not in fluid communication with the ambient air port, and a second configuration, in which the first filter region is in fluid communication with the ambient air port and not in fluid communication with the first connection interface.

Alternatively or additionally, in any combination, where the master control assembly is configured to reverse the flow of air through the first filter region without the use of electrical power.

Alternatively or additionally, in any combination, further including a transition passage extending between and open to the second connection interface and the exterior of the housing, and a valve assembly positioned in the transition passage, where the valve is adjustable between an open configuration, in which air can flow through the transition passage, and a closed configuration, in which air cannot flow through the transition passage.

Alternatively or additionally, in any combination, where the master control assembly is configured to adjust the valve between the open configuration and the closed configuration.

Alternatively or additionally, in any combination, where the master control assembly is configured to coordinate adjusting the valve between the open and closed configurations and reversing the flow of air through the first filter region.

Alternatively or additionally, in any combination, where the transition passage extends between and is open to both the first connection interface and the second connection interface.

Alternatively or additionally, in any combination, further including a first coupling element positioned proximate the first connection interface for releasably connecting the housing and the power head, and a second coupling element positioned proximate the second connection interface for releasably connecting the housing with the collection container.

In another instance, a filter assembly for use with a power head having a blower assembly with a blower inlet contained therein, and a collection container defining a collection volume, the filter assembly including a housing, where the housing includes a first connection interface configured to releasably attach to the power head, and a second connection interface configured to releasably attach to the collection container, a first filter region, the first filter region having a first end open to and in fluid communication with the second connection interface and a second end opposite the first end, a second filter region, the second filter region having a third end open to and in fluid communication with the second connection interface and a fourth end opposite the first end, an ambient air inlet open to the exterior of the housing, a first valve assembly adjustable between a first configuration, in which the second end of the first filter region is in fluid communication with the first connection interface and not in fluid communication with the ambient air inlet, and a second configuration, in which the second end of the first filter region is in fluid communication with the ambient air inlet and not in fluid communication with the first connection interface, and a second valve assembly adjustable between a third configuration, in which the fourth end of the second filter region is in fluid communication with the first connection interface and not in fluid communication with the ambient air inlet, and a fourth configuration, in which the fourth end of the second filter region is in fluid communication with the ambient air inlet and not in fluid communication with the first communication interface.

Alternatively or additionally, in any combination, where the first connection interface is in fluid communication with the blower inlet of the blower assembly when the filter assembly is attached to the power head, and where the second connection interface is in fluid communication with the collection volume when the filter assembly is attached to the collection container.

Alternatively or additionally, in any combination, further including a master control assembly including a shaft rotatable relative to the housing, a first cam mounted to the shaft for rotation together therewith, where the first cam is configured to operatively engage the first valve assembly, a second cam mounted to the shaft for rotation together therewith, where the second cam is configured to operatively engage the second valve assembly, and where rotating the shaft in a first direction causes the first valve assembly to adjust from the first configuration to the second configuration and causes the second valve assembly to remain in the third configuration, and where rotating the shaft in a second direction opposite the first direction causes the first valve assembly to remain in the first configuration and causes the second valve assembly to adjust from the third configuration to the fourth configuration.

Alternatively or additionally, in any combination, where the first cam and the second cam are mounted 180 degrees apart.

Alternatively or additionally, in any combination, further including a transition passage open to and extending between the second connection interface and the exterior of the housing, and a third valve assembly positioned in the transition passage, where the valve is adjustable between an open configuration, in which air can flow through the transition passage, and a closed configuration, in which air cannot flow through the transition passage.

Alternatively or additionally, in any combination, further including a master control assembly, where the master control assembly in operable communication with the first valve assembly, the second valve assembly, and the third valve assembly, and where the master control assembly is configured to initiate adjusting the third valve assembly before initiate adjusting the second valve assembly or the third valve assembly.

In another aspect, a filter assembly for use with a power head having a blower assembly with a blower inlet contained therein and a collection container defining a collection volume, the filter assembly including a housing, where the housing includes a first connection interface configured to releasably attach to the power head, and a second connection interface configured to releasably attach to the collection container, a first filter passageway extending between and open to both first connection interface and the second connection interface, a first filter region positioned within the first passageway between the first connection interface and the second connection interface, and a filter cleaning mechanism configured to clean the first filter region.

Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include hydraulic or electrical connections or couplings, whether direct or indirect.

illustrate a filter assemblyfor use with a vacuum assembly(e.g., a two-piece wet/dry vac). The filter assemblyis configured to be incorporated into the airflow path of the pre-existing vacuum assemblywithout the need of any dedicated hoses, external connections, or external electrical power sources. In some embodiments, the filter assemblymay be installed (e.g., stacked) between the power headand the collection containerof the vacuum assemblywhere the filter assemblyincorporates one or more filters,into the airflow path upstream of the blower assemblyof the power head(discussed below). In some embodiments, the filter assemblyalso includes a filter cleaning assembly configured to clean the one or more filters,contained therein without having to remove or otherwise access the filter,directly. In the illustrated embodiment, the filter assemblydoes so by selectively manipulating the airflow passing through each of the one or more filters,. In still further embodiments, the filter assemblyis configured to manipulate the airflow passing through each of the one or more filters,while the blower assemblyof the corresponding power headgenerates a constant airflow.

While the illustrated filter assemblyis shown installed in a pre-existing wet/dry vacuum assemblyas a separate accessory, it is understood that in other embodiments the filter assemblymay be incorporated into one of the power heador collection container. Furthermore, the filter assemblyis not limited for use in wet/dry vacuums. Rather, the present application is more generally directed to air-moving devices that utilizes a filter. For example, air-moving devices may include, but are not limited to, upright vacuums, stick vacuums, air compressors, air conditioning units, furnaces, and the like.

The vacuum assemblyofis a form of wet/dry vacuum assembly including a collection vessel or containerdefining a collection volumetherein, and a power headcouplable to the collection container.

The containerof the vacuum assemblyincludes a bodyat least partially defining the collection volumetherein. More specifically, the bodyincludes a base wall, and a plurality of side wallsextending from the periphery of the base wallto define an open endopposite thereof. The resulting open endestablishes a first connection interface and provides access to the collection volume. In the illustrated embodiment, the base wallis generally octagonal in shape having eight side wallsextending upwardly therefrom. However, in other embodiments, different shaped containers may be present.

As shown in, the open endof the containerforms a connection interface to which other devices (e.g., the power heador the filter assembly) may be releasably attached. During use, the open endserves to physically align the connected elements (e.g., vertically, horizontally, and rotationally) while also establishing an internal connection region where various operable connections (e.g., airflow passage connections, electrical connections, debris passage connections, and the like) may be made and the transfer of material (e.g., air, dust, debris, and the like) may occur within the confines of the assembled vacuum's structure.

The containermay also include a coupling elementpositioned proximate the open endand configured to form a releasable connection with a corresponding coupling elementof either the power heador the filter assembly.

As shown in, the power headof the vacuum assemblyincludes a housingat least partially defining a power head volume, a blower assemblyat least partially positioned within the power head volume, and an inlet passageopen to the exterior of the housing.

The housingof the power headincludes a series of walls positioned to at least partially enclose the power head volumetherein. More specifically, the housingincludes a bottom or base wall, one or more side wallsextending from the base wall, and a top wallenclosing the side wallsopposite the base wall. In the illustrated embodiment, the housingalso forms one or more battery ports (not shown) into which rechargeable batteries (not shown) may be inserted to power the blower assembly. In still other embodiments, an electrical outlet or extension cord (not shown) may be incorporated into the housingin lieu of or to supplement the battery ports.

The inlet passageof the power headincludes a fluid passage or channel configured to receive untreated air from a hose or other vacuum accessory (not shown) and convey the untreated air to one of the collection volumeand/or the filter assembly. More specifically, the inlet passageincludes a first endthat is open to the exterior of the housingto serve as a mounting point to which a hose or other vacuum accessory (not shown) may be releasably attached during use. The inlet passagealso includes second endopposite the first endthat extends downwardly away from the base wallto form an open distal end (see).

The blower assemblyof the power headincludes a blower or fan configured to generate an airflow within the vacuum assembly. More specifically, the blower assemblyincludes a blower inletthat is in fluid communication with and draws air into the blower assembly(i.e., from the collection volumeand/or the discharge air port, discussed below), and a blower outletthat is open and exhausts air to the exterior of the housing. During operation, the blower assemblyis intended to draw power from a power source such as a rechargeable battery, a wall outlet, and the like.

In the illustrated embodiment, the blower inletincludes a passageway that is open through the base wall. Furthermore, the illustrated blower inletincludes a filter assembly. In such embodiments, the filter assemblymay be releasably attached to the base wallwhereby the filter itself extends downwardly away from the base wallof the housing. During use, the filter assemblyis oriented and positioned such that it will extend into one of the collection volume(e.g., when the power headis attached directly to the container; see) or the discharge air port(e.g., when the power headis attached directly to the filter assembly; see).

As shown in, the base wallof the housingof the power headat least partially forms a second connection interface to which other devices (e.g., the containeror the filter assembly) may be releasably attached. Similar to the open endof the container, the base wallof the housingserves to physically align the connected elements while also establishing a second internal connection region through which operable connections and material exchange may occur within the confines of the combined vacuum structure.

The power headmay also include a coupling elementpositioned proximate the base walland configured to form a releasable connection with a corresponding coupling elementof either the containeror the filter assembly.

As shown in, the filter assemblyis configured to be stacked between a power headand a containerto position one or more filters,within the air path of the vacuum assemblyupstream of the blower assembly. In some embodiments, the filter assemblyis configured to position a plurality of filters,(i.e., two filters) in a parallel flow orientation with respect to one another (see). In still other embodiments, the filter assemblyforms a plurality of passageways extending between and being open to a container connection interface and a power head connection interface (discussed below) with a corresponding filter,being positioned within each passageway. Once the filter assemblyis stacked between the power headand the container, each passageway extends between and is in fluid communication with the blower inletand the collection volumevia the power head connection interface and container connection interface, respectively.

In the illustrated filter assembly, each filter,represents a corresponding filter region, where the flow of air through each filter region,may be independently manipulated by the user without having to remove or otherwise access the filters,directly. In other embodiments, a single filter may be installed on the filter assemblythat is subdivided into a plurality of filter regions. In such embodiments, the flow of air through each filter region within the single filter may be independently manipulated by the user without having to remove or otherwise access the single filter.

The illustrated filter assemblyincludes a housingat least partially defining a filter assembly volume, one or more filters,removably coupled to the filter housing, one or more filter control assemblies,each associated with a corresponding filter,, an ambient air port, and a discharge air port. The filter assemblyalso includes a transition passageextending between and providing a fluid pathway between the second endof the inlet passageand the collection volumeof the collection container. The filter assemblyalso includes a transition control assemblyto selectively control the flow of air through the transition passageduring use.

The filter assembly housingincludes a perimeter wallextending around the perimeter of the filter assemblyto produce a first or container end, and a second or power head endopposite the first end. The first container end, in turn, defines the first or container connection interface to which the collection containermay be releasably attached. During use, the container connection interface serves to physically align an internal connection region where various operable connections (e.g., airflow passage connections, debris passage connections, and the like) may be made and the transfer of material (e.g., dust, air, debris, and the like) may occur within the confines of the assembled vacuum's structure. When the containeris attached to the filter assembly, the container connection interface is open to and in fluid communication with the collection volume.

The second enddefines the second or power head connection interface to which the power headmay be releasably attached. During use, the power head connection interface serves to physically align an internal connection region where various operable connections (e.g., airflow passage connections, debris passage connections, and the like) may be made and the transfer of material (e.g., dust, air, debris, and the like) may occur within the confines of the assembled vacuum's structure. When the power headis attached to the filter assembly, the power head connection interface is in fluid communication with blower inletand the second endof the inlet passage.

The perimeter wallalso encloses and defines the filter assembly volume. As shown in, the first endof the perimeter wallhas a cross-sectional shape that generally corresponds to the cross-sectional shape of the open endof the containerwhile the second endof the perimeter wallhas a cross-sectional shape that generally corresponds to the shape of the base wallof the power head. In the illustrated embodiment, both the first endand the second endhave a generally octagonal shapes similar to the octagonal cross-sectional shapes of the containerand power head unit, respectively.

The filter assembly housingalso includes a base walloriented generally perpendicular to the perimeter walland positioned proximate the first end. When the filter assemblyis mounted to the container, the base wallis positioned such that the underside thereof is open to and at least partially encloses a portion of the collection volume.

As shown in, the ambient air portof the filter assemblyincludes an access point permitting the ingress of clean, ambient air into the flow path of the filter assembly. More specifically, the illustrated ambient air portprovides a fluid passage between each of the filters,and the exterior of the vacuum assemblythrough which clean, ambient air may be drawn into the filter assemblyfor the filter cleaning process (discussed below). In some embodiments, the ambient air portprovides a fluid passage between the second ends,of the filters,(discussed below) and the exterior of the vacuum assembly. While the illustrated filter assemblyincludes a single ambient air portin selective fluid communication with both of the filters,, it is understood that in other embodiments, multiple dedicated ambient air portsmay be present.

As shown in, the discharge air portof the filter assemblyprovides a fluid passage between both filters,and the inletof the blower assembly. In the illustrated embodiment, the discharge air portincludes a chamberat least partially defined by the housingof the filter assemblyand that is in fluid communication with the inlet, the second endof the first filter, and the second endof the second filter(described below).

In embodiments where the power headincludes a filter assembly, the discharge air port(i.e., the chamber) may be sufficiently sized so that the filter assemblymay be at least partially positioned therein such that the filter assemblyof the power headis positioned downstream of both filters,of the filter assembly. In embodiments where no filter assemblyis included in the power head, the blower inletof the blower assemblymay be open to the discharge air portdirectly.

As shown in, each filter,of the filter assemblyis releasably attached to the filter housingand includes a first end or opening,, a second end or opening,, and one or more filter elements,positioned fluidly between the first end,and the second end,. During use, air or other fluids may flow through each filter,in a first direction A or a second direction B. When flowing through a given filter,in the first direction A, air enters the filter,via the first end,, passes through the one or more filter elements,, and exits via the second end,(see). When flowing in the second direction B, air enters the filter,via the second end,, passes through the one or more filter elements,, and exits via the first end,(see).

The filter assemblyincludes two filters,each having a single filter element,. Each filter,, in turn, is releasably mounted to the base wallof the housingsuch that the first end,of each filter,is open to the collection volumeof the container(see). In the illustrated embodiment, each filter,is releasably mounted to the base wallof the housingin a substantially horizontal orientation (i.e., parallel to the base wall) so that any dust or debris that is dislodged from the filter,(i.e., during the cleaning process) will more easily fall under the force of gravity into the collection volume.

As shown in, the filter assemblyalso includes one or more filter control assemblies, each associated with and configured to at least partially control the flow of air through a corresponding filter,. Each filter control assembly,, in turn, includes a series of passages and valves that, together, selectively place and isolate the second end,of a corresponding filter,in fluid communication with the ambient air portor the discharge air port. During use, each filter control assembly,is adjustable between a first or standard operating configuration, in which the second end,of the corresponding filter,is in fluid communication with the discharge portand fluidly isolated from the ambient air port(see first and second filter control assemblies,of), and a second or cleaning configuration, in which the second end,of the corresponding filter,is in fluid communication with the ambient inlet portand fluidly isolated from the discharge port(see first filter control assemblyofand second filter control assemblyof). In the illustrated embodiment, the filter assemblyincludes two filter control assemblies,, with each filter control assembly,being associated with the first and second filters,, respectively.