Vacuum Cleaner

The present invention relates to a vacuum cleaner.

Vacuum cleaners rely on a suction generator to generate an airflow, which is used to pick up dirt from a surface to be cleaned. The airflow is passed through one or more filters to separate dirt from the airflow before the airflow is ejected from the vacuum cleaner. The separated dirt may accumulate in a collection chamber, which is then subsequently emptied by a user.

According to a first aspect of the present invention, there is provided a vacuum cleaner comprising an suction generator to generate an airflow, a dirt separator comprising an opening to permit the airflow to pass into the dirt separator, a filter assembly to separate dirt from the airflow, and a dirt collection chamber to collect dirt separated from the airflow, and an attachment attached to the dirt separator. The attachment comprises a housing comprising a duct to deliver the airflow to the opening of the dirt separator, and a compaction member movable between a first position in which all of the compaction member is upstream of the opening, and a second position in which the compaction member extends through the opening of the dirt separator and into the dirt collection chamber to compact dirt collected in the dirt collection chamber.

Compacting dirt in the collection chamber with the compaction member frees up some of the space within the dirt collection chamber. As a result, the vacuum cleaner may be used for a longer period of time before emptying of the dirt collection chamber is required.

The compaction member may be arranged such that movement of the compaction member to the second position causes the dirt to be pushed upwards, against gravity (with the vacuum cleaner in an orientation for cleaning a floor surface). The compaction member may be arranged to compact the dirt at an opposite end of the dirt collection chamber to the opening. Such arrangements may help to prevent clogging at the opening of the dirt separator.

The compaction member may be movable between the first and second positions in a direction parallel to a longitudinal axis of the attachment. This may provide a space-efficient, simple arrangement, which may be more intuitive to a user.

A longitudinal axis of the dirt separator may be parallel to the longitudinal axis of the attachment. This may provide a space-efficient and ergonomic vacuum cleaner.

An end of the compaction member may be disposed at an acute angle relative to a direction of travel of the compaction member between the first and second positions. This may help to prevent the compaction member impeding airflow along the duct when the compaction member is in the first position.

The compaction member may comprise a wiper configured to wipe a surface of the dirt separator, for example a surface of the dirt collection chamber, as the compaction member is moved between the first and second positions. The wiper may be at a periphery of the compaction member. The wiper may dislodge dirt on the surface of the dirt separator to increase an amount of dirt that is compactable by the compaction member. The wiper may wipe a surface of the filter assembly. Wiping of the surface of the dirt separator by the wiper may increase a time between necessary emptying of the dirt collection chamber and/or replacement or cleaning of the filter assembly.

The wiper and compaction member may have an outer profile that substantially matches a cross-sectional profile, in a plane normal to the longitudinal axis, of the dirt collection chamber. This may allow the wiper to wipe a plurality of surfaces of the dirt collection chamber as the compaction member is moved between the first and second positions.

The attachment may comprise a recess defined in the housing and arranged to accommodate the compaction member. This may better separate the compaction member from the duct to prevent disruption to the airflow by the compaction member.

The attachment may comprise a sealing element disposed at an opening of the recess through which the compaction member extends in the second position, and the sealing element may be arranged to provide a seal between the housing and the compaction member when the compaction member is in the first position. This may help to prevent airflow from entering the recess in use of the vacuum cleaner with the compaction member in the first position, which would otherwise lead to a loss of suction.

The compaction member may comprise a user actuator configured to cause the compaction member to move between the first and second positions upon application of a force to the user actuator by a user. Manual actuation of the compaction member negates a need for complex assemblies to move the compaction member between the first and second positions, which may increase the cost, weight and power requirements of the vacuum cleaner.

The user actuator may comprise a recess in an outer surface of the compaction member that is accessible from outside of the housing. This may provide a smooth exterior of the vacuum cleaner, free of protrusions that may catch on nearby objects during use of the vacuum cleaner.

The user actuator may protrude through a slot in the housing. The slot may extend parallel to the longitudinal axis of the attachment and the user actuator may be movable along the slot to move the compaction member between the first and second positions. This may provide an ergonomic, intuitive arrangement.

The attachment may comprise a biasing assembly to bias the compaction member towards the first position. This may help to ensure that the compaction member is not left in a position that obstructs the duct. This may allow a user to apply a force to the compaction member in only one direction to move the compaction member towards the second position. This may help to ensure a better seal between the compaction member and the housing when the compaction member is in the first position.

The filter assembly may extend parallel to the longitudinal axis of the dirt separator. This may allow the compaction member to compact dirt in a direction parallel to the filter assembly, to move dirt away from a filtration surface of the filter assembly. In turn, this may increase a time between necessary replacement or cleaning of the filter assembly. This may also allow an overall diameter of the vacuum cleaner to be reduced.

The dirt separator may comprise a valve disposed at the opening. The valve may be movable between a closed position in which airflow is prevented from entering the dirt separator via the opening, and an open position in which airflow is permitted to enter the dirt separator via the opening. The valve may be biased to the closed position. This may help to prevent inadvertent escape of dirt from the dirt collection chamber when the vacuum cleaner is not in use.

Movement of the compaction member from the first position to the second position may cause the valve to move to the open position to permit entry of the compaction member into the dirt separator. Movement of the compaction member from the second position to the first position may cause the valve to move to the closed position, for example under a biasing force towards the closed position, to prevent inadvertent escape of dirt from the dirt collection chamber. This may provide a space-efficient arrangement.

The attachment may be removably attached to the dirt separator. This then has the benefit that the attachment may be removed for particular cleaning tasks. For example, by removing the attachment, the length of the vacuum cleaner may be reduced, thereby making it easier to manoeuvre and manipulate the vacuum cleaner over surfaces such as upholstery, mattresses, and other small spaces around the home.

According to another aspect of the present invention, there is provided a dirt separator for a vacuum cleaner, the dirt separator comprising an opening to permit the airflow to pass into the dirt separator, a filter assembly to separate dirt from the airflow, a dirt collection chamber to collect dirt separated from the airflow, a valve positioned at the opening and movable between a closed position, in which airflow is prevented from entering the dirt collection chamber via the opening, and an open position, in which airflow is permitted to enter the dirt collection chamber via the opening, and a compaction member positioned in the dirt collection chamber and movable, when the valve is in the closed position, between a first position in which the compaction member is a first distance from the valve, and a second position in which the compaction member is a second, lesser distance from the valve, to compact dirt collected in the dirt collection chamber against the valve.

Compacting dirt in the collection chamber with the compaction member frees up some of the space within the dirt collection chamber. As a result, the vacuum cleaner may be used for a longer period of time before emptying of the dirt collection chamber is required.

Providing the compaction member in the dirt collection chamber provides a space-efficient and relatively intuitive arrangement for a user to compact the dirt. This also allows the dirt to be compacted without the need for an additional tool, separate from the dirt separator.

The compaction member may be movable between the first and second positions in a direction parallel to a longitudinal axis of the dirt separator. This may provide a space-efficient and simple arrangement, resulting in a less complex dirt separator compared to one comprising a compaction member movable in a different direction.

The dirt separator may comprise an outer wall surrounding the filter assembly and defining a wall of the dirt collection chamber, and the compaction member may be attached to the outer wall such the compaction member and outer wall move as a single body between the first and second positions. This may provide a space-efficient arrangement and facilitate movement of the compaction member parallel to the longitudinal axis.

The filter assembly may be exposed to ambient air when the compaction member and the outer wall are moved to the second position. This may permit removal of the filter assembly from the dirt separator for cleaning and/or replacement.

The compaction member may be movable between the first and second positions upon application of a force by a user to the outer wall. This may provide a simple, relatively intuitive arrangement.

An inner surface of the outer wall may comprise a region having a greater surface roughness than a remainder of the inner surface. This region may help to draw compacted dirt away from the valve as the compaction member is moved from the second position to the first position due to friction between the region and the compacted dirt. For example, this may ensure that movement of the valve to the open position during dirt separation is not inhibited by the compacted dirt. This region may also help to retain the compacted dirt in a desired position within the dirt collection chamber, for example to minimise any negative impact on the performance of the dirt separator by the compacted dirt. This may also help to ensure that the compacted dirt does not escape from the dirt collection chamber under gravity when the valve is moved to the open position during dirt separation.

The compaction member may comprise a wiper configured to wipe a surface of one or more of the dirt collection chamber and the filter assembly as the compaction member is moved between the first and second positions. The wiper may be at a periphery of the compaction member. The wiper may dislodge dirt on the dirt collection chamber and/or the filter assembly to increase an amount of dirt that is compactable by the compaction member. This may increase a time between necessary emptying of the dirt collection chamber and/or replacement or cleaning of the filter assembly.

The wiper and compaction member may have an outer profile that substantially matches a cross-sectional profile, in a plane normal to the longitudinal axis, of the dirt collection chamber. This may allow the wiper to wipe a plurality of surfaces of the dirt collection chamber as the compaction member is moved between the first and second positions.

The dirt separator may be biased to the first position, for example by a biasing assembly. This may help to ensure that the compaction member is not left in a position that obstructs the airflow passing through the dirt separator and/or affects the filtration performance of the filter assembly. This may also allow a user to apply a force to the compaction member in only one direction to move the compaction member towards the second position, so simplifying a compaction sequence performable by a user.

The filter assembly may extend parallel to the longitudinal axis of the dirt separator and the compaction member may be movable between the first and second positions parallel to the filter assembly. This may help to move dirt away from a filtration surface of the filter assembly. In turn, this may increase a time between necessary replacement or cleaning of the filter assembly. This may also allow an overall diameter of the vacuum cleaner to be reduced.

When the compaction member is in the first position, the compaction member may be further from the opening than the filter assembly. This may help to ensure that the compaction member is not in a position that obstructs the airflow passing through the dirt separator and/or affects the filtration performance of the filter assembly.

The dirt separator may comprise a frame having one or more guiding elements for guiding movement of the compaction member between the first and second positions. For example, the guiding elements may engage with the outer wall of the dirt separator. The guiding elements may ensure that the compaction member moves in a reliable, repeatable manner, which may improve the safety and/or longevity of the dirt separator.

The filter assembly may be removably attached to the frame. This allows movement of the compaction member relative to the filter assembly and permits removal and replacement of the filter assembly when the compaction member is in the second position.

The valve may be attached to the frame. This may ensure that the valve remains in a correct position to prevent dirt from escaping the dirt collection chamber.

The valve may be biased to the closed position such that the valve is in the closed position when the dirt separator is not operating to separate dirt from an airflow. This may help to prevent inadvertent escape of dirt from the dirt collection chamber, and allow the dirt to be compacted against the valve by the compaction member.

According to yet another aspect of the present invention, there is provided a vacuum cleaner comprising a dirt separator according to the another aspect of the present invention.

The vacuum cleaner may comprise a tool or wand removably attached to the dirt separator and configured such that, when the tool or wand is attached to the dirt separator, movement of the compaction member between the first and second positions may be inhibited. When the tool or wand is removed from the dirt separator, movement of the compaction member between the first and second positions is permitted.

The example vacuum cleanerofcomprises a main body, a attachmentand a cleaner head. The cleaner head has an inlet aperturearranged to face a surface to be cleaned by the vacuum cleaner, and an outletfluidly connected to the inlet aperture. The attachmentin this example is a tool, but in other examples may be a wand or other suitable attachment type. In any event, the attachmentcomprises a ductbetween a first endand a second, opposite endof the attachment. When assembled, as shown in, the cleaner headis removably attached to a first endof the attachment, and a second endof the attachmentis removably attached to the main bodysuch that an airflow pathway is formed from the cleaner head, through the attachment, to the main body.

When attached to the main body, the attachmentis arranged co-axially with a central longitudinal axisof the main body. In this example, the main bodyand the attachmentare generally cylindrical in shape, with each having an outer housing,of a substantially constant outer diameter. The outer housingof the main bodysurrounds a suction generatorto generate an airflow along the airflow pathway, and a battery assemblyto power the suction generator. It will be appreciated that in other examples, the main bodymay be provided with a power supply unit, to replace or supplement the battery assembly, for connection to a mains power outlet.

The main bodycomprises a dirt separator(shown in more detail in) upstream of the suction generator. As with the outer housing, the dirt separatoris also cylindrical in shape and has a substantially constant outer diameter. The dirt separatorcomprises an openingat an interface between the main bodyand the attachment. The openingserves as both an air inlet and a dirt outlet of the dirt separator. When serving as an air inlet, the openingpermits the airflow generated by the suction generatorto pass into the dirt separatorfrom the ductin a direction parallel to the longitudinal axisof the main body(which is co-axial with a longitudinal axis of the dirt separator). The dirt separatoralso comprises an air outletfluidly connected to the suction generator, to permit airflow to exit the dirt separator.

The dirt separatorcomprises a framethat extends parallel to the longitudinal axisof the main body. The frameis fixed at a first end to the outer housingof the main body. A second opposite endof the framepartially defines the openingof the dirt separator.

A filter assemblyis removably attached to the frame. The filter assemblyis configured to separate dirt D from dirt-laden airflow received via the opening, and comprises a plurality of layers of filtration materialfor doing so. The filter assemblyis substantially u-shaped, as viewed in a plane normal to the longitudinal axis, and is elongate in a direction parallel to the longitudinal axis. Accordingly, airflow enters the dirt separatorin a direction parallel to the filter assemblyso that the airflow scrubs the filter assemblyto help attenuate dirt accumulation on the filter assembly.

The filter assemblyforms a wall of a dirt collection chamber. The dirt collection chamberreceives dirt-laden airflow via the openingduring vacuum cleaning and fills up with dirt D separated from the dirt-laden airflow by the filter assembly. The dirt collection chamberis elongate in shape and extends between the openingat one end, and the outer housingof the main bodyat an opposite end. The dirt collection chamberextends alongside the filter assemblyand has a substantially constant cross-sectional profile along the length of the filter assembly, as viewed in a plane normal to the longitudinal axis. The elongate shape of the dirt collection chamberallows for a larger volume for a given diameter of the dirt separator.

A valveis connected to the second endof the framesuch that the valveis positioned at the opening. The valveis movable between a closed position (as shown in) and an open position (as shown in). In the closed position, the valveis configured to obstruct the opening, and therefore the airflow pathway. That is, when in the closed position, the valveobstructs the openingsuch that airflow is prevented from entering the dirt collection chambervia the openingand dirt D is prevented from escaping the dirt collection chambervia the opening. In the open position the openingis unobstructed by the valvesuch that dirt-laden airflow is permitted to enter the dirt collection chamber.

The dirt separatorcomprises an outer wallextending along a length of the dirt separatorand surrounding the frame, the filter assemblyand the valve.

The dirt collection chamberis therefore defined along one side by the outer walland along an opposite side by the frameand the filter assembly. The openingthen provides an opening into the dirt collection chamber.

The outer wallcomprises a first end that abuts or is proximal the main body, and a second endthat is distal from the main body. Along with the frame, the outer wallpartially defines the openingat the second end. The valveis arranged to abut the inner surfaceof the outer wallwhen in the closed position, to form a seal between the frameand the outer wallat the opening. This seal prevents dirt D from inadvertently escaping the dirt collection chamber.

During vacuum cleaning, as shown in, the suction generated by the suction generatorcauses the valveto move to the open position. The suction generatorgenerates an airflow that passes from the inlet apertureof the cleaner head, through the ductof the attachmentand through the dirt separator. Dirt-laden airflow enters the dirt separatorvia the openingand travels in a direction parallel to the filter assemblyso that dirt D is encouraged towards an opposite endof the dirt collection chamberto the opening. The dirt-laden airflow passes through the filter assemblyto separate the dirt D from the airflow, and a filtered airflow exits the dirt separatorvia the outlet. Larger and/or heavier dirt entrained in the airflow has a greater momentum than smaller and/or lighter dirt. This momentum causes the larger and/or heavier dirt to push smaller and/or lighter dirt within the dirt collection chambertowards the opposite endof the chamber. As a result, smaller and/or lighter pieces of dirt also collect at the opposite endof the dirt collection chamber, as shown by the accumulation of dirt D in. After vacuum cleaning, as shown in, the valvereturns to the closed position to prevent the dirt D falling out of the dirt collection chamberunder gravity when the suction generatoris switched off. In the example, the valveis biased to the closed position and therefore returns to the closed position when the suction generated by the suction generatoris removed.