Surface Cleaning Apparatus

This application is a continuation of U.S. patent application Ser. No. 18/113,838, filed on Feb. 24, 2023, which itself is a continuation of U.S. patent application Ser. No. 16/797,929, filed on Feb. 21, 2020, and issued as U.S. Pat. No. 11,612,283 on Mar. 8, 2023, which itself is a continuation of co-pending U.S. patent application Ser. No. 15/499,151, filed on Apr. 27, 2017 and issued as U.S. Pat. No. 10,602,894 on Mar. 31, 2020, which itself is a continuation of co-pending U.S. patent application Ser. No. 14/932,816, filed on Nov. 4, 2015 and issued as U.S. Pat. No. 9,693,666 on Jul. 4, 2017, which itself is a continuation of U.S. patent application Ser. No. 13/040,676, filed on Mar. 4, 2011 and issued as U.S. Pat. No. 9,211,044 on Jul. 4, 2017, the content of each of which is herein incorporated by reference in its entirety.

The disclosure relates to surface cleaning apparatuses, such as vacuum cleaners.

Various constructions for surface cleaning apparatuses, such as vacuum cleaners, are known. Currently, many surface cleaning apparatuses are constructed using at least one cyclonic cleaning stage. Air is drawn into the vacuum cleaners through a dirty air inlet and conveyed to a cyclone inlet. The rotation of the air in the cyclone results in some of the particulate matter in the airflow stream being disentrained from the airflow stream. This material is then collected in a dirt bin collection chamber, which may be at the bottom of the cyclone or in a direct collection chamber exterior to the cyclone chamber (see for example WO2009/026709 and U.S. Pat. No. 5,078,761). One or more additional cyclonic cleaning stages and/or filters may be positioned downstream from the cyclone.

The following summary is provided to introduce the reader to the more detailed discussion to follow. The summary is not intended to limit or define the claims.

According to one broad aspect, a surface cleaning apparatus has a main body with a removable air treatment member, which preferably comprises a cyclone bin assembly, comprising a cyclone chamber and a dirt collection chamber. The surface cleaning apparatus also has a suction hose connector to which a flexible suction hose may be connected, and optionally releasably connected. The downstream side of the suction hose connector is in fluid communication with the cyclone chamber.

Preferably, the suction hose connector is fixedly connected to the main body, so that the suction hose connector remains connected to the body when the cyclone bin assembly is removed. An advantage of this configuration may be that it allows the cyclone bin assembly to be separated from the suction hose connector, and the associated suction hose, when the cyclone bin assembly is detached from the body. This may allow a user to manipulate the cyclone bin assembly without also having to handle the flexible suction hose.

Preferably, at least a portion of the suction hose connector is nested within the cyclone bin assembly. For example, the downstream end of the suction hose connector can be nested within the dirt collection chamber. An advantage of this configuration may be that the overall size of the surface cleaning apparatus may be reduced. Further, the suction hose connecter may be protected or partially protected from impact.

Preferably, the downstream side of the suction hose connector is connectable to a tangential air inlet of the cyclone chamber. More preferably, the tangential air inlet is automatically connected to the suction hose connector when the cyclone bin assembly is placed on the main body.

In accordance with this broad aspect, a surface cleaning apparatus comprises an air flow path extending from a dirty air inlet to a clean air outlet. The surface cleaning apparatus may also comprise a main body comprising a suction motor provided in the air flow path. A cyclone bin assembly may be provided in the air flow path and may be removably mounted to the main body. The cyclone bin assembly may comprise a cyclone chamber. A hose connector may be provided on the main body. The hose connector may comprise a portion of the air flow path from the dirty air inlet to the cyclone bin assembly.

The hose connector may be nested in the cyclone bin assembly when the cyclone bin assembly is mounted to the main body.

The hose connector may be in line with a tangential inlet of the cyclone chamber.

The cyclone bin assembly may comprise a dirt collection chamber and the hose connector may be nested in the dirt collection chamber.

The main body may comprise a platform on which the cyclone bin assembly is removably mounted. The hose connector may be provided on the platform.

The hose connector may be fixedly provided on the platform.

The cyclone bin assembly may have a recess for removably receiving the hose connector.

The recess may be provided in a lower surface of the cyclone bin assembly.

The hose connector may be slidably receivable in the recess.

The cyclone bin assembly is mountable on the main body upon movement in a particular direction. The hose connector may have a flange at an air outlet end of the hose connector and the flange may be sealingly mateable with a wall extending in the particular direction.

The surface cleaning apparatus may comprise a flexible suction hose extending between a cleaning head or cleaning tool and the hose connector.

The surface cleaning apparatus may be a portable surface cleaning apparatus.

The cyclone bin assembly further may comprise a handle for the surface cleaning apparatus.

In accordance with this broad aspect, a surface cleaning apparatus may alternately comprise an air flow path extending from a dirty air inlet to a clean air outlet. The surface cleaning apparatus may also comprise a main body comprising a suction motor provided in the air flow path. A cyclone bin assembly may be provided in the air flow path and may be removably mounted to the main body. The cyclone bin assembly may comprise a cyclone chamber. The hose connector may comprise a portion of the air flow path from the dirty air inlet to the cyclone bin assembly wherein the hose connector is nested in the cyclone bin assembly.

The hose connector may be in line with a tangential inlet of the cyclone chamber.

The main body may comprise a platform on which the cyclone bin assembly is removably mounted.

The cyclone bin assembly may have a recess provided in a lower surface of the cyclone bin assembly in which the hose connector is mounted.

The surface cleaning apparatus may be a portable surface cleaning apparatus and, preferably, the cyclone bin assembly further comprises a handle for the surface cleaning apparatus.

Referring to, an embodiment of a surface cleaning apparatusis shown. In the embodiment illustrated, the surface cleaning apparatusis a hand operable surface cleaning apparatus. In alternate embodiments, the surface cleaning apparatus may be another suitable type of surface cleaning apparatus, including, for example, an upright vacuum cleaner, a canister vacuum cleaner, a stick vac, a wet-dry vacuum cleaner and a carpet extractor. Power can be supplied to the surface cleaning apparatusby an electrical cord (not shown) that can be connected to a standard wall electrical outlet. Alternatively, or in addition, the power source for the surface cleaning apparatus can be an onboard power source, including, for example, one or more batteries.

Referring to, the surface cleaning apparatushas a dirty air inlet, a clean air outlet(see for example) and an airflow passage extending therebetween. In the embodiment shown, the dirty air inletis the air inletof a suction hose connectorthat can be connected to the downstream endof a flexible suction hoseor other type of cleaning accessory tool, including, for example, a wand and a nozzle. From the dirty air inlet, the airflow passage extends through an air treatment member that can treat the air in a desired manner, including for example removing dirt particles and debris from the air. In the illustrated example, the air treatment member comprises a cyclone bin assembly. The cyclone bin assemblyis mounted on a main body. Alternatively, the air treatment member can comprise a bag, a filter or other air treating means. A suction motor() is mounted within the bodyand is in fluid communication with the cyclone bin assembly.

Referring to, the clean air outlet, which is in fluid communication with an outletof the suction motor, is provided in the body. In the illustrated example, the dirty air inletis located toward the front of the surface cleaning apparatus, and the clear air outletis located toward the rear.

Referring to, in the illustrated example, cyclone bin assemblyincludes a cyclone chamberand a dirt collection chamber. The cyclone chamberis bounded by a sidewall, a first end walland a second end wallthat are configured to preferably provide an inverted cyclone configuration. A tangential air inletis provided in the sidewall of the cyclone chamberand is in fluid communication with the air outlet() of the hose connector. Air flowing into the cyclone chambervia the air inletcan circulate around the interior of the cyclone chamberand dirt particles and other debris can become disentrained from the circulating air. It will be appreciated that the cyclone chamber may be of any configuration and that one or more cyclone chambers may be utilized. In the example illustrated the cyclone bin assembly, and the cyclone chamberare arranged in a generally vertical, inverted cyclone configuration. Alternatively, the cyclone bin assemblyand cyclone chambercan be provided in another orientation, including, for example, as a horizontal cyclone.

Cyclone chambermay be in communication with a dirt collection chamberby any means known in the art. Preferably, as exemplified, the dirt collection chamberis exterior to cyclone chamber, and preferably at least partially surrounds and, more preferably completely surrounds, cyclone chamber. Accordingly, cyclone chamberis in communication with dirt collection chambervia a dirt outlet. Preferably, the dirt outletcomprises a slotformed between the sidewalland the first end wall. Slotcomprises a gap between an upper portion of cyclone chamber sidewalland the lower surface of first end wall. Preferably, the gap extends only part way around sidewall. Debris separated from the air flow in the cyclone chambercan travel from the cyclone chamber, through the dirt outletto the dirt collection chamber.

Air can exit the cyclone chambervia an air outlet. In the illustrated example, the cyclone air outlet includes a vortex finder. Optionally, a removable screencan be positioned over the vortex finder. The cyclone chamberextends along a longitudinal cyclone axis(). In the example illustrated, the longitudinal cyclone axisis aligned with the orientation of the vortex finder.

The dirt collection chambercomprises a sidewall, a first end walland an opposing second end wall. In the illustrated example, at least a portion of the dirt collection chamber sidewallis integral with a portion of the cyclone chamber sidewall, at least a portion of the first cyclone endwallis integral with a portion of the first dirt collection chamber end walland/or and at least a portion of the second cyclone end wallis integral with a portion of the second dirt collection chamber end wall. The dirt collection chamberextends along a dirt collection axis(). Optionally, the dirt collection axiscan be parallel to and offset from the cyclone axis.

The dirt collection chambermay be emptyable by any means known in the art and is preferably openable concurrently with the cyclone chamber. Preferably, the second dirt collection chamber end wallis pivotally connected to, e.g., the dirt collection chamber sidewall, such as by hinges. The second dirt collection chamber end wallcan be opened () to empty dirt and debris from the interior of the dirt collection chamber. In the illustrated example, the second cyclone end wallis integral with, and is openable with, the second dirt collection chamber end wall. Accordingly, opening the second cyclone end wallcan allow dirt and debris to be emptied from the cyclone chamberand the dirt collection chamber. The second dirt collection chamber end wallcan be retained in the closed position by any means known in the art, such as by a releasable latch.

Alternately, or in addition, as shown in the illustrated example, the first cyclone end wallmay be integral with, and is openable with, the first dirt collection chamber end wall. Accordingly, opening the first cyclone end wallcan allow dirt and debris to be emptied from the cyclone chamberand the dirt collection chamber. The first dirt collection chamber end wallcan be retained in the closed position by any means known in the art, such as by a releasable latch.

A handleis provided on the top of the cyclone bin assembly. The handleis configured to be grasped by a user. When the cyclone bin assemblyis mounted on the body, the handlecan be used to manipulate the surface cleaning apparatus. When the cyclone bin assemblyis removed from the body, the handlecan be used to carry the cyclone bin assembly, for example to position the cyclone bin assemblyabove a waste receptacle for emptying. In the illustrated example, the handleis integral with a lidof the cyclone bin assembly.

Referring to, optionally, the cyclone bin assemblyis detachably connected to the body. Preferably, as exemplified, the cyclone bin assemblyis detachably mounted on a platform. One or more releasable latches may be used to secure cyclone bin assemblyto main body. As exemplified, the rear surface of the cyclone bin assemblyabuts against the front wall of the suction motor housingof the main body. Accordingly, a single releasable latch(see for example) can be used to secure a front edge of the cyclone bin assemblyto the bodyand thereby secure the cyclone bin assemblyto the main body. Alternately, two or more securing members may be provided.

Referring to, a main power switchfor the surface cleaning apparatus(e.g. for controlling the operation of the suction motor) is removable with cyclone bin assemblyand is preferably provided on the lidof the cyclone bin assembly. The power switchis connected to the suction motorby a control circuit, and is operable to control the supply of power from a power source to the suction motor. Preferably, the power switchis positioned in close proximity to the handle. Providing the power switchclose to, or optionally on, the handlemay help allow a user to operate the power switchwith the same hand that used to grasp the handle.

Control circuitmay be of various designs which include main power switchand enable main power switchto be used to selectively actuate the suction motor. As exemplified in, the control circuitcomprises electrical conduits, for example wires, which can be provided internally in cyclone bin assembly(e.g., in an internal handle conduit). The plurality of wirescan electrically connect the switchto a power source in the bodyand/or the suction motor.

Referring to, optionally, the control circuitbetween the power switchand the suction motorcomprises a decoupling member and is interruptible, and the power switchcan be detachable from the body. In the illustrated example, the decoupling member comprises first and second power connectors,. The lidof the cyclone bin assemblycomprises a first power connectorand the bodycomprises a second, mating power connector. When the cyclone bin assemblyis mounted on the body, the first power connectoris electrically coupled to the second power connector. Connecting the first and second power connectors,can complete an electrical control circuitbetween the power switchand the suction motorsuch that main power switchmay control the actuation of the suction motor. The first and second power connectors,are releasably coupled and can be separated from each other to interrupt the electrical connection between the power switchand the suction motor. In the illustrated example, separating the cyclone bin assemblyfrom the bodyautomatically separates the first and second power connectors,.

In the illustrated example the first power connectoris a male power connector, comprising two prongs, and the second power connectoris a female power connector comprising a two corresponding receptaclesto receive the prongs. Accordingly, the second power connectorcan remain connected to a power supply when the cyclone bin assemblyis removed. Providing a female power connectoron the body, instead of a pair of exposed prongs, may help reduce the risk of electric shock to a user when the cyclone bin assemblyis removed, and the second power connectoris exposed.

Alternatively, instead of providing a continuous electrical connection between the power switchand the suction motor, the connection between cyclone bin assemblyand the bodycan be another type of control system. For example, instead of providing electrical wiresin the handle conduit, the control circuitcan comprise an electrical circuit housed in the main body that is interruptible by movement of main power switch, e.g., with the cyclone bin assembly, away from an in use position on main body. For example, a mechanical linkage system may be used. The mechanical linkage system (e.g., an abutment member such as a post) can be configured to translate movements of the power switchto open and close a circuit in the main body. For example, the post may be driving connected to a relay positioned on the bodyand that forms part of the circuit. The relay can then convert the movements of the mechanical linkage into electrical signals, optionally via onboard electronics, to control the suction motor. For example, removing the cyclone bin assemblyfrom the bodywould move the post out of engagement with the relay thereby permitting the relay to open the circuit.

In another example, the power switchmay be connected to an RF (or other type of wireless transmitter) in the cyclone bin assembly, and the bodycan include an RF receiver that can control the operation of the suction motor(or vice versa). The surface cleaning apparatuscan also include a proximity sensor configured to sense whether the cyclone bin assemblyis mounted on the body. In this example, moving the power switchmay generate a wireless control signal that is received by the RF receiver. The proximity sensor can be communicably linked to at least one of the RF transmitter or RF receiver and can be configured to deactivate at least one of the RF transmitter or RF receiver when the cyclone bin assemblyis removed from the base. Alternately, the proximity sensor could be drivingly connected to a relay or the like to close the relay when the cyclone bin assembly is mounted to main body. For example, the proximity sensor could be provided in main bodyand could be actuated by a magnet provided at a suitable location in cyclone bin assembly.

Optionally, the lidneed not be attached to cyclone bin assembly. Instead, lidmay be moveably mounted on main body, or removable therefrom, to permit cyclone bin assemblyto be removed. As exemplified in, the lidmay be pivotally mounted to main bodyby a hingeand moveable between an open position () wherein the cyclone bin assemblymay be removed and a closed position () wherein the cyclone bin assembly is secured in position. In the illustrated example, the hingeis provided toward the rear of the cyclone bin assembly. The lidmay be releasably retained in the closed position by any means, such as a latchprovided toward the front of the cyclone bin assembly. Opening the lidmay allow a user to access the interior of the dirt collection chamberand cyclone chamber. Optionally, the screenand/or the vortex findercan be removable from the cyclone chamberand can be removed via the top of the cyclone bin assemblywhen the lidis opened.

Referring again to, the platformmay comprise a generally planar bearing surfacefor supporting the cyclone bin assembly. Optionally, the main body may comprise at least one alignment member configured to engage the cyclone bin assemblyand thereby align and/or orient the cyclone bin assembly for mounting on main body. Preferably at least one of the alignment members is provided on the platform. Providing at least one alignment membermay help a user to replace the cyclone bin assemblyon the platformin a desired, operating position.

In the illustrated, the at least one alignment membercomprises a vortex finder insertextending from the platform. The vortex finder insertis a hollow conduit and is configured to fit within the vortex finderin the cyclone bin assembly. In this configuration, the vortex finder insertcan comprise a portion of the air outlet of the cyclone chamber, and can comprise a portion of the air flow path between the dirty air inletand the clean air outlet.

Optionally, the vortex findercan include an annular mounting shoulderthat is configured to rest on the upper faceof the vortex finder insert(see also). With the cyclone bin assemblyseated on the platform, and the insertreceived in the vortex finder, air exiting the cyclone chambercan flow through both the vortex finderand vortex finder insertand into a filter chamberin the body.

In the illustrated example, both the vortex finderand vortex finder inserthave a circular cross sectional shape. Locating the vortex finder insertwithin the vortex findercan provide lateral alignment and front/back alignment of the cyclone bin assemblyon the platform, but may still allow relative rotation between the cyclone bin assemblyand the body.

Optionally, an engagement member can be provided to help retain the vortex finder insertwithin the vortex finder. For example, a detent connection can be provided between the vortex finder insertand the vortex finderto help retain the vortex finderon the insert.

Optionally, the cyclone bin assemblycan be configured so that vortex finder insertserves as the vortex finderin the cyclone chamber. In this configuration, vortex finder insertmay be removable received in the cyclone chamber. For example, the second cyclone endwallmay comprise an aperture that is sized to receive the vortex finder insertand to create a generally air tight seal. With the cyclone bin assemblyseated on the platform, the vortex finder insertis inserted into cyclone chamberand may then serve as the vortex finder within the cyclone chamber. When the cyclone bin assemblyis removed, the vortex finder insertis removed from cyclone chamberand no vortex finder remains in cyclone chamber. Optionally, a relatively short annular lip can be provided around the perimeter of the aperture. The inner surface of the lip can rest against the outer surfaces of the vortex finder insertand may help seal the cyclone chamber. The lip and/or vortex finder insertcan each be tapered, and optionally can be configured as a morse taper to help seal the cyclone chamber. Alternatively, the bodymay not include a vortex finder insert, and the outlet of the vortex findercan be sealed against an air inlet aperture in the platform.