Dual Fluid Channel Vacuum Apparatus

CROSS REFERENCE APPLICATIONS

[0001] This application is a non-provisional application claiming the benefits of provisional application no. 62/216,212 filed September 9, 2015 and 62/257,962 filed November 20, 2015 and hereby incorporates both of them in their entirety for all purposes.

[0002] This application relates to U.S. Pat. No. 6,725,500; U.S. Pat No. 7,665,181 and U.S. Pat. No. 7,778,765 and incorporates them by reference to the extent not inconsistent with the disclosure herein.

BACKGROUND

[0003] One of the well-known limitations of conventional, non-circulating vacuums is that they often require rotating brushes and/or beater bars to agitate the carpet fibers to increase the amount of material being suctioned out of the rug. Conventional full sized vacuums also require wheels on the bottom surface to allow the vacuum cleaning surface to be moved across the surface to be cleaned. Additionally, the suck-down effect of conventional vacuums creates additional resistance to movement when they are in operation. An additional problem with conventional vacuum cleaners is that they cannot be used to clean "loose" fabrics, that is fabrics that are not mounted to a surface or sewn into pillows, because the strong suction necessary to pull up debris causes the loose fabric to be pulled into the intake nozzle of the vacuum. This means that loose fabric, including, but not limited to, clothing, bedding, curtains, throw rugs and lap rugs cannot be cleaned with a vacuum cleaner. The combination of these problems means that conventional vacuums both have severe limitation of use and maneuverability, increase carpet wear, can be difficult and tiring to use and are not very efficient in terms of energy use.

[0004] Most prior vacuum systems have a non-circulating fluid stream. The fluid flow comes in to the intake, is drawn through the debris container and then exits through a fluid exhaust that is spatially removed from fluid intake. Therefore, all of the force to lift up debris is generated by suction into the fluid intake. It is for this reason that loose fabrics get pulled into the intake of the vacuum.

[0005] A different type of vacuum system is disclosed in US Pat. No. 6,725,500 by Allen et al. entitled Air Recirculating Surface Cleaning Device. The vacuum system disclosed in this document re-circulates the fluid flow in the vacuum, instead of having the fluid blown out the back of the vacuum. The exhaust fluid is directed to the surface to be cleaned in a specific manner to create turbulence and increase the suction to loosen debris to increase the amount of suction and cleaning effectiveness generated with the same amount of power from the main motor. The loosened debris are then sucked up by the fluid intake, which is carefully aligned to the exhaust. See, for example, Fig. 40 of Allen et al. This can be referred to as a two fluid stream cleaning system.

[0006] Although the re-circulating plenum of Allen has many advantages, there are times when it cannot be used because the recirculating stream of fluid is not strong enough to create the requisite turbulence and force to generate the increased cleaning power and suction for one reason or another. Additionally, there are applications where the amount of power required to generate an adequate flow of exhaust fluid onto the surface to be cleaned is prohibitive, or the exhaust fluid has too much variability in flow or similar issues.

[0007] An additional issue with the device shown in Allen is that the necessity of two fluid flow channels in the area of the vacuum having the surface cleaning opening means that the cleaning head is taller than in other similar sized vacuums, creating issues with cleaning under furniture.

[0008] The foregoing example of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.

SUMMARY

[0009] One aspect of the present disclosure is to provide supplemental fluid flow in a recirculating vacuum system to ensure the exhaust fluid impinging on the surface to be cleaned has sufficient force for use in a dual fluid stream vacuum system.

[0010] Another aspect of the present disclosure is to allow the use of a dual fluid stream system in situations where the fluid flow expelled from the main motor cannot be used as the second fluid stream on to the surface to be cleaned for any reason. .

[0011] Another aspect of the present disclosure is to provide a housing for the dual fluid channel vacuum head that is a light as possible.

[0012] Another aspect of the present disclosure is to provide a housing for the dual channel vacuum head that has as low of profile as possible.

[0013] Another aspect of the present disclosure is to provide an embodiment of the dual channel vacuum that can be used to clean clothing.

[0014] Another aspect of the present disclosure is to provide a hand held version that has a fluid dispenser to allow the application of a cleaning fluid on to the surface being cleaned. [0015] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tool and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above described problems have been reduced or eliminated, while other embodiments are directed to other

improvements.

[0016] In one embodiment an additional fluid flow creator is provided to supplement to or create a fluid flow such that a two fluid stream system can function properly.

[0017] In one embodiment, the additional fluid flow creator is provided on the head of a canister vacuum, creating a second fluid flow to generate the two flow effect. The additional flow creator can be a ducted fan, a screw compressor, a roots type supercharger (positive displacement fluid pump) or other types of fluid movement devices, depending on the application.

[0018] In one embodiment, a dual channel vacuum has an fluid exhaust channel defining a flow path therethrough, said exhaust channel having a redirection member proximate to the distal end of said flow path,;a fluid intake channel defining a flow path therethrough; wherein said fluid exhaust channel and said fluid intake channel terminate in a fluid exhaust port and a fluid intake port respectively, said ports being proximate to the redirection member; a vacuum blower motor operative to draw fluid into said fluid intake channel said redirection member being configured to reflect fluid expelled from said fluid exhaust channel toward said fluid intake channel such that the reflected fluid agitates the surface to be cleaned; said redirection member terminating at least a given distance from the termination of the suction port; and an outflow generator separate from the vacuum blower motor providing at least some of the fluid flow to expel fluid out of said fluid exhaust channel.

[0019] In another embodiment, a dual channel vacuum comprising: a set of substantially fluid tight fluid plenums; a fluid exhaust channel defining a flow path through the fluid plenums, said exhaust channel having a redirection member proximate to the distal end of said flow path; a fluid intake channel defining a flow path through the fluid plenums; wherein said fluid exhaust channel and said fluid intake channel terminate in a fluid exhaust port and a fluid intake port respectively, said ports being proximate to the redirection member; a vacuum blower motor operative to draw fluid into said fluid intake channel said redirection member being configured to reflect fluid expelled from said fluid exhaust channel toward said fluid intake channel such that the reflected fluid agitates the surface to be cleaned; said redirection member terminating at least a given distance from the termination of the suction port; and the fluid plenums being formed of an upper element, center element and bottom element, wherein the upper element and the center element form the fluid exhaust channel and the center element and the lower element form the fluid intake channel.

[0020] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a cross sectional, schematic view of the basic two flow cleaning head.

Figure 2 is a cross sectional, schematic view of the standard recirculating fluid flow pattern. Figure 3 is a partial cut away view of a canister vacuum with a ducted fan creating the

outflow.

Figure 4 is a schematic, cross sectional view of a canister vacuum with a ducted fan.

Figure 5 is a schematic drawing of two possible alternate locations for ducted fans on a canister vacuum.

Figure 6 is a perspective drawing of a screw compressor, a possible alternate fluidflow

generator.

Figure 7 is a perspective view of a roots type supercharger creating a fluid flow.

Figure 8 is a perspective view of an upright vacuum with a fluid intake for an fluid flow generator...

Figure 9 is a cross sectional view of one embodiment of the cleaning body of either the

upright or hand held embodiments of the present invention

Figure 10 is a partial cut away view of one embodiment of the cleaning body of either the upright or hand held embodiments of the present invention.

Figure 11 is an exploded view of the plenum assembly of Figure 9.

Figure 12 is a top plan view of a hand held embodiment of the dual flow vacuum that can be used to clean clothing or other loose fabrics.

Figure 13 is a side plan view of Figure 12.

Figure 14 is a bottom plan view of the hand held embodiment.

[0021] Before explaining the disclosed embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown, since the invention is capable of other embodiments. Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting. Also, the terminology used herein is for the purpose of description and not of limitation.

DETAILED DESCRIPTION

[0022] Referring now to Figures 1 and 2, one embodiment of a dual flow vacuum 100 is depicted. Vacuum nozzle 1250 includes an outflow port 116 and a suction port 117. Arrows 200 and 201 show the path of fluid flow in outflow channel 115 and suction channel 114, respectively. In one embodiment, suction port 117 has a width of approximately 12.7 mm (0.5 inches) and outflow port 116 has a decreasing dimension toward its exit which terminates with a width of approximately 2.3813 mm (0.09375 inches). All measurements given herein are by way of example, not limitation, and should not be considered to be limiting. Where the proportion of sizes matters, it will be specifically noted.

[0023] In front of both ports there is a redirection member, or fluid damn 111 positioned in the path of fluid expelled from outflow port 116 to redirect the expelled fluid. The fluid damn 111 is configured to reflect expelled fluid toward suction port 116. For example, fluid damn 111 could be arcuate in shape with a curvature to reflect fluid toward suction port 116. The dual flow effect works with any amount of fluid flow, in theory. However, the system generally works better as the volume and velocity of the fluid flow increases. It has been demonstrated to work effectively at 1.13 cubic meter per minute fluid flow measured using an unobstructed fan measured in a full diameter tube using an Anemometer right at the exit of fan. It is believed that for many standard floor vacuum cleaners, the fluid flow should be designed to produce a flow rate above 2.832 cubic meter per minute, and perhaps 4 cubic meters per minute or higher.

[0024] The fluid flow thru the vacuum 100 is shown in schematic form in Figure 2. The fluid flow is created by motor 118. The fluid is sucked up through fluid intake channel 114 into the debris chamber 119. In the debris chamber, the debris can be trapped by a filter, by a cyclonic device or other known means. The fluid flows up through the fan (not shown) to be exhausted through fluid outflow channel 115. In the depicted embodiment the fluid exhaust 115 has a smaller cross section than the fluid intake 114, approximately 2.38 mm to 17.46 mm (3/32 inch to 11/16 inch) respectively. The fluid intake opening 117 and fluid outflow opening 116 are both located near leading edge 132. In the depicted embodiment, the leading edge 132 is formed into an fluid dam 111. The fluid dam 111 is spaced apart from fluid intake opening 117 and fluid exhaust opening 116, creating fluid flow space 127. This created the dynamic turbulation effect discussed in the prior patents. The fluid exhaust channel 115 and opening 117 can be at an angle to the fluid intake channel 114 and opening 116 and spaced back from fluid opening 117, as disclosed in the '500 patent to Allen.

[0025] Below the fluid dam 111 is fluid flow opening 128, which is the location of the fluid flow into the vacuum 100. In the depicted embodiment fluid flow opening 128 has an internal width of approximately 19.05 mm ( ¾ inch), and is spaced back from the front by 22.23 mm (7/8 inch). As the vacuum 100 is moved over a surface to be cleaned, fluid flow opening 128 is moved over the surface the fluid flow into fluid flow opening pulls loose debris of the surface to be cleaned and into the fluid intake channel 114 and the dynamic turbulation loosen dirt and lifts up fibers as discussed in the prior patents. A filter or cyclonic device (not shown) can be added into the fluid flow after the fan to catch any additional particles to prevent them from being blown back onto the vacuumed surface.

[0026] The exact configuration of the parts with relation to each other can be varied from what is depicted in the drawings, so long as the operational affect described herein is achieved. The relative location of the pieces to each other will have to be determined experimentally for each configuration of the device. The fluid dam 111 curves such that the end point 2112 is generally directed towards fluid intake opening 117. The fluid flow out of fluid exhaust opening 116 is shown in arrows. Most of the fluid flow has too much velocity to be immediately pulled into fluid intake opening 117. A portion of the fluid flow, is pulled directly into the fluid intake opening 117 by the fluid flow into the fluid intake opening. The remainder of the fluid flow continues towards the fluid dam 111, being somewhat directed downward by the fluid dam 111 and the fluid intake fluid flow and is then re-directed back towards the fluid intake opening 117 by the fluid dam 111. Some of the fluid flows downward out of fluid flow opening 128, and as it slows, it is then pulled into fluid intake opening 117. This fluid and the dynamic turbulation effect creates a "cushion" that prevents the suck down of a standard vacuum and allows the vacuum 100 to "float" over a surface. The fluid "cushion" also agitates the surface to be cleaned and the debris on the surface, causing more debris to be pulled in to the fluid flow into the vacuum. However, the pull of the fluid flow is not sufficient to pull loose fabric into the fluid intake opening 117, allowing the dual channel vacuum head 100 to be used on loose fabrics as well as solid surfaces. This effect also vibrates and loosens any fibers that are compacted from use or wear in carpets or clothing. [0027] Referring next to Figures 3 and 4, a canister vacuum 300 has a body 301 and a vacuum head 302 connected by a hose 303. The vacuum head 302 has an intake channel 314 that is roughly parallel to the surface to be cleaned. Outflow channel 315 is mostly parallel to the intake channel 315 along the top of the vacuum head 302. Other arrangement of the intake and outflow system could be used as well, including, but not limited to all of the different configurations shown in the Allen' 500 patent.

[0028] The "exhaust" fluid flow is generated (or supplemented) by ducted fan 320, which in the depicted embodiment is located on the connection tube 321 that connects the vacuum head 302 to the hose 303. A movable section 340 provides a bendable connection to allow the cleaning head to clean under furniture and similar items. The ducted fan 320 is enclosed in a housing 322 with an intake grill 332. The housing 320 is connected to the outflow channel 315. In the depicted embodiment, the ducted fan 320 is DC current powered fan. Other possible fluid flow generator could be used in this embodiment, as discussed below. No limitation to a ducted fan is intended, or should be inferred.

[0029] An alternate location of the ducted fan or other outflow generator is depicted in Figure 5. The outflow generator 420 can be placed in a housing on either side of the connection tube 321 to create a lower profile to allow the vacuum head to be moved under furniture etc. with a lower clearance and increased power of fluid flow, as seen in Figure 4. In Figure 5, two fans are shown on the sides of the hose 321. Either two smaller fans can be used and placed on the sides, or a single larger fan can be placed on one side, depending on the design configurations needs in terms of profile and power.

[0030] Two alternate flow generators are shown in Figures 6 and 7. A screw compressor 520 could be used, as could a root type supercharger 620. Centrifugal fans could be used as well.

[0031] Figure 8 depicts an upright vacuum 800 with an intake grill 832 for a fluid flow source to create the second fluid flow. This could be used to either separately create the "exhaust" fluid flow or to supplement the exhaust fluid flow to ensure there is sufficient force of the exhaust flow for it to function as described in the Allen patent. If desired, fluid flow monitors could be used to control the fluid flow created by the second fluid flow source to ensure appropriate fluid flow to create and maintain the fluid cushion and increased suction disclosed in the Allen patents. The intake grill could also be in other locations on the vacuum, no limitation to the depicted embodiment is intended, or should be inferred.

Although a bagged upright vacuum is depicted the two flow system would work equally well with bagless uprights and other types of upright vacuum cleaners. No limitation is intended for should be inferred.

[0032] Referring next to Figures 9-11, some embodiments require a low profile and/or lightweight cleaning head. Figure 9 is a cross section of one possible embodiment to the cleaning head 900 that can be used on either of the upright and hand held versions of the disclosed invention where light weight or low profile is a desired/needed characteristic. The fluid flow is created by at least fan 927 powered by motor 926 and is shown by arrows. The fluid is sucked up through fluid intake channel 914 into the debris chamber 119. Any particles are removed from the fluid flow by filter (not shown). The fluid flows up through the fan 227 to be exhausted through fluid exhaust channel 915. In the depicted embodiment the fluid exhaust channel 915 has a smaller cross section than the fluid intake 914. This smaller size can act to accelerate the fluid coming out of the fluid exhaust channel 915, helping to create the desired turbulence. The exact ratio of sizes will depend on the application of the device. The fluid intake opening 916 and fluid exhaust opening 917 are both located near leading edge 132. In front of fluid openings is located a fluid dam 911. The fluid dam 911 is spaced apart from fluid intake opening 916 and fluid exhaust opening 917, creating fluid flow space 920. The fluid exhaust channel 915 and opening 917 can be at an angle to the fluid intake channel 914 and opening 916 and spaced back from fluid opening 916, as disclosed in the '500 patent to Allen.

[0033] Below the fluid dam 911 is fluid flow opening 928, which is the location of the fluid flow into the cleaning head 900. As the cleaning head 900 is moved over a surface to be cleaned, fluid flow opening 928 is moved over the surface the fluid flow into fluid flow opening pulls loose debris of the surface to be cleaned and into the fluid intake channel 914. As noted above, the dual flow effect creates a cushion of fluid as well as agitating the surface being cleaned to loosen particle to be vacuumed. This cushion and agitating effect combine to allow the vacuum to not suck down on the surface, making it easier to move and in many embodiments allows the elimination of the beater brushes. This effect also allows loose fabrics to be cleaned without having them suck up into the intake channel.

[0034] Fan housing 928 has a reduced forward opening 929 and baffle 930 to direct fluid flow in the correct direction in the fluid exhaust channel 915. This reduces turbulence in the fluid exhaust channel, increasing the effective force of the fluid flow out of the fluid exhaust channel for a given amount of fluid flow generated by the fan. This increases the overall efficiency of the vacuum. The motor 926 can be placed outside of the fluid flow as seen in Figure 10. This allows for better cooling of the motor, as it is not being heated by the cleaning fluid flow coming from the fluid intake channel, which by this point in the process has been heated by friction in the fluid channels.

[0035] It is helpful to have the vacuum head 900 have as little weight as possible and have as low of profile as possible, to reduce the effort required of a user and to allow for the maximum usefulness of the device such that it can fit under many objects for easy use.

However, the fluid plenums need to have little or no leakage along their length, to prevent loss of power due to loss of fluid flow and/or the creation of too much turbulence in the fluid flow channels. In the prior disclosures, US Pat. N. 6,725,500; U.S. Pat No. 7,665,181 and U.S. Pat. No. 7,778,765, the fluid plenums are each made individually, with a top and bottom to the plenum, and then they are stacked on top of each other as required. The present disclosure provides a lower profile and lower weight alternative to this design, by forming the top of the fluid intake channel out of the bottom of the fluid exhaust channel as seen in Figures 9, 10 and 11. Figure 11 is an exploded view of the three component parts that form the fluid intake and exhaust plenums, referred herein as a stacked plenum 1120 for ease of reference. Upper element 1101, center element 1102, and bottom element 1103 are stacked together to form the fluid intake channel of the stacked plenum 1120 as seen in Figures 9 and 10. The base 1110 and side walls 1111, 1112 of bottom element 1103 form the bottom and side walls of fluid intake channel 914. The base 1115 of center element is both the top of fluid intake channel 915 and the bottom of fluid exhaust channel 915 of the stacked plenum 1120. The side walls 1114, 1115 or the center element 1102 form the side walls of fluid exhaust channel 915. The top of fluid exhaust channel 915 is formed from upper element 1101.

[0036] The low profile plenum is particularly suited to hand held embodiments of the dual channel vacuum, such as can be seen in Figures 12 to 14. A hand held dual channel vacuum 400 has the stacked plenum 1120 in the dual channel vacuum element 401. A handle 402 has an on/off button for the vacuum. Additionally, the handle can have a button 404 to allow a user to activate a fluid dispenser 405 with a pressurized canister 406 of a desired cleaning fluid. Alternatively, instead of a pressurized canister, a standard tank and pump system could be used as well. The cleaning fluid is dispensed on to the surface being cleaned through holes 407 located on the bottom surface 408 of the vacuum 400. The holes 407 can be located in front of the fluid flow opening 409 of the dual channel vacuum, or behind it (not shown). The holes are connected to the pressurized canister 406 by fluid channels (not shown) in a well-known manner. The pressurized canister 405 would a removable canister that would be changes out when empty or when a different fluid was desired. The fluid could be a sanitizing fluid, a dry cleaning fluid, a scented fluid or any combination. A hand-held dual channel vacuum 400 is particularly suited to an embodiment used as a clothing cleaner for use while traveling or between drying cleanings of garments. The vacuum can remove any loose dirt and/or debris on the fabric and the fluid dispenser 405 can be used to spray a self-drying cleaning fluid like Fabreze ®, and spray on dry cleaning fluids to remove odors and stains. If desired, a lint pick-up fabric area 410 can be provided behind the fluid flow opening 409 on the bottom surface 408 to remove any lint that was not vacuumed off.

[0037] The hand held dual channel vacuum 400 has a removable section 411 to allow the vacuumed debris to be removed from the vacuum after use.

[0038] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and subcombinations therefore. It is therefore intended that the following appended claims hereinafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations are within their true spirit and scope. Each apparatus embodiment described herein has numerous equivalents. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims. Whenever a range is given in the specification, all intermediate ranges and subranges, as well as all individual values included in the ranges given are intended to be included in the disclosure.