TECHNICAL FIELD

The present invention relates to a dirt separator for a vacuum cleaner and to a vacuum cleaner comprising the dirt separator.

BACKGROUND

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.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention, there is provided a dirt separator for a vacuum cleaner, the dirt separator comprising a filter assembly to separate dirt from an airflow moving through the dirt separator, a bin to collect dirt separated from the airflow, the bin comprising an opening, and a valve movable between a closed position in which the opening is obstructed by the valve, a first open position in which the opening is unobstructed by the valve, and a second, different open position in which the opening is unobstructed by the valve, wherein the valve is moveable from the closed position to the first open position in response to suction within the dirt separator, the bin is moveable relative to the valve between a first position and a second position, and the valve is moveable from the closed position to the second open position in response to movement of the bin from the first position to the second position.

Suction in the dirt separator, more specifically suction in the bin when the bin is in the first position, causes the valve to move to the first open position to generate airflow through the dirt separator. Dirt entrained in the airflow is separated from the airflow by the filter assembly and collects in the bin. The combination of the bin and the valve enable the dirt collected in the bin to be evacuated from the dirt separator by movement of the bin from the first position to the second position.

Movement of the bin from the first position to the second position causes the dirt to move past the valve. This provides a space-efficient arrangement because the dirt enters and exits the dirt separator along the same path. By synching movement of the valve between the closed position and the second open position with movement of the bin between the first and second positions, dirt within the bin may be emptied in an effective and relatively intuitive way.

The valve may be movable to the closed position in response to removal of the suction within the dirt separator. This may help prevent dirt collected in the bin from escaping the bin via the opening upon removal of the suction, for example under gravity.

The valve may be moveable from the second open position to the closed position in response to movement of the bin from the second position to the first position. This not only prevents the dirt moving back past the valve, but actively pushes the dirt out of the opening in the bin. This may also help prevent inadvertent ingress or escape of airflow and/or dirt to or from the bin.

The valve may be biased towards the closed position, for example by a biasing assembly or due to a property of a material from which the valve is formed. This may ensure that the valve returns to the closed position when the bin is not acting on the valve. This may ensure that the valve returns to the closed position when there is no suction within the dirt separator, so that the dirt cannot escape the bin inadvertently via the opening.

The valve may be formed from an elastically deformable material biased towards the closed position. This may negate a need for an additional biasing assembly, which may reduce cost and/or simplify the assembly.

When moving between the first position and the second position, the bin may act upon the valve to move the valve between the closed position and the second open position. This may provide a simple mechanism, without the need for a further component to ensure movement of the valve in response to movement of the bin. This may provide a more reliable system to ensure that the valve is in the correct position with respect to the movement and/or position of the bin.

The bin may comprise an inwardly protruding ridge that acts upon the valve. This may provide a reliable way of causing movement of the valve between the closed position and the second open position during movement of the bin between the first and second positions, without unduly obstructing the opening. The ridge may exert a substantially constant force on the valve during movement of the bin between the first and second positions, which may ensure that the valve remains in the second open position.

The ridge may be broken along its length, or have a length shorter than a length of travel of the bin between the first and second positions. This may enable any pressure exerted on the valve by the ridge to be relieved when the bin is in the first or second position. For example, if the valve is biased towards the closed position, this may help to ensure that the valve can return to the closed position as soon as movement of the bin from the second position to the first position is initiated so that no dirt is moved back past the valve.

The bin may be movable parallel to a longitudinal axis of the dirt separator between the first and second positions. This may provide a space-efficient arrangement. This may also enable the dirt separator to have a substantially constant outer diameter, which may ease manufacture and assembly of the dirt separator.

The bin may be movable between the first and second positions upon application of a force by a user to an outer surface of the bin. This may provide an ergonomic and intuitive arrangement.

The bin may be biased towards the first position, for example by a biasing assembly. This may help to ensure that the bin is correctly positioned relative to the valve and the filter assembly during dirt separation.

The dirt separator may comprise a locking assembly to retain the bin in the first position. This may help to ensure that the bin is correctly positioned relative to the valve and the filter assembly during dirt separation.

The bin may comprise a substantially tubular portion and, when the bin is in the first position, a majority of the tubular portion may be located on a first side of the valve and, when the bin is in the second position, a majority of the tubular portion may be located on a second, opposite side of the valve. This may increase a dirt storage capacity of the bin in the first position, and therefore the dirt separator may be used for a longer period of time before emptying of the bin is required. The bin, for example the tubular portion, may surround the filter assembly when the bin is in the first position. This may provide a space-efficient arrangement that ensures dirt separated from the airflow by the filter assembly is collected in the bin.

The valve may be movable between the closed, first open and second open positions about a pivot axis. The pivot axis may be perpendicular to a longitudinal axis of the dirt separator. This may enable the valve to move without the need for a powered actuator, for example under force by the bin and/or suction in the dirt separator, between the closed, first open and second open positions.

The valve may be movable about the pivot axis by a living hinge. This may help simplify manufacture and assembly of the dirt separator.

The valve may be movable from the closed position to the first open position in a first direction about the pivot axis, and from the closed position to the second open position in a second, opposite direction about the pivot axis. This may help to prevent dirt catching on the valve during movement of the bin from the first position to the second position.

The first open and second open positions may be the same position. This may provide a space-efficient and simple arrangement.

The bin may comprise a lip against which the valve abuts when in the closed position. This may help to maintain the valve in the closed position, for example when dirt in the bin rests against the valve under gravity when the dirt separator is not in use.

The bin and the valve may be arranged such that, when the valve is in the closed position, an outer perimeter of the valve forms a seal with the bin. This may help to ensure that dirt does not inadvertently move past the valve. This may also help to prevent inadvertent airflow through the dirt separator, which may, for example, help to trap undesirable odours emitted by dirt in the bin.

The bin may define a dirt collection chamber that extends alongside the filter assembly, and a section located between the dirt collection chamber and the valve, the section having a greater cross-sectional area than the dirt collection chamber. This may provide an area adjacent to and downstream of the valve in which dirt in the dirt collection chamber can rest when the dirt separator is not in use. This may help to reduce a force per unit area exerted on the valve by the dirt, which may help to ensure that the valve does not inadvertently move away from the closed position and allow the dirt to escape the dirt collection chamber.

The bin may comprise a projection and, during movement of the bin from the first position to the second position, the projection moves towards the valve to push the dirt towards the valve. The projection may push the dirt past the valve. This may help to ensure that substantially all of the dirt in the bin or dirt collection chamber is evacuated.

The projection may have a cross-sectional profile substantially corresponding to a cross- sectional profile of the dirt collection chamber. The cross-sectional profiles are in the plane normal to the longitudinal axis of the dirt separator. This may further help to ensure that substantially all of the dirt in the bin or dirt collection chamber is evacuated.

The bin may comprise a wiper at a periphery of the projection, and the wiper wipes a surface of the filter assembly when the bin moves between the first and second positions. The wiper may dislodge dirt on surface of the filter assembly to increase an amount of dirt that is compactable by the projection. This may increase a time between necessary replacement or cleaning of the filter assembly.

When the bin is in the first position, the projection may be further from the valve than the filter assembly. This may prevent the projection from interfering with filtration performance of the filter assembly.

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

At least part of the filter assembly may be removably attached to the frame. This allows movement of the bin relative to the filter assembly and permits removal and replacement of the at least part of the filter assembly when the bin is in the second position.

The valve may be attached to the frame. This may ensure that the valve remains in a correct position relative to the bin and the filter assembly. The valve may be removably attached to the frame. This may allow simple replacement of the valve by a user. The valve may be substantially flat and/or planar. This may provide a space-efficient arrangement.

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

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

According to another aspect of the present invention, there is provided a dirt separator for a vacuum cleaner, the dirt separator comprising a filter assembly to separate dirt from an airflow moving through dirt separator, a dirt collection chamber to collect dirt separated from the airflow, the dirt collection chamber comprising an opening through which dirt may be evacuated, and a valve assembly comprising a valve rotatable between a closed position, in which the opening is obstructed by the valve, and an open position, in which the opening is unobstructed by the valve, and a motor to rotate the valve between the open and closed positions.

In conventional vacuum cleaners, the closure to a dirt collection chamber can become stuck in the closed position, for example due to a build-up of dirt. The closure therefore does not move from the closed position when actuated by a user, or does not move all the way to the open position, which impacts emptying of the vacuum cleaner. Often a user must manually open the closure, which can transfer dirt to their hand. Providing a valve as the closure and using a motor to move the valve between the closed and open positions reduces the likelihood of the closure becoming stuck in the closed position, enabling dirt to be emptied from the dirt collection chamber via the opening without the risk of the user getting their hand dirty.

Airflow may enter the dirt separator via the opening, such that the opening forms an air inlet to the dirt collection chamber. That is, during dirt separation the valve may be in the open position so that dirt-laden airflow enters the dirt collection chamber via the opening and dirt is separated from the dirt-laden airflow by the filter assembly. This provides a space-efficient arrangement because the dirt enters and exits the dirt separator along the same path. Accordingly, the dirt collection chamber may only have a single opening. A conventional vacuum may include a closure or valve for closing the inlet to a dirt separator. However, the closure may become trapped in the open position or may fail to fully move to the closed position. As a result, dirt may inadvertently escape the dirt separator via the inlet. By providing a valve as a closure to the inlet, and by using a motor to actively move the valve between the closed and open positions, the likelihood of dirt escaping via the inlet may be reduced.

Airflow may pass through the opening along a flow axis, and the valve may be rotatable between the closed and open positions about a valve axis parallel to the flow axis. Consequently, when moving between the open and closed positions, the valve is not required to move in opposition to the force exerted by the airflow and suction on the valve. As a result, a smaller torque may be required to move the valve, and therefore a smaller, less powerful motor may be employed.

The dirt separator may be elongated, and the valve may be rotatable between the closed and open positions about a valve axis parallel to a longitudinal axis of the dirt separator. After dirt separation, dirt in the dirt collection chamber may fall under gravity along the longitudinal axis to rest against the valve in the closed position. Rotation of the valve about the valve axis may cause the valve to rotate between the closed and open positions perpendicularly to a direction in which the dirt resting against the valve applies a force to the valve. In turn, this may reduce the torque required by the motor to move the valve between the open and closed positions. Additionally, rotation of the valve about an axis parallel to the longitudinal axis means that no additional length of the dirt separator is required to accommodate movement of the valve between the open and closed positions. The valve axis may be co-axial with the longitudinal axis of the dirt separator. This may provide a space-efficient arrangement that allows an overall diameter of the dirt separator to be reduced.

The motor may be connected to the valve by one or more gears rotatable by the motor to move the valve between the open and closed positions. This may allow more design variation with regard to a position of the motor relative to the valve. For example, the valve may rotate about a valve axis, and the motor may be located off-axis. The provision of gears may also provide more control over a speed and/or a torque of the valve movement. The valve may be in the form of a radial disc with an aperture. In the open position, the aperture may align with the opening to maximise the cross-sectional area of the opening. In the closed position, a portion of the radial disc that does not comprise the aperture may align with the opening to that all of the opening is obstructed by the valve. The aperture may be a sector of the radial disc. This may increase the available cross-sectional area of the opening.

The dirt separator may comprise a passage between the opening and the dirt collection chamber, and the motor may be positioned alongside the passage. As a result, a relatively compact arrangement for the dirt separator may be achieved. Additionally, the motor may be located adjacent the valve at a position that does not impede or otherwise restrict the airflow.

The passage may have a cross-sectional area that is substantially equal to a cross-sectional area of the opening and/or the dirt collection chamber. The passage does not therefore present a restriction to the airflow. Additionally or alternatively, the passage may extend linearly and parallel to the longitudinal axis of the dirt separator. This may also allow airflow to pass from the opening to the dirt collection chamber without significant losses. Additionally, dirt is less likely to be trapped within the passage during excavation from the dirt collection chamber.

The motor may be contained in a motor chamber. This may help to protect the motor from dirt in the dirt separator, and may help prevent the motor from interrupting airflow entering the dirt separator or dirt being evacuated from the dirt collection chamber. The valve may rotate between the open and closed positions about an end of the motor chamber and a seal may be provided between the end of the motor chamber and the valve. This may prevent dirt from getting caught between the valve and the motor chamber.

The filter assembly may extend parallel to a longitudinal axis of the dirt separator and separate the dirt collection chamber from an outlet chamber. This may enable a larger surface area of the filter assembly for the same diameter of the dirt separator, which may increase performance. This may also increase the space available in the dirt collection chamber which may increase a time between necessary emptying of the dirt collection chamber. The dirt separator may comprise an upper longitudinal portion that comprises the passage and the dirt collection chamber, and a lower longitudinal portion that comprises the motor chamber and the outlet chamber. The motor chamber may be positioned longitudinally adjacent to the outlet chamber, for example at an end of the outlet chamber closest to the inlet. As a result, a relatively compact arrangement for the dirt separator may be achieved. For example, the motor may be positioned in an otherwise unused area of the dirt separator.

The dirt separator may comprise a frame that extends along a length of the dirt collection chamber, and electrical wires for delivering electrical power to the motor. The electric wires may be mounted to and extend along the length of the frame. The filter assembly may be removably mounted to the frame. This may provide a space-efficient way of both supporting the filter assembly and delivering electrical power to the motor. This may also enable simple removal and replacement of the filter assembly, for example so that the filter assembly can be cleaned to restore filtration performance.

The valve assembly may be mounted to the frame so that at least the valve is rotationally mounted to the frame, which may help to ensure that the valve is suitably positioned relative to the opening. This may also help to provide a relatively simple route for the electric wires to the motor.

The dirt separator may have a length no less than 150 mm. As a result, a relatively good dirt capacity may be achieved in a dirt collection chamber having a relatively small width or diameter. Additionally, a relatively long filter assembly having a good surface area may be employed, which in turn can improve performance and increase the time between replacement or cleaning.

The dirt separator may have a width, or diameter, no greater than 60 mm. That is, a maximum dimension of the dirt separator in a plane normal to the longitudinal axis may be no greater than 60 mm. More specifically, the dirt separator may have a width in the region of 35-40 mm. This can help to decrease an overall diameter of a vacuum cleaner in which the dirt separator is employed. This could be particularly advantageous in a handheld vacuum cleaner in which size and weight are significant considerations. This may be particularly ergonomic, allowing an outer perimeter of the dirt separator to form a handle for a user to hold the vacuum cleaner during use. The dirt separator may be substantially cylindrical. This may help to provide smooth, curved walls of the dirt collection chamber and outlet chamber that are substantially free of sudden changes in direction. This may contribute to smoother airflow through the dirt separator.

According to a second aspect of the present invention, there is provided a vacuum cleaner comprising a dirt separator according to the first aspect, a suction generator for generating an airflow, and a control system arranged to receive a signal indicative of a user desire to empty the dirt collection chamber and, in response to receiving the signal, cause the motor to move the valve to the open position. This may allow emptying of the dirt collection chamber without a risk to a user getting dirt on their hands.

The control system may comprise a switch or sensor arranged to detect an input indicative of a user desire to empty the dirt collection chamber and, in response to detecting the input, generate the signal. This may enable automatic opening of the valve to permit evacuation of dirt from the dirt collection chamber, which may be more ergonomic and intuitive for a user.

The control system may be arranged to cause the motor to move the valve to the open position in response to a signal indicative of a user desire to power on the vacuum cleaner. This may enable dirt-laden airflow to enter the dirt separator as soon as the vacuum cleaning is to be initiated.

In response to the signal indicative of a user desire to power on the vacuum cleaner, the control system may be arranged to cause the motor to move the valve to the open position after the suction generator is powered on. This may help to ensure that there is always airflow being generated by the suction generator when the valve is open, which may prevent dirt in the dirt collection chamber escaping inadvertently, e.g., under gravity.

In response to a signal indicative of a user desire to power off the vacuum cleaner, the control system may be arranged to cause the motor to move the valve to the closed position before the suction generator is powered off. This may help to ensure that there is always airflow being generated by the suction generator when the valve is open, which may prevent dirt in the dirt collection chamber escaping inadvertently, e.g., under gravity. The signal indicative of a user desire to power off the vacuum cleaner may be a cessation of the signal indicative of a user desire to power on the vacuum cleaner. In response to a signal indicative that a remaining percentage of battery power of the vacuum cleaner has fallen below a threshold, the control system may be arranged to cause the motor to move the valve to the closed position before the suction generator is powered off

BRIEF DESCRIPTION OF THE DRAWINGS

Examples will now be described, with reference to the accompanying drawings, in which:

Figure l is a front view of a vacuum cleaner according to an example;

Figure 2 is a cross-sectional side view of the vacuum cleaner of Figure 1;

Figure 3 is an exploded view of the vacuum cleaner of Figure 1;

Figure 4a is a sectional slice through a dirt separator of the vacuum cleaner in the plane A— A indicated in Figure 2;

Figure 4b is a sectional slice through a dirt separator according to a further example;

Figure 5 is a cross-sectional side view through a centre of the dirt separator, wherein a valve of the dirt separator is in a closed position;

Figure 6 is the same cross-sectional view as that of Figure 5, wherein the valve is in an open position;

Figure 7 is the same cross-sectional view as that of Figure 5, wherein the valve is in the open position and dirt is in the dirt separator;

Figure 8 is the same cross-sectional view as that of Figure 5, wherein the valve is in the closed position and dirt is in the dirt separator;

Figure 9 is a cross-sectional view of the dirt separator in an emptying configuration;

Figure 10 is the same cross-sectional view as that of Figure 5, wherein the valve is in the closed position and dirt is outside the dirt separator;

Figure 11 is a cross-sectional side view of a portion of a dirt separator according to a further example, wherein a valve of the dirt separator is in a closed position;

Figure 12 is the same cross-sectional side view as that of Figure 11, wherein the valve is in an open position;

Figure 13 is a cross-sectional side view of a portion of a dirt separator according to a still further example;

Figure 14 is a perspective cutaway view of the portion of the dirt separator of Figure 13; Figure 15 is a perspective view of the portion of the dirt separator of Figure 13, wherein a valve of the dirt separator is in a closed position; and Figure 16 is the same perspective view as that of Figure 15, wherein the valve is in an open position.

DETAILED DESCRIPTION

The example vacuum cleaner 1 of Figures 1-3 comprises a main body 10, an attachment 20 and a cleaner head 30. The cleaner head has an inlet aperture 32 arranged to face a surface to be cleaned by the vacuum cleaner 1, and an outlet 34 fluidly connected to the inlet aperture 32. The attachment 20 in this example is a tool, but in other examples may be a wand or other suitable attachment type. In any event, the attachment 20 comprises a duct 21 between a first end 22 and a second, opposite end 24 of the attachment 20. When assembled, as shown in Figures 1 and 2, the cleaner head 30 is removably attached to a first end 22 of the attachment 20, and a second end 24 of the attachment 20 is removably attached to the main body 10 such that an airflow pathway is formed from the cleaner head 30, through the attachment 20, to the main body 10.

When attached to the main body 10, the attachment 20 is arranged co-axially with a central longitudinal axis 2 of the main body 10. In this example, the main body 10 and the attachment 20 are generally cylindrical in shape, with each having an outer housing 12, 23 of a substantially constant outer diameter. The outer housing 12 of the main body 10 surrounds a suction generator 14 to generate an airflow along the airflow pathway, and a battery assembly 16 to power the suction generator 14. It will be appreciated that in other examples, the main body 10 may be provided with a power supply unit, to replace or supplement the battery assembly 16, for connection to a mains power outlet.

The main body 10 comprises a dirt separator 100 upstream of the suction generator 14. The dirt separator 100 is shown in more detail and in various configurations in Figures 4- 10. As with the outer housing 12, the dirt separator 100 is also cylindrical in shape and has a substantially constant outer diameter.

The dirt separator 100 comprises an opening 102 at an interface between the main body 10 and the attachment 20. The opening 102 serves as both an air inlet and a dirt outlet of the dirt separator 100. When serving as an air inlet, the opening 102 permits the airflow generated by the suction generator 14 to pass into the dirt separator 100 from the duct 21 in a direction parallel to the longitudinal axis 2 of the main body 10 (which is co-axial with a longitudinal axis of the dirt separator 100). The dirt separator 100 also comprises an air outlet 106 fluidly connected to the suction generator 14, to permit airflow to exit the dirt separator 100. In this example, when assembled, a ratio of the cross-sectional areas of the opening 102 and the outlet 106 is substantially 1.

In this example, the dirt separator 100 comprises a frame 104 that extends parallel to the longitudinal axis 2 of the main body 10. The frame 104 is fixed at a first end to the outer housing 12 of the main body 10. A second opposite end 105 of the frame 104 partially defines the opening 102 of the dirt separator 100.

The frame 104 supports electrical terminals 17 and electrical wires 18. The electrical terminals 17 are located at the second end 105 of the frame 104, and the electrical wires 18 extend along the length of the frame 104 from the main body 10 to the electrical terminals 17. The electrical terminals 17 mate with corresponding terminals (not shown) of the attachment 20 to transfer electrical power from the main body 10 to the cleaner head 30.

A filter assembly 120 is attached to the frame 104. The filter assembly 120 is configured to separate dirt D from dirt-laden airflow received via the opening 102, and comprises two filtration layers 122, 124 for doing so, as best shown in Figure 4a. It will be appreciated that in other examples, the filter assembly 120 may comprise a different number of filtration layers.

The filter assembly 120 comprises a mesh or screen 122 fixedly attached to the frame 104 and a filter cartridge removable attached to the frame 104. In this example, the mesh or screen 122 is the uppermost filtration layer 122 shown in Figure 4a, and is formed of a metal.

The filter cartridge is located downstream of the mesh 122 and comprises a filter frame and filter media 124 held by the frame. The mesh 122 protects the filter media 124 from impacts by debris in the dirt separator 100. The filter media 124 is the lowermost layer 124 shown in Figure 4a. Being removable allows the filtration media 124 to be replaced and/or washed to restore filtration performance of the filter assembly 120. Although not shown in Figure 4a, in some examples the filter media 124 has a plurality of filtration layers of differing filtration properties. For example, the filter media 124 may comprise a layer formed from fleece upon a layer formed from an electrostatic medium. The mesh 122 is substantially curved, as viewed in a plane normal to the longitudinal axis 2 (Figure 4a), and the filter media 124 is substantially planar. It will be appreciated that in other examples, the mesh 122 may be, for example, v-shaped or planar.

Figure 4b shows an example of an alternative filter assembly 120b in the dirt separator 100. The alternative filter assembly 120b is very similar to the filter assembly 120 except that in this example the filter media 124b is substantially curved. Providing a substantially planar filter media 124, as shown in Figure 4a, allows a thicker lower-most filtration layer 124 to be employed within the same overall diameter of the dirt separator 100 compared to a curved filter media 124b, as shown in Figure 4b, which can increase the filtration performance of the filter assembly 100. Conversely, providing a curved filter media 124b increases the surface area of the filter media 124b compared to the surface area of the filter media 124, which may also provide filtration benefits such as increasing a time between required replacement or cleaning of the filter media 124b. References herein to the filter assembly 120 may equally apply to the alternative filter assembly 120b.

The filter assembly 120 is elongate in a direction parallel to the longitudinal axis 2. Accordingly, airflow enters the dirt separator 100 in a direction parallel to the filter assembly 120 so that the airflow scrubs the mesh 122 of the filter assembly 120 to help attenuate accumulation of dirt D on the filter assembly 120.

The filter assembly 120 forms a wall of a dirt collection chamber 108. The dirt collection chamber 108 receives dirt-laden airflow via the opening 102 during vacuum cleaning and fills up with dirt D separated from the dirt-laden airflow by the filter assembly 120. The dirt collection chamber 108 is elongate in shape and extends between the opening 102 at one end, and the outer housing 12 of the main body 10 at an opposite end. The dirt collection chamber 108 extends alongside the filter assembly 120 and has a substantially constant cross-sectional profile along the length of the filter assembly 120, as viewed in a plane normal to the longitudinal axis 2. The elongate shape of the dirt collection chamber 108 allows for a larger volume for a given diameter of the dirt separator 100.

The filter assembly 120 separates the dirt collection chamber 308 from an outlet chamber 103 downstream of the filter assembly 120. The outlet chamber fluidly connects the filter assembly 120 to the air outlet 106. The dirt separator therefore comprises an upper longitudinal portion comprising the dirt collection chamber 108 and a lower longitudinal portion comprising the outlet chamber 103. The outlet chamber 103 also has a constant cross-sectional area along the length of the filter assembly 120. In this example, the ratio of the cross-sectional areas of the dirt collection chamber 108 to the outlet chamber 103 is substantially 1. Since the cross- sectional area of the outlet chamber 103 is substantially constant along its length, suction is unbalanced along the length of the filter assembly 120. In particular, suction is greatest at the end of the filter assembly 120 adjacent the outlet 106 and is weakest at the end of the filter assembly 120 adjacent the opening 102. Dirt D is therefore encouraged to fill the dirt collection chamber 108 in a direction from the outlet 106 (where suction is greatest) to the opening 102 (where suction is weakest). As a result, the dirt collection chamber 108 is able to store a greater quantity of dirt D within the dirt collection chamber 108 before emptying is required.

The dirt separator 100 comprises a tubular outer wall, orbin, 130 extending along a length of the dirt separator 100 and surrounding the frame 104, the filter assembly 106 and the valve 110. The outer wall 130 defines a cylindrical dirt separation chamber 101 of the dirt separator 100, the chamber 101 comprising the dirt collection chamber 108 and the outlet chamber 103. In this example, the dirt separation chamber 101 is around 8 times longer than it is wide. The dirt collection chamber 108 is therefore defined along one side by the outer wall 114 and along an opposite side by the frame 104 and the filter assembly 106.

A valve 110 is connected to the second end 105 of the frame 104 such that the valve 110 is positioned at the opening 102. The valve 110 is movable between a closed position (as shown in Figures 5, 8 and 10), a first open position (as shown in Figures 6 and 7) in response to suction within the dirt separator 100 generated by the suction generator 14, and a second open position (as shown in Figure 9). The valve 110 is movable between the different positions about a pivot axis 112 that is normal to the longitudinal axis 2. In the present example, the valve is formed of an elastically deformable material, such as rubber, and is configured to pivot about a hinge at the base of the valve 110.

In the closed position, the valve 110 obstructs the opening 102 such that dirt D is prevented from escaping the dirt collection chamber 108 via the opening 102. The valve 110 abuts a lip 134 of the outer wall 130 when in the closed position, as best shown in Figures 5 and 8. The lip 134 acts to help maintain the valve 110 in the closed position, particularly when dirt D in the dirt collection chamber 108 rests against the valve, as shown in Figure 8. In the closed position, an outer perimeter of the valve 110 forms a seal with the frame 104 and the outer wall 130 at the opening 102. This seal prevents dirt D from inadvertently escaping the dirt collection chamber 108.

The valve 110 moves from the closed position to the first open position in response to suction within the dirt collection chamber 108. In the first open position, the opening 102 is unobstructed by the valve 110, thereby enabling dirt-laden airflow to be drawn from the inlet aperture 32 of the attachment, through the duct 21 and into the dirt separator 100 via the opening 102. In moving to the first open position, the valve 110 pivots about the pivot axis 112 in a first direction towards the interior of the dirt collection chamber 108. The valve 110 then provides a smooth surface for the airflow, which can help to prevent dirt within the airflow from catching on the valve 110 as it passes into the dirt collection chamber 108.

As described below in more detail, the valve 110 moves from the closed position to the second open position during emptying of the dirt separator 100. In the second open position, the opening 102 is unobstructed by the valve 110, thereby enabling dirt D in the dirt collection chamber 108 to exit the dirt separator 100, for example under gravity, via the opening 102. In moving to the second position, the valve 110 pivots about the pivot axis 112 in a second opposite direction to that of the first open position. The valve 110 then provides a smooth surface to help prevent the dirt D from catching on the valve 110 as it passes out of the dirt collection chamber 108

The valve 110 is biased to the closed position such that, in the absence of force acting on the valve 110, the valve 110 remains or returns to the closed position.

The dirt separator 100 comprises a well 109 located downstream of the opening 102, between the valve 100 and the dirt collection chamber 108. The well 109 has a greater cross-sectional area than the dirt collection chamber 108. When the dirt separator 100 is not in use, dirt D collected in the dirt collection chamber 108 may fall under gravity and come to rest against the valve 110, as shown in Figure 8. In examples of a dirt separator that do not have a well 109, the accumulation of dirt D on one side of the valve 100 may hinder movement of the valve 110 to the first open position. Accordingly, a relatively large force may be required to move the valve 110 against the weight of the dirt D to the first open position. If there is too much dirt D in the dirt collection chamber 108, the dirt D may cause the valve 110 to become stuck in the closed position, or at least prevent the valve 110 from moving fully to the first open position under the suction generated by the suction generator 14. The well 109 provides a larger space behind the valve 110 to accommodate dirt D that falls under gravity. This can reduce the force required to move the valve 110 to the first open position, and therefore help to prevent the valve 110 from getting stuck in the closed position.

Build-up of dirt D in the dirt collection chamber 108 can negatively impact the pick-up performance of the vacuum cleaner 1. Performance can be at least partially restored by emptying the dirt D from the dirt collection chamber 108. Accordingly, the dirt separator 100 is arranged to allow a user to perform a simple dirt emptying sequence to empty dirt D from the dirt collection chamber 108, as will now be described.

The dirt emptying sequence is performed with the attachment 20 detached from the main body 10 and the suction generator 14 powered off.

The outer wall 130 is movable relative to the valve 110 and the frame 104 between a first position (as shown in Figures 5-8) and a second position (as shown in Figure 9). Movement of the outer wall 130 between the first and second positions is in a direction parallel to the longitudinal axis 2 of the main body 10. In the first position, the outer wall 130 surrounds all of the frame of the main body 10. A majority of the outer wall 130 is therefore located downstream of the valve 100 when the outer wall 130 is in the first position. A small portion, or cuff, of the outer wall 130 extends upstream of the valve 110 when the outer wall 130 is in the first position, and serves to protect the electrical terminals 17 and to receive and form an attachment with the end 24 of the attachment 20. In the second position, a majority of the outer wall 130 is located upstream of the valve 100 such that the opening 132 is further from the main body 10 than when in the first position.

The outer wall 130 comprises a pair of ridges 136 protruding inwardly from an inner surface 131 of the outer wall 130 (as best shown in Figures 4a and 4b). The ridges 136 extend longitudinally along opposite sides of the outer wall 130. The pair of ridges 136 act upon the valve 110 to move the valve 110 from the closed position to the second open position (as shown in Figure 9) as the outer wall 130 is moved from the first position to the second position. In the second open position, the opening 102 is unobstructed by the valve 110. Accordingly, movement of the outer wall 130 from the first position to the second position opens the opening 102 such that dirt D in the dirt collection chamber 108 can be evacuated under gravity via the opening 102. It will be appreciated that in other examples alternative actuator elements may be employed to move the valve 110 to the second open position.

The dirt separator 100 comprises a plunger 116 attached to the outer wall 130 and positioned in the dirt collection chamber 108. In this example, the plunger 116 protrudes from the inner surface 131 of the outer wall 130 into the dirt collection chamber 108 along a plane normal to the longitudinal axis 2 of the main body 10. The plunger 116 and the outer wall 130 are movable as a single body between the first and second position.

When the outer wall 130 is in the first position, the plunger 116 is adjacent the main body 10. As the outer wall 130 moves towards the second position, the plunger 116 pushes dirt D in the dirt collection chamber towards and/or past the valve 110.

To assist in pushing as much of the dirt D in the dirt collection chamber 108 as possible, the plunger 116 comprises a resilient wiper 118 (as best shown in Figure 3) at a periphery of the plunger 116. The wiper 118 is configured to wipe a surface of the mesh 122 of the filter assembly 120 as the outer wall 130 is moved between the first and second positions. The wiper 118 dislodges dirt D from the mesh 122 to better restore filtration performance of the filter assembly 120.

In a first stage of an emptying sequence, a user applies a force to the outer wall 130 to move the outer wall 130 and the plunger 116 from the first position to the second position, as shown in Figure 9. Accordingly, dirt D in the dirt collection chamber 108 is pushed towards the valve 110. Movement of the outer wall 130 from the first position towards the second position causes the pair of ridges 136 to push the valve 110 to the second open position so that the dirt D can be pushed and/or fall under gravity past the valve 110.

In a second stage of the emptying sequence, a user applies a force to the outer wall 130 to move the outer wall 130 and the plunger 116 from the second position to the first position, as shown in Figure 10. Due to the nature of dirt D that is typically collected during use of a vacuum cleaner, the dirt D tends to gather together as a single clump, for example due to entangled hair or fibres. This can cause the dirt clump D to remain within the outer wall 130 even after it has passed the valve 110 during the first stage of the emptying sequence. Accordingly, the dirt separator 100 is arranged such that, during the second stage of the emptying sequence, the valve 110 is moved from the second open position to the closed position so that the dirt clump D is pushed out of the opening 132 by the valve 110. In this example, the pair of ridges 136 have a length that is shorter than a length of travel of the outer wall 130 between the first and second positions. Consequently, as the outer wall 130 nears the second position, the ridges 136 pass the valve 110 and so stop acting upon the valve 110. The valve 110 therefore returns to the closed position under the biasing force. As the outer wall 130 is then moved from the second position to the first position, the ridges 136 again act upon the valve 110. However, the force applied by the ridges 136 is insufficient to move the valve 110 to the first open position, such that the valve 110 remains in the closed position during the second stage of the emptying sequence.

The frame 104 comprises slots 111 adjacent to the outer wall 130, as best shown in Figures 4a and 4b. The slots 111 extend parallel to the longitudinal axis 2 of the main body 10 and engage with the ridges 136 on the inner surface 131 of the outer wall 130. The ridges 136 are slidable in the slots 111 to constrain rotational movement of the outer wall 130 relative to the frame 104.

Although not shown in this example, the dirt separator 100 may comprise a biasing assembly to bias the outer wall 130, and thus the plunger 116, towards the first position. The biasing assembly may comprise a spring disposed in each of the slots 111 and attached to the respective ridges 136. In biasing the outer wall 130 and the plunger 116 towards the first position, the biasing assembly assists in ensuring the outer wall 130 returns fully to the first position.

In this example, the user grips an outer surface of the outer wall 130 to perform the emptying sequence. It will be appreciated that in other examples, the dirt separator 100 may comprise a handle, knob, collar or other suitable element connected directly or indirectly to the outer wall 130 for a user to grip and cause the outer wall 130 to slide parallel to the longitudinal axis 2 relative to the frame 104.

Figures 11 and 12 show a portion of a dirt separator 200 according to a further example. In this further example, the dirt separator 200 is for use in a vacuum cleaner having the same features as the vacuum cleaner 1 shown in Figure 1. The portion is a distal end of the dirt separator 200 relative to the main body 10. The dirt separator 200 differs from the dirt separator 100 described with reference to Figures 1-10 in the arrangement of the valve 210. Other features of the dirt separator 200 are substantially identical to those of the dirt separator 100 and have the same reference numbers, but increased by 100. In this further example, the first and second open positions of the valve 210 are the same position, and will be referred to herein as the open position.

The valve 210 is formed from a rigid material and is biased to the closed position (as shown in Figure 11) by a spring 214. The spring 214 is attached to the frame 204 and is located in the well 209. In order to prevent dirt D in the dirt collection chamber 208 from entering the well 209 and potentially damaging the spring 214, the valve 210 is v-shaped, having a first arm 217 and a second arm 219.

The first arm 217 of the valve 210 is pivotally attached to the frame 204 by a pivot pin

211. The valve 210 therefore pivots about the pivot axis 212 between the open position and the closed position. The second arm 219 of the valve extends from the opposite end of the first arm 217 to that of the pivot pin 211. When the valve 210 is in the open position, the first arm 217 defines part of the airflow pathway along which airflow enters the dirt separator 200, and the second arm 219 is located in the well 209 and therefore out of the airflow pathway. When the valve is 210 is in the closed position, the first arm 217 contacts the lip 234 of the outer wall 230 and forms a seal with the outer wall 230, and the second arm extends between the outer wall 230 and the frame 204 to prevent dirt D in the dirt collection chamber 208 from entering the well 209 (as shown in Figure 11).

The valve 210 is movable from the closed position to the open position (as shown in Figure 12) in response to suction within the dirt separator 200 generated by the suction generator 14. Suction in the dirt collection chamber 208 causes a drop in pressure in the dirt collection chamber 208 such that ambient air outside the dirt separator 200 applies a force on the valve 210 to overcome the biasing force of the spring 214 to move the valve 210 to the open position.

The valve 210 is also movable to the open position to permit emptying of dirt D from the dirt collection chamber 208 (as shown in Figure 12). Ridges on the inner surface of the outer wall 230 (as described above with reference to Figures 1-10) cooperate with the valve 210 as the outer wall 230 is moved towards the second position. The ridges push the valve 210 downwards to the open position. Removal of force by the ridges upon the valve 210 allows the spring 214 to move the valve 210 back to the closed position. During movement from the closed position to the open position, the v-shaped nature of the valve 210 means that the second arm 219 slides relative to dirt D resting against the arm 219, rather than pushes against the dirt D. This can reduce the chance of the valve 210 becoming stuck in the closed position and reduce a moment about the pivot axis 212 that is required to open the valve 210.

Figures 13 to 16 show a portion of a dirt separator 300 according to a still further example. In this still further example, the dirt separator 300 is for use in a vacuum cleaner having the same features as the vacuum cleaner 1 shown in Figure 1. The portion is a distal end of the dirt separator 300 relative to the main body 10. The dirt separator 300 differs from the dirt separator 100 described with reference to Figures 1-10 and the dirt separator 200 described with reference to Figures 11 and 12 in the arrangement of the valve 310. Other features of the dirt separator 300 are substantially identical to those of the dirt separator 100 and have the same reference numbers, but increased by 200.

The dirt separator 300 comprises a valve 310 rotatable about a pivot axis, or valve axis, 312 by a motor 315 between a closed position and an open position. The pivot axis 312 is co-axial with the longitudinal axis 2 of the main body 10, and therefore parallel to a direction of flow entering the dirt separator 300 via the opening 302. It will be appreciated that in other examples, the pivot axis 312 may not be co-axial with the longitudinal axis 2.

In the closed position (as shown in Figures 13-15), the valve 310 is configured to obstruct the opening 302, and therefore the airflow pathway. The valve 310 therefore prevents dirt D from escaping the dirt collection chamber 308 via the opening 302 when in the closed position.

In the open position (as shown in Figure 16), the opening 302 is unobstructed by the valve 310. The valve 310 may be moved to the open position when the suction generator is powered on to enable dirt-laden airflow to be drawn into the dirt separator 300 via the opening 302. Alternatively, the valve 310 may be moved to the open position when the suction generator is powered off to enable dirt D within the dirt collection chamber 308 to be emptied via the opening 302.

In this example, the valve 310 is in the form of a radial disc having a diameter substantially equal to an inner diameter of the outer wall 330. The valve 310 has an aperture 340, in this case a sector of almost 180 degrees, cut out of it. In the open position, the aperture 340 is aligned with the opening 302 such that the valve 310 does not obstruct the opening 302. In the closed position, the aperture 340 is misaligned with the opening 302 such that the valve 310 obstructs the opening 302. As with the valve 210 described with reference to Figures 11 and 12, during movement from the closed position to the open position, the valve 310 slides relative to dirt D resting against the valve 310, rather than pushing against the dirt D. This can reduce the chance of the valve 310 becoming stuck in the closed position and reduce the torque required from the motor 315 to open the valve 310.

In this example, the valve 310 is driven by the motor 315 via a pair of gears 344,346. This then allows the position of the motor 315 to be offset from the pivot axis 312 (i.e., the rotational axis of the motor 315 may be offset from the pivot axis 312).

In this example, the dirt separator 300 comprises a passage 348 extending from the opening 302 to the dirt collection chamber 308 and the motor is positioned alongside the passage 348. The passage is comprised in the upper longitudinal portion of the dirt separator 300. A cross-sectional area of the passage 348 is equal to a cross-sectional area of the opening 302 and the dirt collection chamber 308, to provide a smooth air pathway to the dirt collection chamber 308.

The motor 315 is contained in a motor chamber 350 to prevent dirt D affecting performance of the motor 315. The motor chamber 350 is comprised in the lower longitudinal portion of the dirt separator 300, longitudinally adjacent to the passage 348.

In this example, electrical wires (not shown) are mounted to the frame 304 and extend along a length of the frame 304. The electrical wires deliver electrical power from the battery assembly 16 to the motor 315.

In this example, the vacuum cleaner 1 comprises a control system (not shown) arranged to receive a signal indicative of a user desire to empty the dirt collection chamber 308 and, in response to receiving the signal, cause the motor 315 to move the valve 310 to the open position. The control system comprises a switch located on the outer housing 12 of the main body 10 that is actuable by a user to indicate a desire to empty the dirt collection chamber 308. Actuation of the switch causes the control system to generate the signal. Accordingly, the valve 310 is movable to the closed position to evacuate dirt D from the dirt collection chamber 308.

The control system is also arranged to cause the motor 315 to move the valve 310 between the open and closed positions in response to a signal indicative of a user desire to power on and off the vacuum cleaner 1. In response to the signal indicative of a user desire to power on the vacuum cleaner 1, the control system is arranged to cause the motor 315 to move the valve 310 to the open position after the suction generator 14 is powered on. In response to the signal indicative of a user desire to power off the vacuum cleaner 1, the control system is arranged to cause the motor 315 to move the valve 310 to the closed position before the suction generator 14 is powered off. This ensures that the suction generator 14 is always powered on when the valve 310 is in the open position so that dirt D does not inadvertently escape the dirt collection chamber 308 during vacuum cleaning. In an embodiment, a dirt separator for a vacuum may be provided with the following clauses.

1. A dirt separator for a vacuum cleaner, comprising: a filter assembly to separate dirt from an airflow moving through dirt separator; a dirt collection chamber to collect dirt separated from the airflow, the dirt collection chamber comprising an opening through which dirt may be evacuated; and a valve assembly comprising: a valve rotatable between a closed position, in which the opening is obstructed by the valve, and an open position, in which the opening is unobstructed by the valve; and a motor to rotate the valve between the open and closed positions.

2. A dirt separator according to clause 1, wherein the airflow enters the dirt separator via the opening.

3. A dirt separator according to clause 2, wherein the airflow passes through the opening along a flow axis, and the valve is rotatable between the closed and open positions about a valve axis parallel to the flow axis.

4. A dirt separator according to any preceding clause, wherein the dirt separator is elongated, and the valve is rotatable between the closed and open positions about a valve axis parallel to a longitudinal axis of the dirt separator. 5. A dirt separator according to clause 4, wherein the valve axis is coaxial with the longitudinal axis of the dirt separator.

6. A dirt separator according to any preceding clause, wherein the motor is connected to the valve by one or more gears rotatable by the motor to move the valve between the open and closed positions.

7. A dirt separator according to any preceding clause, comprising a passage between the opening and the dirt collection chamber, wherein the motor is positioned alongside the passage.

8. A dirt separator according to clause 7, wherein the passage has a cross-sectional area that is substantially equal to a cross-sectional area of the opening.

9. A dirt separator according to clause 7 or 8, wherein the motor is contained in a motor chamber, the filter assembly extends parallel to a longitudinal axis of the dirt separator and separates the dirt collection chamber from an outlet chamber, and the dirt separator comprises an upper longitudinal portion that comprises the passage and the dirt collection chamber, and a lower longitudinal portion that comprises the motor chamber and the outlet chamber.

10. A dirt separator according to clause 9, wherein the motor chamber is positioned longitudinally adjacent to the outlet chamber.

11. A dirt separator according to any preceding clause, comprising a frame that extends along a length of the dirt collection chamber, and electrical wires for delivering electrical power to the motor, wherein the filter assembly is mounted to the frame, and the electric wires are mounted to and extend along the length of the frame.

12. A dirt separator according to any preceding clause, wherein the dirt separator has a length no less than 150 mm, and a width no greater than 60 mm.

13. A vacuum cleaner comprising: a dirt separator according to any preceding clause; a suction generator for generating an airflow; and a control system arranged to receive a signal indicative of a user desire to empty the dirt collection chamber and, in response to receiving the signal, cause the motor to move the valve to the open position.

14. A vacuum cleaner according to clause 13, wherein the control system comprises a switch or sensor arranged detect an input indicative of a user desire to empty the dirt collection chamber and, in response to detecting the input, generate the signal.

15. A vacuum cleaner according to clause 13 or 14, wherein the control system is arranged to cause the motor to move the valve to the open position in response to a signal indicative of a user desire to power on the vacuum cleaner.

16. A vacuum cleaner according to clause 15, wherein, in response to the signal indicative of a user desire to power on the vacuum cleaner, the control system is arranged to cause the motor to move the valve to the open position after the suction generator is powered on.

17. A vacuum cleaner according to any of clauses 13 to 16, wherein, in response to a signal indicative of a user desire to power off the vacuum cleaner, the control system is arranged to cause the motor to move the valve to the closed position before the suction generator is powered off.

The above embodiments are to be understood as illustrative examples of the invention. Further embodiments of the invention are envisaged. For example, the dirt separators 200, 300 may comprise any of the features of the dirt separator 100 described with reference to Figures 1-10. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.